Introduction
ANGUIL ENVIRONMENTAL SYSTEMS, INC.
Innovative Air Pollution Control Solutions
Air Pollution Abatement Technologies for the
Oil and Natural Gas Processing Industries.
Jeff Kudronowicz / Application Engineering Manager / Anguil
Presentation Outline
• Oxidation Overview, Industry
Applicability & Operating Cost Comparison
• Technology Review & Design
Considerations
• Case Studies
ANGUIL
Background
Founded in 1978
Family owned and operated Headquartered in Milwaukee, WI
with additional offices across the world
Committed to quality and application-driven engineering
• Largest Supplier of Thermal Oxidizers to the Gas Industry
• Members of the Gas Processors
Supplier Association (GPSA) Deb,Gene and Chris Anguil ANGUIL
www.anguil.com/industries-served/petroleum-natural-gas.aspx
What is Oxidation?
Definition: CnH2m + (n + m/2) O2 n CO2+ mH2O + heat
Temperature: Based on the VOCs that need to be destroyed there is a temperature at which the compounds can be oxidized.
Time: Relates to how long a compound needs to be at a certain temperature in order for it to be oxidized.
Turbulence: A fixed condition built into the equipment design that ensures a proper mixture of VOCs and oxygen for combustion.
Specific compounds and desired destruction rate efficiency determine temperature and residence time.
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Oxidizer Technology Overview:
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Catalytic Recuperative Oxidizers Thermal Recuperative Oxidizers
Concentrators
Regenerative Thermal Oxidizers (RTO) Direct-Fired Thermal Oxidizers
ANGUIL Green Completions in Natural Gas Development
www.epa.gov/airquality/oilandgas/pdfs/20120417summarywellsites.pdf
Suitable Technologies for Gas Producers:
• Regenerative Thermal Oxidizer (RTO) ANGUIL
Industry Standard for Gas Plants
• Catalytic Recuperative Oxidizers
• Thermal Recuperative Oxidizer
• Direct-Fired Thermal Oxidizers / Flares
• Concentrators: Zeolite and Carbon
Emerging, Energy-Efficient Alternative Not Recommended for Gas Plants Not Recommended for Gas Plants Unsuitable for Gas Plants
Pollutants Addressed by the Oil and
Natural Gas Sector NSPS and NESHAP
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Assumptions:
1. 5,000 SCFM Process Exhaust Flows 2. 21,000 btu/lb. VOC heat of combustion 3. Auxiliary Fuel Cost of $4/mmbtu 4. 90% Thermal Energy Recovery on RTO 5. No Thermal Energy Recovery on DFTO/Flare
Why Technology Changes Are Coming…
Operating Cost Comparison
VOC Loading (BTU/ft3) 0
10 20 30 40 50 60
0 6 15
RTO DFTO / Flare Operating
Cost ($/hr.)
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Why Technology Changes Are Coming…
CO2 Emission from from Different Control Equipment
0 200 400 600 800 1000 1200 1400 1600 1800
Direct Fired Thermal Oxidizer (Flare)
Thermal Recuperative Oxidizer
Catalytic Recuperative Oxidizer
Regenerative Thermal Oxidizer Emission Control Technology
CO2 Emission (lbs/hr)
CO2-Natural Gas Emission CO2-Solvent Combustion Process Assumptions:
-5,000 SCFM -6 BTU/ft3 in Process Gas -Primarily Methane Emissions
Regenerative Thermal Oxidizer
Typical Applications: Oil and Gas, Chemical, Composites, Metal Decorating, Expanded Polystyrene, Painting, Pharmaceutical, Wood Finishing, Coating, Printing
• Air Flow Range:
2,500-70,000scfm / Single Unit 70,000-500,000scfm / Multiple Units
• Concentration Range: 0%-25% LEL
• True 95%+ Thermal Energy Recovery
• 99% plus Rate Efficiency (DRE)
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RTO Mode of Operation
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Valves
Types of Valves:
Poppet Valves (Horizontal and Vertical) Butterfly Valves
Rotating (Single) Valves Modes of Operation
Pneumatic Hydraulic
Why Vertical Poppet Valves?
Maintenance Design Cost ANGUIL
Poppet Valve Operation
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Types of RTO Heat Recovery Media
Random Packing
· Typically 1” or 1½”
· ½” – 3” Available
Extruded Honeycomb Monolith
· Variety of cell sizes and wall widths
· Typical block size: 150 x 150 x 300
Multi-Layered Media
· Style and Size Options ANGUIL
Sour Streams & the
Presence of Sulfur
H2S + O2 SO2 / SO3
SO2+ H2O H2SO3
SO3+ H2O H2SO4
Condensation of H
2SO
4(sulfuric acid) should
raise corrosion concerns.
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Acid Dew Point Considerations
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• If the acid dewpoint is reached in the oxidizer the acid will condense and possibly cause corrosion.
• Will the addition of fresh, dilution air cause condensing? Fresh air may need to be heated.
• High RTO thermal efficiency leads to low outlet temperatures. Check acid dewpoint temperatures and select appropriate materials of construction.
Corrosion Protection Strategy
• Pre-heat the inlet air stream above the acid dewpoint
• Upgrade materials of critical items to protect against potential corrosion from acids
• Corrosion resistant outer reactor shell to protect against dew point corrosion – Vinyl Ester coating ANGUIL
Certain amine processes require metals be upgraded
to specialty alloys!
Media: Proper Design
A difference of 1,440,000 BTU/Hr
RTO Thermal Efficiency RTO Fuel Usage 95% Thermal Efficiency 40,000 BTU/Hr 93% Thermal Efficiency 310,300 BTU/Hr 91% Thermal Efficiency 702,000 BTU/Hr 89% Thermal Efficiency 1,100,000 BTU/Hr 87% Thermal Efficiency 1,480,000 BTU/Hr
Operating Scenario:
• 8,100 SCFM
• 2.2 BTU/ft3
24/7 operation and $4/MMBTU = $50,000 per year ANGUIL
Hot Side Bypass
● Allows unit to handle high VOC loads
● Damper position controlled by PLC and driven with pneumatic actuator with positioner
● Internally lined bypass duct to plenum of grade
● Duct and plenum are internally insulated ANGUIL
Dilution Air
• Preheating fresh air
prevents condensation
and subsequent
corrosion
• Steam coil, electric
heater or burner are
typically used
Will the addition of fresh, dilution air cause
condensing?
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Coating Application Process:
• Surface and insulation pins should be sandblasted to near white and inspected by a third party inspector
• First coat is applied to surface and insulation pins
• First coating application should be inspected by a third party inspector
• Final coat is applied
• Final coating application should be inspected by a third party inspector
• To make sure there are no hot spots present on the shell infrared images should be taken during start-up ANGUIL
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Amine Tail Gas RTO
-5,000 SCFM -Sour gas system w/
H2S present -Fresh air is heated to 340oF with slip stream from hot side bypass
-316L SS media support and poppet valves
-Vinyl Ester Coating
-15,000 SCFM -Sour gas system w/
H2S present -Fresh air is heated to 340oF with slip stream from hot side bypass
-316L SS media support and poppet valves
-Vinyl Ester Coating
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Amine Tail Gas RTO
Thank You!
ANGUIL ENVIRONMENTAL SYSTEMS, INC.
8855 N. 55thStreet · Milwaukee, Wisconsin 53223 Phone : 414-365-6400· Fax : 414-365-6410
www.anguil.com
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More Information on Gas & Oil Abatement Technologies:
www.anguil.com/industries-served/petroleum-natural-gas.aspx
