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www.carbovac.com
Vapour Recovery Solutions
for petroleum industry
CARBOVAC © Copyright – All rights reserved
- October 2015 -
www.carbovac.comCARBOVAC © Copyright – All rights reserved
1. Introduction
2. Why installing a VRU?
3. Carbovac « dry technology » VRU
4. VRU implementation
5. Some references
www.carbovac.com
ALMA and CARBOVAC, as part of the holding group S.A. LE GARREC & Cie,
have been working together for 10 years now, developing their respective, but
complementary, business areas.
Transport Metering
Solutions
Terminal
Metering Solutions
Vapour Recovery
Solutions
Global Maintenance
Services + Expertise
1. IntroductionPresentation
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Supporting clients worldwide | Servicing downstream activities
Oil companies
BP, Shell, Total,
ExxonMobil,
Lukoil, IOCL,
Saudi Aramco…Storage &
Trading
companies
Vopak, Oiltanking,
Eurotank, VTTI,
Rubis…
Engineering
companies
Technip, Samsung,
Petrofac, Jacobs,
DPL…
1. IntroductionOur clients
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CARBOVAC has three representations: France (HQ), Russia and Middle-East
And has managed more than 80 projects …
… in more than 25 countries, since 2005.
1. IntroductionCarbovac Worldwide
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1. IntroductionReference letters & certificates
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1. Introduction
2. Why installing a VRU?
3. Carbovac « dry technology » VRU
4. VRU implementation
5. Some references
www.carbovac.com
To reduce VOC impact on environment.
To protect human health (drivers, operators… neighborhood).
To reduce the pollution of the troposphere: ozone creation at ground level.
To increase the safety on the terminal.
To recover a valuable product.
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2. Why installing a VRU?Reasons
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2. Why installing a VRU?Legislation
1980: 1st legislation in USA “Clean air Act”
Emission limit: 80 g/m3 loaded----------
Improvement in the technology has led to more stringent legislation
Emission limit: 35 g/m3 loaded (general case) and 10 to 6 g/m3 loaded (loacally)
EPA: 35 g/m3 of gasoline loaded (many states ask lower emissions)----------
1994: European Directive EC94/63
Application for fuels with RVP > 276 mbar 35 g/m3 of air emitted to atmosphere----------
1999: Gothenburg Protocol
Emission limit: 10 g/m3 of air emitted to atmosphere----------
TA-Luft 01 (Germany) / LRV (Switzerland) / NER (Netherlands)
If emissions mass flow is > 3 kg/m3 50 mg/m3 for HC and 1 mg/m3 for benzene
Methane is excluded (difficult to recover, only destruction possible by combustion with secondary emissions)
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• Energy consumption increases with lower emission requirements !
• Basis 1200 g/m3 HC in the inlet to the VRU
• Energy consumption difference between 1 g/m3 and 0.15 g/m3 is more than x 2
• Extra 0,5 gram recovered costs 0.1 kWh or 200 kWh per kg
• To make this energy we need to burn 75 x the equivalent as fuel
Emissions limit
(g/m3)
35
(EU)20
10
(France)
1
(Optimum)
0.15
(Germany/Holland)
Energy required
(kWh/m3)0.08 0.09 0.09 0.1 0.2
Recovery
(g/m3)1179 1188 1194 1194.4 1199.916
Recovery delta
(g)9 6 5.4 0.5
2. Why installing a VRU?Recuperation vs. energy consumption
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2. Why installing a VRU?Emission measurement
In USA: emissions measured as a function of loaded gasoline
Complex system required for EPA compliance test
Measurement of the entire volume during 6 hours
Measurement of the average hydrocarbon concentration
Measurement of the total volume of gasoline loaded during 6 hours
Calculation of the mass emitted/litre loaded averaged over 6 hours
Continuous measuring system with complex and expensive devices:
CIM : Control Inlet Monitoring
CEM : Continuous Emissions Monitoring
In Europe: emissions measured as real emission concentration
Simple emissions monitor in the outlet line (infra-red detector) or analyzer with
separation of methane and non methane components.
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It is very difficult to have an accurate measurement of the recovered product:
the recuperation is only a small percentage of the absorbent circulation used to reabsorb the vapours
The existing meters accuracy is not sufficient (flow, level…)
Agreement between tax authorities and oil companies are reached to implement a fixed rate of recovery:
this rate is around 1.4 and 1.5 liter per m3 of gasoline entering the terminal
1.5 liter/m3 of gasoline loaded is exempted from taxes
(in most European countries)
2. Why installing a VRU?Recovery measurement
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• Hypotheses:
Vapour inlet concentration: 40% HC when vapours return from service station
Average outlet concentration: 2 g / Nm3
Average MW: 65 Gasoline vapours
• Calculation:
Mass of HC at inlet per m3:
Mass of HC recovered: 1158.7 g/m3 of inlet vapour
• The recovery rate:
The effective recovery rate is: 1.49 L/m3 of inlet vapour
Vapour recovery rate: 99.9%
2. Why installing a VRU?Recovery calculation
0.4 x 65= 1160.7 g/m3
22.4 x 10-3
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1. Introduction
2. Why installing a VRU?
3. Carbovac « dry technology » VRU
4. VRU implementation
5. Some references
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Step 1 Adsorption of the hydrocarbons on activated carbon
Step 2 Regeneration of the carbon by means of vacuum = desorption
Step 3 Re-absorption of the hydrocarbons in a liquid product
3. Carbovac dry technology VRUAdsorption / Desorption / (re)Absorption
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Activated carbon most used adsorbent in the World
Obtained through carbonization and activation of natural products
The adsorption capacity depends on:
Specific internal surface, up to 1800 m2/g
Pore size and distribution
Base material properties / hardness
3. Carbovac dry technology VRUActivated carbon
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HC molecules
Air
To atmosphere
with emission
monitoring
Purge
Inlet vapours
HC molecules Air
3. Carbovac dry technology VRUActivated carbon filter
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• The emission level of the system depends on:
Carbon type / Vacuum Level / Amount of purge air
30 mbar for 50 to 100 mg/m3
100 mbar for 1 to 5 g/m3
• The saturation rate of the “outlet” layer of carbon
must always stay low
• The transition zone of the carbon bed provides a
buffer for variations in flow rate and concentration
• The mass transfer zone removes the bulk of the
hydrocarbons
3. Carbovac dry technology VRUActivated carbon
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Mass transfer zone
Purge air during
vacuum regeneration
Vapour mixture inlet
Transition zone
Emission zone
Clean air outlet
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Gas inlet Gas Outlet
Cooling liquid
Gear oil
3. Carbovac dry technology VRUDry screw technology pumps
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DRY SCREW VACUUM PUMP
The dry screw technology permits to reduce the system to the essential components
required for optimistically functioning.
The vacuum pumps used in the Carbovac technology are totally dry and cause no pollution of the recovered products,
eliminating all corrosion and abrasion problems related to “wet” systems.
The absence of glycol or any other seal fluids (compatibility problem) and a
deep vacuum level offers the possibility to treat a vast range of products:
3. Carbovac dry technology VRUDry screw technology pumps
Methanol
EthanolETBE MTBE Benzene Crude oil Gasoline Naphtha …
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1510
Typical pump speed curve
Cycle time (in minutes)
Pressure in the adsorber
(in mbar)
500
1000
100Air Purge
3. Carbovac dry technology VRUDesorption curve
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3. Carbovac dry technology VRURe-absorption column
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Same unit before and after we changed the vacuum system …
Liquid ring vacuum system Dry screw vacuum system
3. Carbovac dry technology VRULiquid ring pumps vs. Dry screw pumps
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3. Carbovac dry technology VRUMajor advantages of Carbovac VRUs
OPTIMIZED / HIGHER LIFETIME OF VACUUM PUMPS
• Robust design
• No internal touching parts, no internal wear
• Overhaul of the pumps only after more than 40,000 operating hours
HIGHER LIFETIME OF ACTIVATED CARBON
• Reverse flow (no dusting)
• Pressure controlled desorption process
• Optimized pore size distribution
• Low pressure drop
LOWER ENERGY CONSUMPTION < 0.12 kwh/m3 of vapours treated
• Regeneration energy proportional to the mass of hydrocarbons absorbed
• Pumps equipped with VFDs to adapt the energy consumption to the mass of HC to be treated
LOWER MAINTENANCE COSTS
• No corrosion and abrasion (absence of glycol)
• Very simple process: system optimized and limited to its mere elements
• Selection of high quality equipment
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1. Introduction
2. Why installing a VRU?
3. Carbovac « dry technology » VRU
4. VRU implementation
5. Some references
www.carbovac.com
Important data for VRU sizing (trucks and railcars loading):
Q(i)
PEAK FLOW RATE Maximum flow rate generated by the loading facility
(i.e.: max number of loading points connected simultaneously x flow rate per point)
• Determination of the pressure drop of the VRU and the vapour collecting system
• Determination of the lines size, carbon bed diameters
• All vapours have to pass through the VRU. Influence on price is small.
Q(c)
MAX. THROUGHPUT PER CYCLE Max. vapour amount generated in 15 min (for truck loading)
(i.e.: number of loading bays x volume loaded per cycle or vessel capacity)
• Determination of the activated carbon volume in the beds
• For continuous throughputs the cycle time is usually fixed at 12 minutes
Q(4)
MAX. THROUGHPUT IN 4 HOURS Evaluation of the intensity of the activity during a “peak” period
• Determination of the required vacuum capacity
• Determination of the re-absorber and absorbents circulation pumps
Q(d)MAX. DAILY THROUGHPUT Evaluation of the loading profile per day
• Adjustment of the vacuum capacity
4. VRU implementationVRU base design data
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Vapour treatment, at the terminal:
The truck vapour return arm is connected to the VRU directly.
Balancing System: vapours are balanced with the tank and vapours from the tank (filling and breathing) go to the VRU.
4. VRU implementationTruck / Railcar loading facilities
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BOTTOM LOADING FOR TRUCKS
4. VRU implementationTruck / Railcar loading facilities
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TOP LOADING FOR TRUCKS
4. VRU implementationTruck / Railcar loading facilities
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4. VRU implementationTruck / Railcar loading facilities
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3 m
Storage tank piquage on one
side, must see 3 meters between
the two pipes.
Also, it is recommended to have
an alternative absorbent product
storage tank line (in order to
operate maintenance operations
on the storage tanks without
puting the VRU off.
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4. VRU implementationMarine loading operations
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Marine loading arm with vapour connection
4. VRU implementationMarine loading operations
Hoses for vapour connection on ship
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Berth connection:
Vapour line with shut down valve and
detonation arrestor.
4. VRU implementationMarine loading operations
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• Hydrocarbon vapours are heavier than air and form a layer on top of the product.
• This layer prevents further evaporation.
Product
loading arm
Vapour return
line Product and vapour
headers on board
Vapours from
Previous Cargo
Layer of new
Vapours
4. VRU implementationMarine loading operations
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Product
loading arm
Vapour return
lineProduct and vapour
headers on board
Layer of new
Vapours
• After 80% of the loading time, the new vapours start leaving the vessel.
• At the end of the loading operation, the relative saturation will reach approx. 80%.
4. VRU implementationMarine loading operations
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Product
unloading arm
Inert gas
Inert gas generator or
exhaust gasesProduct and vapour
headers on board
Vapour mixture from
previous cargo and
inert gas
• During unloading of the tanker, inert gas or exhaust vapour is injected into the tanker.
• The oxygen content is less than 5% by volume.
• Overall vapour concentration after unloading is relatively low.
4. VRU implementationMarine loading operations
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25%
5%
Loading Time in %
0% 80% 100%Vap
our
Con
cent
ratio
n in
% b
y
Vol
ume
Typical concentration profile for gasoline loading versus time
4. VRU implementationMarine loading operations
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Absorbent circulation:
Recovered Product Solutions:
• Return to loading Line
• Re-absorption in an other available light Product
• Liquefaction of the desorbed Vapour by Compression and Cooling
4. VRU implementationMarine loading operations
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4. VRU implementationVRU interface with the terminal
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4. VRU implementationPLC and MCC connections
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4. VRU implementationSafety
VRU are installed in environments containing liquid combustible and explosive gases
Risks of fire and explosions with toxic emissions
Preventive measures must be taken and risk analysis must be performed:
> HAZOP
> Explosion Protection Document
> SIL (Safety Integrity Level) risk assessment
EC declaration of conformity for the whole unit (§ 3.7.1.1)
Manufacturer assumes responsibility for compliance with the directive
Manufacturer should provide a conformity assessment of the whole assembly
Manufacturer provides clear instructions for assembly / installation / operation /
maintenance… in the operating manual.
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4. VRU implementationSafety
Some of the VRU safety features
The whole system is explosion
proof to 9 barg
All valves with limit switch
Gasoline pumps installed
below liquid level
High-high and low-low level
switches on the re-absorber
Temperature monitoring in the
activated carbon beds
Outlet temperature of the
vacuum pumps < 50°C
Detonation arrestor at the inlet
of the VRU
Two positive closing valves in
each gasoline circulation line
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1. Introduction
2. Why installing a VRU?
3. Carbovac « dry technology » VRU
4. VRU implementation
5. Some references
www.carbovac.com
Client: IOCL
Location: Jasidih
Type: Trucks loading operations
Products: Motor Spirit
Capacity: 480 m3 / h
Emissions: 10 g / m3
5. Some references
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Client: IOCL
Location: Chitoor
Type: Trucks loading operations
Products: Motor Spirit
Capacity: 480 m3 / h
Emissions: 10 g / m3
5. Some references
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Client: HPCL
Location: Vishakhaptnam
Type: Trucks loading operations
Products: Motor Spirit
Capacity: 528 m3 / h
Emissions: 10 g / m3
5. Some references
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Thank you for your attention.
We are at your disposal for any further information.
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Your CARBOVAC contacts
4 A boulevard de la Gare, Porte 1
94470 BOISSY SAINT LEGER
France
Your MP ENGINEERING contacts:
1003/1004, Lodha Supremus III
I Think Techno Campus, Off JVLR
Kanjurmarg (E), MUMBAI – 400 042
INDIA