concawe presentation to iiasa workshop by henk schipper pm controls in refineries for iiasa workshop...

CONCAWE presentation to IIASA workshop by Henk Schipper

PM Controls in Refineries

For IIASA workshop

by Henk Schipper

Technical Coordinator - CONCAWE


Sources of particulates in refineries

Oil fired equipment

• process heaters

• boilers (burning oil)

Fluids Catalytic Cracking Unit (FCCU)

• catalyst regenerators of such units


PM from Oil fired Equipment

Types of PM in flue gases

soot, the particle size is below 1 µm – visible smoke from a stack is caused by all particles but mainly 0.5 to 5 µm

cenospheres : they originate from the liquid phase residues of combustion of heavy oil droplets, at relatively low temperature (< 700 °C), the size is equal to or larger than that of the original oil droplets

coke particles, formed through liquid phase cracking in combustion at high temperatures (> 700 °C). The particle size is generally from 1 to 10 µm.

fine particles (< 0,01 µm): their contribution to the total mass emission is negligible.


Catalyst Regeneration

• Coke deposited on catalyst is passed through a regenerator, where it is burned off. The combustion gasses are passed through cyclones before disposal to the stack. About 90% is < 10 m. The main control for PM emissions is correct operating conditions! Basic design includes 2 stage cyclones

Further improvements by (very site specific):

tertiary cyclones multi cyclones electrostatic precipitators wet flue gas scrubbers


Coking Plants

– Coking as described here is a severe thermal cracking process that maximises the severity to the extent that coke is formed while production of the more profitable light products is maximised

– Unburnt gases from the calciner are burned in an incinerator, then passed through a waste heat boiler before being released to the atmosphere via a dust collection system

PM emissions from:

furnace flue gas;

coke fines (particulates) from handling of coke

the calciner.

– Controls same as for Cat Cracker. In addition bag filters can be used for handling of coke fines at a Capex of about 5 M EUR.


Process Fired Heaters

Emission reductiontechnique

Reduction efficiency Capital cost Operating cost

Particulate abatement Not applied to processfired heaters, asparticulate loads aregenerally low.

Change burner design(Steam atomisation)

To improve burnerefficiency and minimisenon-ash particulateformation

3 M EUR (40 burnerinstallation) (a)

Not applicable

Lower metalscontaining fuel oil (asan incidentalconsequence ofmeeting lower fuelsulphur contentrequirements) (C )

Depends on crude oilselection to havereduced sulphur content

Not applicable Depends on higher costmargin for lower sulphurcrudes

Change fuel to lighterfuel or (natural) gas (asan incidental conseq. ofmeeting other limits e.g.lower sulphur oxidesemission requirements) (c )

Up to 99% Depends on installationcosts for supply, mayrequire feeder pipeline.

Depends on differentialbetween purchasednatural gas and sale ofdisplaced fuel oil


BOILERSEmissionreductiontechnique

Reductionefficiency

Capital cost Operating cost

Particulateabatement

<50 mg/m3

particulates inrelease, heavymetals undefined

2.5 M Eur (1.2 x 109

m3 gas year-1) (a)

6M Eur (5.2 x 109 m3

gas year-1) (a)

4 – 6M Eur (109 m3

gas year-1) (b)

0.2 M Eur year-1 (a)


0.25-0.5 M Eur year-1

(b)

Lower metalscontaining fuel oil (asan incidentalconsequence ofmeeting lower fuelsulphur contentrequirements)

Depends on crudeoil selection tohave reducedsulphur content

Not applicable Depends on highercost margin for lowersulphur crudes

Change fuel tonatural gas (as anincidentalconsequence ofmeeting other limitse.g. lower sulphuroxides emissionrequirements (c )

Up to 99% Depends oninstallation costsfor supply, mayrequire feederpipeline.

Depends ondifferential betweenpurchased natural gasand sale of displacedfuel oil


Cat Cracker & Coker

Emission reductiontechnique

Reduction efficiency Capital cost Operating cost

Particulate abatement,Multi-cyclones

50-70%, 60-250 mg/m3

particulates in release,heavy metals undefined

1-2 M Eur (109 m3 gasyear-1) (b)

0.1 M Eur year-1 (b)

Particulate abatement,Electrostaticprecipitator

90-95%, <50 mg/m3


2.5 M Eur (1.2 x 109 m3

gas year-1) (a)

4 – 6M Eur (109 m3 gasyear-1) (b)


0.25-0.5 M Eur year-1 (b)

Particulate abatement(and sulphur oxidescontrol), Wet gasscrubbing

Up to 95%, <50 mg/m3


4 – 6M Eur (109 m3 gasyear-1) (b)

2-5 M Eur year-1 (b)

Particulate abatementfor off-gas incinerator,Electrostaticprecipitator

90-95%, <50 mg/m3


2.5 M Eur (1.2 x 109 m3

gas year-1) (a)

4 – 6M Eur (109 m3 gasyear-1) (b)


0.25-0.5 M Eur year-1 (b)

As above, Fabric Filter <25 mg/m3 particulatesin release, heavy metalsundefined

5M Eur (109 m3 gas year-

1) (b)0.25-0.5 M Eur year-1 (b)

concawe presentation to iiasa workshop by henk schipper pm controls in refineries for iiasa workshop...

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