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Installing Vapor Recovery Units to Reduce Methane Losses. Lessons Learned from Natural Gas STAR Small and Medium Sized Producer Technology Transfer Workshop Bill Barrett Corporation, Evergreen Resources Inc, Southern Gas Association and EPA’s Natural Gas STAR Program June 29, 2004. - PowerPoint PPT Presentation
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Installing Vapor Recovery Units to Installing Vapor Recovery Units to Reduce Methane LossesReduce Methane Losses
Lessons Learned Lessons Learned
from Natural Gas STARfrom Natural Gas STAR
Small and Medium Sized Producer Technology Transfer Small and Medium Sized Producer Technology Transfer WorkshopWorkshop
Bill Barrett Corporation, Evergreen Resources Inc,Bill Barrett Corporation, Evergreen Resources Inc,
Southern Gas Association and EPA’s Natural Gas STAR ProgramSouthern Gas Association and EPA’s Natural Gas STAR Program
June 29, 2004June 29, 2004
Page 2Reducing Emissions, Increasing Efficiency, Maximizing Profits
Vapor Recovery Units: AgendaVapor Recovery Units: Agenda
Methane LossesMethane Losses
Methane RecoveryMethane Recovery
Is Recovery Profitable?Is Recovery Profitable?
Industry ExperienceIndustry Experience
Discussion QuestionsDiscussion Questions
Page 3Reducing Emissions, Increasing Efficiency, Maximizing Profits
Sources of Methane LossesSources of Methane Losses
~ 5.56 Bcf methane lost from storage tanks ~ 5.56 Bcf methane lost from storage tanks each year from small and medium sized each year from small and medium sized producersproducers
Flash losses - occur when crude is transferred Flash losses - occur when crude is transferred from containment at higher pressure to from containment at higher pressure to containment at atmospheric pressurecontainment at atmospheric pressure
Working losses - occur when crude levels Working losses - occur when crude levels change and when crude in tank is agitatedchange and when crude in tank is agitated
Standing losses - occur with daily and seasonal Standing losses - occur with daily and seasonal temperature and pressure changestemperature and pressure changes
Source: EF from Inventory of U.S. Greenhouse Gas Source: EF from Inventory of U.S. Greenhouse Gas Emissions and Sinks, AF from EIA financial reporting Emissions and Sinks, AF from EIA financial reporting system (FRS)system (FRS)
Page 4Reducing Emissions, Increasing Efficiency, Maximizing Profits
Vapor Recovery UnitsVapor Recovery Units
Capture up to 95% of hydrocarbon vapors Capture up to 95% of hydrocarbon vapors vented from tanksvented from tanks
Recovered vapors have higher Btu content Recovered vapors have higher Btu content than pipeline quality natural gasthan pipeline quality natural gas
Recovered vapors are more valuable than Recovered vapors are more valuable than natural gas and have multiple uses natural gas and have multiple uses Re-injected into sales pipelineRe-injected into sales pipeline Used as on-site fuelUsed as on-site fuel Sent to processing plants for recovering NGLsSent to processing plants for recovering NGLs
Page 5Reducing Emissions, Increasing Efficiency, Maximizing Profits
Types of Vapor Recovery UnitsTypes of Vapor Recovery Units
Conventional vapor recovery units (VRUs)Conventional vapor recovery units (VRUs) Use rotary compressor to suck vapors out of Use rotary compressor to suck vapors out of
atmospheric pressure storage tanksatmospheric pressure storage tanks Require electrical power or engineRequire electrical power or engine
Venturi ejector vapor recovery units (EVRUsVenturi ejector vapor recovery units (EVRUsTMTM)) Use Venturi jet ejector in place of rotary Use Venturi jet ejector in place of rotary
compressorcompressor Do not contain any moving partsDo not contain any moving parts Require source of high pressure gas and Require source of high pressure gas and
intermediate pressure systemintermediate pressure system
Page 6Reducing Emissions, Increasing Efficiency, Maximizing Profits
Standard Vapor Recovery UnitStandard Vapor Recovery Unit
Crude Oil Stock
Tank(s)
ControlPilot
Vent LineBack Pressure
Valve
SuctionScrubber
SuctionLine
Condensate Return
BypassValve
ElectricControlPanel
Electric DrivenRotary Compressor
Gas SalesMeter Run
Gas
Liquid Transfer Pump
Check Valve
Source: Evans & Nelson (1968)Sales
Page 7Reducing Emissions, Increasing Efficiency, Maximizing Profits
Venturi Jet Ejector*Venturi Jet Ejector*
High-PressureMotive Gas(~850 psig)
Flow Safety Valve
Pressure Indicator Temp Indicator
PI TI
TI
PI
(-0.05 to 0 psig)
Low-Pressure Vent Gas from Tanks(0.10 to 0.30 psig)
PI TI
Discharge Gas
(~40 psia)
EVRUTM Suction Pressure
*Patented by COMM Engineering
Page 8Reducing Emissions, Increasing Efficiency, Maximizing Profits
Vapor Recovery with EjectorVapor Recovery with Ejector
Oil to Sales
Gas to Sales@ 1000 psig
LP Separator
Oil
Gas
Compressor
Ejector
Oil & Gas Well
5,000 Mcf/d Gas5,000 Bbl/d Oil
900 Mcf/d
Ratio Motive / Vent = 3 = 900/300
300 Mcf/d Gas
40 psig
6,200 Mcf/d
Crude Oil Stock Tank
(19 Mcf/d Incr.fuel)
281 Mcf/dNet Recovery
Page 9Reducing Emissions, Increasing Efficiency, Maximizing Profits
Example Facility for EVRUExample Facility for EVRUTMTM
Oil production:Oil production: 5,000 Bbl/d, 30 Deg API5,000 Bbl/d, 30 Deg API
Gas production:Gas production: 5,000 Mcf/d, 1060 Btu/cf5,000 Mcf/d, 1060 Btu/cf
Separator:Separator: 50 psig, 10050 psig, 100ooFF
Storage tanks: Storage tanks: 4 - 1500 Bbls @1.5oz 4 - 1500 Bbls @1.5oz reliefrelief
Gas compressor:Gas compressor: Wauk7042GSI/3stgArielWauk7042GSI/3stgAriel
Suction pressure:Suction pressure: 40 psig40 psig
Discharge pressure:Discharge pressure:1000 psig1000 psig
Measured tank vent:Measured tank vent: 300 Mcf/d @ 1,850 Btu/cf300 Mcf/d @ 1,850 Btu/cf
Page 10Reducing Emissions, Increasing Efficiency, Maximizing Profits
Emissions Before EVRUEmissions Before EVRUTMTM
CO2 EquivalentsCO2 Equivalents
Engine exhaust: Engine exhaust: 3,950 Tons/yr @ 790 Hp load3,950 Tons/yr @ 790 Hp load
Tank vents: Tank vents: 14,543 Tons/yr14,543 Tons/yr
Total CO2 equivalents:Total CO2 equivalents: 18,493 Tons/yr18,493 Tons/yr
Fuel consumption @ 9000 Btu/Hp-hr = 171 MMBtu/dFuel consumption @ 9000 Btu/Hp-hr = 171 MMBtu/d
Gas sales:Gas sales: 5,129MMBtu/d5,129MMBtu/d
Gas value:Gas value: $25,645/d @ $5/MMBtu$25,645/d @ $5/MMBtu
Page 11Reducing Emissions, Increasing Efficiency, Maximizing Profits
Emissions After EVRUEmissions After EVRUTMTM
CO2 EquivalentsCO2 Equivalents Motive gas required:Motive gas required: 900 Mcf/d900 Mcf/d Engine exhaust:Engine exhaust: 4,897 Tons/yr @ 980 Hp load4,897 Tons/yr @ 980 Hp load Tank vents:Tank vents: 0 Tons/yr0 Tons/yr Fuel consumption @ 9000Btu/Hp-hr:Fuel consumption @ 9000Btu/Hp-hr: 190 MMBtu/d190 MMBtu/d Total COTotal CO22 equivalents: equivalents: 4,897 Tons/yr4,897 Tons/yr Reduction:Reduction: 13,596 Tons/yr (73.5%)13,596 Tons/yr (73.5%) Total COTotal CO22 equivalents: equivalents: 4,897 Tons/yr4,897 Tons/yr Reduction:Reduction: 13,596 Tons/yr (73.5%)13,596 Tons/yr (73.5%) Gas sales:Gas sales: 5,643 MMBtu/d5,643 MMBtu/d Gas value:Gas value: $28,215/d @ $5/MMBtu$28,215/d @ $5/MMBtu Income increase:Income increase: $2,570/d = $77,100/mo$2,570/d = $77,100/mo EVRU cost installed:EVRU cost installed: $75,000$75,000 Installed cost per recovered unit of gas: Installed cost per recovered unit of gas: $0.68/Mcf/yr$0.68/Mcf/yr Payout:Payout: <1 month<1 month
Page 12Reducing Emissions, Increasing Efficiency, Maximizing Profits
Vapor Recovery Unit Decision ProcessVapor Recovery Unit Decision Process
IDENTIFY possible locations for VRUsIDENTIFY possible locations for VRUs
QUANTIFY the volume of lossesQUANTIFY the volume of losses
DETERMINE the value of recoverable lossesDETERMINE the value of recoverable losses
DETERMINE the cost of a VRU projectDETERMINE the cost of a VRU project
EVALUATE VRU project economicsEVALUATE VRU project economics
Page 13Reducing Emissions, Increasing Efficiency, Maximizing Profits
Criteria for Vapor Recovery Unit Criteria for Vapor Recovery Unit LocationsLocations
Steady source and sufficient quantity of lossesSteady source and sufficient quantity of losses Crude oil stock tankCrude oil stock tank Flash tank, heater/treater, water skimmer ventsFlash tank, heater/treater, water skimmer vents Leaking valve in blanket gas systemLeaking valve in blanket gas system
Outlet for recovered gasOutlet for recovered gas Access to pipeline or on-site utilitiesAccess to pipeline or on-site utilities
Tank batteries not subject to air regulationsTank batteries not subject to air regulations
Page 14Reducing Emissions, Increasing Efficiency, Maximizing Profits
Quantify Volume of LossesQuantify Volume of Losses
Estimate losses from chart based on oil Estimate losses from chart based on oil characteristics, pressure and temperature at characteristics, pressure and temperature at each location (each location (±± 50%) 50%)
Estimate emissions using the E&P Tank Model Estimate emissions using the E&P Tank Model ((±± 20%) 20%)
Measure losses using ultrasonic meter (Measure losses using ultrasonic meter (±± 5%) 5%)
Measure losses using recording manometer Measure losses using recording manometer and orifice well tester (and orifice well tester (±± 100%) 100%)
Page 15Reducing Emissions, Increasing Efficiency, Maximizing Profits
Estimated Volume of Tank VaporsEstimated Volume of Tank Vapors
Pressure of Vessel Dumping to Tank (Psig)Pressure of Vessel Dumping to Tank (Psig)
Vap
or V
ente
d fr
om T
anks
- cf
/Bbl
- G
OR
Vap
or V
ente
d fr
om T
anks
- cf
/Bbl
- G
OR
110110
100100
9090
8080
7070
6060
5050
4040
3030
1010
2020
1010 2020 3030 4040 5050 6060 7070 8080
Under 30° APIUnder 30° API
30° API to 39° API
30° API to 39° API40° API and Over
40° API and Over
Page 16Reducing Emissions, Increasing Efficiency, Maximizing Profits
Quantify Volume of LossesQuantify Volume of Losses
E&P Tank ModelE&P Tank Model Computer software developed by API and GRIComputer software developed by API and GRI Estimates flash, working and standing lossesEstimates flash, working and standing losses Calculates losses using specific operating Calculates losses using specific operating
conditions for each tankconditions for each tank Provides composition of hydrocarbon lossesProvides composition of hydrocarbon losses
Page 17Reducing Emissions, Increasing Efficiency, Maximizing Profits
What is the Recovered Gas Worth?What is the Recovered Gas Worth?
Value depends on Btu content of gasValue depends on Btu content of gas
Value depends on how gas is usedValue depends on how gas is used On-site fuel - valued in terms of fuel that is On-site fuel - valued in terms of fuel that is
replacedreplaced Natural gas pipeline - measured by the higher Natural gas pipeline - measured by the higher
price for rich (higher Btu) gasprice for rich (higher Btu) gas Gas processing plant - measured by value of Gas processing plant - measured by value of
NGLs and methane, which can be separatedNGLs and methane, which can be separated
Page 18Reducing Emissions, Increasing Efficiency, Maximizing Profits
Value of Recovered GasValue of Recovered Gas
Gross revenue per year = (Q x P x 365) + NGLGross revenue per year = (Q x P x 365) + NGL
Q = Rate of vapor recovery (Mcfd)Q = Rate of vapor recovery (Mcfd)
P = Price of natural gasP = Price of natural gas
NGL = Value of natural gas liquidsNGL = Value of natural gas liquids
Page 19Reducing Emissions, Increasing Efficiency, Maximizing Profits
Cost of a VRUCost of a VRU
Major cost items:Major cost items: Capital equipment costsCapital equipment costs Installation costsInstallation costs Operating costsOperating costs
Page 20Reducing Emissions, Increasing Efficiency, Maximizing Profits
Cost of a VRU (cont’d)Cost of a VRU (cont’d)
Capacity CompressorCaptial Costs Installation Costs O&M Costs
(Mcfd) Horsepower ($) ($) ($/year) 25 5-10 15,125 7,560 - 15,125 5,25050 10-15 19,500 9,750 - 19,500 6,000100 15 - 25 23,500 11,750 - 23,500 7,200200 30 - 50 31,500 15,750 - 31,500 8,400500 60 - 80 44,000 22,000 - 44,000 12,000
Vapor Recovery Unit Sizes and Costs
Note: Cost information provided by Partners and VRU manufacturers.
Page 21Reducing Emissions, Increasing Efficiency, Maximizing Profits
Value of NGLsValue of NGLs1 2 3 4
Btu/gal MMBtu/gal $/gal
$/MMBtu1,
2
(=3/2)Methane 59,755 0.06 0.32 5.32 Ethane 74,010 0.07 0.42 5.64 Propane 91,740 0.09 0.59 6.43 n Butane 103,787 0.10 0.73 7.06 iso Butane 100,176 0.10 0.78 7.81 Pentanes+ 105,000 0.11 0.85 8.05 Total
5 6 7 8 9 10 11
Btu/cf MMBtu/Mcf $/Mcf $/MMBtuVapor
Compostion
Mixture (MMbtu/Mcf
)Value
($/Mcf)
(=4*6)(=(8*10)/1
000)
Methane 1,012 1.01 5.37$ 5.32 82% 0.83 4.41$ Ethane 1,773 1.77 9.98$ 5.64 8% 0.14 0.80$ Propane 2,524 2.52 16.21$ 6.43 4% 0.10 0.65$ n Butane 3,271 3.27 23.08$ 7.06 3% 0.10 0.69$ iso Butane 3,261 3.26 25.46$ 7.81 1% 0.03 0.25$ Pentanes+ 4,380 4.38 35.25$ 8.05 2% 0.09 0.70$ Total 1.289 7.51$
1 Nautral Gas Price assumed at $5.32/MMBtu as on mar 5 at Henry Hub
2 Prices of Indvidual NGL components are from Platts Oilgram for Mont Belvieu, TX, March 05,2004
3 Other NGl information obtained from Oil and Gas Journal, refining Report, March 19, 2001, p-83
Page 22Reducing Emissions, Increasing Efficiency, Maximizing Profits
What Is the Payback?What Is the Payback?
Peak Capacity (Mcfd)
Installation &
Capital Costs1
O & M Costs
($/year)Value of Gas2
($/year)Annual Savings
Payback
period3
(months)
Return on
Investment4
25 26,470 5,250 34,242$ 28,992$ 11 107%50 34,125 6,000 68,484$ 62,484$ 7 182%100 41,125 7,200 136,967$ 129,767$ 4 315%200 55,125 8,400 273,935$ 265,535$ 2 482%500 77,000 12,000 684,836$ 672,836$ 1 874%
1 Unit Cost plus esimated installation at 75% of unit cost2 $7.51 x 1/2 capacity x 365, Assumed price includes Btu enriched gas (1.289 MMBtu/Mcf)3 Based on 10% Discount rate for future savings. Excludes value of recovered NGLs4 Calculated for 5 years
Financial Analysis for a conventional VRU Project
Page 23Reducing Emissions, Increasing Efficiency, Maximizing Profits
Trade OffsTrade OffsConventional Conventional
VRUVRUEjectorEjector
Fuel for electricity (Mcf/yr)Fuel for electricity (Mcf/yr) 2,2812,281 __
Fuel (Mcf/yr)Fuel (Mcf/yr) __ 6,9356,935
Operating factorOperating factor 70%70% 100%100%
MaintenanceMaintenance HighHigh LowLow
Installed cost per recovered Installed cost per recovered unit of gas ($/Mcf/yr)unit of gas ($/Mcf/yr)
$1.00$1.00 $0.68$0.68
Payback (excl. maintenance)Payback (excl. maintenance) 3 to 27 months3 to 27 months <1 month<1 month
Page 24Reducing Emissions, Increasing Efficiency, Maximizing Profits
Technology ComparisonTechnology Comparison
Mechanical VRU advantagesMechanical VRU advantages Gas recoveryGas recovery Readily availableReadily available
Mechanical VRU disadvantagesMechanical VRU disadvantages Maintenance costsMaintenance costs Operation costsOperation costs Lube oil contaminationLube oil contamination ~ 70% runtime~ 70% runtime Sizing/turndownSizing/turndown
EVRU advantagesEVRU advantages Gas recoveryGas recovery Readily availableReadily available Simple technologySimple technology 100% runtime100% runtime Low maintenance/ Low maintenance/
operation /install costsoperation /install costs Sizing/turndown (100%)Sizing/turndown (100%) Minimal space required Minimal space required
(mount in pipe rack)(mount in pipe rack) EVRU disadvantagesEVRU disadvantages
Need HP Motive GasNeed HP Motive Gas Recompression of motive Recompression of motive
gasgas
Page 25Reducing Emissions, Increasing Efficiency, Maximizing Profits
Lessons LearnedLessons Learned
Vapor recovery can yield generous returns when Vapor recovery can yield generous returns when there are market outlets for recovered gasthere are market outlets for recovered gas Recovered high Btu gas or liquids have extra Recovered high Btu gas or liquids have extra
valuevalue
VRU technology can be highly cost-effectiveVRU technology can be highly cost-effective
EVRUEVRUTMTM technology has extra O&M savings, technology has extra O&M savings, higher operating factorhigher operating factor
Potential for reduced compliance costs can be Potential for reduced compliance costs can be considered when evaluating economics of considered when evaluating economics of VRU/EVRUVRU/EVRUTMTM
Page 26Reducing Emissions, Increasing Efficiency, Maximizing Profits
Lessons Learned (cont’d)Lessons Learned (cont’d)
VRU should be sized for maximum volume VRU should be sized for maximum volume expected from storage tanks (rule-of-thumb expected from storage tanks (rule-of-thumb is to double daily average volume)is to double daily average volume)
Rotary vane or screw type compressors Rotary vane or screw type compressors recommended for VRUs where there is no recommended for VRUs where there is no source of high-pressure gas and/or no source of high-pressure gas and/or no intermediate pressure systemintermediate pressure system
EVRUsEVRUsTMTM recommended where there is gas recommended where there is gas compressor with excess capacitycompressor with excess capacity
Page 27Reducing Emissions, Increasing Efficiency, Maximizing Profits
Top Gas STAR Partners for VRUsTop Gas STAR Partners for VRUs
Top five companies for emissions reductions using VRUs in 2003Top five companies for emissions reductions using VRUs in 2003
CompanyReduction
(Mcf)Marathon Oil Company 1,333,484Kerr-McGee Corporation 633,919Chevron 532,134Union Pacific Resources Group, Inc. 403,454Burlington Resources, Inc. 299,609Source: Natural GasSTAR Program
Page 28Reducing Emissions, Increasing Efficiency, Maximizing Profits
Case Study – ChevronCase Study – Chevron
Chevron installed eight VRUs at crude oil Chevron installed eight VRUs at crude oil stock tanks in 1996stock tanks in 1996
Project Economics – Chevron
Methane Loss
Reduction (Mcf/unit/yr)
Approximate Savings per
Unit1
Total Savings
Total Capital and Installation
Costs
Payback
21,900 $43,800 $525,600 $240,000 <1 yr 1 Assumes a $3 per Mcf gas price; excludes value of recovered NGLs. Refer to the Lessons Learned for more information.
Page 29Reducing Emissions, Increasing Efficiency, Maximizing Profits
Vapor Recovery UnitsVapor Recovery Units
Profitable technology to reduce gas lossesProfitable technology to reduce gas losses Can help reduce regulatory requirements Can help reduce regulatory requirements
and costsand costs Additional value of NGLs further improves Additional value of NGLs further improves
cost-effectivenesscost-effectiveness Exemplifies profitable conservationExemplifies profitable conservation
Page 30Reducing Emissions, Increasing Efficiency, Maximizing Profits
Discussion QuestionsDiscussion Questions
To what extent are you implementing this To what extent are you implementing this BMP?BMP?
How can this BMP be improved upon or How can this BMP be improved upon or altered for use in your operation(s)?altered for use in your operation(s)?
What is stopping you from implementing this What is stopping you from implementing this technology (technological, economic, lack of technology (technological, economic, lack of information, focus, manpower, etc.)?information, focus, manpower, etc.)?