Port Arthur Refinery – H2S Scrubber Control

Port Arthur Refinery – H2S Scrubber Control

Portfolio Categories: All, Case Studies, Vapor Control, and Vapor Scrubbing.

Challenge

A customer was facing EPA fines in the tens of thousands of dollars per day for the release of H2S and VOC’s to atmosphere from a tank not permitted to contain H2S-laden material. The customer reached out to Envent to solve the problem within a short deadline of three months.

 

Solution

Envent was able to design and construct a specialized vapor control system that stripped the vapors of a sticky aerosol residue and pull the H2S-laden vapors through a bank of Envent ESCRUB 1000 circulating scrubbers. This system operates continuously at 1,000 CFM and treats 7,000 PPM of H2S.

 

Benefit

For nearly three years, Envent has operated this system with ZERO breakthrough of H2S and ZERO safety incidents. Envent crews have operated this system safely and efficiently, day and night, 24/7/365. The onsite Envent technicians have been able to optimize the system to utilize as few consumables as possible, lowering the costs to the customer. The customer was able to avoid EPA fines and now has the time to design and construct a permanent process unit slated for construction in 2020.

RTO Breakdown Emergency Mobile Replacement

Portfolio Categories: Case Studies and Vapor Control.

Challenge

West Coast customer challenged Envent to create an immediate temporary solution which would enable them to continue production during the 1.5 month lead time it would take to manufacture, transport, and install their new system.

                               

Solution

Envent supplied a Temporary Air Handling and Treatment System consisting of three separate trains of custom built Envent paint particulate filters followed by three 14,000K lbs. / 20,000 CFM carbon units. The particulate filter housings were equipped with pressure differential gauges making it easy to anticipate change outs. The high flow carbon units were equipped with multiple air sample ports providing the opportunity to anticipate potential breakthrough. Envent also supplied a nitrogen source due to possible reactions and overheating. Envent’s treatment system was designed to safely enable high flows continuously during potential recharging events.

 

Benefit

Envent’s vapor control solution and project management support enabled this West Coast customer to meet their aggressive production goals during this short outage for less than 1% of their potential liability.  
 

Golden Triangle Refinery Turnaround


Challenge

An 80,000 bbl. /day crude distillation unit underwent a month long planned shutdown in order to perform maintenance on their exchangers, and pressure vessels. The shutdown began with the de-inventory and decon of the unit, often heralded as an unavoidable slow measure. Depressurizations, high flow nitrogen sweeps, and liquid deinventory can lead to many unanticipated delays. Due to the relatively small size of the unit, footprint was a concern, which added an additional layer of hazards.

Solution

Fortunately for this refinery, Envent designed, engineered, and executed a system that mitigated any potential hazards, as well as effectively and efficiently decreased decon time by three whole days. Liquid carryover was mitigated by adding low point drains in strategic sections of the process lines. Barriers were erected to limit foot traffic through the small footprint. Hose diameters were upsized to reduce pressure drop and allow for higher flows during depressurizations. Additionally, an injection port was installed into the process line to allow for enrichment of high nitrogen flows. These and many other factors contributed to Envent’s success in this turnaround, which shaved off three entire days from the refinery’s schedule!

Benefit

The refinery Turnaround planning team, anticipated at least seven days of runtime with Envent equipment. However, once process began to flow into the thermal oxidizers, higher flows were achieved. This allowed the refinery to complete their objections within four days! Once shutdown was complete, all equipment was removed, cleaned, and out of the refinery within 48 hours of job completion. A refinery turnaround lead summarized it best,” I want to express my appreciation for a job well done! The Envent team showed professionalism and a spirit of team work that allowed us to turn over the unit ahead of our original schedule…Thank you and we look forward to upcoming projects with Envent.”

Gasoline Product Pipeline Degassing

Portfolio Categories: Case Studies, Degassing, and Vapor Control.

Challenge

A West Coast oil company needed to purge 20 miles of pipeline with crude and hydrogen sulfide vapors.  The oil company needed a solution to vapor degas this large volume of crude and H2S vapor from this pipeline to allow pipeline repairs. Safe degassing of the vapors also ensured that odors and toxic vapors did not contaminate the neighborhood.

Solution

Envent offered an engineered solution for this industrial degassing project.  Envent provided a vapor-liquid separation vessel and then to the EMTOS (Envent Mobile Thermal Oxidizer System).  The vapor-liquid separation vessel was set up to handle up to 100 BBL of liquid product if needed, and the EMTOS unit was optimized to handle up to the hydrogen sulfide.  High-pressure flange hoses were used to ensure leaks didn’t occur.  During the project, 60,000 SCF of vapor were safely depressurized from 100 PSIG to 0 PSIG in less than an hour.  Less than 10 BBL of liquid product were received in the separation vessel.

Benefit

The midstream oil company realized both cost and a safety benefit through Envent’s industrial degassing solution.  With the nitrogen depressurization taking less than an hour, a large amount of time was saved when compared to alternative solutions allowing pipeline work to be performed in a safe manner.  It also eliminated the requirement to report an EPA benzene release (anything over 10 lbs. per day of benzene is a reportable quantity).  This pipeline was safely and successfully degassed.

 

Mid-West, USCG Certified Marine Vapor Recovery System


Challenge

A Mid-West refinery was preparing for an internal pipeline maintenance project and was exploring options for how to take the vent and a refined product pipeline out of service to sustain refinery production and continue to ship refined project to market. Vapors emissions had to be controlled by a USCG Certified Marine Vapor Recovery System. Vapors and order issues were a major concern. Being in compliance with vapor emission limits was necessary. The refinery may be able to sell product from their dock, greatly increasing flexibility and cost effectiveness to potential customers.                                 

Solution

Envent proposed a temporary, portable United States Coast Guard approved Marine Vapor Control System (MVCS) to load the product into barges at the North side of the refinery. The barges would then float down river and offload at the South side of the refinery. This eliminated nearly all of the risks associated with the pipeline option. Envent’s MVCS is all pre-certified by the US Coast Guard, setup and operational testing occurred within a few days’ time. Upon project completion, the MVCS was quickly removed without a trace. The Envent system consisted of a Dock Safety Unit (DSU) with a vapor scrubber and Envent Emission Control Systems (EMECS). 

Benefit

Not only did Envent’s MVCS control vapor emissions to achieve compliance and eliminate the risks associated with the pipeline option, it reduced refinery cost and minimized resources. The refinery now has a 5 year certified Envent Dock Safety Unit (DSU) and MVCS they call back on site for any emergency loading. The refinery was able to continue to load and ship product to market without interruption. The net result was estimated at $3 Million in lost opportunity costs if Envent was not able to engineer a system that would allow the refinery to load ships.

Midwest Refinery Turnaround Services


Challenge

A Midwest refinery contracted Envent to provide degassing and vapor control services.  The refinery planned a major turnaround and had multiple critical-path process units that needed industrial degassing and industrial vapor control services for safe entry into process vessels.  EPAs mandates and RSR vapor control regulations on flareless turnarounds required eliminating flaring activity and capacity of recovery units, an alternative was needed to remove bottlenecks and minimize delays.

Solution

Envent Turnaround Degassing Services Group engineered solution that included H2S Scrubbers and thermal oxidizers for industrial degassing of vessels and pipe systems.  Envent’s engineers worked with the refinery Operations, Turnaround Coordinators, and Environmental group to provide a safe process for vapor freeing using Envent’s mobile degassing systems.

The Envent solution included H2S Scrubbers – 2 x ASME-rated circulating scrubbers.  The hot-wash system would receive steam and non-condensable material from the low-pressure system through heat exchangers, knock out vessels, ASME H2S Vapor Scrubbers which would vent to Envent’s Mobile Emission Control Systems (EMECS 70s) the largest mobile vapor control systems.  Water collected will be processed through an Envent Mobile Wastewater Treatment System.

Benefits

The results from using this system expedited the decontamination period, prior to a turnaround, from 3 weeks to 7 days.

 

Safety is our #1 priority.

Southern California Refinery Excess Fuel Gas Elimination Project

Portfolio Categories: All, Case Studies, Degassing, and Vapor Control.

Challenge

A Southern California Refinery needed to bring down their Hydrogen Plant to perform critical maintenance outside of the normal turnaround cycle. To bring down the unit that utilizes most of the produced fuel gas of the refinery while maintaining operations in the rest the plant, approximately 3 million standard cubic feet per day of gas needed to be processed. Such a release to the flare system would have been an extraordinary event. The refinery needed a Flare Minimization Plan. Envent Corporation was contracted to provide the solution and execute.

Solution

Envent Corporation went to work to provide an engineered solution, complete with the necessary environmental permits for the Refinery Flare Minimization effort. We provided upfront engineering necessary to complete a design of the vapor management systems, culminating with the Process Hazards Analysis (PHA). Envent was able to handle an excess 3 million scf per day to avoid Flaring events. Envent provided a High Pressure Knock Out Vessel followed by 3 EMECS units. Envent’s solution did not stop there, our project engineers maintained strong oversight, minimizing noise and maintaining the refinery’s good neighbor priorities.

Benefits

Envent delivered an efficient solution to support the refinery’s Hydrogen Plant Shutdown only had to oversee the Management of Change (MOC) process and provide our tie-in points. The project was a huge success and the customer was very pleased. Flaring excess gas was avoided during this effort.

Quote from Project Manager

“I wanted to thank you guys for the great work in execution of this project. It was definitely a success, and everyone was happy with the outcome. NO FLARING!”

In June 2017, Envent Corporation achieved 1 million man-hours without an OSHA recordable injury. We maintain a TRIR of 0.0 for 6 years. We believe Safety is No Accident.

Emergency Vapor Scrubbing – Southern California Refinery


Challenge
A refinery in Southern California experienced severe plugging in a section of piping downstream of their coker unit.  In order to eliminate the restriction, the refinery needed to perform a line break and attempt to clear the line.  The column attached to the line contained high concentrations (2500 ppm) of ammonia vapors and the facility was unable to empty this column using their existing equipment.  This outage was severely impacting production and had the potential to affect ongoing maintenance work – the refinery needed a contractor to mobilize immediately to provide an emergency vapor scrubbing solution.

Solution
Envent is a specialist – and we mobilize 24/7/365 to provide customized, engineering solutions.  The Envent engineers designed an SCAQMD permitted vapor control system using the ESCRUB 2000-SS, a dual-column, recirculating scrubber preloaded with phosphoric acid to neutralize the ammonia vapors, followed by two granular activated carbon vessels to remove all hydrocarbon contaminants.  Envent staffed the job around the clock with two technicians for the next week.

Benefit
The customized solution was mobilized within 24 hours and all of the ammonia vapors were neutralized successfully.  The customer greatly appreciated the fast call to action and a reliable solution that worked from the start.

Freeport, Texas, Out of Service Storage Tank Contaminated Water Treatment

Portfolio Categories: All and Mobile Water Treatment.

Challenge
A facility on the Gulf Coast had an out of service tank that once contained Pyrolysis Gasoline (Pygas), but had recently been used to store various waste streams and contaminated water.  The 132′ diameter, 56′ tall internal floating roof tank was due for inspection and the facility had no way to treat the contaminated water, which contained a myriad of oils and particulates.

Solution
Envent engineers began with a job walk and gathered samples from the tank.  The team tested a number of coagulants during an extensive bench test and worked with the facility to ensure that the selected coagulant was compatible with their downstream treatment processes.  Envent used the coagulant with the Envent Cavitated Air Flotation (CAF) Unit – an 88 GPM workhorse to treat suspended particles in water.  The CAF unit was under vapor control to ensure safe operation, the waste stream was stored for disposal, and the effluent was held in a temporary tank to allow sampling prior to discharging to the facility’s downstream treatment process.

Benefit
Envent estimated that the job would take eight days to process 1,000,000 gallons of contaminated water.  The project lasted just under six days and all of the processed water was free from oil and suspended particles.  The facility was able to process the water and begin the tank inspection process.  The treatment system saved the customer time and money compared to deep-welling or attempting to run the contaminated water through their own system.

Deer Park Refinery, Complete Turnaround Solution

Portfolio Categories: All, Case Studies, and Turnaround Services.

Challenge
A refinery conducted a turnaround on a Hydrocracker unit in the Deer Park area, and they required a complete turnaround solution.  Having worked with Envent before, the customer knew that we could solve all of their needs. We first needed to depressure the Hydrocracker unit, initially comprised of nearly pure Hydrogen, and then perform multiple nitrogen sweeps. Simultaneously, Envent provided vapor control for temporary frac tanks used to store chemical wash water. Finally, we were able to decontaminate the chemical wash water once the decommissioning was complete.

Solution
The engineers at Envent developed three separate systems, including the use of the Envent Turnaround Safety Skid, to surpass the customer’s requests.  The Turnaround Safety Skid, equipped with redundant high pressure regulators and shutdown systems for both the process stream and the supplemental fuel stream, along with the EMECS 70 and two EMECS 42s, safely depressured the unit. An exchanger and receiver were used in conjunction with the EVAC 1000 to control the vapors from the temporary frac tanks. Lastly, liquid phase carbon scrubbing vessels were available to process the contaminated chemical wash water. Three separate systems, working together, to provide a total, engineered solution.

Benefit
Envent provided all of the equipment, technicians, and engineers to complete the job safely and ahead of schedule. In fact, this was the fastest the Hydrocracker had ever been decommissioned in the history of the facility – a full day ahead of schedule. The Envent engineering team supported all phases of the design and implementation process, including all PHA, HAZOP, and MOC processes leading up to the turnaround, working in tandem with the customer.

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