flare recovery system

7/25/2019 Flare Recovery System

1/56

nvirocomb imited

FLARE GASRECOVERY SYSTEMS


2/56

LIquidLIquidRIngRIng COmpressorCOmpressorStandard SystemStandard System

GASESGASES

AcidAcid GasesGases OthersOthers

H2SH2S NOXNOX CO2CO2 H2 H2 COSCOS CondensableCondensable HCHC mixturesmixtures

etc.etc.

APPLICATIONAPPLICATION..

PROCESSPROCESS RECOVERYRECOVERY

Topping FlareTopping FlareGasGas FCC Off GasFCC Off Gas VacuumVacuum Steamer Off GasSteamer Off Gas CokingCoking Flash GasFlash Gas

VisbreakingVisbreaking VOCVOC etc. etc. etc. etc.


3/56

nvirocomb imited

WHY INSTALL

A FLARE GASRECOVERY SYSTEM?


4/56

nvirocomb imited

THE ENVIRONMENTTHE ENVIRONMENT

Removal of three types of pollution:

Atmospheric (smoke, SO2, NOx, etc.)

Light

Noise

NB: In many parts of the world continuous flaring is not permitted.


5/56

nvirocomb imited

THE ECONOMIC ARGUMENTTHE ECONOMIC ARGUMENT

Consider a typical plant with continuous flaring of 1 ton/h:

Value of flared gas: 8000 x 1 x $150 = US$ 1,200,000 per year

First Year Operational Costs (Electricity & Water): = US$ 150,000 (approx)

Total installed cost of flare gas recovery system: = US$ 700,000 (approx)

Payback achieved in 8.5 months!

Subsequent yearly operational savings = US$ 1.050,000!

For larger systems the payback is shortened!


6/56

nvirocomb imited

TYPICAL FLARE GAS

RECOVERY SYSTEM& COMPONENTS


7/56

nvirocomb imited

FGRS COMPONENTSFGRS COMPONENTS


8/56

nvirocomb imited

TYPICALTYPICAL FLARE GASFLARE GASRECOVERY SYSTEMRECOVERY SYSTEM


9/56

nvirocomb imited


10/56

nvirocomb imited

THECOMPRESSOR


11/56

nvirocomb imited

TYPES OF COMPRESSORTYPES OF COMPRESSORGenerally three types of compressor have been used for flare

gas recovery systems:

Reciprocating, screw and liquid ring

Reciprocating and screw type compressors are more efficient

but they are also more expensive, require more maintenance

and downtime, result in compressed gases being at high

temperature and are not tolerant to condensates being present

in the gas.

For flare gas recovery liquid ring compressors have many

advantages.


12/56

nvirocomb imited

ADVANTAGESADVANTAGESOFOF

LIQUID RING COMPRESSORSLIQUID RING COMPRESSORS

Liquid ring compressors are generally the best to use for flare

gas recovery systems for the following reasons:

Able to handle gases containing condensates

Able to handle gases containing particulates

Able to handle wet gases

Able to handle toxic, flammable and corrosive gases

Works without lubricants

Gas temperature rise is low - 10OC

Because of liquid ring, compressors are inherently safe

System tolerates sudden gas and condensate surges


13/56

nvirocomb imited


14/56

nvirocomb imited

DESIGN BASISDESIGN BASIS


15/56

nvirocomb imited

TYPICAL LIQUID RING VACUUM PUMPTYPICAL LIQUID RING VACUUM PUMP

Radial Forces


16/56

nvirocomb imited

THE GARO DESIGNTHE GARO DESIGN


17/56

nvirocomb imited

THE GARO DESIGNTHE GARO DESIGN


18/56

nvirocomb imited

GARO is the preferred supplier of liquid ring compressors due to many

technical advantages.

Double lobe casing to balance radial pressures acting on overhung

impeller with a single mechanical seal.

Noise is dictated by the electric motor

Reduced vibration levels give bearingsa longer life

Potential leakage point with

atmosphere reduced to one mechanicalseal

The mechanical seal is the onlycomponent subject to wear and is easilyreplaced.


19/56

nvirocomb imited

FRONT PULL OUTFRONT PULL OUT

Fast access to compressor

internals without putting the

machine in vertical position.

Lower power consumption

DISTRIBUTION CONEDISTRIBUTION CONE


20/56

nvirocomb imited

CONE & IMPELLER ALIGNMENTCONE & IMPELLER ALIGNMENT

Easy checking of internalclearances without any need toopen the machine (two spannersand a dial gauge are all thatsrequired)


21/56

nvirocomb imited

The GARO machines are customengineered to meet process

requirements. Dimensional changes to

internal components alter the

machines operational capability.

Each size of compressor can be

adjusted to vary pressures, flow rates

and power consumption within a range.This optimizes performance in relation

to the required conditions of service.

Post supply process changes can oftenbe accommodated without the need to

replace the machine.

Casing

Impeller

Cone


22/56

nvirocomb imited

CROSS SECTIONCROSS SECTION


23/56

nvirocomb imited

TYPICAL LIQUID RING COMPRESSORTYPICAL LIQUID RING COMPRESSOR


24/56

nvirocomb imited

MAINTENANCE


25/56

nvirocomb imited

EASY MAINTENANCEEASY MAINTENANCE

OVERHUNG IMPELLEROVERHUNG IMPELLER


26/56

nvirocomb imited




27/56

nvirocomb imited




28/56

nvirocomb imited

BETWEEN BEARINGS DESIGNBETWEEN BEARINGS DESIGN

TRADITIONAL DESIGNTRADITIONAL DESIGN

Liquid ring compressor AM 850 maintenance costs


29/56

nvirocomb imited

T he table underneath show s the realm aintenance costs of a single stage G aro's co m pressor A M 850 operating

D ate C ause Shut dow n in T otal costs in U SD ,

hours incl. labor costs**

1 7 .0 8 .89 S ulphur rem o val* fro m filter 1 1 8

1 4 .0 9 .89 S ulphur rem o val* fro m filter 1 3 8

18.10.89 Sulphur rem oval* fro m filter, pipe and 1 2 3 0 0

valve upstream filter.

0 7 .1 1 .89 N ew filter installed* 4 8 * * * 4 .9 0 0

1 9 9 0 - - -

0 3 .0 6 .91 M ech. seal rings 8 1 .3 3 01 6 .1 0 .91 S et o f bearings 1 2 * * * 1 .5 4 3

0 5 .0 5 .9 2 M ech. seal gaskests 8 1 7 0

1 6 .1 1 .9 2 N ew filter cartridge 4 9 1 3

1 9 9 3 - - -

2 6 .0 1 .9 4 C o m plete m ech. seal 1 2 * * * 2 .1 4 8

0 9 .0 2 .9 5 R ing + gaskets o f m ech. seal 8 1 .4 5 0

2 1 .0 2 .9 5 R efitting due to w ro ng assem bly 4 1 9 02 0 .0 8 .9 5 S et o f bearings 1 2 * * * 1 .6 8 0

1 9 9 6 - - -

1 2 .0 2 .9 7 M ech. seal 8 3 .2 8 5

2 6 .0 5 .9 7 N ew filter cartridge 4 1 .3 6 1

1 9 9 8 - - -

T otal U SD 19.326

*In 1989 the refinery plant started refining crude oil w ith high sulphur content w hich led to frequent filters

clogging: in N ovem ber 1989 the filter w as rep laced by a self cleaning type.

**1 U S D = 1 ,071 2 E U R O

***D uring general plant shutdow n.

at a refinery p lant in S annazzaro de B urgund i, P avia -Italy- from 1989 up to 1998.

(C o st calcu latio n m eth o d : fro m 17.08.89 u n til 31.12.98 = 112 m o n th s. 19.326/ 112 x12= 2.070 U S D p er y ear.)

U S D 2.070A verage annual cost:


30/56

nvirocomb imited

FLARE SAFETY


31/56

nvirocomb imited

P1 = 0.03 bar g

1000 m3/h

0 am3/h

1 0 0 0

m

3 / h

P2= 0.02 bar g

P3 = 0.01 bar g

P T

1000 m3/h

1000 m3/h

NO BY- PASS REQUIRED

Pilots Only

NORMAL OPERATIONNORMAL OPERATION


32/56

nvirocomb imited

P1 = 0.02 bar g

800 m3/h

0 am3/h

8 0 0 m3

/h

P2= 0.016 bar g

P3 = 0.01 bar g

P T

1000

m3/h

800 m3/h

BY- PASS OPEN

Pilots Only

200 m3/h

REDUCED GAS FLOWREDUCED GAS FLOW

NO GAS FLOWNO GAS FLOW


33/56

nvirocomb imited

P1 = 0,01 bar g

No gas = 0 m3/h

0 am3/h

0 m3 /h

P2= 0,01 bar g

P3 = 0,01 bar g

P T

1000 m3/h

0 m3/h

100% BY- PASS OPEN

Pilots Only

1000 m3/h

PSL

Shut-down of compressor

NO GAS FLOWNO GAS FLOW


34/56

nvirocomb imited

CAPACITIES


35/56

nvirocomb imited

Vol. capacity ^ P 5 ^ P 7 Mod. Flow power cons.

in Tonnes / h bar abs bar abs Garo in m 3/h in kW

Approx. operating conditions

0,4 - 0,8 x AM 400 400 - 800 88

x AB 600 " 107 1200 - 1800 RPM 71 k W - 143 k W Inle t Pr es s. 1 bar abs

0,8 - 1,1 x AM 800 800 - 1100 140 Inlet Tem p. 20 -40 Cx AB 850 " 170 1300 - 1600 RPM 143 kW - 197 kW

Cooling water 30 - 35 C

1,1 - 1,4 x AM 1100 1100 - 1400 185

x AB 1100 " 280 1100 - 1400 RPM 197 kW - 251 kW Frequency 50 Hz

1,4 - 2,0 x AM 1500 1400 - 2000 251 Mol. Weight 15-45 Kg/kmol.

x AB 1500 " 305 900 - 1200 RPM 251 kW - 359 kW

2,5 - 3,0 x AM 2500 2500 - 3200 444

x C 250-6,3 X/SP " 538 800 - 980 RPM 420 kW - 568 kW

*** 4,0 - 5,0 AM/AB 5000 4000-7500 660 - 1200 RPM 430 - 620 Kw *** Double support compressor

System Single or duoble stage Garo compressor ( mech.seals, flushing system, couplings, baseframe )

Garo basic scope of supply as per enclosed annexe 1

Execution: All parts in carbon steel.

Compressor in 316 and other parts in carbon steel ( for H2S )

Other materials required ( S.S., Duplex etc. )

NOTES 1) Garo AB 600-850-1500 can reach 14 bar abs

2) Different eccentricity of the impeller and cone can change performances for each GARO COMPRESSOR TYPE


36/56

nvirocomb imited

AM=Single Stage AB=Double stage


37/56

nvirocomb imited

PLOT SIZE

PLOT SIZE


38/56

nvirocomb imited

PLOT SIZEPLOT SIZE

TWO COMPRESSOR SYSTEMTWO COMPRESSOR SYSTEM G AG A


39/56

nvirocomb imited

TWO COMPRESSOR SYSTEMTWO COMPRESSOR SYSTEMG.A.G.A.


40/56

nvirocomb imited

REFERENCESFLARE GAS RECOVERY

REFERENCE LIST FOR FLARE GAS &REFERENCE LIST FOR FLARE GAS &


41/56

nvirocomb imited

REFERENCE LIST FOR FLARE GAS &REFERENCE LIST FOR FLARE GAS &

HYDROCARBONS RECOVERYHYDROCARBONS RECOVERY SYSTEMSSYSTEMS

1986/1992 AGIP PETROLI, SANNAZZARO DE BURGONDI REFINERY (PV) - ITALYThree liquid ring compressors type AM 850 each handling 850 m^3/h of flare gas from 1 to 4 bar abs

1996 ISAB PRIOLO, COOGENERATION PLANT ERG PETROLI, PRIOLO (SR) - ITALYOne liquid ring compressor type AB 1500 handling 1400 m^3/h of flare gas from 1 to 7 bar abs

1997 AGIP PETROLI, GELA REFINERY (CL) - ITALYFour liquid ring compressors type AB 2500 (former C250-X/SP) each handling 2700 m^3/h of flare gas

from 1 to 6,5 bar abs

1997 AGIP PETROLI, TARANTO REFINERY - ITALYOne liquid ring compressor type AM 2500 handling 2700 m^3/h of flare gas from 1 to 3,8 bar abs

1997 SARAS, SARROCH REFINERY (CA) - ITALYTwo liquid ring compressors type AB 850 each handling 900 m^3/h of flare gas from 1 to 7 bar abs

1998 ITALIA ENERGIA E SERVIZI (I.E.S.), MANTOVA REFINERY - ITALYOne liquid ring compressor type AB 850 handling 900 m^3/h of flare gas from 1 to 7 bar abs

1999 ERG PETROLI, PRIOLO GARGALLO REFINERY, PRIOLO (SR) - ITALYOne liquid ring compressor type AM 1500 handling 1600 m^3/h of flare gas from 1 to 4 bar abs

2000 SHELL, DOCK SUD, AVELLANEDA - ARGENTINATwo liquid ring compressors type AB 850 IX each handling 600 m^3/h of flare gas from 1 to 8 bar abs

2000 SNP PETROM BRANCH PETROBRAZI BRAZI PRAHOVA ROMANIA


42/56

nvirocomb imited

2000 SNP PETROM BRANCH PETROBRAZI, BRAZI PRAHOVA - ROMANIAOne liquid ring compressor type AM 2500 handling 2800 m^3/h of flare gas from 1,05 to 4,05 bar abs

2001 LION OIL, EL DORADO, ARKANSAS - U.S.A.Seven liquid ring compressors type AB 1100 each handling 1200 m^3/h of flare gas from 1,05 to 7,5 bar abs

2001 ADCO, SAHIL - UNITED ARAB EMIRATESOne liquid ring compressor type AB 850 IX handling 450 m^3/h of flare gas from 1 to 6,5 bar abs

2001 REPSOL YPF, ESCOMBRERAS, CARTAGENA - SPAIN

One liquid ring compressor type AB 850 handling 950 m^3/h of flare gas from 1,05 to 7,5 bar abs

2001 CONOCO REEFINERY, PONCA CITY, OKLAHOMA U.S.A.Three liquid ring compressor type AB 1500 handling 1820 m^3/h of flare gas from 1,08 to 6,85 bar abs

2001 R.A.M. RAFFINERIA DI MILAZZO (ME) - ITALYOne liquid ring compressor type AB 2500 (former C250-X/SP) handling 2300 m^3/h of flare gas from

1 to 7,85 bar abs

2001 REPSOL YPF PETRONOR, REF. DE SOMORROSTRO, BILBAO SPAINOne liquid ring compressor type AB 850 handling 900 m^3/h of flare gas from 1 to 8 bar abs

2001 STATOIL, MONGSTAD REFINERY - NORWAYTwo liquid ring compressors type AB 2500 (former C250-X/SP) each handling 2600 m^3/h of flare gas

from 1 to 5 bar abs

2001 BP OIL, CASTELLON - SPAINOne liquid ring compressor type AB 1500 handling 1450 m^3/h of flare gas from 1 to 7, 5 bar abs(from different flare)


43/56

nvirocomb imited

2002 SHELL OIL CO. PORT ARTHUR, TX - U.S.A.Four liquid ring compressors type AB 1500 each handling 1500 m^3/h of flare gas from 1 to 8 bar abs

2002 SHELL OIL CO. NORCO, LA - U.S.A.Three liquid ring compressors type AB 1500 each handling 1500 m^3/h of flare gas from 1 to 8 bar abs

2002 SHELL OIL CO. CONVENT, LA - U.S.A.

Four liquid ring compressors type AB 1500 each handling 1500 m^3/h of flare gas from 1 to 8 bar abs

2002 SHELL OIL CO. DEER PARK, TX - U.S.A.Five liquid ring compressors type AB 1500 each handling 1500 m^3/h of flare gas from 1 to 8 bar abs

2002 CARMEL OLEFINS - ISRAELTwo liquid ring compressorstype AB 600 each handling 570 m^3/h of flare gas from 1,1 to 9 bar abs

2002 AGIP ECUADOR EPSS VILLANOTwo liquid ring compressors type AB 600 each handling 720 m^3/h of flare gas from 1,2 to 6,5 bar abs

2002 RELIANCE INDUSTRIES LIMITES INDIAOne liquid ring compressor type AB 1500 handling 3600 m^3/h of flare gas from 1,1 to 8 bar abs

2003 REPSOL YPF PETROLEO RAFFINERIA DE PUERTOLLANO SPAINTwo compression systems each with four liquid ring compressors type AB 1500 each handling 1650 m^3/h

of flare gas from 0,95 to 7 bar abs


44/56

nvirocomb imited

GAS WASHING

6


45/56

nvirocomb imited

1

2 3 4

5

6

1. Sour gas

2. Regenerated amine

3. Skimmed hydrocarbons4. Semi-rich amine to be sent to a medium pressure absorber or to regenerator

5. Regenerated amine to the final clean up column

6. Sweet gas to fuel gas network

FLARE GAS RECOVERY INTEGRATEDFLARE GAS RECOVERY INTEGRATED SYSTEMSYSTEM


46/56

nvirocomb imited

EQUIPPEDEQUIPPEDWITHWITH LIQUIDLIQUIDRINGRING COMPRESSORCOMPRESSOR

Process water

M edium pressure absorber

Slop

Blow Down

Fuel gas

Am ine washing unit

SW S treatm ent

Cooling water

Am ine regeneration unit


47/56

nvirocomb imited

LIQUID RINGCOMPRESSOR

APPLICATIONS


48/56

nvirocomb imited

Main applicationsMain applications Chlorine (wet and dry)

Vinyl Chloride Monomer

Ethylene Flare and vent gases (any kind)

Carbon monoxide / dioxide

Hydrogen

Hydrogen sulphide

Nitrogen oxides

Hydrochloric acid

Ethylene dichloride

Typical Applications


49/56

nvirocomb imited

A P P LIC A T IO N G A S H A N D LE D S E R V IC E LIQ U ID

V inyl A cetate E thylene (R ecovery) A cetic A cidP V C V C M (R ecovery) W ater

P ulp & P aper W et C hlorine W ater

P ulp & P aper C O 2 (R ecovery) W ater

C hlorine D ry C hlorine S ulphuric A cid

S ugar C O 2 W ater

S ugar C H 4 W ater

H 2O 2 H 2 (R ecovery) S olvent (U hde)

H 2O 2 H 2 (R ecovery) W ater

E D C D ry C hlorine S ulphuric A cid

E D C E D C (R ecovery) E D C

E D C V ent G ases (C O 2) C entrifugal

T iO 2 D ry C hlorine S ulphuric A cid

V C M V ent G ases (C 2H 4) E D C

A dipic A cid N O x N itric A cid & w ater

F ertiliser N O x N itric A cid & w ater

C aprolactam N O x N itric A cid & w ater

E xplosives N O x N itric A cid & w ater

N 2 N O x N itric A cid & w ater

H C l H C l S ulphuric A cid

N uclear P ow er H 2S W ater

O lefins B F 3 (B oron F luoride) X ylols

P olyolefins O lefins W ater

E nergy R ecovery (R e finery) B low D ow n G ases W ater/G asoline

D esalination C O 2 W ater


50/56

nvirocomb imited

REFERENCESGENERAL APPLICATIONS

GENERAL REFERENCE LISTGENERAL REFERENCE LIST


51/56

nvirocomb imited



52/56

nvirocomb imited



53/56

nvirocomb imited



54/56

nvirocomb imited



55/56

nvirocomb imited



56/56

nvirocomb imited

flare recovery system

Documents