Southern California Refinery, Turnaround Support Services

Southern California Refinery, Turnaround Support Services

Portfolio Categories: Turnaround Services.

Challenge
A Southern California Refinery needed to conduct maintenance activities on a number of connected process units.  The goal was to complete several hot taps on each unit and cleaning to remove years of product buildup.  These units contained high levels of residual VOCs, sulfurous compounds, and other process byproducts.

Solution
Envent worked with a cleaning contractor to provide a turnkey solution for this large scale turnaround.  Envent’s cleaning contractor efficiently and effectively treated each process unit sequentially so that the refinery could quickly complete their necessary changes.  The cleaning contractor injected high pressure steam into the process units to break up the unwanted deposits. Envent’s engineers sized and staged a set of mobile heat exchangers to condense the contaminated steam exiting the process units.  The contaminated condensate was then transferred into Envent’s temporary storage tanks.  Envent’s reliable carbon systems were installed to maintain an odor-free and emission-free environment and ensure that the turnaround was fully compliant with the South Coast Air Quality Management District’s stringent requirements.

Benefit
Envent was able to provide an efficient solution to support the refinery’s turnaround needs.  Not only was Envent able to supply their industry-leading vapor control equipment, but Envent used their engineering expertise to size and implement a cost-effective solution to control the contaminated steam from the cleaning process.  Some competitor’s may boast about similar vapor control technology, but industry leaders understand the true benefit of an environmental service provider founded on engineering solutions.

Norco, Louisiana, Marine Vapor Recovery

Portfolio Categories: Marine Vapor Recovery.

Challenge
The refinery uses sulfuric acid for their processing and brings in the fresh acid by barge. Once used, the spent sulfuric acid is pumped in to the barge. There were numerous odor and air quality complaints in the vicinity of the plant.

Solution
We developed a scrubber and thermal oxidizer system to eliminate the odors and the hazardous releases. Envent utilized the ESCRUB 1000 to eliminate the SO2 vapors, which at times is up to 30% and the EMTOS 2500 to destruct any residual hydrocarbons. Pressure drop study to account for pulling through the recirculating scrubber and all of the hoses to make sure the scrubber and thermal oxidizer blower size was sufficient. Ensuring the right concentration of caustic to still mitigate the vapors and last a sufficient amount of time vs. having too high a concentration and it solidifying in the piping and vessel.

Benefit
With our engineered solution, the refinery has been able to operate without nuisance odor or the associated costly air board fines.

Westlake, Refinery, Vapor Scrubbers

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

Challenge
A Westlake Louisiana refinery required vapor control on their tank while a robotic crawler made entry into the tank. The company was trying to recover $10,000,000 worth of catalyst that had carried over from their Catalytic Cracking Unit. Envent was also requested to provide vacuum rated carbon containers. The tank vapors were of a high concentration which required Envent to reduce the Lower Explosive Limit to 10% which was required for any kind of entry, including robotic.

Solution
Envent efficiently provided an engineered scrubber system including EVAC 3000 blower system, ESCRUB 6000 filled with our custom VapoScrub™EX5 scrubbing solution followed by the BD 16,000 carbon vessel filled with 16,000 lbs of reactivated carbon and the Envent 5000 CFM blower. Envent also placed specialized engineered vacuum carbon containers in line with the robotic crawler to capture suction vapors that were created while recovering the catalyst.

Benefit
Using Envent’s custom engineered solution the company was able to keep odors from the tank catalyst recovery operation from shutting down turnaround operations in the immediate surrounding area. Envent was able to support the job and prolong the carbon media using VapoScrub™EX5. In addition to being able to recover $10,000,000 worth of catalyst safely and ahead of schedule, Envent was able to prevent surrounding crane operations from being disrupted saving $250,000 an hour.

Kept odors from the tank catalyst recovery operation from shutting down turnaround operations

Louisiana Refinery, H2S Vapor Control, Recirculating Vapor Scrubbers

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

Challenge
A refinery with a sour water tank high in H2S needed vapor control provided during a turnaround while maintenance was done in the surrounding area. The H2S concentration was as high as 500,000 ppmv during parts of refinery operations. The H2S needed to be reduced to a safe level while the vapors were treated and vented to atmosphere.

Solution
Vapors from the tank were routed to a liquid recirculating scrubber, which reduced the H2S concentration to an acceptable limit to where the vapors could be sent to a thermal oxidizer. Envent monitored the inlet and outlet of the liquid scrubber to ensure efficient reduction of the H2S. When liquid break through was approached, the media was changed out to guarantee the thermal oxidizer was always combusting vapors that were below the threshold of EPA mandated levels of H2S combustion.

Benefit
Envent was able to successfully reduce the H2S emissions in the area so a turnaround could continue. Also, Envent was able to adjust to severe cold conditions and prevent solidification of the liquid media. This prevented costly delays while maintaining safe turnaround operations, eliminated odors and kept the customer in compliance. No releases, environmental and no exposure.  A satisfied customer!

Successfully reduced the H2S emissions in the area so turnaround could continue.

Texas Refinery, Port Arthur, Vapor Scrubbers

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

Challenge
A large Texas refinery was in need for a long term vapor control solution for their refinery.  Over a period of 6 months, the customer would need to slowly and continuously route acid from one tank to the next.  Due to the low flow, a passive vapor control method would be preferred.  A system that was specifically engineered for the concentration of VOCs and SOx.

Solution
The ideal solution for the customer was a scrubber that used one of Envent’s chemically engineered scrubbing media.  The liquid scrubber was chosen due to the passive flow of the vapors, and the hazards of the acid.  Due to low flow and VOC concentrations, a thermal oxidizer would not be cost effective.  The vapors were routed through the scrubbers in order to safely neutralize any harmful VOCs to the environment in the most effective manner.

Benefit
By capturing nearly all potential VOCs and SOx, the refinery avoided any and all potential fines from TCEQ.

Neutralized any harmful VOCs to the environment in the most cost effective manner.

San Francisco Refinery, Pipeline Depressurization & Degassing

Portfolio Categories: All, Case Studies, and Degassing.

Challenge
A large refinery in California needed vapor control on a propane recovery line. The refinery was to introduce a nitrogen stream into the pipeline to sweep out and purge the propane. In order to stay within the permit, the refinery would have to degas the pipeline to accommodate the Bay Area AQMD limits. A quick and easy vapor control solution was needed.

Solution
An EMTOS, or Envent Mobile Thermal Oxidizer System was chosen for this job. The process began by isolating the section of pipe, and connecting one end to the EMTOS. A nitrogen purge was then introduced from the opposite end to replace the displaced propane vapors. The EMTOS flowed at an average of 1900 SCFM, and was able to remove approximately 600 pounds of VOC’s. This was accomplished in just under five hours, with destruction efficiency greater than 99.9%.

Benefit
The customer was able to easily depressurize and control the unwanted propane vapors. This solution ensured that the refinery avoided any unnecessary fees associated with the release of VOC’s into the environment. Hundreds of thousands of dollars were saved by keeping the refinery in operation without any regulatory fines.

600 pounds of VOC’s removed just under five hours

Texas, Butadiene Sphere Tank Degassing

Portfolio Categories: All, Case Studies, and Degassing.

Challenge
A petrochemical company needed both vapor control, and degassing for a spherical 30,000 barrel Butadiene tank. The customer needed to transfer the residual product from the spherical tank into two frac tanks. Vapor control would be provided during this fill up. Once empty, the degassing of the spherical tank would begin. An independent tank cleaning company would then spray and clean the tank.

Solution
Envent engineered a solution to utilize the Envent Mobile Emission Control System, or EMECS, for this project. With a capacity for burning 42 million BTU/hr, the EMECS was chosen due to the high BTU content of Butadiene. For added safety, the EMECS was used in conjunction with an additional knockout pot, and a group B detonation arrestor. This added an extra layer of safety for the butadiene, as well as helped prevent liquid carryover during the filling of the frac tanks.

Benefit
The customer was able to easily empty, and clean their spherical tank without releasing unwanted vapors. The EMECS unit provided by Envent was able to quickly switch from a vapor control, to a degassing service with little to no downtime, and ahead of schedule.

Degassing and Vapor Control on Spheres Made Easy

Northern California Terminal, Pipeline Degas

Portfolio Categories: All, Case Studies, and Degassing.

Challenge
An Oil and Gas terminal had mixed 350 BBL of product (278 BBL of isobutane and 72 BBL of distillate) inside a 1.9 mile long section of pipeline. The company was going to push the mixed product to a LPG transport truck using a pig, and Envent was requested to control vapors on the truck to prevent it from overpressuring.

Solution
Envent provided a 20 million Btu/hour EMTOS, Envent Mobile Thermal Oxidizer, to handle the inflow of vapors into the LPG transport truck. Envent first depressured the LPG transport truck, which was at 55 PSI of propane before connecting to the pipeline. Envent also put a vacuum onto the truck so the isobutane could flash off from the distillate at a greater rate.

Benefit
The pipeline was successfully purged of the mixed product in 6 hours of operation. Also, because Envent was able to flash off most of the isobutane, only one transport truck was needed for the distillate to be loaded into. According to Envent’s calculations, if the isobutane had not been flashed off and destroyed as rapidly, then multiple transport trucks would have been needed. This added time would have more than doubled the completion time of the project.

Successfully purged the pipeline of the mixed product in 6 hours of operation

Seattle, Washington, Butane Tank Degassing

Portfolio Categories: All and Degassing.

Challenge
A terminal located on the Northwest had to meet their deadline inspection on a large, 350,000 BBL Butane storage tank. In addition to taking the tank out of service they had a narrow window to complete the degas, turnaround work and return the tank back to service. Regulatory permit support was also needed to obtain the mandatory permit.

Solution
Due to the size of the tank and location within the site, careful planning and HAZOP considerations were discussed among our project engineers, the site representatives and other contractors. The tank was safely degassed under an inert atmosphere with nitrogen up to 4000 CFM. Two EMECS 42 MMBTU/hr thermal oxidizers were utilized to meet the customer schedule which could have taken 100 times longer with other units. Envent’s constant coordination between the control room and our nitrogen contractor resulted in a safe and regulatory compliant degas. Per environmental regulations, and the local air boards site inspection, the tank was certified degassed.

Benefit
Envent’s vapor control solution and project management support aided the customer in executing the project in a timely manner. This allowed the customer to continue with their turnaround efforts safely with zero incidents. Millions of dollars were at stake by taking a vital tank out of service and Envent project engineers onsite, every effort possible was made to keep the project on schedule.

Project: Butane Tank Location: Washington Product: Butane

Southern California Tank Degassing

Portfolio Categories: All, Case Studies, and Degassing.

Challenge
A 180,000 BBL southern California refinery waste water tank, frac tanks and centrifuge equipment needed vapor control and degassing during sludge removal. The two month long project needed redundancy and great attention to detail to abide by the permitting requirements. Backup systems were required to service the generator and still operate with in the air district rules. Moisture had to be taken in to consideration to prevent plugging process vapor lines.

Solution
After analyzing, a simple integrated system was utilized in this project based on Envent’s experience on previous centrifuge operations. Envent was able to optimize efficiency by mobilizing a redundant passive vapor control system to maintain 24/7 operation while making the short generator service intervals. The vapor control and degas was handled safely and allowed the sludge removal process to proceed without interruption from Envent’s scope of work. With close communication between all parties, Envent was able to finish the job on time and within budget.

Benefits
Envent chose the optimal units to for the job to save the customer money on over or undersized equipment. The treatment system also provided the most economical and efficient system by eliminating down time.

Maintained 24/7 operation while making the short generator service intervals.

Houston Ship Channel, Natural Gasoline Sphere Tank Degas

Portfolio Categories: All and Degassing.

Challenge
A Houston ship channel refined product storage terminal requested our degassing expertise to engineer a solution for an unconventional sphere tank. Due to the unconventional design of the tank, previous attempts by competitors failed and the customers budget was blown. Other degassing contractors lack Envent’s engineering expertise and equipment.

Solution
Envent engineers assessed the original tank drawings and performed detailed job walks with experienced field supervisors to coordinate the most effective method of degassing. We engineered a solutions using a 42 MMBTU per hour Envent Mobile Emission Control System (EMECS).

Benefit
Once on the job, Envent depressured the tank within the first couple hours and was able to turn multiple tank volumes by the next day. Due to an effective strategy, the tank maintained below 10% LEL sooner than expected, allowing cleaning of the tank to commence earlier, reducing the cost of degassing and cleaning by 56% and the duration of the outage by 5 times. This alone amounted to an estimated $140,000 revenue improvement.

Project: Sphere Tank Location: Houston, Texas Product: Gasoline

Houston Area, Refinery Turnaround Support Services

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

Challenge
A refinery needed a contractor to “…handle our vapor control and compliance needs during this major turnaround. We need you to keep us in compliance and provide accurate and complete records upon completion.” We can do that – it is what we do.  The challenge was to handle the vapor control for 250 frac tanks and the blow downs from the towers, columns, and vapors from the vacuum trucks.

Solution
The engineers at Envent developed a plan that involved staffing the turnaround with engineers, providing vapor scrubbers that fit the service, and using thermal oxidizers engineered and sized for the task. We had 17 scrubbers, both passive and recirculating, and 3 thermal oxidizers from 5 MMBTU to 40 MMBTU being manned and operated at one time.

Benefit
Our engineers and technicians executed the entire 60 day turnaround incident free and the customer was extremely satisfied.  The success of the turnaround was the result of Envent’s experience and highly specialized and trained personnel.

Envent’s 24 hour manned operation ensured the turnaround vapor control activities were done correctly and safely, and we remained in compliance.

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