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3/7/16 Page 1Authorization Process for Pressure Assisted MultiPoint Ground Flares

Authorization Process for Pressure Assisted MultiPoint Ground Flares

Anne Inman, P.E.Technical SpecialistOperational Support SectionAir Permits DivisionTexas Commission on Environmental Quality


Overview of Regulatory Authorization Process for MPGF• Federal Regulation Applicability

• AMEL Introduction and Streamline Framework

• Project Scope and Background

• Performance Demonstration

• Monitoring and Operating Conditions

• Public Notice Proposal and Final Decision by EPA

• State/Regional Parallel Authorizations


Federal Regulatory Applicability• 40 CFR 60, Standards of Performance for New Stationary Sources

(NSPS) – 88 Subparts A-OOOO

• 40 CFR 61, National Emission Standards for Hazardous Air Pollutants (NESHAPs) - 22 Subparts A-FF

• 40 CFR 63, National Emission Standards for Hazardous Air Pollutants Source Categories (a.k.a. Maximum Achievable Control Technology) (MACT) – 134 Subparts A - HHHHHHH


Federal Regulatory Applicability• NSPS, NESHAPs, MACT regulate sources and mandate emission

limitations

• Flares are a common control with design & operating specifications • 40 CFR §60.18 and 40 CFR §63.11

• Continuous Pilot

• Net Heating Value

• Flare Tip Velocity

• Smokeless


Pressure Assisted Multi-Point Ground Flares (MPGF)Flare systems:

• Characterized by one or more flare headers and groupings

• Operate at high pressures

• Varying stream characteristics and flows

• 99%+ Destruction Rate Effectiveness (DRE) for VOCs and HAPs

• Cannot meet flare tip velocity requirements in federal regulations §60.18(c) or §63.11(c)


Alternate Means of Emission LimitationsAMEL IntroductionFCAA §111(h)(3)

• Alternative Means of Emission Limitation (AMEL)

• Satisfy Administrator (EPA – not delegated)

• Achieve equivalent emission reduction

• Each regulated air pollutant and subpart

• Notice and opportunity for public hearing

• EPA Authorization


MPGF AMELs by EPADocket EPA-HQ-OAR-2014-0738• Proposal Dow and Exxon – 2/13/2015 FR pgs 8023-30

• Approval Dow and Exxon, Proposal OCC – 8/31/2015 FR pgs 52426-35

• Streamline Framework Proposal – 8/31/2015 FR pgs 52435-36

• Pending Actions at EPA: OCC (1), CPCHEM (2), R&H (2)


AMELs Streamline Framework• Submit AMEL request to EPA

• Copy corresponding state/tribal/local permitting programs and agencies

• Each request stands-alone (documentation)

• Must have all needed information to satisfy EPA Administrator


AMEL Project Scope and Background• Identify site, company, permits, reference IDs

• Describe processes and operational conditions which generate emissions

• Details of typical and worst-case waste gas compositions, flows, profiles

• Anticipated start of construction and operation


AMEL Project Scope and Background• MPGF utilization (routine operations, planned MSS, upsets, etc.)

• Applicable NSPS, NESHAPs, MACT standards

• Authority to request AMEL (FCAA plus subparts)


AMEL MPGF• Identify burner manufacturer, design, specifications (type,

geometry, size)

• Describe operational scenarios (low pressure, high pressure)

• Details on capacity, rows/stages, burners, pilots per stage, staging curve

• Include any unique design or operational details


AMEL MPGF Performance • Must achieve equivalent control (DRE)

• Most stringent applicable standard• VOC

• HAPs

• Individual constituents

• Demonstration options• Test

• Engineering assessment


AMEL MPGF Performance Demonstration Testing• Test

• PFTIR and Extractive

• Specific manufacturer and design

• Representative fuel/waste gas OR Worst-case substitute

• Minimum 3 runs

• Report


AMEL MPGF Performance DemonstrationTest Report Contents• Test description

• Protocols and methodologies

• Quality assurance/quality control

• Raw field and laboratory data

• Summary report sheets

• Calibration standards and curves

• Date, time, duration


AMEL MPGF Performance DemonstrationTest Report Contents• Fuel/waste gas composition and justification

• Highest operating pressure/sonic velocity conditions

• Visible emissions observation forms

• Calculate average DRE and combustion efficiency

• Flowrates and velocity of gas

• Calculate NHVcz and/or LFLcz of gas


Gas Net Heating Value in Combustion Zone (NHVcz)

𝑁𝐻𝑉%& = (𝑥*𝑁𝐻𝑉*

+

*,-

• Based on compositional analysis data

• NHVcz = Net heating value of flare vent gas (Btu/scf).

• i = Individual component in flare vent gas & n = Number of components in vent gas

• xi = Concentration of component i in flare vent gas, volume percent.

• NHVi = Net heating value of component i


Gas Lower Flammability Limitin Combustion Zone (LFLcz)

𝐿𝐹𝐿01 =1

∑ 𝜒*𝐿𝐹𝐿*

+*,-

• Based on compositional analysis data

• LFLcz = Lower flammability limit of flare vent gas, volume fraction

• i = Individual component in flare vent gas & n = Number of components in vent gas

• xi = Concentration of component i in flare vent gas, volume percent.

• LFLi = Lower flammability limit of component i


AMEL MPGF Performance DemonstrationTest Report Contents• MPGF burner tip pressure

• Waste gas temperature

• Meteorological conditions

• Observed flameouts

• Results analysis and summary


AMEL MPGF Performance DemonstrationEngineering Assessment• Demonstrate effectiveness by prior testing

• Similar equivalent burner

• Representative fuel/waste gas OR worst-case substitute

• Address all other factors

• Include supporting documentation/prior tests

• Persuasive conclusions


AMEL MPGF Performance DemonstrationEngineering Assessment

Equivalent burner destruction/combustion effectiveness • Design principles of burner type

• Burner size

• Burner geometry

• Air-fuel mixing

• Combustion principles to assure smokeless operation

• Spectrum and variety of operating conditions


AMEL MPGF Performance DemonstrationStability Testing

Key Importance – Lit, Stable Flame and Smokeless

Conduct long-term stability test• Spectrum and range of operating conditions

• Representative or worst-case waste gas stream

• Smokeless operation

• Stable flame to flameout point


AMEL MPGF Performance DemonstrationStability Testing• Design and complete test

• Purpose to determine point of flame instability and flameout

• Stable minimum 5 minutes• Highest operating pressure/sonic flow conditions

• Most challenging composition

• Document all relevant conditions and parameters


AMEL MPGF Performance DemonstrationStability Testing• Replicate results

• Minimum and maximum operating conditions• At least 15 minutes at each condition

• At least 3 test runs

• At or above NHVcz or below LFLcz• Highest operating pressure/sonic flow conditions

• Most challenging composition

• Document and report all relevant conditions and parameters


AMEL MPGF Performance DemonstrationCross Lighting• Design and complete test

• Purpose to show all stages will light under range of conditions• Vary operating pressure / velocity

• Appropriate design and installation spacing and pilot locations

• Boundaries• At least 3 test runs at each condition

• NHVcz or LFLcz

• Minimum of 3 burners must light in each stage


AMEL MPGF Performance DemonstrationCross Lighting• Report Contents

• Description of the testing

• Protocol of test methodology

• Test method QA/QC parameters

• Time, length, and duration of the test


AMEL MPGF Performance DemonstrationCross Lighting• Report continued…..

• Waste gas composition

• Waste gas temperature

• NHVcz and/or LFLcz of the gas tested

• Velocity (or Mach speed ratio) of the waste gas tested


AMEL MPGF Performance DemonstrationCross Lighting• Report continued…..

• Burner tip pressure

• Whether successful cross-light was observed over all of the burners

• Length of time it took for the burners to cross-light

• Maintaining a stable flame after a successful cross-light

• Duration of stable flame observed


AMEL MPGF Performance DemonstrationOther Reduction Considerations• Alternatives to flaring or flare reduction measures

• Evaluate flare gas recovery

• Justify MPGF utilization


AMEL MPGF Operating Conditions• Each stage equipped with at least two (2) pilots

• No visible emissions when operating

• NHVcz ≥ 800 Btu/scf

• LFLcz ≤ 6.5 vol %


AMEL MPGF Monitoring• Install, operate, calibrate, maintain, record data, record

downtime & out of compliance periods

• At all times:• Pilot flames on each stage present (thermocouple)


AMEL MPGF Monitoring• Receiving material

• Downtime for maintenance, instrument adjustments, calibrations (max 5%)

• Component concentrations in vent gas (LFLcz) or measure, calculate and record heating value of vent gas (NHVcz)

• Monitor vent gas flow rate

• Pilot flame / opacity video camera

• Pressure monitors on main header, each staging valve


AMEL MPGF Review• EPA staff will review details of request

• Provide all documentation

• Request for Information – respond promptly to avoid delays

• Draft site-specific AMEL approval or disapproval


AMEL Notice and Action• Publish proposal in Federal Register

• 30-day comment and hearing request period

• EPA evaluates all comments

• Publish final AMEL in Federal Register• Approval or Disapproval

• Revisions to AMEL conditions as proposed

• Respond to comments


State/Tribal/Regional Authorizations

• Each state/region/tribe/local government has different requirements

• Actions possible• Amend or Revise New Source Review Permits

• Administrative Revision to Federal Operating Permits

• Alternate Method of Compliance or Control (AMOC) Requests

• Public notice and comment/hearing opportunities

• Plans may parallel or be different than EPA AMEL

• May process simultaneously or consecutively


Anne Inman, P.E.Air Permits Division, TCEQ

Mail Code 163P.O. Box 13087

Austin, TX 78711

[email protected]

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Authorization Process for Pressure Assisted MultiPoint ...content.4cmarketplace.com/presentations/InmanTCEQ.pdfMultiPoint Ground Flares Gas Lower Flammability Limit in Combustion Zone