Air Emission Management-KNPC Experience

The 2nd Joint Qatar-Japan EnvironmentSymposium

"Sustainable Environment, Climate Change andRenewable Energy for Oil and Gas Industry",

February 5-6, 2013, Doha, Qatar

Abhay Kumar KashyapSenior Engineer, Environment Services

Kuwait National Petroleum Company (KNPC)

•Since 2001: Environment Division, KNPC

•1995-2001 : Manager, Environment, Hindustan Petroleum CorporationLtd (HPCL), Visakhapatnam , India

•1984-1995 : Operations, HPCL, Mumbai

•1984 : B.Tech., Chemical Engineering, Indian Institute of Technology,Kanpur India

About the Speaker

1. KNPC

2. Development of Air emission Management Program

3. Programs / Projects

4. Questions.

Index

KNPC Core BusinessKNPC is a Government owned refining company of Kuwait

3 Petroleum Refineries with total refining capacity of 936,000 bbls/ Day.

A LPG/Gas Plant with 3 trains.

Local Marketing facilities

MINA AL-AHMADI

REFINERY

466 M BPDMINA

ABDULLAH

REFINERY

270 M BPD

LOCAL

MARKETING

39 FillingStations

2 DepotsSabhan

&Ahmadi

LPG / GAS

PLANT

3 Trains x560 MMSCFD

SHUAIBA

REFINERY

200 M BPD

LPG

NAPTHA

MOGAS

KERO / ATK

DIESEL

MARINE DIESEL

High SulphurFuel Oil

Low SulphurFuel Oil

BITUMEN

SULPHUR

COKE

466 MBPD

200 MBPD

270 MBPD

Inputs which have shaped KNPC’s Air EmissionManagement programs:

•Air Emission Regulations at Kuwait

•Implementation of ISO 14001

•KPC HSE Strategies

•Community concerns and voluntary initiatives

Development of Air Emission Management Program

Source Pollutant Scale

First : Fixed Source

1.1 All emission sources - Particulate Darkness level should not exceed 20% (max .limit)

- Asbestos No emissions are allowed

1.2 Stacks of Products - Particulate Darkness level should not exceed 20% (max .limit)

1.3 Stacks - Particulate 115 mg/m3

Darkness level must not exceed 20% (max. limit)

2. Facilities Operated by

Combustion

- Particulate 43 Nanograms /Joule

Fossil fuel fired Boilers and furnaces

with heat energy input more than 30 MW

(100 MBTU/hr)

- SO2 512 Nanograms / Joule

- Nox 86 Nanograms/Joule facilities burning natural gases

- Nox 130 Nanograms/Joule facilities burning fuel oil

- Opacity Should not exceed more than 20%

3.3 Petroleum Refineries

3.1 FCC Unit (with incinerator or waste

heat boiler)

- Particulate 1.0 Kg/Metric ton of coke burn off

- SO2 9.8 Kg/Metric ton of coke burn off

- CO 500 ppmv

- Opacity Should not exceed 30% for more than 6 minutes / hr

3.2 Fuel gas used in combustion - H2S 230 mg per dry standard cubic meter

3.3 Claus unit for Sulfur recovery &

capacity exceeding 20 T/day.

- SO2 250 ppmv in stack with oxidation or reduction and

incineration

Appendix 20“Environmental Requirement and Standards in the State of Kuwait” Kuwait Al Youm

Appendix of issue no 533 year 47 dated October 2, 2001

Electrostatic Precipitator (ESP) at Fluidized Catalytic Cracking Unit(FCCU) at Mina Al Ahmadi (MAA) Refinery

Particulate Matter, Kg/ton of coke

KEPA Limits

Low NOx Burners in Heaters and Boilers

• KNPC uses gaseous Fuel

• KEPA limit for Gas combustion is 86 Nano Gram / Joule (Approximately165 ppmv reported at 3 % O2 in stack)

• 10 Heaters & Boilers were identified as not meeting the limit.

• 1 Heater and 1 Boiler Burners are replaced with 120 ppmv NOx burners.Burners in two more heaters are under replacement.

• 69 ppmv NOx burners are being installed at 5 boilers in the second phase.

• Option of lower specification is being studied for some additional existingheaters and new projects.

Low NOx Burners in Heaters and Boilers

Low NOx Burners in Heaters and Boilers

Lowering H2S in Fuel Gas

• KNPC uses a mix of Refinery generated fuel gas and imported gas (afterextraction of C3, C4 and other useful components)

• Part treatment of Imported gas.

• Split streams generated from Ethane Recovery unit which was low in H2S hasresulted in KEPA Fuel gas H2S limit being met at MAA Refinery.

• KNPC has initiated two FGRU projects at its MAA & MAB Refineries

• Flare Gas Recovery Unit to minimize flaring through the RefineryModernization Project ( RMP) units and Future Up gradation Project (FUP)units Flare systems at MAA is expected to be commissioned in 2013.

• Study phase is completed for Flare Gas Recovery Unit to minimize flaringthrough Flares at MAB Refinery.

• The two projects are expected to reduce Green House Gasesemissions by approximately 140,000 Tons Co2 eq per year.

Flare Gas Recovery Units (FGRU) at MAA Refinery and MAB Refinery

Emission Monitoring program

Sr. Source Category Parameters Frequency

A. Gas fired combustion Equipment (Boiler &

Process Heaters)

H2S in Fuel Gas Header Daily

NOx in Stack Once in a month by the contractor

B. Fuel oil fired / Mixed firing combustion

Equipment (Boiler & Process Heaters)

As in A above

and

Sulfur in fuel oil

As in A above

Every batch

C. Sulphur Recovery Unit (SRU) SOx, Continuous

and twice in a week by the contractor.

H2S As required to confirm incineration.

Continuous in new facilities.

D. FCCU Particulate, SOx, CO Continuous and once a week by the

Contractor

E. Hydrocarbon flares Quantity flared Reported monthly

F. Acid gas flares Quantity of SO2 emitted Reported monthly

G. Combustion equipment (Boilers, Heater,

Compressor engines, FCCU, flares) &

Hydrogen Unit

CO2 Reported monthly

The monitoring is carried out by a contractor and also continuous monitoring systems havebeen provided at some stacks.

Odor Management System (OMS) and Associated Programs

• Public Perception about an industry within community is affectedconsiderably by odor and flaring.

• KNPC took up an Environmental Objective of developing an “OdorManagement System” (OMS) which went beyond conventional fugitiveemission management programs driven by regulations.

• Odors sources/locations have been detected, identified and quantifiedthrough an odor survey which consisted of review of previous work,incidents & complaints, walk through in Refinery sites includingmaintenance areas and interview with Operators/Supervisors.

• A Complaint Recording and Tracking System was developed to captureboth Internal and External Environmental Complaints in future.

Odor Management System (OMS) and Associated Programs

Some of the key programs arising out of this objectives are

OMS Program Description

Chemical

Decontamination:

Preparing the unit/vessels for shut down through steaming and water washing is a source of odor.

Use of Chemical Decontamination process reduces this problem and also reduces the downtime.

However, the effluent disposal is closely regulated as it impacts Effluent Treatment Plant.

Bulk Chemical handling: Handling of chemicals procured in small drums and disposal of empty drums are another source

of odor. KNPC has started procurement in ISO Tanks (Figure 5) or Tote Bins (Figure 6) for

many chemicals.

Relief Gas Management: To reduce routine loss of hydrocarbon to flare due to passing Pressure Relief Valves, a team

carries out a systematic and regular check of identified bad actors (valves) using an acoustic

meter (Vacpac) and a Thermal IR camera. Review of shutdown and start up procedures have

been done to reduce flaring through sequencing of shut down activities.

Other site specific actions H2S scavenging for Eocene Desalter drain in MAA, Cover CPI/API, Vapor Recovery System atFilling stations, Closed Loop Sampling, Welding Flume extractor at Welding shops (LocalMarketing Facilities).

Leak Detection & Repair

Program

KNPC has implemented a smart LDAR program to control fugitive emissions from leaky

components like valves, flanges, pumps drains and vents etc. Hydrocarbon leaks are identified

through infrared camera (Figure 7,8) followed by conventional method of measuring the

concentration of leak and repair. Non hydrocarbon sources are included in the program and

follows the conventional method of listing all components and monitoring it at fixed frequency.

Thank You

Questions???????

ISO Tank

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Boiler chemicals being handled in Tote Containers at MAB Refinery

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LDAR using IR Camera

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