Featured Project: Record-Breaking Flareless Turnaround Decontamination – Midwest Refinery (EPA Refinery Sector Rule / MACT 2 Compliance)
A Midwest refinery planned a major turnaround requiring flareless decontamination of multiple critical-path units under the EPA’s Refinery Sector Rule (RSR) – 40 CFR Part 63 Subpart UUU (Refinery MACT 2). New work-practice standards prohibit routine flaring during MSS activities and require ≥98% destruction efficiency on all depressuring vents.
The refinery needed a complete, single-vendor flareless solution to cut decontamination time from 3 weeks to under 7 days.
The Challenge
- Multiple high-H₂S process vessels and piping systems
- No flare capacity allowed under RSR work-practice standards
- Must meet 40 CFR §63.670(o) flare monitoring & minimization requirements
- Hot wash water treatment required before discharge
- Zero safety incidents, zero schedule slippage
Envent’s Integrated Flareless Turnaround Solution
| System | Equipment & Link | Purpose |
|---|---|---|
| H₂S Scrubbing | 2× ASME-rated ESCRUB recirculating scrubbers | >99% H₂S removal from low-pressure vapors |
| High-Capacity Destruction | Multiple EMECS-70 (70 MMBTU/hr) | >99.9% DRE of hydrocarbons & residual H₂S |
| Heat Exchange & Knockout | Custom exchangers + KO drums | Phase separation & cooling |
| Contaminated Wash Water Treatment | Envent Mobile Wastewater System | Oil/TSS/BTEX removal before discharge |
Execution Highlights
- Full integration with refinery hot-wash system
- Real-time LEL, H₂S, temperature, and flow monitoring
- 24/7 Envent operators + direct coordination with refinery turnaround team
- All emissions documented for EPA RSR reporting
Result: Decontamination completed in just 7 days — 2 full weeks faster than historical baseline.
Proven Results – Fastest Flareless Decon Ever
| Benefit | Delivered Outcome |
|---|---|
| Decontamination Time | 7 days vs. 21 – new plant record |
| Flaring Eliminated | 100% flareless – full RSR / MACT 2 compliance |
| Safety | Zero incidents across multiple high-H₂S units |
| Cost & Schedule | Millions saved in reduced downtime |
| Regulatory Assurance | Full documentation for EPA & state audits |
This remains the fastest documented flareless decontamination of a Midwest refinery under the Refinery Sector Rule.
Planning Your Next RSR-Compliant Flareless Turnaround? Get your Free EPA MACT 2 / RSR Compliance Review & Quote today. Call Envent’s Turnaround Division at 888-997-9465 or email [email protected] — we make 3-week jobs finish in 7 days.
