Office o f Air Qua1ib' Planning and Standards Research TriangletP.ark:NC 27711
Aprll 997
EPA-4531R-94..079a
Air
National Emission Standards for Hazardous Hazar dous Air Pollutants Pollutant s for · Source Categories: Categories: Oil ,a ,and nd Natu Na tura rall Gas Production and Natural Gas · Transmission and t o r ~ g e Background Backgro und Informat Info rmation ion ·for Proposed Standards Standards
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TECHNIC
L REPORT
DATA
Please read Instructions on reverse before completing) 1. REPORT NO.
EPA-453/R-94-079a
2.
3. RECIPIENT S ACCESSION NO.
4. TITLE AND SUBTITLE
National Emission Standards for Hazardous Air Pollutants for National Source Categories: Oil and Natural Gas Production Pr oduction and Natural Gas Transmission and Storage - Background Information for Proposed Standards
S. REPORT DATE
Apri11 Apri11997 997
6. PERFORMING ORGANIZATION CODE
7. AUTHOR S)
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
10. PROGRAM ELEMENT NO.
U.S. Environmental Protection Agency Office o f Air Qualit Quality y Planning and Standards Research Triangle Par Park, k, NC 27711
.
11. CONTRACT/GRANT NO.
68D60008
13. TYPE OF REPORT AND PERIOD COVERED
12. SPONSORING AGENCY NAME AND ADDRESS
Director Office of Air Quality Planning and Standards Office o f ir and Radiation U.S. Environmental Protection Agency Research Triangle Par Park, k, NC 277 27711 11
14. SPONSORING AGENCY CODE
EPA/200/04
15. SUPPLEMENTARY NOTES
16. ABSTRACT
This background information document provides the basic information which was :used as background in the development of the two standards 1) National Emission Standards for Hazardous Air Pollutants from· Oil and Natural Gas Production Facilities and 2) National Emission Standards for Hazardous Air Pollutants Pollutan ts from Natural Gas Transmission and St Storage orage Facili Facilities. ties. A description o f the industries, control technologies available, cost of controls, modeling used in the estimation o f national emission emiss ion estimate estimatess and costs are included. KEY WORDS AND DOCUMENT ANALYSIS
17.
a.
DESCRIPTORS
NESHAP, MACT, Oil and Natural Gas Production, Natural Gas Transmission and Storage. 18. DISTRIBUTION STATEMENT
Release Unlimited .
.
EPA Form 2220-1 (Rev. 4-77
b. IDENTIFIERS/OPEN ENDED TERMS
. Air Pollution control
19. SECURITY CLASS Report)
Unclassified
20
SECURITY CLASS Page)
Unclassified PREVIOUS EDITION IS OBSOLETE
c. COSATI Field/Group
21. NO. OF PAGES
124
22. PRICE
EPA-453/R-94-079a
Emissions Standards f o r Hazardous A i r P o l l u t a n t s f o r S o u r c e C a t e g o r i e s O i l a n d N a t u r a l Gas P r o d u c t i o n a n d N a t u r a l Gas T r a n s m i s s i o n a n d S t o r a g e Background Information f o r Proposed S ta nda r ds
National
Emission Standards Division
Environmental P r o t e c t i o n Agency O ffic e of Air and Ra dia tion O f f i c e o f A i r Q u a l i t y P l a n n i n g .and S t a n d a r d s Research Triangle Park North Carolina 27711 A p r i l 1997 U.S.
DISCLAIMER
This r e p o r t has been reviewed by the Emission Standards Division U.S. Environmental O f f i c e o f A i r Q u a l i t y Planning and Standards P r o t e c t i o n Agency a n d a p p r o v e d f o r p u b l i c a t i o n . ~ i n t i o n of trade nam es o r c o m m e r c i a l p r o d u c t s i s n o t i n t e n d e d t o c o n s t i t u t e Copies o f t h i s r e p o r t a r e endorsement o r recommendation f o r u s e . available through the Library Services Office MD-·35), U . S . E n v i r o n m e n t a l P r o t e c t i o n Agency R e se a r c h T r i a n g l ~ P a rk N o rt h o r from t h e N at i o n al Te c hnic a l Inj:ormation C a rol i na 27711 Services
5 2 8 5 P o r t R o y a l R oad
Springfield
V i r g i n i a 22161.
T BLE OF
1.0
2.0
CONTENTS
1 1 1 1 1 1
INTRODUCTION PURPOSE OF DOCUMENT ST TUTORY BASIS OF RULE SCOPE OF THE SOURCE CATEGORIES DOCUMENT CONTENTS DOCKET REFERENCE REFERENCES
1.1 1.2 1.3 1.4 1.5 1.6
1-5
THE OIL ND N TUR L G S PRODUCTION ND N TUR L G S TRANSMISSION ND STOR GE SOURCE CATEGORIES INTRODUCTION 2.1 SOURCE C TEGORY CHARACTERIZATION 2.2
2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.2.6
Production Wells Dehydration Units
Tank B a t t e r i e s N a t u r a l Gas P r o c e s s i n g P l a n t s
Offshore Production Platforms N a t u r a l Gas T r a n s m i s s i o n a n d S t o r a g e
Facilities
2.3
EXTR
2.4
H P Constituents DESCRIPTION OF INDUSTRY COMPONENTS
2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.4.1
2.4.2
2.4.3
CTED
STRE
MS
ND
RECOVERED
PRODUCTS
Crude O i l Condensates N a t u r a l Gas Produced Water Othe r Recovered Hydrocarbons
Production Wells 2.4.1.1 We l l h e a d A s s e m b l y 2.4.1.2 P r o d u c t i o n Methods 2 . 4 . 1 . 2 .·1 Primary Recovery 2.4.1.2.2 Secondary Recovery 2.4.1.2.3
Tertiary
Enhanced)
Dehydration Glycol Dehydration S o l i d Desiccant Dehydration
2.4.2.1 2.4.2.2
Tank B a t t e r i e s
2.4.3.1 2.4.3.2 2.4.3.3
Separators
Dehydration Heater Treaters iv
1 1 1 2 3 3
2 1 2 1
2-2 2-2 2-3 2-3 2-4 2 4 2 2 2 2 2 2 2 2
5 5 5 6 6 7 7 7
2 2 8 8 2 8
2-10
2 10
Recovery
2-10 2-10 2-10 2-11
2 12 2 12 2 14
2-14
2 14
TABLE OF CONTENTS
Continued)
2.4.3.4 2.4.3.5 2.4.3.6 2.4.3.7
2-14 2-15 2-15 2-16 2-16 2-17
e sosnedsi t i o n i n g P r o c e s s e s 2.4.4P . 3r o cC 2.4.4.4 Fractionation 2.4.4.5 P r o d u c t T r a n s f e r and M e t e r i n g
F r e e W a t e r K n o c k o u t s FWKOs) Gun B a r r e l S e p a r a t i o n Tanks S t o r a g e Tanks a n d O t h e r V e s s e l s Custody T r a n s f e r 2.4.4 N a t u r a l Gas P r o c e s s i n g P l a n t s 2.4.4.1 Dehydration 2.4.4.2 S w e e t e n i n g and S u l f u r R e c o v e r y
2.5
2.6 2.7 3.0
2.4.5 2.4.6 2.4.7 2.4.8
Offshore Production Platforms
Compressor S t a t i o n s Underground S t o r a g e Other Processes and Operations
HAP EMISSION POINTS 2.5.1 HAP E m i s s i o n P o i n t s 2.5.1.1 Process Vents 2.5.1.2 Storage Vessels 2.5.1.3 Equipm ent Leaks
BASELINE EMISSION ESTIMATES 2.6.1 Bas i c Methodology 2.6.2 F a c i l i t y Em i s s i o n E s t i m a t e s REFERENCES
CONTROL OPTIONS AND PERFORMANCE OF CONTROLS 3.1
3.2
3.3 3.4
INTRODUCTION PROCESS VENTS
Vapor Recovery 3.2.1 3.2.2 Combustion 3.2.3 Pollution Prevention STORAGE VESSELS EQUIPMENT LEAKS 3.4.1 L e a k D e t e c t i o n and R e p a i r 3.4.1.1 Summary o f C o n t r o l Te c h n i q u e s
Guideline
3.4.1.2
3-1 3-1 3-1 3-1 3 -3 3-3 3 -4 3-5 3-5 3-6
3-6 Summary o f Equipm ent Leak R e q u i re m e n t s Under t h e H a z a r d o u s O r g a n i c 3-6 NESHAP R e g u l a t o r y N e g o t i a t i o n 3 -7 3.4.2 Equipment M o d i f i c a t i o n 3-7 Valves 3.4.2.1 3-7 3.4.2.3 Pumps a n d C o m p r e s s o r s 3 -7 3.4.2.3 Sampling Connections 3-8 3.4.2.4 Pressure R elie eff D e v i c e s 3 -8 3.4.2.5 Open-Ended L i n e s 3-8 3.4.2.6 C o n n e c t o rs Flanges) 3 -8 CONTROL OPTIONS AND HAP EMISSION POINTS 3-10 REFEREN REFERENCES CES
Standards 3.4.1.3
3.5 3 6
Summary o f New S o u rc e P e rfo rm a n c e
2 2 -2 -35 1
T
4.0
MODEL
4.1 4.2
4
5.0
3
OF
PLANTS INTRODUCTION DESCRIPTIONS OF
Continued)
CONTENTS
PLANTS
MODEL
Glycol Dehydration Units 4. 2 .1.1 Glycol Dehydration Units 4.2.1.2 D i s t r i b u t l o n o f Model U n i t Populations 4.2.1.3 N a t u r a l Gas L i f e C y c l e 4.2.2 Condensate Tank B a t t e r i e s 4.2.3 N a t u r a l Gas P r o c e s s i n g P l a n t s 4.2.4 Offshore Production Platforms in S t a t e Waters · 4.2.5 N a t u r a l Gas T r a n s m i s s i o n a n d S t o r a g e
REFERENCES
5.4
•
OF
CONTROL
4-2
•
4-3 4-6 4-7 4-7 4-9
4-.12
4-12
·
ENVIRONMENT L ND ENERGY IMPACTS 5.1 INTRODUCTION AIR POLLUT NT IMPACTS 5.2
5.3
4-1 4-1 4-2 4-2
•
4.2.1
5.2.1 5.2.2
6.0
BLE
5-1 5-1 5-2 5-2 5-6 5-6
OPTIONS
Primary Air Pollutant Impacts Secondary A i r Pollutant Impacts
ND SOLID W STE W TER ENERGY IMPACTS
IMPACTS
5-8
6-1 6-1 6-1 6-1 6-2 6-2
COSTS OF CONTROL OPTIONS INTRODUCTION 6.1 SUMM RY OF COST METHODOLOGY 6.2
Ge ne ra l Approach M o n i t o r i n g Equipment Product Recovery Monitoring, Inspection Recordkeeping, Reporting 6.2.5 Costs o f H P Emission Control Options 6.2.5.1 Process Vents 6.2.5.2 S t o r a g e Tanks 6.2.5.3 Equipment Leaks 6.2.1 6.2.2 6.2.3 6.2.4
6.3
MODEL
6.3.1 6.3.2 6.3.3 6.4 6.5
PL
NT
B
SED
CONTROL
and
6-3 6-3
6-3 6-4
6-4 6-4
COSTS
Glycol Dehydration Units C onde ns a t e Tank B a t t e r i e s N a t u r a l Gas P r o c e s s i n g P l a n t s
6-5 6-5 6-5 6-5
EX MPLE REFERENCES
APPENDIX A. EVOLUTION OF DOCUMENT
6-12 THE
B
CKGROUND
NATIONAL IMPACTS METHODOLOGY APPENDIX B . B.1 INTRODUCTION OVERVIEW OF METHODOLOGY B.2 B.3 MODEL PL NT DEVELOPMENT
vi
INFORMATION
•
·
A
1
B
1
B-1 B-1 B-1
Continued)
TABLE OF CONTENTS
B.4 B.S
B.6 B.7
CONTROL OPTIONS . . MODEL PL NT IMPACTS
B.S.1 B.S.2 B.S.3
Emissions Costs Other Impacts
.
.
.
.
NATIONAL IMPACTS ESTIMA NATIONAL ESTIMATE TE . REFERENCES REFERENC ES . . . . . . . .
APPENDIX C . MONITORING INSPECTION REPORTING COST METHODOLOGY . . C. 1 INTRODUCTION INTRODUCTION . . . . . . C 2
C.2.1
C.2.3 C.2.4 C.2.5
. .
RECORDKEEPING . . . . . . . . . . . . . .
Exam pl e C o s t s o r M a j o r S o u r c e MIRR Number o M a j o r S o u r c e s . . Exam pl e C o s t s o r A r e a S o u r c e MIRR Number o A r e a S o u r c e s Continuous Monitoring
BASELINE NATIONAL EMISSION ESTIMATES FOR ALL IDENTIFIED HAP EMISSION SOURCES I N THE OIL AND NATURAL GAS PRODUCTION 2 24 SOURCE CATEGORY MAJOR AND AREA HAP SOURCES) . . . . .
2 4
BASELINE NATIONAL EMISSION ESTIMATES FOR IDENTIFIED MAJOR HAP EMISSION SOURCES I N THE OIL AND NATURAL GAS PRODUCTION 2 26 SOURCE CATEGORY . . . . . . . . . . . . . . . . . . .
2 5
BASELINE NATIONAL EMISSION ESTIMATES FOR IDENTIFIED AREA HAP EMISSION SOURCES I N THE OIL AND NATURAL GAS PRODUCTION . . . . . . . . . . . . . . . . . . . SOURCE CATEGORY 2 27
2 6
BASELINE NATIONAL EMISSION ESTIMATES FOR ALL IDENTIFIED HAP EMISSION SOURCES IN THE NATURAL GAS TRANSMISSION AND STORAGE 2 28 SOURCE CATEGORY {MAJOR AND AREA HAP SOURCES) . . . . .
2 7
BASELINE NATIONAL EMISSION ESTIMATES FOR IDENTIFIED MAJOR HAP EMISSION SOURCES I N THE NATURAL GAS TRANSMISSION AND . . . . . . . . . . . . . . . 2 STORAGE SOURCE CATEGORY
2 8
IDENTIFIED
HAP BASELINE ESTIMATES FOR EMISSION NATIONAL SOURCES INEMISSION THE NATURAL STORAGE GAS TRANSMISSION AND AREA SOURCE CATEGORY . . . . . . . . . . . . . 2 30
3 1
SUMMARY OF CONTROL OPTIONS PER HAP EMISSION POINT
4 1
MODEL TRIETHYLENE GLYCOL
4 2
MODEL ETHYLENE GLYCOL
4
MODEL CONDENSATE TANK BATTERIES.
3
4 4
29
{TEG)) {TEG
EG)
DEHY DEHYDRA DRATIO TION N UN IT S
DEHYDRATION UNITS
MODEL NATURAL GAS PROCESSING PLANTS
viii
.
3
9
4 4
4 5 4 8 4 10
L IS T OF TABLES
Continued)
4-5
MODEL OFFSHORE PRODUCTION PLATFORMS
5-1
EXAMPLE NATIONAL PRIMARY AIR POLLUTANT IMPACTS FOR MAJOR SOURCES I N THE OIL AND NATURAL GAS P R O D U T I O ~ J SOURCE CATEGORY . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3
S-2
EXAMPLE NATIONAL PRIMARY AIR POLLUTANT I M P A C J ~ S FOR MAJOR SOURCES I N THE NATURAL GAS TRANSMISSION AND STORAGE SOURCE CATEGORY . . . . . . . . . . . . . . . . . . . . . . . . 5 - 4
5-3
EXAMPLE NATIONAL PRIMARY AIR POLLUTANT IMPACTS FOR AREA SOURCE GLYCOL DEHYDRATION UNITS IN THE OIL AliT NATURAL GAS PRODUCTION SOURCE CATEGORY . . . . . . . . . . . . . . . S- 5
5-4
EXAMPLE NATIONAL SECONDARY AIR POLLUTANT I M P l ~ T S DUE TO FLARING FOR MAJOR AND AREA SOURCES IN THE OII s AND NATURAL . . 5-7 GAS PRODUCTION SOURCE CATEGORY . . .
5-5
EXAMPLE NATIONAL ENERGY REQUIREMENTS
6-1
EXAMPLE CONDENSER CAPITAL COSTS FOR MODEL GLYCOL DEHYDRATION
UNI T TEG-C
6-2
.
.
.
.
.
.
.
.
.
.
4-11
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
5-9
.
.
.
.
6-7 EXAMPLE CONDENSER ANNUAL COSTS FOR MODEL GLYCOL DEHYDRATION UNI T TEG-C . . . . . . . . . . . . . . . . . . . . . 6-8
6-3
EXAMPLE CLOSED VENT SYSTEM CAPITAL COSTS FOR MODEL CONDENSATE TANK BATTERY TB- G . . . . . . . . . . .
6-4
EXAMPLE CLOSED VENT SYSTEM ANNUAL COSTS FOR MODEL CONDENSATE . . . . . . . . . . 6-10 TANK BATTERY TB- G
6-5
EXAMPLE MODEL PLANT COST IMPACTS
A-1
EVOLUTION OF
C-1
EXAMPLE ANNUAL MIRR COSTS PER GLYCOL DEHYDRATION UNIT DESIGNATED AS OR LOCATED AT A MAJOR HAP EMISSION SOURCE . . . . . . . . . . . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
6-9
6-11
.
THE BACKGROUND INFORMATION DOCUMENT
.
.
A-2
C-4
C-2
EXAMPLE ANNUAL MIRR COSTS PER STORAGE VESSEL OR CONTAINER LOCATED AT A MAJOR HAP EMISSION SOURCE . . . . . . . . . C-5
C-3
EXAMPLE ANNUAL MIRR COSTS PER LEAK DETECTION AND REPAIR LOCATED AT A MAJOR HAP EMISSION SOURCE . . . . . . . . .
C-4
TOTAL ESTIMATED EXAMPLE MIRR COSTS FOR MAJOR HAP EMISSION SOURCES I N THE OIL AND NATURAL GAS PRODUCTION SOURCE CATEGORY . . . . . . . . . . . . . . . . . . . C-7 ·
x
C-6
LIST OF TABLES
Continued)
C-5
NNU L MIRR COSTS PER GLYCOL DEHYDR EX MPLE S N H P EMISSION SOURCE DESIGNATED RE
C-6
TOT L ESTIMATED MIRR COSTS FOR GLYCOL DEHYDR TION UNITS THE OIL ND N TUR L G S PRODUCTION SOURCE C TEGORY DESIGNATED S RE SOURCES
TION UNIT ·
C-9 IN
C -1 0
LIST O
FIGURES
1 1
O i l a n d N a t u r a l Gas I n d u s t r y
2 1
Flow D i a g r a m o f B a s i c G l y c o l D e h y d r a t i o n U n i t
1 4
2 13
INTRODUCTION
1.0
1.1
PURPOSE OF DOCUMENT National emission standards
NESHAP)
for hazardous a i r pol l ut a nt s
are being developed for the o i l
and n a t u r a l gas
produc tion source c a te gory and the n a t u r a l gas transmission and
s t o r a g e s o u rce c a t e g o r y by t h e U.S.
Agency
EPA) .
Environmental P r o t e c t i o n
T h i s b a c k g r o u n d i n f o r m a t i o n docum ent
BID)
information and a na lyse s supporting
describes technical
d e v e l o p m e n t o f t h e NESHAPs f o r p r o p o s a l i n t h e F e d e r a l R e g i s t e r . 1.2
STATUTORY BASIS OF RULE
· The NESHAPs f o r t h e o i l a n d n a t u r a l g a s a n d n a t u r a l g a s t r a n s m i s s i o n and s t o r a g e source c a t e g o r i e s a r e being developed
u n d e r t h e a u t h o r i t y o f § 1 1 2 d ) of. t h e C l e a n A i r A c t a s am ended i n 1990 CAA) . 1 S e c t i o n 1 1 2 d ) o f t h e CAA d i r e c t s t h e EPA Administrator
air pollutant
to promulgate regulations establishing hazardous
emission standards for each category of.major
HAP)
a n d a r e a s o u r c e s o f HAP t h a t h a s b e e n l i s t e d b y t h e EPA f o r regulation under § 112 c).
The 1 8 8 p o l l u t a n t s
that
r ~
designated
a s HAP a r e l i s t e d i n § 1 1 2 b ) . A major source i s defined as a s t a t i ona r y source o r group of s t a t i ona r y sources
l o c a t e d w i t h i n a contiguous a r e a and u n d e r
common c o n t r o l t h a t e m i t s , considering controls
o r has t h e p o t e n t i a l - t o - e m i t
10 t o n s p e r y e a r
tpy)
PTE)
o r g r e a t e r o f any
o n e HAP o r 2 5 t p y o r g r e a t e r o f a n y c o m b i n a t i o n o f HAP.
n
s o u r c e i s any s t a t i o n a r y source t h a t i s not a major s o u rc e . Special provisions
in §112 n)
4)
f o r . o i l and gas wells and
p i p e l i n e c o m p r e s s o r a n d pump s t a t i o n f a c i l i t i e s
a f f e c t major
source de te rmina tions f o r these f a c i l i t i e s and a l s o i n d i c a t e 1-1
area
u n d e r what c i r c u m s t a n c e s
t h e EPA may r e g u l a t e o i l
and n a t u ra l gas
p r o d u c t i o n w e l ls ls a s a n a r e a s o u r c e c a t e g o r y .
T h e CAA p r e s c r i b e s t h e minimum d e g r e e o f e m i s s i o n r e d u c t i o n t h a t must be r e q u i r e d by s t an d ard s developed under §112 d)
for
S t a n d a r d s 1:or e x i s t i n g
e x i s t i n g a n d new m a j o r s o u r c e s o f HAP.
m a j o r s o u r c e s may n o t b e l e s s s t r i n g e n t t h a n t h e a v e r a g e e m i s s i o n l i m i t a t i o n a c h i e v e d b y t h e b e s t p e r f o r m i n g 12 p e r c e n t o f t h e e x i s t i n g sources f o r which t h e Administrator has ernissions information.
Standards that
are e s t a b l i s h e d f o r major sources
technology
a r e r e f e r r e d t o a s maximum a c h i e v a b l e c o n t r o l standards.
Standards
MACT)
f o r new m a j o r s o u r c e s m u s t r e f l e c t t h e
maximum d e g r e e o f e m i s s i o n r e d u c t i o n a c h i e v e d i n p r a c t i c e b y t h e
best controlled similar source
best
of
the best) .
F o r s o u r c e c a t e g o r i e s w i t h f e w e r t h a n 30 s o u r c e s ,
standards
may n o t b e l e s s s t r i n g e n t t h a n t h e a v e r a g e e m i s s i o n l i m i t a t i o n achieved by the b e s t performing
five
sources.
Standards
for
e x i s t i n g m a j o r s o u r c e s may b e m o r e s t r i n g e n t t h a n t h e s e minimums, b u t must c o n s i d e r co s t, impacts,
n o n - a i r q u a l i t y h e a l t h and environmental
and energy requirements.
T h e CAA g i v e s d i s c r e t i o n t o t h e A d m i n i s t r a t o r when s e t t i n g s t a n d a r d s under §112 d)
f o r a r e a s o u r c e s o f HAP.
a r e a s o u r c e s may e i t h e r b e b a s e d o n MACT,
o r on g e n e r a l l y a v a i l a b l e c o n t r o l 1.3
as
Standards for
for major sources,
technology
GACT) .
SCOPE OF THE SOURCE CATEGORIES The o i l and n a t u r a l g a s p r o d u c t i o n s o u r c e c a t e g o r y i n c l u d e s
t h e p r o c e s s i n g and upgrading o f crude o i l p r i o r to custody t r a n s f e r and n a t u r a l gas p r i o r to
the point
of
entering· the p i p e l i n e
systems a s s o c i a t e d w i t h t h e n a t u r a l gas transmission and s t o r a g e source category.
Included in t h i s
p r o d u c t i o n p la l a t fo fo r m s
source category are offshore
located in State waters.
handle hydrocarbon liquids
Facilities that
from t h e p o i n t o f c u s t o d y t r a n s f e r a r e
in the organic liquids distribution
non-gasoline)
source
category.
For natural gas streams,
the n atu r al gas
transmission and
storage source category includes the pipeline transport,
1-2
storage,
and processing of n a t u r a l gas p r i o r to e n t e r i n g the f i n a l p i p e l i n e o f t h e l o c a l d i s t r i b u t i o n com pany natural gas to the fin a l
that delivers
The s c o p e s o f t h e s e s o u r c e
i l l u s t r a t e d in Figure 1-1.
categories are 1.4
end us e r .
LDC)
CONTENTS
DOCUMENT
T h i s BID i s i n t e n d e d t o p r o v i d e
ba s i c information on t he
1)
process o p e r a t i o n s and H P emission p o i n t s a s s o c i a t e d with o i l
and n a t u r a l gas p r o d u c t i o n and n a t u r a l gas t r a n sm i ssi o n and s t o r a g e and
2)
i n f o r m a t i o n o n c o n t r o l s a n d t h e i m p a c t s of.
c o n t r o l s a v a i l a b l e to reduce H P emissions
emission points.
from i d e n t i f i e d H P
The d e s c r i p t i o n a n d a n a l y s i s o f r e g u l a t o r y
a l t e r n a t i v e s w i l l b e p r e s e n t e d i n o t h e r EPA d o c u m e n t s .
Chapter 2.0 p r e s e n t s an overview o f th e source c a t e g o r i e s . C h a p t e r 3 . 0 i d e n t i f i e s c o n t r o l o p t i o n s f o r HAPs t h a t a r e id e n tif ie d H P emission points in the source
applicable to
categories.
C h a p t e r 4 . 0 p r e s e n t s t h e model p l a n t s d e v e l o p e d f o r
use i n estimating the impacts of applying the c o n t r o l options. Chapter 5.0 addresses t h e environmental and o t h e r impacts r e s u l t i n g from ap p l y i n g c o n t r o l o p t i o n s to
identified H P
emission points in the source categories.
Chapter 6.0 p r e s e n t s
the costs
and c o s t - e f f e c t i v e n e s s of the cont rol opt i ons.
Additional information i s presented in three appendices to
t h i s document.
The a p p e n d i c e s i n c l u d e
o f t h e BID,
Appendix B - National
3)
2)
Appendix C - Monitoring,
1)
Appendix A - Ev o lu tio n
Impacts Methodology,
Inspections
Recordkeeping,
and
and
Rep o rt i n g Cost Methodology. 1.5
DOCKET
REFERENCE
The d o c k e t f o r t h e s e r e g u l a to to r y a c t i o n s i s d e s i g n a t e d a s
D o c k e t No. A - 9 4 - 0 4 . of the
The d o c k e t i s a n o r g a n i z e d a n d c o m p l e t e f i l e
information submitted to o r otherwise
considered by the
EPA i n t h e d e v e l o p m e n t o f t h i s p r o p o s e d r u l e m a k i n g . p r i n ci p al purposes of the docket are
1)
The
to allow in te r e s te d
p a r t i e s a m eans t o i d e n t i f y a n d l o c a t e d o c u m e n t s s o t h a t e f f e c t iv e l y p a r t i c i p a t e i n t h e rulemaking proc·ess and
1-3
2)
they can
to
i }
d Natural
Tank BaHery
Gas
t
Gas Plant
Local
~ ~ = =
d
d
p
N TUR L G S TR NSMISSION ND STOR GE SOURCE C TEGORY
I I I
Distribution Comoan Como an
I
I I I I I
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I I I
HydroCJirbon Uquads
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ustody l _ _ r ~ ~ ~ ~ ~ ~
~ ~
f 1
I
Tank BaHery
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I I I
: I I
HydrOC Irbon Liquids
~
~
OIL
Custody Transfer
II
\
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vi
r \.
LEGEND
d
* ® W
r \,1
1::\:lUn T
Land
Offshore State Waters
Figure 1 1.
O i l a n d N a t u r a l Gas
the record in case of
j u d i c i a l review
Dehydration Dehydrati on Uni Unitt OiiWell GasWell Offshore Production Platform
ndustry
serve as
interagency review materials
(§307(d) (7) A)
(except for
o f t h e CAA).
The d o c k e t i s a v a i l a b l e f o r p u b l i c i n s p e c t i o n a n d c o p y i n g
between 8 : 3 0 a . m .
and 4 : 3 0 p . m . ,
EPA s A i r and R a d i a t i o n Docket, P r o t e c t i o n Agency, ·401 M S t r e e t ,
Monday t h r o u g h F r i d a y , Room M1500,
SW,
U.S.
Washington,
at the
Environmental DC
2046.0.
A
r e a s o n a b l e f e e may b e c h a . r g e d f o r c o p y i n g .
1.6
REFERENCES
1.
U n i t e d S t a t e s C o n g r e s s . C l e a n A i r A c t a s am ended Novem ber U.S. 1 9 9 0 . 42 U . S . C . 7401, e t s e q . W a s h i n g t o n , DC Governm ent P r i n t i n g O f f i c e .
I
----------
ND N TUR L G S
PRODUCTION Trn r- I
efine~
November 1 9 9 0 .
1-5
2.0 N TUR L
2.1
THE
G S
INTRODUCTION
OIL
ND N
TRANSMISSION
TUR ND
L
G S
PRODUCTION
STOR GE SOURCE
ND
CATEGORIES
The o i l a n d n a t u r a l g a s p r o d u c t i o n a n d n a t u r a l g a s transmission and storage source categories
separation,
upgrading,
storage,
primarily hydrocarbons
wells.1
and t r a n s f e r o f e x t r a c t e d st reams
t h a t a r e recovered from p r o d u c t i o n
T h i s c h a p t e r i n c l u d e s a summary c h a r a c t e r i z a t i o n o f
source categories,
these
include the
along with descriptions o f e x t r a c t e d
st reams and recovered products, and t h e b a s i c processes and operations involved with o il
and n a t u r a l gas p r o d u c t i o n and
This chapter also presents
n a t u r a l gas t r a n s m i s s i o n and s t o r a g e . descriptions
i d e n t i f i e d hazardous a i r p o l l u t a n t
of
points associated with the processing, handling of
these materials
and general
storing,
and p r o d u c t s .
The e x t r a c t e d s t r e a m s a n d r e c o v e r e d p r o d u c t s f o r
source categories include crude o i l , produced water.
emission
HAP)
condensate,
t h ~ s
natural gas,
and
The t y p e s o f p r o c e s s e s a n d o p e r a t i o n s i n t h e s e
source categories include production wells,
dehydration units,
natural gas processing plants,
tank batteries,
production platforms,
offshore
and p i p e l i n e t r a n s m i s s i o n f a c i l i t i e s ,
including underground storage operations.
The p r i m a r y H P
emission points associated with these source categories that are
being evaluated include process vents,
storage vessels,
and
equipment l e a k s . E x t r a c t e d st reams and r e c o v e r e d . p r o d u c t s , operations,
and
H
P
processes and
emi ssi on p o i n t s are described below.
This
c h a p t e r a l s o a d d r e s s e s HAPs a s s o c i a t e d w i t h t h e s e s t r e a m s a n d
2-1
products, H
P
2.2
facilities,
and emission p o i n t s ,
and inc lude s b a s e l i n e
emission estimates. SOURCE
C
TEGORY
CHARACTERIZATION
The o i l a n d n a t u r a l g a s p r o d u c t i o n s o u r c e
c a t E ~ g o r y
t h e p r o c e s s i n g and upgrading o f crude o i l p r i o r to custody t r a n s f e r and n a t u r a l
includes
the point of
gas p ri o r to entering the pipeline
systems a s s o c i a t e d w ith t h e n a t u r a l gas t r a n s m i s s i o n and s t o r a g e source category.
This source c a t e g o r y inc lude s ofj:shore
production platforms located in State waters. handle hydrocarbon liquids
Facilities that
a f t e r the point of custody t r a n s f e r
non
are included as part of the organic liquids di s t r i but i on gasoline
source category.
For natural gas streams,
the natural
gas t r a n s m i s s i o n and s t o r a g e source c a te gory inc lude s t h e pipeline transport,
and proc e ssing of n a t u r a l gas p r i o r
storage,
t o e n t e r i n g t h e f i n a l p i p e l i n e o f t h e l o c a l d i s t r i b u t i o n com pany t h at delivers natural gas to the f i na l
LDC)
of these source categories are
end us er.
The s c o p e
i l l u s t r a t e d in F igure 1-1 o f
C h a p t e r 1 . 0 o f t h i s b a c k g r o u n d i n f o r m a t i o n documen1:
BI D) .
Production Wells
2.2.1
I n 1992, t h e r e were an e s t i m a t e d 590,000 c ru d e o i l and condensate production wells in the U.S., with a t o t a l annual production o f over 2.6 b i l l i o n barrels
and approxitnately 3
t r i l l i o n cubic f e e t o f co-produced n a t u r a l ga s. decrease of 3 percent
T h i s w as a
i n b o t h t h e number o f w e l l s and i n c r ude
o i l p r o d u c t i o n a s compared w i t h 1991 l e v e l s . 2 t o t a l num ber o f c r u d e o i l a n d c o n d e n s a t e p r o d u c t i o n
Of t h i s wells,
o v e r 70 p e r c e n t
are classified as stripper
are production wells t ha t are production rate of less
1)
~ ~ e l l s
nearing depletion or
t h a n 10 b a r r e l s
o f o i l p e r day
which 2)
have a
BOPD) .
S t r i p p e r w e l l p r o d u c t i o n a c c o u n t s f o r a p p r o x i m a t e l : t 14 p e r c e n t o f
t o t a l domestic crude o i l production. In addition,
f o r 1992,
t h e r e were an e stima te d 280,000
n a t u ra l gas production wells in the U.S.,
with a
total estimated
a n n u a l p r o d u c t i o n o f o v e r 18 t r i l l i o n c u b i c f e e t . represents
This estimate
a 3 p e r c e n t i n c r e a s e i n t h e num ber o f w e l l s a n d 1
2-2
percent
increase
i n n a t u r a l g a s p r o d u c t i o n a s c o m p a r e d w i t h 1991
levels.3 2.2.2
Dehydration Units Once t h e n a t u r a l g a s h a s b e e n s e p a r a t e d from a n y l i q u i d
materials o r products residual
crude o i l ,
ent rai ned water vapor i s
dehydration.
form h y d r a te s, corrosion or
condensate,
o r produced water ,
removed from t h e n a t u r a l g a s b y
D e h y d r a t i o n i s n e c e s s a r y b e c a u s e w a t e r v a p o r may that are ice-like structures, 2)
t h a t can
1)
cause
there
are
pl ug equipment l i n e s .
The Gas R e s e a r c h I n s t i t u t e
GRI)
estimates that
o v er 44,000 d e h y d r a t i o n u n i t s i n t h e U.S. TEG)
Triethylene glycol
account f o r most o f t h i s e s t i m a t e d
dehydration units
with ethylene glycol
population of dehydration units,
EG),
DEG) , a n d s o l i d d e s i c c a n t d e h y d r a t i o n u n i t s
diethylene glycol
accounting for the remaining port i on.4 TEG d e h y d r a t i o n u n i t s may b e
stand-alone units
1)
that
d e h y d r a t e n a t u r a l g as from an i n d i v i d u a l w e l l o r s e v e r a l w e l l s o r 2)
one of various processing u n i t s a t
natural
gas processing plants,
transmission facilities, Available
c o n d e ~ s
tank bat t er i es,
t e
offshore production platforms,
and
including underground storage s i t e s .
information indicates
that,
on average,
there
i s one
TEG d e h y d r a t i o n u n i t p e r c o n d e n s a t e t a n k b a t t e r y 5 a n d two t o f o u r
TEG,
dehydration units
processing plant,
EG,
o r solid desiccant
per natural
gas
depending upon throughput c a p a c i t y and t y p e o f
processing configuration.6
2.2.3
Tank B a t t e r i e s
A tank b a t t e r y r e f e r s to t h e c o l l e c t i o n of process equipment
used to separate,
treat,
store,
condensate, natural gas,
and t r a n s f e r crude o i l ,
and produced water.
t y p i c a l l y handle crude o i l ,
condensate,
These f a c i l i t i e s
or naturalogas prior to
t r a n s f e r to a r e f i n e r y o r natural gas processing p l a n t .
B a s e d o n a n a n a l y s i s o f two s t u d i e s c o n d u c t e d f o r t h e American Petroleum I n s t i t u t e P r o t e c t i o n Agency
EPA)
API),
t h e U.S.
Environmental
e s t i m a t e s t h a t t h e r e were approxi m at el y
94,000 tank b a t t e r i e s in 1989.7,8,9
Over 8 S · p e r c e n t o f t a n k
2-3
b a t t e r i e s 1 0 o r an es t i m at ed 81,000 f a c i l i t i e s black oil little
if
tank batteries.
any,
are classified as
Black o i l r e f e r s to crude o i l t h a t has
associated gas production.
The r e m a i n d e r ,
o r an estimated 13,000 tank b a t t e r i e s
c l a s s i f i e d as condensate tank b a t t e r i e s . referred to as retrograde gas
Condensate,
Gas P r o c e s s i n g P l a n t s
are
but: become l i q u i d
in e i t h e r the wellbore o r the production process. Natural
also
consists of hydrocarbons t h at
i n a gaseous s t a t e under r e s e r v o i r conditions 2.2.4
are
1)
The m a i n f u n c t i o n s o f n a t u r a l g a s p r o c e s s i n g p l a n t s i n c l u d e conditioning the gas by separation of na t ura l gas liquids
from f i e l d gas and
NGL)
f r a c t i o n a t i o n o f NGL i n t o s e p a r a t e
2)
As o f J a n u a r y 1 ,
components.
1993,
t h e r e w e r e a p p r o x i m a t e l y 700
natural gas processing plants.11
Offshore Production Platforms
2.2.5
Offshore production platforms are used to produce, and s e p a r a t e crude o i l
condensate,
water from production f i e l d s
and produced
natural gas
Processes and
in offshore areas.
operations a t offshore production platforms are
treat
similar to those
l ocat ed a t onshore f a c i l i t i e s except t h a t 1) t h e r e i s g e n e r a l l y little o r no s t o r a g e c a p a c i t y a t o f f s h o r e p l a t f o r m s and 2) t h e s e
f a c i l i t i e s have l i m i t e d a v a i l a b l e space. I n 1993,
t h e U.S.
Management S e r v i c e
Department o f I n t e r i o r • s M in erals
MMS)
estimated that
there w
n ~
approximately
3,800 o f f s h o r e p r o d u c t i o n p l a t f o r m s and o t h e r s t r u c t u r e s i n The m a j o r i t y o f t h e s e o f f s h o r e p r o d u c t i o n
Federal waters.12
p l a t f o r m s and o t h e r s t r u c t u r e s
are located in the Central
and
W e s t e r n G u l f o f M e x i c o , w i t h a l i m i t e d n u mb e r l o c a t e d i n o t h e r Federal waters.
The o f f s h o r e f a c i l i t i e s
waters are under the
l o c a t e d :in F e d e r a l
j u r i s d i c t i o n o f t h e MMS f o r i3.ir e m i s s i o n s
r e g u l a t i o n a n d n o t t h e EPA.13
There a r e an e s t i m a t e d 300
o f f s h o r e p r o d u c t i o n p l a t f o r m s i n S t a t e w a t e r s tha·t a r e u n d er t h e
EPA s
j u r i s d i c t i o n f o r a i r e m i s s i o n s . r e g u l a t i o n 1·4 w i t h t h e
majority of these facilities o f Texas,
Louisiana
located in the State waters offshore
a n d Alabama. 2-4
2.2.6
N a t u r a l Gas T r a n s m i s s i o n a n d S t o r a g e F a c i l i t i e s
The n a t u r a l g a s t r a n s m i s s i o n a n d s t o r a g e s o u r c e c a t e g o r y consists of gathering lines,
compressor s t a t i o n s ,
pressure transmission pipeline.
and high
I t is estimated that there are
approximately 1,900 compressor s t a t i o n s and over 480,000 kilometers
300,000 miles)
pipeline.15,16
of high-pressure transmission
In addition,
t h i s s e c t o r i n c l u d e s o v e r 300
underground st ora ge s i t e s . 1 7 , 1 8 as temporary storage f a c i l i t i e s
These s i t e s a r e t y p i c a l l y u s e d t o m e e t p e a k dem and p e r i o d s ,
p a r t i c u l a r l y d u r i n g c o l d e r weather months; Processes and o p e r a t i o n s t h a t may o c c u r a t f a c i l i t i e s i n t h i s s o u r c e c a t e g o r y include dehydration,
2.3
EXTR CTED
and p i p e l i n e pigging a c t i v i t i e s .
storage,
STRE MS
ND
PRODUCTS
RECOVERED
The e x t r a c t e d s t r e a m s a n d r e c o v e r e d p r o d u c t s f r o m p r o d u c t i o n wells
have d i f f e r i n g c h a r a c t e r i s t i c s t h a t can i n f l u e n c e t h e l e v e l
o f H P emissions g e n e r a t e d by t h e e m i s s i o n p o i n t s
natural
in the o i l and
ga s p r o d u c t i o n and n a t u r a l gap t r a n s m i s s i o n and s t o r a g e
source categories.
Section 2.3)
This section
describes the
primary e x t r a c t e d streams and recovered products a s s o c i a t e d w i t h t h e t wo s o u r c e c a t e g o r i e s .
2.3.1
Crude O i l
E a c h p r o d u c i n g c r u d e o i l a n d n a t u r a l g a s f i e l d h a s i t s own
unique properties,
in that
the composition of
t h e a t t e n d a n t n a t u r a l gas and r e s e r v o i r are different
the crude o i l and
field)
characteristics
from t h a t o f any o t h e r f i e l d . 1 9
Crude o i l can be broadly c l a s s i f i e d as p a r a f f i n i c ,
naphthenic
or asphalt-based),
or intermediate.
Generally,
p a r a f f i n i c crudes are used in the manufacture of lube o i l s
k ero s en e and have
and
high concentration of str a ig h t chain
h y d r o c a r b o n s a n d a r e r e l a t i v e l y low i n s u l f u r com pounds. Naphthenic crudes a r e g e n e r a l l y used i n t h e manufacture o f
h i g h c o n c e n t r a t i o n o f o l e f i n and
g a s o l i n e s and a s p h a l t and have
a r o m a t i c h y d r o c a r b o n s a n d may c o n t a i n s u l f u r com pounds.
high concentration of
Intermediate crudes are
those that are not
c l a s s i f i e d i n e i t h e r o f t h e above c a t e g o r i e s . 2 0
2-5
Another c l a s s i f i c a t i o n measure o f crude o i l
h y d r o c a r b o n s i s b y API g r a v i t y .
API g r a v i t y i s
a nd o t h e r a
weight per u n i t
volume measure o f a hydrocarbon l i q u i d a s determined b y a method re c o mme n d e d b y t h e A P I . 2 1
A
h e a v y o r p a r a f f i n i c cirude o i l
t y p i c a l l y o n e w i t h a n API g r a v i t y o f 2 0 ° o r l e s s , o r naphthenic crude o i l ,
atmospheric conditions,
while
a
is light
which t y p i c a l l y flows f r e e l y a t u s u a l l y h a s a n API g r a v i t y · i n t h e r a n g e
o f t h e h i g h 3 0 s t o t h e low 4 0 s . 2 2
Crude o i l s recovered in the production phase o f the
p e t r o l e u m i n d u s t r y may b e r e f e r r e d t o a s l i v e c r u d e s . Live c r u d e s c o n t a i n e n t r a i n e d o r d i s s o l v e d g a s e s w h i c h may b e r e l e a s e d
during
processing o r storage,
whereas dead cru d es ar e those t h a t
have gone t h ro u g h v a r i o u s s e p a r a t i o n and st o r a g e phases and c o n t a i n little
any,
if
entrained or dissolved gases.23
Condensates
2.3.2
Condensates
by s t a n d a r d i n d u s t r y d e f i n i t i o n )
hydrocarbons t h a t are in conditions,
a
are
gaseous s t a t e under r e s e r v o i r
b u t become l i q u i d i n e i t h e r t h e w e l l b o r e o r t h e
production process.24
Condensates,
including volatile
oils,
t y p i c a l l y h a v e a n API g r a v i t y i n t h e 4 0 o r g r e a t e r d e g r e e range.25 I n a d d i t i o n , c o n d e n s a t e s may i n c l u d e h y d r o c a r b o n l i q u i d s r e c o v e r e d from ga se ous s tream s
from v a r i o u s o i l and
n a t u r a l ga s product i on o r n a t u r a l gas t rans m i s s i on and s t o r a g e processes and operations.
2.3.3
Natural Natural
G as
gas i s
a
mixture o f hydrocarbons and varyi ng
q u a n t i t i e s o f non-hydrocarbons t hat e x ists
in a gaseous phase o r
in s o l u t i o n with crude o i l o r ot her hydrocarbon l i q u i d s i n N a t u r a l g a s may c o n t a i n
nat ur al underground re s e rvoi rs .
c onta m ina nts, such a s hydrogen s u l f i d e C02), m ercap tan s, and e n t r a i n e d s o l i d s . Natural gas H2 S a r e
2S),
carbon dioxide
s t r e a m s t h a t c o n t a i n t h r e s h o l d c o n c e n t r a t io io n s o f
c l a s s i f i e d as sour gases and_those with tl1reshold
c o n c e n t r a t i o n s o f co 2 a r e c l a s s i f i e d a s a c i d g a s e s . The p r o c e s s e s b y w h i c h t h e s e two c o n t a m i n a n t s a r e removed f r o m t h e
2-6
natural gas stream i s c a l l e d sweetening.
The m o s t common
s w e e t e n i n g m e t h o d i s am ine t r e a t i n g . S o u r g a s c o n t a i n s a H2 S c o n c e n t r a t i o n o f g r e a t e r t h a n 0 . 2 5 g r a i n p e r 100 s t a n d a r d c u b i c f e e t , a l o n g w i t h t h e p r e s e n c e o f
C o n c e n t r a t i o n s o f H2S a n d C02, a l o n g w i t h o r g a n i c s u l f u r 2. O v e r 75 p e r c e n t o f com pounds, v a r y w i d e l y among s o u r g a s e s . t o t a l onshore n a t u r a l gas p r o d u c t i o n and n e a r l y a l l o f o f f s h o r e natural gas production i s c l a s s i f i e d as sweet.26 N a t u r a l g a s may b e c l a s s i f i e d a s w e t g a s o r d r y g a s .
Wet
gas i s unprocessed o r p a r t i a l l y processed-natural gas produced from a r e s e r v o i r t h a t c o n t a i n s condensable hydr oc a r bons. 27 Dry gas i s
1)
n a t u r a l g a s whose w a t e r c o n t e n t h a s b e e n r e d u c e d
through dehydration o r
natural gas t h a t contains
2)
o r no
littl
recoverable l i q u i d hydrocarbons.28
Produced Water
2.3.4
Produced w a t e r i s t h e w at er reco v ered from a p r o d u c t i o n , Produced water i s s e p a r a t e d from t h e e x t r a c t e d
well.29
hydrocarbon streams i n t h e v a r i o u s p r o d u c t i o n p r o c e sse s and operations described in this
2.3.5
chapter.
Other Recovered Hydrocarbons V a r i o u s h y d r o c a r b o n s may b e r e c o v e r e d t h r o u g h t h e p r o c e s s i n g
o f t h e e x t r a c t e d hydrocarbon streams.
m i x e d NGL, n a t u r a l g a s o l i n e ,
petroleum gas
These hydrocarbons
propane,
butane,
include
and l i q u e f i e d
Definitions f or these hydrocarbons can be
LPG) .
found i n Reference 27. 2.3.6
H
P
Constituents
The p r i m a r y i d e n t i f i e d
constituents associated with o i l
H P
and nat ur al gas production f a c i l i t i e s e t h y l benzene, BTEX),
and mixed x y l en es
and n-hexane.30
include benzene,
toluene,
c o l l e c t iv iv e l y r e f e r r e d t o a s
In addition,
r e f e r e n c e h a s b e e n made t o
the presence of 2,2,4-trimethylpentane
iso-octane),
g e n e r a l r e f e r e n c e to the presence of formaldehyde,
along with
acetaldehyde,
and e t h y l e n e g l y c o l i n c e r t a i n p r o c e s s and emission streams a s s o c i a t e d with o i l and n a t u r a l gas production.31
cs 2 ) ,
carbon d isu lfid e
and c a r bonyl s u l f i d e
COS)
Also,
BTEX,
may b e p r e s e n t
2-7
in the
tail
g a s s t r e a m s a s s o c i a t e d w i t h amine t r e a · t i n g u n i t s and (SRUs) . 3 2 , 3 3
su lfu r recovery units
Table 2-1
lists
H
P
c o n s t i t u e n t s and c o n c e n t r a t i o n s f o r
e x t r a c t e d s t r e a m s a n d r e c o v e r e d p r o d u c t s f o r t h e two s o u r c e categories. of the
listed
The p r i m a r y s o u r c e s o f d a t a u s e d i n t h e d e v e l o p m e n t H
P
c o n c e n t r a t i o n e s t i m a t e s were
(1)
a summary o f
t h e i n d u s t r y r e s p o n s e s t o t h e EPA s A i r Emissipn Survey Questionnaires,34
(2)
a data base,
p r o v i d e d b y GRI, o f n a t u r a l
g a s a n a l y s e s from v a r i o u s s o u r c e c a t e g o r y o p e r a t i o n s , 3 5 and
(3)
a
d a t a ba se pr ovide d by API.36 2.4 DESCRIPTION OF INDUSTRY COMPONENTS 2.4.1
P r oduc tion Wells
A well,
a s d e f i n e d b y API a n d u s e d i n t h i s BID,
is
h o l e - i n - t h e - g r o u n d d r i l l e d from t h e p o i n t o f e n t r y a t
depth of the hole
surface to
the total
crude o i l ,
condensate,
e a r t h s surface.37
the
the e a r t h s
for the recovery of
and n a t u r a l g as from fo rm atio n s below t h e
The r e c o v e r e d p r o d u c t s a n d e x t r a c t e d s t r e a m s
f r o m p r o d u c t io io n w e l l s a r e n a t u r a l l y o r a r t i f i c i a l l y b r o u g h t t o the
s u r f a c e where t h e hydrocarbon p r o d u c t s
(crude o i l ,
condensate, and n a t u r a l gas) a r e s e p a r a t e d from produced w a t e r and o t h e r i m p u r i t i e s , such as sand. Depending on t h e p r o d u c t i o n and t h e recovery r a t e s f o r crude
c h a r a c te r is tic s of the well,
oil,
condensate, and nat ural gas,
a w e l l may o r may n o t b e p u t
into production. 2.4.1.1
Wellhead Assembly.
s u r f a c e equipment used to co n tr o l maintain production pressure.
the casinghead,
gauges.38
The w e l l h e a d a s s e m b l y i s the production
f:rom a w e l l a n d
The w e l l h e a d a s s e m l , l y c o n s i s t s o f
Christmas t r e e ,
t ubi ng head,
the
and p r e s s u r e
These components a r e d e s c r i b e d below.
The c a s i n g h e a d i s t h e c o l l e c t i o n o f f i t t i n g s
and hold the casing in place. for the tubing.
that
support
The t u b i n g h e a d p r o v i d e s s u p p o r t
The t u b i n g h e a d a l s o s e a l s o f f p r e s s u r e b e t w e e n
the casing and tubing,
and pr ovide s c onne c tions f o r c o n t r o l l i n g
the flow of produced fluids
from t h e w e l l .
The C h r i s t m a s t r e e
2-8
TABLE 2 - 1 . AVERAGE HAP COMPOSITION OF EXTRACTED STREAMS AND RECOVERED PRODUCTS HAP c o m p o s i t i o n o f e x t r a c t e d s t r e a m o r r e c o v e r e d p r o d u c t
Natural gas
(ppmv)b,c
HAP
Crude o i l ( W eight )
Benzene
0.25
Condensate ( W eight )
0.99
Produced water ppmw) a 10
Direct
from
Wet
Otherd
88
5
wells
104
is
Toluene
0.48
3.50
6
56
44
6
Ethyl
0.12
0.48
6
6
4
l
0.55
4.90
13
34
20
n-Hexane
1.50
2.80
4
420
410
66
BTEXe
1.40
9.90
35
200
160
13
BTEX a n d n-Hexane
2.90
13.00
39
620
570
79
benzene Mixed xylenes
a -
Pa rt s p e r mi l l i o n weight.
b -
Based on a r e vie w o f t h e d a t a c o l l e c t e d i n t h e EPA s A i r Em issions S u r v e y Q u e s t i o n n a i r e s a n d o t h e r r e f e r e n c e s , t h e HAP c o n t e n t o f t h e primary f r a c t i ona t e d products recovered i n na t ur a l gas p r o ces s in g i n c l u d i n g p r o p a n e , b u t a n e , a n d l i q u i f i e d p e t r o l e u m ga s} operations been i dent i fi ed as i nsi gni fi cant .
c -
P a r t s p e r m i l l i o n volume.
d -
Natural
e -
Benzene,
Note:
T o t a l BTEX a n d BTEX a n d n - h e x a n e v a l u e s h a v e b e e n r o u n d e d .
has
gas p r o ces s ed and s t o r e d a t n a t u r a l gas t r a n s m i s s i o n f a c i l i t i e s and underground s to r ag e f a c i l i t i e s . toluene,
e t h y l benzene,
and mixed x y len es .
2-9
th e c o l l e c t i o n o f valves and f i t t i n g s
mounted on t h e c a s i n g h e a d
and t u b i n g he a d t h a t c o n t r o l s t h e flow o f p r o d u c t from t h e w e l l .
P r o d u c t i o n Me th o d s
2.4.1.2
2.4.1.2.1
P r i m a r y Recovery.
Primary recover}r o f
h y d ro carb o n streams and produced w at er from o c c u r s due t o
reservoir.
the natural pressures
A f t e r some p e r i o d ,
a
production well
that exist in a production
the natural
p r
s s u r
~ s
within a
r e s e r v o i r w i l l u s u a l l y d e c l i n e t o a p o i n t where o t h e r seco n d ary o r enhanced r e c o v e r y methods must be employed t o m a i n t a i n a
w e l l s production. Secondary Recovery. 2.4.1.2.2 reservoir is not sufficient
within a
r e c o v e r y methods o r a r t i f i c i a l
pumping u n i t s ,
gas
for production,
o r s u b s u r f a c e p u mp in g )
lift
s u c k e r r o d pumping,
enhanced,
Enhanced)
Tertiary
are applied to
Waterflooding,
pressure
a n d g a s l i f t a r e common m e t h o d s
o f secondary recovery and a r t i f i c i a l
2.4.1.2.3
secondary
such as s u r f a c e
lift methods
increase the y i e l d of recovered product.
maintenance,
natural pressure
When t h e
lift.39 Recovery.
Tertiary,
or
supplement :natural
r e c o v e r y methods a r e used to
r e s e r v o i r f o r c e s when p r i m a r y a n d s e c o n d a r y r e c o v e r y o f t h e
i s no l o n g e r economical.
product
These methods i n c l u d e chemical
and t h e r m a l methods and gas i n j e c t i o n .
Dehydration40,41
2.4.2
As s t a t e d a b o v e ,
once the n a t u r a l gas has been s e p a r a t e d
from l i q u i d m a t e r i a l s and p r o d u c t s ,
residual
entrained water
v a p o r i s removed from t h e n a t u r a l g as s t r e a m by d e h y d r a t i o n i n 1)
order to
meet c o n t r a c t s a l e s
formation,
hydrate
or
specifications,
2)
limit
improve f u e l h e a t i n g v a l u e s .
3)
T he f o r m a t i o n o f h y d r a t e s w i t h i n a n a t u r a l g a s s t r e a m i s
p r o mo ted by n a t u r a l gas a t o r below l i qui d water present. temperature,
dew p o i n t ,
with
Temperatures below the hydrate formation
high velocity or agitation
high operating pressures,
through p i p i n g , o r equipment,
and p res en ce o f
hydrate,
its w a t e r
w at er tha n hydrocarbons)
presence o f
H s o r
a
small seed c r ys t a l of
w h i c h are· mo re s o l u b l e i n
also influence
the
formation of hydrates
2-10
in natural gas pipelines.42
In addition
hydrate
formation i s
m or e o f t e n e n c o u n t e r e d d u r i n g e x t e n d e d p e r i o d s o f c o l d w e a t h e r .
D e h y d r a t i o n o f n a t u r a l g a s may o c c u r s e v e r a l t i m e s p r i o r t o delivery to o
~ u r
3)
the final
include
1)
consumer.
the production well
the natural gas processing plant
underground s torage f a c i l i t i e s stations 7)
L o c a t i o n s w h e r e d e h y d r a t i o n may
6)
5)
site 4)
2)
the tank battery
removal from
trans mis s ion compressor
i n d u s t r i a l and u t i l i t y customer meter s t a t i o n s
and
a t o r a f t e r the transmission to d i st ri b u t i o n custody t r a n s f e r
which i s t h e p o i n t where n a t u r a l gas t y p i c a l l y changes
stations
ownership from
company
t r a n s m i s s i o n com pany t o a d i s t r i b u t i o n
a
fo r d e l i v e ry to the
This f i n a l point o f custody
consumer.
final
typically referred to as the c i t y gate.
transfer is
Prior to the dehydration process in selected cases
f a c i l i t i e s may p r e v e n t h y d r a t e f o r m a t i o n b y i n j e c t i n g e t h y l e n e g ly co l o r methanol i n t o the n a t u ra l gas stream,
heaters
to heat
2.4.2.1
o r using l i n e
the process stream.
The m o s t w i d e l y u s e d n a t u r a l
Glycol Dehydration.
gas dehydration process i s the glycol dehydration process. Glycol d e h y d r a t i o n i s an a b s o r p t i o n p r o c e s s i n which absorbent
a
liquid
a
d i r e c t l y contacts the natural gas stream,
glycol
w h i c h i s c i r c u l a t e d c o u n t e r c u r r e n t t o t h e g l y c o l fl o w ,
absorbs water vapor in
c o n t a c t tower o r a b s o r p t i o n column.
which has absorbed w a t e r va por from t h e
The r i c h g l y c o l natural gas stream
a
and
l e a v e s t h e bottom o f t h e a b s o r p t i o n column
and i s d i r e c t e d e i t h e r t o
1)
a
gas condensate glycol s e p a r a t o r
and then a r e b o i l e r o r
GCG s e p a r a t o r o r f l a s h t a n k )
2)
directly
t o a r e b o i l e r where t h e w at er i s b o i l e d o f f o f t h e r i c h g l y c o l .
I f the system includes a flash tank, rich glycol is typically either
system,
2)
used for fuel
or
1) 3)
t h e ga s s e p a r a t e d from t h e recycled to
used as
a
h y d r o c a r b o n s t h a t c o n d e n s e c a n b e rem oved a s
the header
stripping gas. a
Any
separate stream
from t h e g l y c o l . The r e g e n e r a t e d o r l e a n g l y c o l i n t o the abs orption tower.
is recirculated
b y pump,
The v a p o r g e n e r a t e d i n t h e r e b o i l e r
2-11
i s directed to the reboiler stack. glycol dehydration unit
2.4.2.2
A flow diagram o f a b as ic
i s p r e s e n t e d i n F i g u r e 2-JL.
Solid Desiccant Dehydration.
dehydration uses adsorption to
rem ove w a t e r .
Solid desiccant
Adsorption r e f e r s
t o t h e s u r f a c e phenom ena i n w h i c h a g a s o r l i q u i d i s a t t r a c t e d t o the surface of a
solid.
S o l i d d e s i c c a n t dehydrat:Lon i s g e n e r a l 1 y
u s e d w hen l a r g e d e w - p o i n t d e p r e s s i o n s a r e r e q u i r e d o r when a n extremely dry gas
i s desired.43
Common s o l i d d e s i c c a n t s u s e d f o r n a t u r a l g a s d e h y d r a t i o n
include s i l i c a - ba s e beads activated alumina silica-gel alumina-gel b a l l s activated bauxite and molecular s i e v e s . 4 4 Desiccant
l i f e ra nge s from one t o f i v e y e a r s b e f o r e t h e d e s i c c a n t
must b e r e p l a c e d . Solid desiccant dehydration requires
tw o o r m ore a d s o r p t i o n
towers f or continuous operation because the s ol i d desiccant within a reached.
t o w e r m u s t b e r e g e n e r a t e d when d e s i c c a n t s a t u r a t i o n i s when o n e t o w e r i s u n d e r g o i n g r e g e n e r a t i o n
Therefore
the other is
switched i n t o operation.
R e g e n e r a t i o n may b e
accomplished by lowering the p r e s s u r e
o r i n c r e a s i n g t h e temperature of the tower o r both. regeneration gas i s
Hot
t y p i c a l l y c i r c u l a t e d through the towers
then cooled through a heat exchanger t h a t
and
condenses w a t e r removed
from t h e tower packing. The condensed w a t e r p ro c e e d s t h ro u g h a s c r u b b e r t o r e c o v e r
hydrocarbons. with the
The r e m a i n i n g g a s s t r e a m i s r e c y c l e d a n d m i x e d
incoming wet n a t u r a l gas stream.45
Tank B a t t e r i e s 4 6 4 7
2.4.3
A t a n k b a t t e r y r e f e r s to the c o l l e c t i o n of proc e ss equipment used to
gas
separate
treat
and produced water.
and s t o r e crude o i l
condensate
natural
from p r o d u c t i o n
The e x t r a c t e d p r o d u c t s
tank b a t t e r y through the production header
wells enter the
which
may c o l l e c t p r o d u c t f r o m many w e l l s .
P r o c e s s e q u i p m e n t a t a t a n k b a t t e r y may i n c l u d e s e p a r a t o r s dehydrators
heater treaters
f r ee water knockouts
FWKOs),
2-12
------------,
~
I I I
c
HOT RICH
0
I I
N T A
I
HOT lEAN
c T
RY
Gf\8 T
8AlES
REBOILEA
VENT
M I S S I O N S
gun
COOL RICH Gl. ICOL
1\. I
FLASH TANK
w
I
I I
L WET
Gf\8 IN
~ C O N O E N S I \ l E
-----------I ACCUMULATOR
Glycol
KEY
0
Figure 2 1.
~
G
a
s
Heal Exchanger
Flow Diagram o f Basic Glycol Dehydration Unit
barrel separation tanks
custody t ra n sfe r
(LACT)
storage tanks
units.
and l e a s e automatic
Each p i e c e o f e q u i p m e n t i s
addressed below.
2.4.3.1
Separators.
The s e p a r a t i o n o f h y d r o c a r b o n p r o d u c t s
from b a s i c sediment and w a t e r production separators.
sediment
(BS W)
i s accomplished by
Basic sediment r e f e r s to the ga s
sand
and o t h e r i m p u r i t i e s mixed w i t h t h e o i l .
Depending on p r o d u c t c h a r a c t e r i s t i c s
production separators
may b e t w o - p h a s e o r t h r e e - p h a s e s e p a r a t o r s . separate the product stream contains
Two-phas e s e p a r a t o r s
i n t o l i q u i d and g as st reams.
crude o i l and produced water.
The l i q u i d
Three-phase
s e p a r a t o r s s e p a r a t e t h e pr oduc t i n t o crude o i l o r condensate
n a t u r a l g a s and o t h e r g as st reams Multi-well
and produced wat er.
f a c i l i t i e s may a l s o i n c l u d e t e s t s e p a r a t o r s
which operate i n p a r a l l e l to product i on s e p a r a t o r s the production rate
composition
quality
to determine
and p r o d u c t i o n
charact eri st i cs of individua l wells. 2.4.3.2
Dehydration.
The d e h y d r a t i o n p r o c e s s e s t h a t may
o c c u r a t t a n k b a t t e r i e s a r e t h e same a s t h o s e d i s c u s s e d i n d e t a i l i n S e c t i o n 2 . 4 . 2 o f t h i s BID. 2.4.3.3
Heater Treaters.
Heater t r e a t e r s are pressure
v e s s e l s u s e d t o b r e a k t i g h t e m u l s i o n s a n d remove w a t e r a n d g a s e s
from crude o i l .
A h e a t e r t r e a t e r i s a combination o f a h e a t e r
f r e e water knockout
and an o i l and g as s e p a r a t o r
The i n l e t e m u l s i o n e n t e r s t h e h e a t e r t r e a t e r a t t h e t o p
a
which al l ows t h e r e l e a s e o f gas e n t r a i n e d i n the l i q u i d to t r a v e l t o t h e v a p o r s p a c e a t t h e t o p o f t h e column.
The e m u l s i o n f l o w s
t o t h e b o t t o m o f t h e v e s s e l t h r o u g h a downcomer p i p e . a p p l i e d t o t h e emulsion a t the bottom o f the v e s s e l .
Heat i s
Some
f a c i l i t i e s a d d a c h e m i c a l d e m u l s i f i e r t o t h e procE: SS s t r e a m t o assist
in the breaking of emulsions.
2.4.3.4
F r e e Water Knockouts
(FWKOs).
I f l a r g e amounts o f
water are produced with the crude o i l a d d i t i o n a l s e p a r a t i o n may b e a c c o m p l i s h e d b y u s e o f a FWKO. Removing t h e f r e e w a t e r e a r l y
2-14
i n t h e s e p a r a t i o n process reduces t h e heating requirements and design throughput WKOs
requirements of the subsequent f i e l d equipment.
may i n c o r p o r a t e t w o - p h a s e
crude o i l / w a t e r / g a s ) applied to the
separation.
liquid/gas}
or three-phase
H e a t o r c h e m i c a l s may b e
incoming stream p r i o r t o t h e
to a s s i s t
WKO
in the
separation process. Gun B a r r e l S e p a r a t i o n T a n k s .
2.4.3.5 tanks,
o r wash t a n k s ,
Gun b a r r e l s e p a r a t i o n
are cylindrical vessels operating a t
atmospheric pressure t h a t separate the production stream emulsion i n t o crude and produced water.
Gun b a r r e l s may b e u s e d f o r
u n s t a b l e e mulsions t h a t w i l l n a t u r a l l y s e p a r a t e due t o g r a v i t y ,
adequate s e t t l i n g time i s provided.
i
St o rag e Tanks and Oth er V e s s e l s .
2.4.3.6 the
separation processes is
or other storage vessels)
Crude o i l from
typically directed to storage tanks
temporary storage.
for
The l a r g e
m a j o r i t y o f s t o r a g e tanks used a t crude o i l production f a c i l i t i e s are fixed-roof
storage
tanks.
the storage tanks used a t
In addition,
t a n k b a t t e r i e s r a n g e i n s i z e f r o m 200
to 1,000 b a rre l capacities.48 tanks
o v e r 95 p e r c e n t o f
Vapor l o s s e s from t h e s t o r a g e
are e i t h e r vented to the atmosphere o r captured by
vapor
recovery device. St orage t anks ar e a l s o used f o r temporary s t o r a g e o f produced water and slop o i l . disposed of
Produced w at er i s t y p i c a l l y where w at er i s i n j e c t e d b a c k i n t o
in injection wells,
the producing
formation f o r enhanced recovery appl i cat i ons ,
t r a n s f e r r e d o f f - s i t e f o r treatment and d i s p o s a l , l i m i t ed cases)
or
in v ery
used for b en ef i ci al purposes.
S l o p o i l i s o i l t h a t does n o t meet q u a l i t y s p e c i f i c a t i o n s .
This o i l i s e i t h e r process o r
2)
1)
r e c y c l e d i n t o t h e s e p a r a t i o n and t r e a t m e n t
s o l d t o an o i l
reclamation f a c i l i t y
for treatment
and r e c o v e r y o f r e s i d u a l crude o i l p r o d u c t . T a n k b a t t e r i e s may h a v e v a r i o u s t y p e s o f s u r f a c e p i t s a n d sumps) l o c a t e d o n - s i t e . im poundm ents These p i t s an d sum ps a r e t y p i c a l l y c l a s s i f i e d a s e m e r g e n c y o r p r o d u c t i o n . Most
2-15
p i t s a n d sum ps a r e c l a s s i f i e d a s e m e r g e n c y p i t s / s u m p s a n d a r e only used during process upset
However ,
production p i t s
separation processes a t
situations.49
a n d sumps may a l s o b e u s e d f o r
tank bat t eri es.
M ost o f p r o d u c t i o n
s u r f a c e i m poundm ent s a r e l o c a t e d i n s e l e c t e d h e a v y c r u d e o i l production areas of
2.4.3.7
California.SO
Custody Tra nsfe r.
LACT u n i t
i s usually used to
m e t e r t h e am ount o f c r u d e o i l o r c o n d e n s a t e p r o d u c · e d a t battery.
LACT u n i t
tank
a
i s an automated device t h a t decreases th e
need fo r the presence of personnel to handle the t r a n s f e r of
crude o i l o r condensate.
The u n i t r e c o r d s t h e a m o u n t o f p r o d u c t
Automatic sampling can be
t r a n s f e r r e d and product temperature. i n c o r p o r a t e d i n t o t h e LACT u n i t
to determine product
q u a l i t y . 51, 52,53 Transfer of e x t r a c t e d streams o r recovered products i s
u s u a l l y accomplished i n p i p e l i n e s . involve
loading crude o i l
tank trucks
railcars
l o a d i n g o r submerged
2.4.4
H ow ever,
condensate,
t r a n s f e r may a l s o
o r produced water into
and barges through the use o f s p l a s h ill
techniques.
N a t u r a l Gas P r o c e s s i n g P l a n t s Natural
g as produc e d from t h e w el l i s s e p a r a t e d from
hydrocarbon products
crude o i l and condensate)
b a t t e r i e s and the n t r a n s f e r r e d processing plant.
via pipeline
and
BS W
a t tank
to a natural
gas
Typical p ro ces s es and o p e r a t i o n s a t n a t u r a l
ga s p r o c e s s i n g p l a n t s a r e de sc ribe d below.
Detailed descriptions
o f p r o c e s s e s and o p e r a t i o n s a t n a t u r a l gas proc e ssing p l a n t s a r e presented in References
As s t a t e d a b o v e , processing plant
41 a n d 4 2 .
the primary functions of a natural
1)
include
c onditioning the n a t u r a l gas by
s e p a r a t i o n o f NGL f r o m t h e f i e l d g a s a n d
i n t o s e p a r a t e components.
propane,
butanes
gas
NGL
2)
f r a c t i o n a t i o n o f NGL
may b e f r a c t i o n a t e d i n t o e t h a n e
and n a t u r a l g a s o l i n e produc ts.
These p r o d u c t s
are then transported p r i m a r i l y i n p:j.peline systems, r e f i n e r i e s and o th er p o in ts of t r a n s f e r o r s a le .
to
2-16
2.4.4.1
Dehydration.
Generally
na tura l gas i s dehydrated
p r i o r to the other processes a t a natural gas processing p l a n t . The n a t u r a l g a s d e h y d r a t i o n p r o c e s s t h a t may o c c u r a t a n a t u r a l
g a s p r o c e s s i n g p l a n t i s t h e same a s n a t u r a l g a s d e h y d r a t i o n p r o c e s s e s t h a t may o c c u r a t o t h e r l o c a t i o n s . processes are discussed in Section 2.4.2
2.4.4.2
o f t h i s BID.
Sweetening and S u l f u r Recovery P r o c e s s e s .
sour o r acid gases.
As
some p r o d u c t i o n f i e l d s p r o d u c e
st at ed ear l i er in Section 2.3.3
Sour gas i s n a t u r a l gas t h a t c o n t a i n s
t h r e s h o l d c o n c e n t r a t i o n s o f H2 s . corrosive
Dehydration
Hydrogen s u l f i d e i s a t o x i c
s u b s t a n c e w h i c h i s u s u a l l y removed b y s w e e t e n i n g
o p e r a t i o n s t h a t occur immediately a f t e r t h e n a t u r a l gas has been s e p a r a t e d and dehydrat ed.
Acid gases are those t h a t co n tain
t h r e s h o l d c o n c e n t r a t i o n s o f co2 The m o s t w i d e l y u s e d m e t h o d o f s w e e t e n i n g t h e s e g a s e s
amine t r e a t i n g .
is
Amine t r e a t i n g u s e s a n a m i n e / w a t e r s o l u t i o n t o
a n d co 2 f r o m t h e n a t u r a l g a s s t r e a m . The r i c h a m i n e s o l u t i o n i s t h e n r e g e n e r a t e d b y s t e a m s t r i p p i n g t o remove
absorb the
H2 s
the sour gas.
The l e a n amine i s r e c i r c u l a t e d t o t h e a b s o r b e r .
The s y s t e m i s s i m i l a r i n d e s i g n t o a g l y c o l d e h y d r a t i o n u n i t .
N a t u r a l g a s f i e l d s may p r o d u c e enough beneficial to recover sulfur.
H2 s
so t h a t
t
is
S u l f u r r e c o v e r y may b e u s e d a t
n a t u r a l gas p r o c e s s i n g f a c i l i t i e s and o f f s h o r e p r o d u c t i o n platforms. A f t e r t h e H2 s i s removed from t h e n a t u r a l g a s s t r e a m
in the sweetening process
the gas
i s introduced i nt o a S U f or
At th e s u l f u r recovery p l a n t
further processing. t h e H2 s i s
converted to elemental sul fur.
the s u l f u r in
The r e c o v e r e d s u l f u r
Any co2 contained in the gas stream w i l l pass through the S U unaltered
can be e i t h e r so l d commercially o r disposed o f properly. and v e n t e d w i t h t h e t a i l g as.
C o n c e n t r a t e d co2 s t r e a m s from t h e
s w e e t e n i n g p r o c e s s may b e v e n t e d o r f l a r e d t o d e s t r o y a n y re sidua l hydrocarbons. 2.4.4.3 Conditioning Processes. Na tural gas processing p l a n t s may b e c h a r a c t e r i z e d b y t h e t y p e o f c o n d i t i o n i n g p r o c e s s
used a t the p l a n t .
The c o n d i t i o n i n g p r o c e s s e s m o s t o f t e n u s e d
2-17
f or separation in natural gas processing plants
cryogenic-expansion
refrigeration
cryogenic-Joule-Thomson
absorption
include
refrigerated absorption adsorption
and compression.
E a c h c o n d i t i o n i n g p r o c e s s r e c o v e r s t h e NGLs f o r f u r t h e r M e t h a n e a n d o t h e r g a s e s a r e rem oved f r o m t h e
treatment.
stream p r i o r to
2.4.4.4
N L
the fractionation process.
Fraction ation.
A f t e r s e p a r a t i n g t h e N L from t h e
t h e N L a re sep arated i n t o i n d i v i d u a l components
field gas
desired products
or
by a process called fractionation.
Fractionation uses the difference in v o l a t i l i t y of the individual
components t o s e p a r a t e t h e mi x t u re. Depending on t h e composition o f th e
N L
mixtu.re
depropanizer
f r a c t i o n a t i o n s y s t e m may i n c l u d e a d e e t h a n i z e r in series.
debutanizer
the
and
T h e s e u n i t s a r e named a c c o r d i n g t o t h e
d e s i r e d p r o d u c t com ing o f f t h e t o p o f e a c h f r a c t i o n a t i o n u n i t .
Primary products include ethane
propane
butane
LPG
m i x e d NGL
and n a t u r a l gasoline. 2.4.4.5
Pro d u ct T r a n s f e r and Metering.
The p r i m a r y m e t h o d
u s e d f o r t r a n s f e r o f g a s e o u s a n d l i q u i d p r o d u c t s f:rom n a t u r a l g a s processing p l a n t s i s by pi pel i nes .
However
loading of condensate o r natural gasoline
railcars
t r a n s f e r may i n c l u d e
into tank trucks
and barges through the use of sp la sh loading o r ill
techniques. submerged The m o s t common d e v i c e u s e d f o r m e a s u r i n g n a 1 : u r a l g a s i s t h e
o r i f i c e meter.
A p r o p e r l y i n s t a l l e d and maintainE:d o r i f i c e me te r
w i l l have an o v e r a l l accuracy o f p l u s o r minus 2 p e r c e n t . 5 4
Offshore Production Platforms55 56
2.4.5
The p r o c e s s e s a n d e q u i p m e n t a t o f f s h o r e p r o d u c t i o n p l a t f o r m s t h a t are used to produce gas
and s e p a r a t e crude o i l
treat
natural
and produced water in offshore areas are b a s i c a l l y i d e n t i c a l
to those a t f a c i l i t i e s operations
except th a t these
located onshore
take place within a
confined space.57
Offshore
p r o d u c t i o n p l a tf tf o r m s a r e c o n s t r u c t e d . j u s t l a r g e e n o u g h t o accom m odate t h e n e c e s s a r y e q u i p m e n t a n d s u p p o r t f a c i l i t i e s
s a f e l y accomplish t h e i r t asks.
to
T h i s i s done b e c a u s e t h e o f f s h o r e 2-18
p r o d u c t i o n p l a t f o r m s a r e s u b s t a n t i a l l y more e x p e n s i v e t o
construct than onshore f a c i l i t i e s .
Most o f f s h o r e p r o d u c t i o n
p l a t f o r m s have m u l t i p l e deck a r e a s s t a c k e d on t o p o f each o t h e r
t o i n c r e a s e t h e am ount o f wor k s p a c e . processes and operations
Detailed descriptions
of
a t offshore production platforms are
p r e s e n t e d i n R e f e r e n c e s 47 a n d 5 5 .
O f f s h o r e p r o d u c t i o n p l a t f o r m s may b e b o t t o m s u p p o r t e d , floating
o r semi-submersible structures.
They c a n b e c l a s s i f i e d
as ei t her gathering platforms or central production platforms. Gathering p l a t f o r m s r e c e i v e p r o d u c t i o n from w e l l s p r o d u c t i o n i n t o l i q u i d and gas streams,
streams by p i p e l i n e t o
a
and then t r a n s f e r t h e s e
At c e n t r a l production p latf o r ms
t h e l i q u i d and gas streams undergo t r e a t m e n t storage.
the
c e n t r a l p r o d u c t i o n p l a t f o r m o r an
onshore production f a c i l i t y . sometimes)
separate
separation
and
Gas t r e a t m e n t may i n c l u d e d e h y d r a t i o n p r i o r
to t r a n s f e r to an onshore f a c i l i t y .
Produced w at er t h a t i s reco v ered from t h e p r o d u c t i o n s t r e a m s may b e d i s p o s e d o f o v e r b o a r d
i
it
meets o r i s below c e r t a i n
c r i t e r i a o f t o t a l o i l and grease concentrations. may a l s o b e r e i n j e c t e d i n t o
a
In addition
pr oduc ing zone w i t h i n
a
it
reservoir
f o r p r e s s u r e maintenance and enhanced recovery o p e r a t i o n s . 2.4.6
Compressor S t a t i o n s Compressor s t a t i o n s a r e f a c i l i t i e s t h a t s u p p l y e ne r gy,
t h e form o f i n c r e a s e d p r e s s u r e
in
t o move n a t u r a l g a s i n
t r a n s m i s s i o n p i p e l i n e s o r i n t o u n d e rg ro u n d s t o r a g e . 5 8
Typically
compressor s t a t i o n s a r e l o c a t e d a t i n t e r v a l s along
a
transmission
pi pel i ne t o maintain desired pressure for natural gas tra n sp o rt.
These s t a t i o n s w i l l use e i t h e r l a r g e i n t e r n a l combustion
IC)
e n g i n e s o r g a s t u r b i n e s a s p r i m e m overs t o p r o v i d e t h e n e c e s s a r y horsepower to mai nt ai n system pre ssure . 2.4.7
Underground Storage
Undergrou?d s t o r a g e f a c i l i t i e s
are subsurface f a c i l i t i e s
t h
~
u t i l i z e d for storing natural gas ha s been t r a n s f e r r e d from its o r i g i n a l l o c a t i o n f o r t h e p r i m a r y p u rp o s e o f l o a d b a l a n c i n g . Load b a l a n c i n g i s t h e p r o c e s s o f e q u a l i z i n g t h e r e c e i p t a n d 2-19
P r o c e s s e s a n d o p e r a t i o n s t h a t may b e
delivery of natural gas.59
located a t underground storage f a c i l i t i e s limited to,
include,
but
are not
compression and dehydration.
Other Processes and Operations
2.4.8
o p e r a t i o n t h a t may o c c u r t h r o u g h o u t t h e s e s o u r c e
n
categories i s pipeline pigging.
inserting a pig, that
disks
Pipeline pigging involves
w h i c h i s a c y l i n d r i c a l d e v i c e made w i t h p l i a b l e
the i n t e r n a l diameter of a pipeline ,
it
p i p e l i n e f o r the purpose of cleaning the l i n e .
moves t h e p i g t h r o u g h t h e l i n e . liquids,
such as condensate,
p i p e l i n e flow,
thus,
into a
Pipeline pressure
Water vapor and hydrocarbon
may c o n d e n s e a n d r e s t r i c t o r b l o c k
leading to the necessity of pigging.
As t h e p i g a p p r o a c h e s t h e r e c e i v i n g s t a t i o n o f a p i p e l i n e , collected fluids
including hydrocarbon liquids)
sump o r o t h e r s t o r a g e v e s s e l t h a t slug catcher.60
are drained to a
is usually referred to as a
P i g g i n g o f p i p e l i n e s i s a common p r a c t i c e f o r
p i p e l i n e s from o f f s h o r e p r o d u c t i o n p l a t f o r m s be c a use o f t h e low
seabed t em p erat u res en co u n tered by t h e o f f s h o r e p i p e l i n e s , causes
which
Pigging of pi pel i nes a t onshore
l i q u i d s t o condense.
f a c i l i t i e s may b e u t i l i z e d d u r i n g s e a s o n s w i t h lm• rer a m b i e n t temperatures,
2.5
2.5.1
H
such a s f a l l and w i n t e r .
P
EMISSION POINTS
H
P
Emission P oi nt s
The t h r e e i d e n t i f i e d
associated with o i l
H
P
e m i s s i o n p o i n t s t h a t may b e
and na t ura l gas production and na t ura l gas
t r a n sm i ssi o n and storage
vessels,
and
(3)
include
(1)
equipment l e a k s .
process vents,
process unit
Process Vents.
storage
Table 2-2 p r e s e n t s t h e b a s i c
f a c i l i t i e s d e s c r i b e d above along w i t h t h e i d e n t i f i e d points. 2.5.1.1
(2)
A process vent
H
P
emission
i s a v e n t from a
t h a t di s charges a gas stream i n t o th e atmosphere
during operation.
Gas s t r e a m s f r o m p r o c e s s v e n t s may b e
d i s c h a r g e d d i r e c t l y t o t h e atmosphere o r dischargred t h r o u g h a product recovery device.
2-20
T
BLE 2 2 . B SIC F CILITY TYPES ND SSOCI TED H P EMISSION POINTS
Facility type
H
P
emission points
Stand alone glycol dehydration uni t
Glycol dehydration u n i t r e b o i l e r v e n t and f l a s h t a n k v e n t
Condensate tan k b a t t e r y
Glycol de hydr a tion u n i t r e b o i l e r v e n t and f l a s h t a n k v e n t
Storage
Natural gas proces s ing p la n t
v ~ s s
l s
Glycol d eh y d r atio n u n i t r e b o i l e r v en t and f l a s h t a n k v e n t
Storage vessels Equipment l e a k s
Offshore production platform in State waters
Glycol d eh y d r atio n u n i t r e b o i l e r ve nt and f la s h tan k v en t
gas t r a n s m i s s i o n and underground storage
Glycol d eh y d r atio n u n i t r e b o i l e r v en t and f l a s h tan k v e n t
Natural
2 21
The g l y c o l d e h y d r a t i o n u n i t r e b o i l e r v e n t i s a s o u r c e o f H P g l y c o l no1: o n l y a b s o r b s
In the glycol contact tower,
emissions.
water but a l s o absorbs sel ect ed hydrocarbons,
n-hexane.
i n c l
BTEX a n d
~ d i n g
The w a t e r a n d h y d r o c a r b o n s a r e b o i l e d - o : E f i n t h e unless a control device is present,
r e b o i l e r and,
· ~ e n t e d
to the
atmosphere. The
GCG
separator or flash tank i s also a potential H P
process vent emission point.
glycol dehydration unit
H
P
includes a
emissions w i l l occur
the
i
f l a s h tank in the system
des i gn and any s e p a r a t e d ga se s a r e vent ed to t h e atmosphere,
instead of being e i t h e r
used for fuel,
or
recycl ed to t h e h ead er system,
1)
2)
used as a s t r i p p i n g gas.
3)
A process vent associated with nat ural gas sweetening operations is
the acid gas vent.
T h i s s t r e a m may c o n t a i n h i g h
c o n c e n t r a t i o n s o f hydrogen s u l f i d e and carbon d i o x i d e .
addition,
BTEX,
cs 2 ,
high concentrations
and
COS
may b e p r e s e n t i n t h i s
o f H2 s a r e p r e s e n t ,
In
stream.
If
a sulfur recovery plant
i s i n s t a l l e d to produce elemental sulfur.
Otherwise,
the
stream
is flared. R e c e n t r e s e a r c h c o n d u c t e d b y GRI i n d i c a t e s t h e p o t e n t i a l f o r significant H P emissions
sweetening processes.61,62
p r i m a r i l y BTEX
The EPA i s
from arrtine-based g as
conducting followup to
t h i s r esear ch in an e f f o r t to determine emission l e v e l s of t h i s p o t e n t i a l H P process vent emission point. 2.5.1.2
Storage
Crude o i l and co n d en s ate a r e
Vessels.
typically stored in fixed-roof
r e s u l t o f working,
breathing,
storage
Emissions are a
tanks.
and f l a s h l o s s e s .
Working l o s s e s o c c u r due t o t h e emptying and f i l l i n g o f storage tanks.
Breathing losses
are the release of gas
associated with daily temperature fluctuations
and ot he r
equilibrium effects. F l a s h l o s s e s o c c u r when a
liquid with entrained gases is h i g h e ~
pressure to a vessel with t r a n s f e r r e d from a v e s s e l w i t h lower pressure, thus allowing entrained gases o r a por t i on of the
liquid to vaporize o r flash.
In the o i l
and na t ura l gas
2-22
production source category,
f l a s h i n g o c c u r s when l i v e c r u d e o i l s
o r c o n d e n s a t e s flow i n t o a s t o r a g e t a n k from a p r o c e s s i n g v e s s e l
a higher pressure.
operated ~
pressure drop,
Typically,
the larger the
t h e more f l a s h i n g e m i s s i o n s w i l l o c c u r i n t h e
storage stage.63
T e m p e r a t u r e o f t h e l i q u i d may a l s o i n f l u e n c e
t h e amount o f f l a s h em i s s i ons .
In addition,
liquids,
HAP e m i s s i o n s may o c c u r when h y d r o c a r b o n
c o l l e c t e d by sl u g catchers64
cleaning) vessels.65
operations,
during p i p e l i n e pigging
are transferred to storage tanks o r other
HAP e m i s s i o n s may o c c u r w i t h t h e f l a s h i n g o f t h e s e
h y d ro carb o n l i q u i d s due t o a r e d u c t i o n i n p r e s s u r e a s c o l l e c t e d fluids
a r e d r a i n e d t o a sump o r o t h e r s t o r a g e v e s s e l .
2.5.1.3 fugitive Equipment Leaks. Equipment l e a k s a r e e m i s s i o n s e m a n a t i n g f r o m v a l v e s , pump s e a l s ,
emissions) flanges,
lines,
compressor s e a l s ,
pressure
open-ended
r e l i e f valves,
and o t h e r p r o c e s s and o p e r a t i o n components.
The amount o f
HAP e m i s s i o n s f r o m e q u i p m e n t l e a k s i s p r o p o r t i o n a l
t y p e a n d number o f e q u i p m e n t c o m p o n e n t s a n d o f HAP c o n s t i t u e n t s
2)
to
the
1)
the
concentration
o f th e stream i n th e components.
Since tank b a t t e r i e s are usual l y small f a c i l i t i e s as compared w i t h o t h e r i n d u s t r i a l o p e r a t i o n s ,
they are generally
c h a r a c t e r i z e d b y a s m a l l e r number o f c o m p o n e n t s .
Natural gas
pr.ocessing p l a n t s , e s p e c i a l l y t hos e us i ng r e f r i g e r a t e d a b s o r p t i o n , t e n d t o h a v e a l a r g e number o f c o m p o n e n t s .
BASELINE EMISSION ESTIMATES
2.6
B a sic Methodology
2.6.1
Based on a v a i l a b l e information, HAP, v o l a t i l e o r g a n i c compound
VOC),
e s t i m a t e s were d ev elo p ed f o r
and methane66 emissions
f r o m i d e n t i f i e d HAP e m i s s i o n p o i n t s i n t h e o i l a n d n a t u r a l g a s p r o d u ctio n and n a t u r a l gas tr an smissio n and st ora ge
categories.
source
Estimates of emissions before the implementation o f
a nat i onal emissions standard for hazardous a i r p o l l u t a n t s are referred to as baseline.emission estimates.
NESHAP)
T a b l e 2 - 3 p r e s e n t s b a s e l i n e HAP, VOC
and methane n a t i o n a l
emission e s t i m a t e s f o r each f a c i l i t y t y p e i n t h e o i l and n a t u r a l 2-23
BASELINE NATIONAL EMISSION S T I ~ ~ T S ALL IDENTIFIED HAP EMISSION SOURCES I N THE
TABLE 2 - 3 .
FOR
OIL AND NATURAL GAS PRODUCTION SOURCE CATH:GORY MAJOR AND AREA HAP SOURCES) B a s e l i n e e m i ssi o n e s t i m a t e s
Megagrams p e r y e a r
Facility type
voc
Methane
55,000
130,000
16,000
6,300
20,000
11,000
N a t u r a l gas processing plantsb
3,200
10,000
7,000
Total
65,000
160,000
34,000
H
G ly co l dehydration
P
unitsa
Storage tanks a t c o n d e n sa t e t a n k batteries
a -
I n c l u d e s e s t i m a t e d em is s io n s from a l l g l y c o l d e h y d r a t i o n u n i t s i n c l u d i n g s t a n d a l o n e u n i t s and t h o s e l o c a t e d a t co n d en s ate t a n k batteries n a t u r a l gas p r o c e s s i n g p l a n t s , and o f f s h o r e p r o d u c t i o n p l a t f o r m s i n S t a t e w a te r s . Does n o t i n c l u d e t h o s e uni1:s i n t h e n a t u r a l g a s t r a n s m i s s i o n and s t o r a g e s o u r ce c a t e g o r y .
b -
Only i n c l u d e s em is s io n s from s t o r a g e t a n k s and equipment l e a k s .
~
Numbers may v a r y due t o r o u n d in g .
2-24
gas production source category.
These
e s t i m
are based on
t ~ s
m odel p l a n t p a r a m e t e r s t h a t h a v e b e e n d e v e l o p e d f o r t h e v a r i o u s types of
f a c i l i t i e s in t h i s source category
t h i s BID).
see Chapter 4.0 o f
Ta ble s 2-4 and 2-5 p r e s e n t a breakdown o f t h e s e
e m i s s i o n s b a s e d o n p o t e n t i a l m a j o r v e r s u s a r e a s o u r c e HAP emission designations f o r the o i l and
n
t u r
~
gas production
source category. T a b l e 2 - 6 p r e s e n t s b a s e l i n e HAP
VOC
and methane n a t i o n a l
emission estimates for each basic f a c i l i t y type in the n a t u r a l gas t r a n s m i s s i o n and s t o r a g e source c a t e g o r y .
These e s t i m a t e s
a r e b a s e d o n m odel TEG d e h y d r a t i o n u n i t p a r a m e t e r s
t h a t have been
developed for various f a c i l i t y types in t h i s source category
see
C ha pte r 4 . 0 o f t h i s BID). Tables 2-7 and 2-8 p r e s e n t a breakdown o f t h e s e emi s s i o n s ba se d on p o t e n t i a l major v e r s u s a r e a s o u r c e HAP e m i s s i o n d e s i g n a t i o n s
for the nat ur al gas tr a n sm issio n and
storage source category.
T h e s e e s t i m a t e s w e r e d e v e l o p e d u s i n g a m odel p l a n t a p p r o a c h . In t h i s
approach,
e m i s s i o n s w e r e f i r s t e s t i m a t e d f o r m odel p l a n t s
s e l e c t e d t o charac.terize th e range o f f a c i l i t i e s categories.
in the source
N a t i o n a l e s t i m a t e s were developed by e x t r a p o l a t i n g
f r o m m odel p l a n t e s t i m a t e s .
The m e t h o d o l o g y f o r d e v e l o p i n g
nationwide emission estimates i s further described in Chapter 5.0 a n d A p p e n d i x B o f t h i s BID. F a c i l i t y Emission Estimates 2.6.2
For glycol dehydration u n i t s g e n e r a t e d f r o m GRI-GLYCalc
emissions are based on r e s u l t s
Version 3.0) .67
This is a personal
c o m p u t e r - b a s e d s c r e e n i n g p r o g r a m d e v e l o p e d b y GRI f o r e v a l u a t i n g HAP a n d VOC e m i s s i o n s f r o m TEG a n d EG d e h y d r a t i o n u n i t s . VOC e m i s s i o n s f r o m p r o d u c t i o n s t o r a g e t a n k s h a v e b e e n e v a l u a t e d p r e v i o u sl y and t h e se f a c t o r s have been a p p l i e d t o t h e estimated populations of these tanks
in these source categories
a n d u s e d a s t h e b a s i s f o r e s t i m a t i n g HAP a n d m e t h a n e e m i s s i o n s from s t o r a g e t a n k s . 6 8
Fugitive emissions
from components a r e
2-25
T
BASELINE NATIONAL EMISSION ESTIMATES FOR IDENTIFIED M JOR H P EMISSION SOURCES IN THE OIL ND N TUR L G S PRODUCTION SOURCE C TEGORY
BLE
2-4.
B a s e l i n e e m i ssi o n e s t i m a t e s Facility type
G ly co l dehydration
Megagrams p e r y e a r
H P
voc
Methane
36,000
85,000
6,200
1,800
5,900
3,200
770
2,500
1,800
39,000
94,000
11,000
unitsa
Storage tanks a t c o n d e n sa t e t a n k batteries
N a t u r a l g as processing plantsb
11
Total
a -
I n c l u d e s e s t i m a t e d em is s io n s from a l l g l y c o l dehydrat.ion u n i t s i n c l u d i n g s t a n d a l o n e u n i t s and t h o s e l o c a t e d a t co n d en s ate t a n k batteries n a t u r a l g as p r o c e s s i n g p l a n t s , and o f f s h o r e p r o d u c t i o n p l a t f o r m s i n S t a t e w a t e r s d e s i g n a t e d a s o r l o c a t e d at: major s o u r c e s o f H P emissions. Does n o t i n c l u d e t h o s e u n i t s i n t h e n a t u r a l gas t r a n s m i s s i o n and s t o r a g e so u r c e c a t e g o r y .
b -
Only i n c l u d e s em is s io n s from s t o r a g e t a n k s and equipment l e a k s .
~
Numbers may v a r y due t o r o u n d in g .
2-26
T
BLE
2-5.
BASELINE NATIONAL EMISSION ESTIMATES
IDENTIFIED RE H P EMISSION SOURCES I N THE OIL ND N TUR L G S PRODUCTION SOURCE C TEGORY
F a c i l i t y type
Baseline emission estimates
Megagrams p e r y e a r )
voc
M e t ha ne
19,000
43,000
9,600
4,500
14,0.00
8,100
2,400
7,800
5,000
26,000
65,000
23,000
H
Glycol
FOR
P
dehydration unitsa
Storage tanks a t condensate tank
batteries Natural gas processing plantsb
Total
a
I n c l u d e s e s t i m a t e d e m i s s i o n s from a l l g l y c o l d e h y d r a t i o n u n i t s i n c l u d i n g s t a n d a l o n e u n i t s and th o s e l o c a t e d a t co n d en s at e tan k
n a tu ra l gas processing p la n ts and o f f sh o r e p r o d u c t i o n platforms in S ta te waters t hat a r e not designated as p o t e n t i a l major sources of H P emissions. Does n o t i n c l u d e t h o s e u n i t s i n t h e n a t u r a l gas t r a n s m i s s i o n and s to r ag e s o u rce categ o r y .
batteries
b
O n l y i n c l u d e s e m i s s i o n s from s t o r a g e t a n k s a n d e q u i p m e n t l e a k s .
N o t e : Numbers may v a r y d u e t o r o u n d i n g .
2-27
TABLE 2 - 6 . BASELINE NATIONAL EMISSION S T I ~ ~ T S FOR ALL IDENTIFIED HAP EMISSION SOURCES IN THE NATURAL GAS TRANSMISSION AND STORAGE SOURCE CATEGORY MAJOR AND AREA HAP SOURCES) B a s e l i n e em i ssi o n e s t i m a t e s
Megagr.ams p e r y ear
acility type
G l yc ol d e h y d ra tio n
HAP
voc
Methane
320
4,200
170
unitsa -
a -
~
I n c l u d e s e s t i m a t e d e m i s s i ons from a l l g l y c o l d eh y d r at i o n u n i t s i n t h e n a t u r a l ga s t r a n s m i s s i o n and s t o r a g e so u r ce c a te g o ry .
Numbers may v a r y due t o r oundi ng.
2-28
T
BLE
2-7.
BASELINE N TION L
EMISSION ESTIMATES
IDENTIFIED M JOR H P EMISSION SOURCES I N THE
N TUR L
G S
TRANSMISSION
ND
STOR
GE
aseline emission estimates
SOURCE
FOR
C TEGORY
Megagrams p e r y e a r )
F a c i l i t y type
Glycol
H P
voc
M e t ha ne
120
1,500
59
dehydration unitsa
a
Includes es tim ated emissions from a l l g l y c o l de hydr a tion u n i t s i n t h e n a t u r a l gas t r a n s m i s s i o n and st o r a g e s o u rce categ o r y d es ig n ated as o r
l o c a t e d a t major sources of H P emissions.
~
Numbers may v a r y d u e t o r o u n d i n g .
2-29
TABLE 2 8 .
BASELINE NATIONAL EMISSION ESTIMATES FOR IDENTIFIED AREA HAP EMISSION SOURCES IN THE NATURAL GAS TRANSMISSION AND STORAGE SOURCE CATEGORY
Facility type
Ba s e lin e e m i s s i on e s t i m a t e s H
Gl yc ol dehydration
P
200
Megagrc:Lms p e r y ear
voc
Methane
2,700
110
unitsa
a
~
I n c l u d e s e s t i m a t e d e m i s s i ons from a l l g l y c o l d e h y d r t i • ~ n u n i t s i n t h e n a t u r a l ga s t r a n s m i s s i o n and s t o r a g e s our c e c a t e g o r y t h a t a r e n o t d e s i g n a t e d a s p o t e n t i a l major s o u r ces o f HAP em i s s i o n s .
Numbers may v a r y due t o r oundi ng.
2-30
based on
1)
s t a n d a r d equipment l e a k e m i s s i o n f a c t o r s 6 9
and
2)
e s t i m a t e d com ponent c o u n t d i s t r i b u t i o n s . HAP
emissions associated with pipeline pigging operations
were n o t e s t i m a t e d due t o t h e l a c k o f d a t a on
procedure occurs in t h i s industry and
1)
how o f t e n t h i s
the quantity of
2)
hydrocarbons t r a n s f e r r e d from s l u g r e c e i v e r s t o f i x e d - r o o f storage tanks or other storage vessels.
p i p e l i n e p i g g i n g w i l l o c c u r more o f t e n o p er atio n s and
2)
As s t a t e d e a r l i e r 1)
a t offshore production·
d u r i n g t h e w i n t e r months.
2.7
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2.
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L e t t e r a n d a t t a c h m e n t f r o m E v a n s , J . M . , Gas R e s e a r c h I n s t i t u t e , t o V i c o n o v i c , G . , EC/R I n c o r p o r a t e d . A p r i l 1 9 , 1 9 9 5 . N a t u r a l g a s BTEX c o n t e n t .
36.
American Petroleum I n s t i t u t e . Trieth y len e Glycol Dehydrator O p e r a t i n g P a r a m e t e r s f o r E s t i m a t i n g BTEX E m i s s i o n s P r e p u b l i c a t i o n D r a f t ) . W a s h i n g t o n , DC. F e b r u a r y 1 9 9 6 . 2-33
37.
Reference 24.
38.
Reference 24.
39.
American Petroleum I n s t i t u t e . I n t r o d u c t i o n to Oil P r o d u c t i o n F o u r t h E d i t i o n . W a s h i n g t o n , DC. 1983 R e a f f i r m e d , May 1988) .
40.
H o w e l l T r a i n i n g Company. G l y c o l D e h y d r a t i o n . A m e r i c a n P e t r o l e u m I n s t i t u t e PROFIT S e r i e s . D e v e l o p e d a n d d i s t r i b u t e d f o r A m e r i c a n P e t r o l e u m I n s t i t u t e . H o u s t o n , TX. 1 9 8 7 .
41.
Gas P r o c e s s o r s S u p p l i e r s A s s o c i a t i o n i n c o o p e r a t i o n w i t h t h e Gas P r o c e s s o r s A s s o c i a t i o n . E n g i n e e r i n g D a t a :Book .- Vol um es I and I I R e v i s e d T e n t h E d i t i o n . T u l s a , OK 1 9 9 4 .
42.
Ik o k u , C.U. N a t u r a l Gas P r o d u c t i o n E n g i n e e r i n g . New Y o r k , NY, J o h n W i l e y Sons. 1984.
43.
Reference 32.
44.
Reference 32.
45.
The U n i v e r s i t y o f Texas a t A u s t i n , Petro leu m Exte nsion S e r v i c e . F i e l d H a n d l i n g o f N a t u r a l Gas Third Ed i t i o n . A u s t i n , TX. 1 9 7 7 .
46.
Arnold,
47.
B r a d l e y , H.R. P e t r o l e u m E n g i n e e r i n g Handbook. R i c h a r d s o n , TX, S o c i e t y o f P e t r o l e u m E n g i n e e r s . 1 9 8 7 .
K. a n d M Volume 1 - D e s i g n Volume 2 - D e s i g n H o u s t o n , TX, G u l f
Gas
Stewart. Surface Production Operations. o f O il- H a ndling Systems and F a c i l i t i e s and o f Gas-Handling Systems and F a c i l i t i e s . P u b l i s h i n g Company. 1 9 8 6 .
48.
U . S . E n v i r o n m e n t a l P r o t e c t i o n Agency. Ev a l u a t . i o n o f Em is s io n s from Onshore D r i l l i n g , Producing, and S t o r i n g o f O i l a n d Gas (EPA 4 5 0 / 3 - 7 8 - 0 4 7 ) . R e s e a r c h T r i a n g l e P a r k , NC. August 1978.
49.
American Petroleum I n s t i t u t e . Environmental Guidance Docum ent. O n s h o r e S o l i d Waste Management i n B x p l o r a t i o n a n d P r o d u c t i o n O p e r a t i o n s . W a s h i n g t o n , DC. J a n u a r y 1 5 , 1 9 8 9 .
50.
C a l i f o r n i a A ir Resources Boa rd/Sta tiona ry Source D ivis ion. T e c h n i c a l S u p p o r t Document f o r S u g g e s t e d Cont:rol M e a s u r e f o r t h e C o n t r o l o f O r g a n i c Compound E m i s s i o n s frQm Sumps u s e d i n O i l P r o d u c t i o n O p e r a t i o n s . S a c r a m e n t o , CA. A u g u s t 1 1 , 1 9 8 8 .
51.
Reference 24.
52.
Reference 47. 2-34
53.
Standards o f Performance f o r V o l a t i l e Organic Liquid Storage Vessels including Petroleum Liquid Storage Vessels) f o r Which C o n s t r u c t i o n , R e c o n s t r u c t i o n , o r M o d i f i c a t i o n Commenced a f t e r J u l y 2 3 , 1 9 8 4 . Code o f F e d e r a l R e g u l a t i o n s , T i t l e 4 0 , P a r t 6 0 , S u b p a r t Kb. A p r i l 8 , 1 9 8 7 . U . S . Governm ent P r i n t i n g O f f i c e , Wa s h i n g t o n , DC.
54.
Reference 41.
55.
Petroleum Extension Service. A Primer o f Offshore Operations Second E d i t i o n . A u s t i n , TX. 1985.
56.
Reference 47.
57.
Reference 39.
58.
Reference 27.
59.
Reference 27.
60.
Reference 21.
61.
Gas R e s e a r c h I n s t i t u t e . TEX a n d O t h e r VOC E m i s s i o n s f r o m a N a t u r a l Gas Amine T r e a t e r G R I - 9 6 / 0 0 4 8 ) . C h i c a g o , I L . F e br ua r y 1996.
62.
Gas R e s e a r c h I n s t i t u t e . Amine- Based Gas S w e e t e n i n g a n d S u l f u r Recovery Pro ces s Chemistry and Waste S t re a m S u rv e y G R I - 9 5 / 0 1 8 7 ) . C h i c a g o , IL. Decem ber 1 9 9 5 .
63.
C a n a d i a n P e t r o l e u m A s s o c i a t i o n . A D e t a i l e d I n v e n t o r y o f CH 4 a n d VOC E m i s s i o n s From U p s t r e a m O i l a n d Gas O p e r a t i o n s i n A l b e r t a . Volumes I t h r o u g h I I I . A l b e r t a , C a n a d a . March 1992
The U n i v e r s i t y o f T e x a s a t A u s t i n ,
64.
Reference 21.
65.
Memorandum f rom A k i n , T . a n d G. V i c o n o v i c , EC/R I n c o r p o r a t e d , t o S m i t h , M . E . , EPA/CPB. May 2 7 , 1 9 9 4 . Summary o f m e e t i n g w i t h U . S . E n e r t e k , I n c o r p o r a t e d o n May 2 3 r d ,
1994.
Departmen t o f Energy. Emissions o f Greenhouse Gases i n t h e U n i t e d S t a t e s 1985 1990 DOE/EIA-0573). W a s h i n g t o n , DC. S e p t e m b e r 1 9 9 3 .
66.
U.S.
67.
Gas R e s e a r c h I n s t i t u t e . T e c h n i c a l R e f e r e n c e Manual f o r GRI GLYCalc™: A P r o g r a m f o r E s t i m a t i n g E m i s s i o n s f r o m G l y c o l GRI-96/0091}. D e h y d r a t i o n o f N a t u r a l Gas, V e r s i o n 3 . 0 C h i c a g o , I L . Mar ch 1 9 9 6 .
68.
Reference 48. 2-35
69.
S ta nda r ds o f Performance f o r Equipment Leaks o f
VOC f r o m O n s h o r e N a t u r a l Gas P r o c e s s i n g P l a n t s . Code o f F e d e r a l Regulations S u b p a r t KKK J u l y 1 1 9 9 2 . T i t l e 40 P a r t 60
U.S.
Government P r i n t i n g O f f i c e
Washington
DC
2-36
3.0
3.1
CONTROL OPTIONS AND PERFORMANCE OF CONTROLS
INTRODUCTION
This chapter addresses control options applicable to i d e n t i f i e d hazardous a i r pollutant
HAP)
emission points in the
o i l and n a t u r a l g as p r o d u c t i o n and n a t u r a l gas t r a n s m i s s i o n and storage source categories. As d i s c u s s e d i n C h a p t e r 2 . 0 , HAP e m i s s i o n p o i n t s i n t h e s e s o u r c e c a t e g o r i e s i n c l u d e 1} p r o c e s s
vents,
2)
storage vessels,
and
3)
equipment l e a k s .
o p t i o n s t h a t may b e a p p l i c a b l e t o e a c h o f t h e s e
Control
i d e n t i f i e d HAP
e m i ssi on p o i n t s are de sc ribe d below. In addition,
performance
measured a s c o n t r o l e f f i c i e n c y
of
e a c h c o n t r o l o p t i o n was e s t i m a t e d b a s e d o n b e s t e n g i n e e r i n g judgement and r e f e r e n c e d l i t e r a t u r e .
Referenced control
e f f i c i e n c i e s o f c o n t r o l o p t i o n s f o r v o l a t i l e o r g a n i c compounds
VOC)
e m i s s i o n p o i n t s w e r e deemed a p p l i c a b l e f o r t h e s e HAP
e m i s s i o n p o i n t s b e c a u s e o f s i m i l a r c h e m i c a l p r o p e r t i e s o f t h e HAP
c o n s t i t u e n t s and VOC.
These c o n t r o l e f f i c i e n c i e s a r e c o n s i s t e n t
with those demonstrated for
3.2
similar applications.
PROCESS VENTS As d i s c u s s e d i n C h a p t e r 2 . 0 ,
reboiler vent is
the glycol dehydration unit
t h e p r i m a r y i d e n t i f i e d p r o c e s s v e n t HAP e m i s s i o n
in these source categories.
point
Several control techniques can
be u s e d t o red u ce emi ssi ons from t h i s p r o c e s s v e n t e m i s s i o n point.
These include vapor recovery
condensation),
combustion.
and p o l l u t i o n prevention. 3.2.1
Vapor Recovery
C o n d e n s a t i o n i s t h e mos t common v a p o r r e c o v e r y c o n t r o l
technique used f o r glycol dehydration u n i t r e b o i l e r vents. 3-1
Condensers c o n v e r t c o n d e n s a b l e components i n t h e v a p o r p h a s e t o t h e l i q u i d phase by reducing the temperature
of
process vent
t h ~
Condensers n o t o n l y reduce emissions, b u t a l s o reco v er c o n d e n s a b l e h y d r o c a r b o n v a p o r s t h a t may i n c r e a s e h y d r o c a r b o n
stream.
l i q u i d production. In addition,
t h e d ry non-condensable o f f - g a s
c o n d e n s e r may b e u s e d a s f u e l . fuel,
t
1
from t h e
I f the off-gas i s not used as
may b e r e c y c l e d i n t o t h e p r o d u c t i o n p r o c e s s o r d i r e c t e d
to a flare,
incinerator,
or other combustion device.
Since
c o m b u s t i o n d e v i c e s a r e s e n s i t i v e t o t h e am ount o f w a t e r c o n t e n t in t h e process stream,
c o n d e n s e r s a r e t y p i c a l l y i n s t a l le le d p r i o r
to combustion p r o c e s s e s .
T h e HAP e m i s s i o n r e d u c t i o n e f f i c i e n c y o f c o n d e n s e r s v a r i e s depending upon a p p l i c a t i o n . 2 Some g l y c o l d e h y d r a t i o n u n i t s u s e
gas condensate glycol separators
GCG s e p a r a t o r s o r f l a s h t a n k s
pri or t o the reboiler to separate entrained gases,
methane and et h an e,
from t h e g l y c o l .
are t y p i c a l l y recovered as fuel production header.
H ow ever,
primarily
The f l a s h t a.nk o f f - g a s e s
o r recycled to
the natural
gas
t h i s p r o c e s s v e n t may a l s o b e v e n t e d
d i r e c t l y to the atmosphere. Fla sh t an k s t y p i c a l l y enhance a
condenser s emission
r e d u c t i o n e f f i c i e n c y by reducing t h e c o n c e n t r a t i o n o f non
condensable gases present in the stream introduced to the
condenser.
Thus,
condensers applied to those uni t s with f l a s h
t y p i c a l l y achieve higher emission reduction e f f i c i e n c i e s as
tanks
compared t o co n d en s ers u s ed a t g l y c o l d e h y d r a t i o n u n i t s t h a t do not
incorporate fl a sh tanks
Condensers,
in t h e i r system design.
u s e d i n c o n j u n c t i o n w i th th f l a s h t a n k s
incorporated into the glycol
c ir c ula tion loop,
9 5 p e r c e n t HAP/VOC e m i s s i o n r e d u c t i o n . 3 glycol dehydration units without flash
t ~ ~ i c
achieve
l l y
Condensers used on tanks
inco:rporated i n t o
t h e g l y c o l c i r c u l a t i o n l o o p may h a v e HAP/VOC r e d u c t i o n
efficiencies
as
low a s 50 p e r c e n t . 4
3-2
Combustion
3.2.2
D e s t r u c t i o n o f t h e H P c o m p o n e n t s i n a p r o c e s s s t r e a m may b e
accomplished by combustion. flares
thermal incinerators
Combustion equipment i n c l u d e s industrial boilers
and p ro c e s s
heaters. Flares are a
common
combustion device found a t o i l and
n a t u r a l gas p ro d u c t i o n f a c i l i t i e s and a t transmission
operations.
A flare
some n a t u r a l g a s
i s an open combustion d e v i c e
where t h e a i r around t h e flame p r o v i d e s t h e n e c e s s a r y oxygen f o r The f l a r e c o m b u s t i o n e f f i c i e n c y d e p e n d s o n v e n t g a s
combustion.
flammability
auto-ignition temperature
heating value
and mixing o f t h e components i n t h e combustion z o n e . s
density
Facilities
t h a t t r e a t s o u r ga s sometimes use f l a r e s to d e s t r o y hydrogen The h y d r o g e n s u l f i d e i s o x i d i z e d t o f o r m s u l f u r sulfide. dioxide
a
l e s s t o x i c com pound.
F l a r e s were e v a l u a t e d as a c o n t r o l o p t i o n f o r g l y c o l dehydration unit
reboiler vents.
are usually present
stream
Because l a r g e amounts o f w a t e r
in the glycol dehydration unit reboiler vent
p r o b l e m s w i t h i n c o m p l e t e c o m b u s t i o n may o c c u r .
Flares
a r e m o s t s u i t a b l e when u s e d i n c o m b i n a t i o n w i t h c o n d e n s e r s t o
combust t h e n o n -co n d en s ab le str e a m
o r when v a p o r c o l l e c t e d
s t o r a g e t a n k s must be d e s t r o y e d .
F l a r e s may a c h i e v e g r e a t e r t h a n a 98 p e r c e n t HAP VOC
from
reduction efficiency.6 of
Based on an e m i s s i o n r e d u c t i o n e f f i c i e n c y 98 p e r c e n t e m i s s i o n r e d u c t i o n
f o r a condenser and a
95 p e r c e n t
e f f i c i e n c y f o r the combustion device
d i r e c t i n g t h e non
condensable stream through
a
closed-vent
system to
a
combustion
device in conjunction with
a
condenser can achieve
a
H
reduction of
P
emission
99 p e r c e n t o r g r e a t e r .
Pollution Prevention
3.2.3
System optimization i s a p o l l u t i o n prevention technique t h a t may b e a n a p p l i c a b l e c o n t r o l o p t i o n f o r some g l y c o l d e h y d r a t i o n
units.
System o p t i m i z a t i o n i n v o l v es.t h e adjustment o f g l y c o l
dehydration unit process variables
to reduce emissions.
3-3
F o r example, glycol than is
g l y c o l d e h y d r a t i o n u n i t s may c i r c u l a t e m ore
n e c e s s a r y t o meet c o n t r a c t
specifications.
C i r c u l a t i o n r a t e s o f 2.0 t o 3 . 0 g a llo n s o f g l y c o l p e r pound o f w a t e r r e m o v e d a r e recom m ended r a t e s t h a t a r e u s u a l l y a d e q u a t e t o
meet t y p i c a l c ont r a c t pi pe l i ne s p e c i f i c a t i o n s f or water content in the n a t u r a l gas stream. 7 Based on a r e c e n t r e p o r t from t h e American Petroleum I n s t i t u t e
(API) ,
the national
c ir c u la tio n r a te for triethylene glycol
TEG)
at ver age g l y c o l
deh}rdration u n i t s
i s 5 . 9 g a l l o n s o f g l y c o l p e r pound o f w a t e r r em oved.B
This c o n tr o l o p t i o n can be ap p l i ed t6 glycol dehydration u n i t s t o i m p r o v e p r o c e s s p e r f o r m a n c e a n d r e d u c e a s s o c i a t e d HAP emissions
from g l y c o l d e h y d r a t i o n u n i t r e b o i l e r
High
V E ~ n t s
g l y c o l c i r c u l a t i o n r a t e s i n c r e a s e t h e amount o f benzene, t o l u e n e , e t h y l benzene, and mixed x y le n e s ( c o l l e c ti v e l y r e f e r r e d t o a s
BTEX)
and n-hexane ab so rb ed from t h e n a t u r a l gas stream.
Therefore,
m o r e BTEX a n d n - h e x a n e a r e r e l e a s e d f r o m t h e g l y c o l
dehydration unit
r e b o i l e r vent during regeneration of the glycol
from t h e s e u n i t s t h a t over c i r c u l a t e g l y c o l .
Thu:s,
optimizing
the glycol dehydration process by adjusting the glycol
c i r c u l a t io i o n r a t e may r e d u c e a s s o c i a t e d HAP e m i s s i o n s . 9 3.3
STORAGE VESSELS The m a j o r i t y o f
source categories are
st orage ta nks and v e s s e l s used in th ese
fixed-roof
storage
tanks.
Most o f t h e
s t o r a g e t a n k s u s e d i n t h e o i l p r o d u c t i o n segment percent)
( o v e r 95
h a v e s h e l l c a p a c i t i e s i n t h e r a n g e o f 200 t o 1 , 0 0 0
barrels.1° I n t e r n a l f l o a t i n g r o o f s t y p i c a l l y cannot be r e t r o f i t t e d to these tanks because i nt er nal
f r i c t i o n between the i n t e r i o r o f
these small diameter tanks will
floating roof.
inhibit proper operation of the
the small quant i t i es of
In addition,
liquid
s t o r e d i n t h e s e t a n k s do not provide s u f f i c i e n t buoyancy t o support floating roofs.ll
E m i s s i o n s f r o m f i x e d - r o o f s t o r a g e t a n k s may b e r e d u c e d b y using a vapor recovery unit
VRU)
to capt ure escaping hydrocarbon
O nce t h e v a p o r f r o m t h e t a n k s i s c a p t u r e d ,
vapors.
t
may b e
3-4
returned to
the natural
gas l i n e for processing o r be routed to a
control device. Natural
storage tanks
gas
typically
use
pressurized
to s t o r e l i g h t natural gas l i q u i d s
propane, butane) losses.12
processing plants
ethane,
and n a t u r a l g a s o l i n e and t o s u p p r e s s e v a p o r a t i v e
However,
hydrocarbons,
including those collected in
slug receivers during pipeline pigging operations,
transferred to non-pressurized fixed-roof 3.4
may b e
storage vessels.13
EQUIPMENT LEAKS The p r i m a r y c o n t r o l o p t i o n u s e d t o r e d u c e e m i s s i o n s from
equipment l e a k s i s a l e a k d e t e c t i o n and r e p a i r LDAR p r o g r a m i n c l u d e s e q u i p m e n t m o n i t o r i n g
LDAR)
program.
(usually with a
A
leak
d e t e c t i o n i nst rument ) on a p r e s c r i b e d s c h e d u l e and t h e r e p a i r i n g o f equipment i n i n s t a n c e s where a l e a k i s d e t e c t e d . Aspects of a
LDAR p r o g r a m a r e d i s c u s s e d b e l o w .
An a l t e r n a t i v e c o n t r o l o p t i o n t o a LDAR p r o g r a m i s m o d i f y i n g o r r e p l a c i n g e x i s t i n g equipment t o red u ce em i s s i o n s .
This option
i s a l s o d iscu ssed below. 3.4.1
Leak D e t e c t i o n and Re pa i r LDAR p r o g r a m s i n v o l v e r e g u l a r l y s c h e d u l e d i n s t r u m e n t
m oni t or i ng o f equipment to determine th e pr e se nc e o f l e a ks. a leak is detected, prescri bed schedule.
t h e equipment
i s tagged and r e p a i r e d on a
On c e
T h e m a j o r f a c t o r s a f f e c t i n g t h e c o n t r o l e f f i c i e n c y o f a LDAR
program are
1)
the
freq u en cy o f equipment i n s p e c t i o n and
leak d e f i n i t i o n t h a t t r i g g e r s r e p a i r requirements.
i m p o r t a n t c o m p o n e n t o f a LDAR p r o g r a m i s t h a t a c c u r a t e r e c o r d s be k e p t on l e a k f r e q u e n c i e s
it
2)
the
Another that
provides
and r e p a i r s .
LDAR p r o g r a m s may i n c l u d e p e r f o r m a n c e s p e c i f i c a t i o n s f o r
An e x a m p l e p e r f o r m a n c e s p e c i f i c a t i o n
i n d i v i d u a l equipment ty p es.
might s t a t e
that
···
if
p e r c e n t o r more o f t h e v a l v e s
in light
l i q u i d s e r v i c e l e a k mo re t h a n 1 0 , 0 0 0 p a r t s p e r m i l l i o n b y v o l u m e ppmv)
o f VOC,
t h e n mo re f r e q u e n t
inspection is
required.
T h r e e d i f f e r e n t l e v e l s o f LDAR w e r e e v a l u a t e d a s o p t i o n s f o r the oi l
and n a t u r a l gas production source category.
The t h r e e
3-5
c o n t r o l o p t i o n s a r e summarized below.
Detailed descriptions
of
t h e LDAR p r o g r a m s a r e p r o v i d e d i n R e f e r e n c e s 1 4 t h r o u g h 1 7 . Summary o f C o n t r o l T e c h n i q u e s G u i d e l i n e . The C o n t r o l T e c h n i q u e s G u i d e l i n e CTG) d o c u m e n t C o n t r o l o f V o l a t i l e
3.4.1.1
O r g a n i c Compound E q u i p m e n t L e a k s f r o m N a t u r a l G a s / G a s o l i n e P r o ces s i n g P l a n t s 14 p r o v i d es guidance fo r l e a k d e t e c t i o n and r e p a i r a t p l a n t s l o c a t e d in ozone non-a tta inm e nt a r e a s . guideline valves
The
includes quarterly monitoring of pressure r e l i e f
valves in light
liquid service
l i q u i d and vapor s e r v i c e
and compressors.
Pumps i n l i g h t
a r e t o be v i s u a l l y i n s p e c t e d on a weekly b a s i s .
i n s t a l l e d o n o p e n - e n d e d l i n e s when n o t i n u s e .
pumps i n l i g h t liquid service
Caps a r e t o b e
Equipment
s e r v i c i n g p r o c e s s s t r e a m s w i t h a VOC c o n c e n t r a t i o n o f 1 . 0 p e r c e n t
b y w e i g h t o r g r e a t e r a r e s u b j e c t t o t h e r e q u i r e m e n t s o f t h e CTG. 3.4.1.2
Summary o f New S o u r c e P e r f o r m a n c e S t a n d a r d s .
New S o u r c e P e r f o r m a n c e S t a n d a r d
NSPS)
The
f o r Equipment L e a k s o f VOC
f r o m O n s h o r e N a t u r a l Gas P r o c e s s i n g P l a n t s 1 5 a p p l i e s t o s u c h p l a n t s w i t h a f f e c t e d equipment cons tructed o r modified a f t e r
January 20
1984.
The NSPS l e a k d e t e c t i o n a n d r e p a i r . p r o g r a m
r e q u i r e s monthly monitoring of pressure r e l i e f v a l v e s
l i g h t l i q u i d and vapor s e r v i c e service.
valves
in
a n d pumps i n l i g h t l i q u i d
Valves i n gas/vapor s e r v i c e and l i g h t l i q u i d s e r v i c e
f o r which a
leak is
n o t d e t e c t e d f o r two c o n s e c u t i v e m o n t h s may
be monitored q u a rt e rl y . Weekl y v i s u a l
i n s p e c t i o n o f pumps i n l i g h t
liquid service is
In ad d itio n to capping open-ended l i n e s
also required.
capture
and v e n t systems a r e to be i n s t a l l e d on compressor s e a l s . E q u i p m e n t s e r v i c i n g p r o c e s s s t r e a m s w i t h a VOC c o n c e n t r a t i o n o f 10 p e r c e n t b y wei g h t o r g r e a t e r a r e s u b j e c t t o t h e r e q u i r e m e n t s o f t h e NSPS. Summary o f Equipment L e a k R e q u i r e m e n t s U n d e r t h e
3.4.1.3
H a z a r d o u s O r g a n i c NESHAP R e g u l a t o r y N e g o t i a t i o n .
O r g a n i c NESHAP
HON)
The Ha z a r d o u s
R e g u l a t o r y N e g o t i a t i o n 1 6 was d e v e l o p e d f o r
t h e s y n t h e t i c organic chemical manufacturing industry.
The
p r o v i s i o n s o f t h i s r e g u l a t i o n i ncl ude monthly monitoring o f
3-6
valves
i n l i g h t l i q u i d a n d v a p o r s e r v i c e a n d pumps i n l i g h t
liquid service.
Pumps i n l i g h t
liquid service are to be vi sual l y
i n s p e c t e d on a weekly b a s i s .
The
HON
R e g u l a t o r y N e g o t i a t i o n a l s o p h a s e s - i n more s t r i n g e n t
r e q u i r e m e n t s f o r v a l v e s a n d pumps b y u s i n g programs and performance l e v e l s .
a
combination of
LD
R
In a d d i t i o n to capping open
ended l i n e s and v e n t systems on compressor s e a l s
1
pressure relief
v alv es ar e to be equipped with r u p tu r e d is k assemblies
and
sampling l i n e s a r e to be equipped with closed-purge systems. Equipment s e r v i c i n g p r o c e s s str e a ms w i t h
H
P
concentration
g r e a t e r t h a n 5.0 percent by weight a r e s u b j e c t to t h e
requirements of the 3.4.2
An
HON
Regulatory Negotiation.
Equipment M o d i f i c a t i o n equipment m o d i f i c a t i o n f o r reducing equipment l e a k
e m i s s i o n s may i n c l u d e t h e i n s t a l l a t i o n o f a d d i t i o n a l e q u i p m e n t o r t h e replacement o f e x i s t i n g equipment.
i s an a l t e r n a t i v e to equipment l e a k s .
LD R
Equipment m o d i f i c a t i o n
programs f o r red u ci n g emi s s i o n s from
Examples o f equipment m o d i f i c a t i o n o r
r e pla c e me nt a r e d e s c r i b e d below. from t h e EPA's
Control e f f i c i e n c i e s are c i t e d
P r o t o c o l f o r Equipm ent L e a k E m i s s i o n
Estimates.n17 3.4.2.1
1
Valves.
Emissions from v a l v e s can be re duc e d by
r e p l a c i n g o l d va lve s with bellows va lve s and diaphragm valves
sealless valves)
The c o n t r o l e f f i c i e n c y f o r s e a l l e s s v a l v e s i s
estimated to be 100-percent.
3.4.2.2
Pumps a n d C o m p r e s s o r s .
c o m p r e s s o r s may b e c o l l e c t e d b y to a control
device.
E m i s s i o n s f r o m pumps a n d
closed-vent
a
system and r o u ted
The c o n t r o l e f f i c i e n c y o f t h i s s y s t e m
depends on t h e percentage o f vapors c o l l e c t e d and t h e e f f i c i e n c y of
the control device.
Pumps a n d c o m p r e s s o r s may a l s o b e
equipped with dual mechanical s e a l s with b a r r i e r f l u i d a t h i g h e r p r e s s u r e than .the process stream. of
the dual mechanical
3.4.2.3
seal
a
The c o n t r o l e f f i c i e n c y
system i s approximately 1 0 0 -p e r c e n t .
Sampling Connections.
Emissions from sa mpling
connections can be reduced by i n s t a l l i n g
a
closed-loop
system
1
3-7
which has an estimated c ont rol e f f i c i e n c y o f 100-percent . clo sed - lo o p sampling system c o l l e c t s th e purged proces s
f l u i d and
t back i n t o the t to a control device o r directs transfers process stream. Pressure-Relief Devices. To r e d u c e e m i s s i o n s f r o m 3.4.2.4
pressure-relief devices
r u p t u r e d i s k s may b e i n s t a l l e d .
Rupture
d i s k s y s t e m s a r e e s t i m a t e d t o h a v e a 100 p e r c e n t c o n t r o l efficiency.
E m i s s i o n s f r o m p r e s s u r e - r e l i e f d e v i c e s may a l s o b e
c o l l e c t e d by a c l o s e d - v e n t syst e m and r o u t e d to a c o n t r o l d e v i c e .
T he c o n t r o l e f f i c i e n c y o f t h i s o p t i o n i s d e p e n d e n t o n t h e p e r c e n t a g e o f vapors c o l l e c t e d and th e e f f i c i e n c y o f t h e c o n t r o l device.
Open-E nded L i n e s . E m i s s i o n s from o p e n - e n d e d l i n e s c a n b e r e d u c e d 100 p e r c e n t b y i n s t a l l i n g a p l u g , c a p , o r s e c o n d 3.4.2.5
v alv e on t h e open end.
3.4.2.6
Connectors
Flanges).
If allowable in the process
c o n n e c t o r s may b e w e l d e d t o g e t h e r t o o b t a i n
a
100-·percent c o n t r o l
efficiency. 3.5
CONTROL OPTIONS
ND
H P
EMISSION POINTS
summary o f c o n t r o l o p t i o n s a p p l i c a b l e t o tl1e i d e n t i f i e d H
P
emission points a t f a c i l i t i e s
i n t h e o i l and n a t u r a l gas
p r o d u c t i o n and n a t u r a l g as t r a n s m i s s i o n and s t o r a 9 e source
categories are
i d e n t i f i e d i n Table 3-1.
This t ab l e includes
estimated emission reduction e f f i c i e n c i e s for each applicable
These r e d u c t i o n e f f i c i e n c i e s a r e b ased on t h e
control option. control
l e v e l a c h i e v e d t h r o u g h r e d u c t i o n o f VOC e t n i s s i o n s ,
otherwise specified.
3-8
T
BLE
3-1.
H P
SUMM RY
OF
emission point
CONTROL
OPTIONS
PER H P
Control options
EMISSION POINT
Estimated control efficiency ( )a
Glycol r e b o i l e r vent
Condenser, w i t h flash tank in dehydration system design
95
Condenser w i t h o u t
s
Combustion
98
flash tank
System o p t i m i z a t i o n
Open-top s t o r a g e tank
Cover p l u s va por c olle .c tion and
Variable
99
redirect
Fixed roof
storage
tank
Vapor c o l l e c t i o n and r e d i r e c t
Equipment l e a k s
a
Estima te s based on re fe re nc e d l i t e r a t u r e
judgement.
6
70 88
and engineering
unless
b
Vapor r e d i r e c t e d t o a c o n t r o l de vic e o p e r a t i n g a t a
c
E s t i mat ed l e v e l o f c o n t r o l ba se d on Reference 13.
d
E s t i mat ed l e v e l o f c o n t r o l ba se d on Reference 14.
e
Estimated l e v e l o f c o n t r o l based on Reference 15.
percent
control efficiency.
3-9
95
3.6
REFERENCES
1.
Gas R e s e a r c h I n s t i t u t e .
P r o c e e d i n g s o f t h e 1992 Gas R e s e a r c h
I nhsi ct a i tgu G.l yS co l t eDmeb heyrd r1a9t 9 o2 r . Air Emissions Conference. C o t, e I L ep
2.
U.S. Environmental P r o t e c t i o n Agency. A l t e r n a t i v e C o n t r o l Te c h n o l o g y Document - O r g a n i c Waste P r o c e s s V e n t s EPA 4 5 0 / 3 - 9 1 - 0 0 7 ) . R e s e a r c h T r i a n g l e P a r k , NC. Decem ber 1 9 9 0 .
3.
Gas R e s e a r c h I n s t i t u t e .
4.
U.S.
5.
U . S . E n v i r o n m e n t a l P r o t e c t i o n Agency. OAQPS C o n t r o l C o s t Manual ( F o u r t h E d i t i o n , EPA 4 5 0 / 3 - 9 0 - 0 0 6 ) . R e s e a r c h T r i a n g l e P a r k , NC. J a n u a r y 1 9 9 0 .
6.
Reference 2.
7.
American P e tr ole um I n s t i t u t e . S p e c i f i c a t i o n f o r Gly co l-Ty p e Gas D e h y d r a t i o n U n i t s API S p e c i f i c a t i o n 12GDU, F i r s t DC. Decem ber 1 5 , 1 9 9 0 . E d i t i o n ) . Wa s h i n g t o n ,
8.
American Petroleum I n s t i t u t e . T r i e t h y l e n e Glycol De hydr a tor O p e r a t i n g P a r a m e t e r s f o r E s t i m a t i n g BTEX E m i s s i o n s P r e p u b l i c a t i o n D r a f t ) . Wa s h i n g t o n , DC. F e b r u a r y 1 9 9 6 .
Glycol Dehydration Operations, E n v i r o n m e n t a l R e g u l a t i o n s , a n d W a s t e S t r e a m S u r v e y (GRI96/0049). Chicago, IL. June 1996.
Environmental P r o t e c t i o n g e n c y ~ Condensation Systems f o r Glycol D e hydr a tor Emissions Modeling and Design (Revised D r a f t R e p o r t , C o n t r a c t No. 6 8 -0 1 -0 0 3 1 , Work A s s i g n m e n t 0 6 7 ) . R e s e a r c h T r i a n g l e P a r k , NC. A u g u s t 3 1 , 1 9 9 4 .
9.
Gas R e s e a r c h I n s t i t u t e . G l y c o l D e h y d r a t o r E m i s s i o n s : S a m p l i n g a n d A n a l y t i c a l Methods a n d E s t i m a t i o n T e c h n i q u e s . Volume I ( G R I - 9 4 / 0 3 2 4 ) . C h i c a g o , IL. Mar ch 1995.
10.
E n t r o p y L i m i t e d . Aboveground S t o r a g e T a n k S u r v e y R e p o r t ) . L i n c o l n , MA A p r i l 1 9 8 9 .
11.
Memorandum f r o m V i c o n o v i c , G . , EC/R I n c o r p o r a t e d , t o P r o j e c t F i l e s . March 6 , 1992. Summary o f c o n v e r s a t i o n w i t h Rob F e r r y , Conservatek I n d u s t r i e s , on p r o d u c t i o n t a n k e m i s s i o n cont rol systems.
12.
Responses t o t h e U.S. Environmental P r o t e c t i o n Age nc y s A i r E m i s s i o n s S u r v e y Q u e s t i o n n a i r e s f o r t h e O i l a n d N a t u r a l Gas
Final
C-a2t 5 eg EPA A i r D o c k e t A - 9 4 - 0 4 , P orno uSgohu r IcIe- D I Ir-oDd-u1c t ti h ) .o r y 1993. 13.
Memorandum f r o m V i c o n o v i c , G . , EPA:WCPG. J u l y 1 0 , 1 9 9 6 .
M.E.,
Items
EC/R I n c o r p o r a t e d , t o S m i t h , Site v isit r e p o r t -
3-10
T r a n s c o n t i n e n t a l Gas P i p e L i n e C o r p o r a t i o n , C o m p r e s s o r Station D i s t r i c t 160, R e i d s v i l l e North Carolina.
14.
U.S. Environmental P r o t e c t i o n Agency. C o n tr o l o f V o l a t i l e O r g a n i c Compound Equipm ent L e a k s f r o m N a t u r a l G a s / G a s o l i n e Research Triangle Processing Plants EPA-450/3-83-007) P a r k , NC Decem ber 1 9 8 3 .
15.
S t a n d a r d s o f P e r f o r m a n c e f o r Equipm ent L e a k s o f VOC F r o m O n s h o r e N a t u r a l Gas P r o c e s s i n g P l a n t s . Code o f F e d e r a l Regulations T i t l e 4 0 , P a r t 6 0 , S u b p a r t KKK J u l y 1 , 1 9 9 2 . U . S . Gover nm ent P r i n t i n g O f f i c e W a s h i n g t o n , DC
16.
N a tiona l Emission Standards f o r Hazardous A ir P o l l u t a n t s ; Announcem ent o f N e g o t i a t e d R e g u l a t i o n f o r E q u i p m e n t L e a k s . V o l . 5 6 , No. 4 4 , p p . 9 3 1 5 - 9 3 3 9 . Mar ch 6 , Federal Register 1 9 9 1 . O f f i c e o f t h e F e d e r a l R e g i s t e r W ashing:ton, DC
17.
U.S. Environmental P r o t e c t i o n Agency. P r o t o c o l f o r Equipment EPA-453/R-93-026). R es earch Leak Emission Estimates T r i a n g l e P a r k , NC J u n e 1 9 9 3 .
3-11
4.0 4.1
MODEL
PL
NTS
INTRODUCTION Due t o
t h e l a r g e number o f f a c i l i t i e s
in t h e o i l and n a t u r a l
g a s p r o d u c t i o n and n a t u r a l g as t r a n s m i s s i o n and s t o r a g e s o u r c e categories
and t h e time and r e s o u r c e s
i n f o r m a t i o n on each f a c i l i t y
t
t
would t a k e t o g a t h e r
was n o t p o s s i b l e t o s i m u l a t e t h e
e f f e c t s o f applying control options a t a l l p o t e n t i a l l y impacted
f a c i l i t i e s in these source categories.
Therefore, an a l t e r n a t i v e
a p p r o a c h i n v o l v i n g t h e u s e o f model p l a n t s was t a k e n t o e s t i m a t e plant-level
and nationwide impacts o f c o n t r o l o p t i o n s .
The m o d e l
p l a n t s developed for these source categories are described in
th is chapter.
A model p l a n t d o e s n o t r e p r e s e n t a n y s i n g l e a c t u a l but
rather
t
represents a range of
characteristics
facility
facilities with similar
t h a t may b e i m p a c t e d b y a s t a n d a r d .
Each model
p l a n t . i s c h a ra c t e ri z e d i n terms o f f a c i l i t y type,
size
and o t h e r
parameters that affect estimates of emissions, control costs secondary environmental impacts.
and
Impacts o f c o n t r o l o p t i o n s a r e
and t h e n e x t r a p o l a t e d t o e s t i m a t e
e s t i m a t e d f o r e a c h model p l a n t
impacts on a nationwide l e v e l . To s p a n t h e r a n g e o f t y p e s
source categories
and s i z e s o f f a c i l i t i e s
a number o f model p l a n t s w e r e d e v e l o p e d .
dehydration units
{2)
natural gas processing p l a n t s
and
Model p l a n t s w e r e d e v e l o p e d f o r
condensate tank b a t t e r i e s 4)
in these
3)
1)
glycol
offshore production platforms in State waters.
T h e s e model p l a n t s w e r e d e v e l o p e d b a s e d o n a v a i l a b l e i n f o r m a t i o n c o l l e c t e d on p r o c e s s e s
pollutant
HAP)
operations
and hazardous a i r
e m i s s i o n p o i n t s i n t h e o i l and n a t u r a l g a s 4-1
p r o d u c t i o n and n a t u r a l gas
transmission and storage
The i n f o r m a t i o n c o n s i d e r e d i n c l u d e
categories.
(1)
source d a t a from
i n d u s t r y responses to t h e U.S. Environmental P r o t e c t i o n Agency s (E PA s) A i r E m i s s i o n s S u r v e y Q u e s t i o n n a i r e s , 1 (2) o b s e r v a t i o n s
made d u r i n g f o u r s e r i e s o f s i t e v i s i t s t o o i l a n d n a t u r a l g a s p r o d u c t i o n and n a t u r a l
gas transmission and storage f a c i l i t i e s
t h a t were designed to c o l l e c t information on processes and o p e r a t i o n s a n d HAP e m i s s i o n p o i n t s , 2
(3)
recommendations and
c o mme n ts r e c e i v e d f r o m members o f t h e A m e r i c a n P e t r o l e u m
Institute CAIG) , 3
(API) (4)
and
ts
a s s o c i a t e d Clean A ir
I s s u e s Gro u p
a data base o f natural gas analyses for various
i n d u s t r y o p e r a t i o n s p r o v i d e d b y t h e Gas R e s e a r c h I n s t i t u t e (GRI) , 4 a n d 4.2
4.2.1
data provided by API.s
DESCRIPTIONS OF MODEL PLANTS
Glycol Dehydration Units 4.2.1.1
unit
5)
Glycol Dehydration Units.
The g l y c o l d e h y d r a t i o n
r e b o i l e r v e n t has been i d e n t i f i e d a s a signii:icant source o f
HAP e m i s s i o n s i n t h e o i l a n d n a t u r a l g a s p r o d u c t i o n a n d n a t u r a l
gas t ra n s m i s s i o n and s t o ra g e source categ o r ies . d e h y d r a t i o n u n i t s may b e dehydrate natural
(1)
stand-alone
Glycol
facilities
that
g as s tream s from an i n d i v i d u a l o r s e r i e s o f
production wells or
(2)
part of the overall production process
l o c a t e d a t condensate tank b a t t e r i e s ,
natural gas processing
plants,
offshore production platforms
in S t a t e and Federal
waters,
and throughout the n a t u ra l gas transmission source
category,
including underground s t o r a g e f a c i l i t i e i 3 .
of glycol dehydration units, diethylene glycol
d e h y d r a t i o n u n i t s account f o r most
TEG)
Triethylene glycol
EG)
with ethylene glycol
and
dehydration units accounting for
DEG)
the
remaining estimated population of glycol dehydration uni t s . B a s e d o n i n f o r m a t i o n r e c e i v e d f r o m A P I S CAIG a n d GRI, e s t a b l i s h e d a n a v e r a g e n u mb e r o f
(1)
t h e EPA
o n e TEG d e h y d r a t i o n u n i t p e r
c o n d e n s a t e t a n k b a t t e r y 6 , 7 and o f f s h o r e p r o d u c t i o n p l a t f o r m and 2}
two t o fo u r de hydr a tion u n i t s
TEG,
EG, o r s o l i d d e s i c c a n t
4-2
depending upon t h r o u g h p u t c a p a c i t y and t y p e o f p ro c e s s i n g c o n f i g u r a t i o n . 8
per natural gas processing plant,
F i v e s e p a r a t e m odel TEG d e h y d r a t i o n u n i t s t h a t r e p r e s e n t t h e s i z e range f o r t h e s e u n i t s within the o i l and n a t u r a l gas produc t i on and n a t u ra l
gas tra nsmission and s t o r a g e source
categories
based on n a t u r a l gas d e s i g n and throughput
capacities)
were developed.
The n a t u r a l g a s t h r o u g h p u t c a p a c i t y
r a n g e s o f t h e f i v e m odel TEG d e h y d r a t i o n u n i t s a r e s t a n d a r d cubic f e e t p e r day >20 t o
5 0 MMSCF/D,
In addition, represent
4)
MMSCF/D),
2)
500 MMSCF/D;
>50 t o
1)
million
~
>5 t o 2 0 MMSCF/D,
and
{5)
3}
> 500 MMSCF/D.
f o u r s e p a r a t e m odel EG d e h y d r a t i o n u n i t s t h a t
the s i z e range of these uni t s within the o i l
natural gas production source category
design and throughput capacities)
and
based on n a t u r a l gas
were developed.
The n a t u r a l
g a s t h r o u g h p u t c a p a c i t y r a n g e s o f t h e f o u r m odel EG d e h y d r a t i o n units are
MMSCF/D,
1)
and
<20 MMSCF/D, 4)
2)
2 0 t o 1 0 0 MMSCF/D,
3)
> 100 t o
500
>500 MMSCF/D.
T a b l e 4 - 1 p r e s e n t s p a r a m e t e r s f o r t h e f i v e m odel TEG dehydration units
and Table 4-2 p r e s e n t s parameters f o r the four
m odel ·EG d e h y d r a t i o n u n i t s .
The p a r a m e t e r s i n t h i s t a b l e a r e t h e
b a s i c i n p u t s u s e d i n GRI-GLYCalc™
Version 3. 0) , 9 a personal
c o m p u t e r - b a s e d e m i s s i o n s s c r e e n i n g p r o g r a m d e v e l o p e d b y GRI f o r
e v a l u a t i n g HAP a n d v o l a t i l e o r g a n i c compound
VOC)
emissions from
TEG a n d EG d e h y d r a t i o n u n i t s . 4.2.1.2
Tables 4-1
D i s t r i b u t i o n o f Model U n i t P o p u l a t i o n s .
a n d 4 - 2 i n c l u d e t h e e s t i m a t e d num ber o f g l y c o l d e h y d r a t i o n u n i t s
based on a p p l i c a t i o n
stand-alone,
natural gas processing plants, natural
condensate tank b a t t e r i e s ,
offshore production platforms,
gas transmission and storage) .
num ber o f d e h y d r a t i o n u n i t s i n t h e U.S.
and
Estimates o f the t o t a l r a n g e .from 2 0 , 0 o o 1 0 t o
recent projections of over 44,000.11,12
The EPA s t a n d a r d i z e d t h e a n a l y s i s f o r d e h y d r a t i o n u n i t s i n .this r e g u l a t o r y development p r o c e s s by u s i n g a
total national
estimated dehydration unit population of approximately 40,000,
which r e p r e s e n t s a l l d eh y d rat i o n u n i t s i n e v e r y s e c t o r o f 4-3
MODEL TRIETHYLENE GLYCOL
TABLE 4 - 1
TEG)
DEHYDRATION UNITS
Model TEG u n i t s
Parameter A
B
c
D
E
.s.5
>5 t o 20
>20 t o 50
>50 t o 500
>500
0.28
10
35
100
500
90
90
90
90
90
700
700
700
700
700
7
7
7
7
7
Percent with fla sh tank in system design
10
40
55
100
100
Glycol c i r c u l a t i o n r a t e Gallons of glycol p e r l b s
5.9
5.9
5.9
5.9
5.9
Stand alone
24,000
200
25
20
---
Condensate t a n k b a t t e r y
12,000
500
100
70
- --
-- -
66
110
54
---
Natural gas
Capacity
MMSCF/D) MMSCF/D)
Throughput Temperature Pressure :
DF)
psig)
Dry g a s w a t e r c o n t e n t Pounds o f w a t e r p e r MMSCF/D)
o f w a t e r r em oved)
Estimated population d i s t r i b u t i o n o f TEG u n i t s
Natural gas processing
pl anta
Offshore production
---
260
40
-- -
---
Natural gas transmission
200
125
25
10
10
platform in State waters
and underground storage MMSCF/D - M i l l i o n o f s t a n d a r d c u b i c f e e t p e r d a y Pounds p e r s q u a r e i n c h g a u g e
psig -
a
-
B a s e d o n o n e o f tw o p a r a l l e l p r o c e s s i n g l i n e s o n l i n e a t a n y o n e t i m e f o r t h e s m a l l n a t u r a l g a s p r o c e s s i n g p l a n t a n d tw o o f t h r e e o n l i n e f o r t h e l a r g e r m ode l n a t u r a l g a s p r o c e s s i n g p l a n t s .
4-4
T BLE
4-2.
MODEL
ETHYLENE
GLYCOL
EG)
DEHYDR TION
UNITS
Model EG u n i t s
Parameter A
c
D
Natural gas Capacity
{MMSCF/D)
Throughput
{MMSCF/D)
I n l e t Temperature
°F)
Contactor Temperature
Pressure
°F)
psig)
Dry gas water content w a t e r p e r MMSCF/D) Percent with fla sh
P ounds o f
tank in
system
<20
20 t o 100
>100 t o 500
>500
10
35
100
500
75
75
75
75
0
0
0
0
1,000
1,000
1,000
1,000
5
5
5
5
100
100
100
100
0.5
0.5
0.5
0.5
66
110
54
30
design
Glycol c i r c u l a t i o n r a t e Gallons o f g l y c o l p e r l b s o f w a t e r re m o v e d )
Estimated population di s t r i but i on o f EG
units Natural
gas processing p l a n t a
rd c u b i c f e e t p e r d a y MMSCF/D - M i l l i o n o f s t a n d a rd
psig -
a -
Pounds p e r s q u a r e i n c h gauge
B a s e d o n o n e o f tw o p a r a l l e l p r o c e s s i n g l i n e s o n l i n e a t a n y o n e t i m e f o r t h e s m a l l n a t u r a l g a s p r o c e s s i n g p l a n t a n d tw o o f t h r e e o n l i n e f o r t h e l a r g e r model n a t u r a l gas p r o c e s s i n g p l a n t s .
4-5
both source categories,
Of t h i s ,
including the offshore production sector.
approximately 38,000 are glycol dehydration u n i t s
( p r i m a r i l y TEG a n d
G
dehydration units)
and 2,000 are s o l i d
desiccant dehydration units.
T h e model g l y c o l d e h y d r a t i o n u n i t d i s t r i b u t i o n f o r n a t u r a l
g a s p r o c e s s i n g p l a n t s r e f l e c t s comments r e c e i v e d f r o m members o f API s
T h e s e comments i n d i c a t e t h a t t h e m a j o r i t y o f n a t u r a l
CAIG.
g a s p r o c e s s i n g p l a n t s p r i m a r i l y employ n o n - g l y c o l d e h y d r a t i o n units
(some f o r m o f s o l i d d e s i c c a n t s y s t e m )
processing stream,
within. t h e i r
with the remaining natural
plants using e ith e r T G o r
gas processing
dehydration units
G
within their
o v e r a l l p r o c e s s i n g system d esig n .l3 4.2.1.3
Natural
G as L i f e C y c l e .
The n u mb e r o f t i m e s t h a t
n a t u r a l ga s i s d eh y d rated by gl ycol de hydr a tion u n i t s dur ing
l i f e cycle
( l i f e c y c l e b e i n g d e f i n e d a s from t h e p o i n t o f
production of natural
gas a t
a
processing and storage stages,
t h e end user)
i n i t i a l analyses,
t h e EP
of times th a t natural
in
ts
well,
through
ts
various
t o t h e t i m e when it: i s consumed b y
i s one o f t h e components i n t h e o v e r a l l methodology
o f d e t e r m i n i n g model p l a n t
units
ts
and nationwide impacts. s e l e c t e d two t i m e s
(2x)
In
ts
a s t h e number
gas i s dehydrated by glycol dehydration
l i f e cycle.
T h i s was b a s e d o n
i n f o r n ~
t i o n
f r o m GRI,
which s t a t e d
a
l o w e r l i m i t o f o v e r l x a n d a n unknown u p p e r
estimate t h a t n a t u r a l gas i s
systems in
ts
The EP
dehydrated several times with glycol
l i f e cycle.l4
revised
ts
e s t i m a t e to approximatel)r 1 . 6 x f o r
n a t u r a l gas dehydrated through a l l
located at all
(including solid desiccant units)
s e c t o r s throughout
the oil
forms o f d e h y d r a t i o n u n i t s operational
and n a t u r a l gas product i on and n a t u r a l
ga s tr an smissio n and s t o r a g e s o u rce c a t e g o r i e s .
~ r
i s
revision
wa s b a s e d o n comments r e c e i v e d f r o m members o f A P I s C IG a n d
t h r o u g h s t u d i e s c o n d u c t e d by· t h i s g r o u p . l 5 , 1 6 , 1 7 estimated l i f e dehydration
cycle factor includes.accounting
(approximately 0.2x)
emissions regulatory
This t o t a l for offshore
i s not under t h e EPA s a i r
that
jurisdiction.
4-6
A r e c e n t GRI r e p o r t e s t i m a t e d t h e n a t u r a l g a s l i f e c y c l e a t This report s t a t e s
between 2x and 3x.
· ..
In our di scussi ons·
with the industry, t was s t a t e d t h a t n a t u r a l g a s i s f r e q u e n t l y dried multiple times, usually during production, before gas
processing,
4.2.2
and i n t h e t r a n s f e r from underground s t o r a g e . n 1 8
C o n d e n s a t e Tank B a t t e r i e s F o u r s e p a r a t e m odel c o n d e n s a t e t a n k b a t t e r i e s t h a t r e p r e s e n t
the s i z e range o f condensate tank b a t t e r i e s
(based on condensate
and n a t u r a l gas d e s i g n and throughput c a p a c i t i e s )
were developed.
The n a t u r a l g a s t h r o u g h p u t c a p a c i t y r a n g e s o f t h e f o u r c o n d e n s a t e
m odel b a t t e r i e s a r e t o 5 0 MMSCF/D
and
(1) (4)
~
MMSCF/D
(2)
>5 t o 2 0 MMSCF/D
(3)
>20
>50 MMSCF/D.
Condensate t a n k b a t t e r i e s g e n e r a l l y have a g l y c o l dehydration unit design of
as a process unit within the overall system
the tank battery.19
dehydration units
However ,
because glycol
a r e a d d r e s s e d a s s e p a r a t e m odel p l a n t s ,
parameters for glycol dehydration uni t s are not included with the m odel c o n d e n s a t e t a n k b a t t e r y p a r a m e t e r s . than glycol
dehydration u n i t parameters)
tank batteries
The p a r a m e t e r s
other
f o r t h e m odel c o n d e n s a t e
are presented in Table 4-3.
A p p r o x i m a t e l y 15 p e r c e n t o f a l l t a n k b a t t e r i e s , e s t i m a t e d 13,000 t a n k b a t t e r i e s ,
o r an
are classified as condensate
A f u r t h e r b r e a k d o w n o f t h e num ber o f
tank batteries.20
c o n d e n s a t e t a n k b a t t e r i e s i n e a c h m odel c o n d e n s a t e t a n k b a t t e r y show n i n T a b l e 4 - 3 .
s iz e range i s
dehydration units
P a r a m e t e r s f o r m odel g l y c o l
are presented in Section 4.2.1
and Tables 4-1
a n d 4 - 2 o f t h i s BID. 4.2.3
N a t u r a l G as P r o c e s s i n g P l a n t s
T h r e e s e p a r a t e m odel n a t u r a l g a s p r o c e s s i n g p l a n t s t h a t size ranges of natural gas processing pl ant s
represent different
(based on n a t u r a l gas des i gn and throughput c a p a c i t i e s )
developed.
The n a t u r a l g a s t h r o u g h p u t c a p a c i t y r a n g e s o f t h e
t h r e e m odel p r o c e s s i n g p l a n t s a r e
MMSCF/D
were
and
(3)
(1)
<20 MMSCF/p
(2)
2 0 t o 100
>100 MMSCF/D.
4-7
MODEL CONDENSATE TANK BATTERIES
TABLE 4 - 3
Model c onde nsa t e
tank bat t er y
Parameter
F
G
H
>5 t o
>20 t o
>50
20
50
0.28
10
35
100
15
100
1,000
5,000
4
2
E
N atur al gas s_
C a p a c i t y (MMSCF/D) Throughput '
(MMSCF/D)
Condensate throughput Fixed-roof product
(BOPD)
storage tanks
210 b a r r e l c a p a c i t y
2
500 b a r r e l c a p a c i t y 1 000 barrel
capacity
2 2
4
Com ponents
Valves
Gas/vapor
30
60
90
150
Light l i qui d
30
60
90
150
H eavy l i q u i d
20
20
40
60
Light l i qui d
2
4
6
10
H eavy l i q u i d
2
2
4
6
Pump s e a l s
Compressor s e a l s
2
4
6
10
Pressure r e l i e f valves
6
10
16
26
170
290
460
750
Sampling connections
2
4
6
10
Open-ended l i n e s
4
8
12
20
270
460
730
1 200
12,000
500
100
70
Flanges and connections
To t al components
Estimated population
MMSCF/D - M i l l i o n o f s t a n d a r d c u b i c f e e t p e r d a y BOPD- B a r r e l s o f o i l p e r day
4-8
P a r a m e t e r s f o r t h e m odel n a t u r a l g a s p r o c e s s i n g p l a n t s a r e presented in Table 4-4.
As w i t h t h e m odel c o n d e n s a t e t a n k
batteries p a r a m e t e r s f o r m odel g l y c o l d e h y d r a t i o n u n i t s a t natural gas processing plants are not presented in Table 4-5.
P a r a m e t e r s f o r m odel g l y c o l d e h y d r a t i o n u n i t s a r e p r e s e n t e d i n S e c t i o n 4 . 2 . 1 and Tables 4-1 and 4-2.
As o f J a n u a r y 1
1993
t h e r e w e r e a p p r o x i m a t e l y 700 d o m e s t i c
n at u r al gas processing plants.21
The c i t e d r e f e r e n c e
includes a
l i s t i n g o f th e se nat ur al gas processing p l a n t s by S t a t e w i t h d e si g n c a p a c i t i e s and e st i m a t e d 1992.throughputs.
t h i s annual survey
estimates of
t h e num ber o f n a t u r a l
p r o c e s s i n g p l a n t s c o r r e s p o n d i n g t o e a c h m odel p l a n t
along Based on
gas
size range
w e r e made a n d a r e i n c l u d e d i n T a b l e 4 - 4 . 4.2.4
Offshore Production Platforms in S t a t e Waters Two m odel
offshore production platforms designed to be
r e p r e s e n t a t i v e o f a s m a l l a n d a medium o f f s h o r e p r o d u c t i o n platform that are
were developed.
typical of those located in State water areas
The p a r a m e t e r s a n d v a l u e s s e l e c t e d t o
c h a r a c t e r i z e t h e s e m odel o f f s h o r e p r o d u c t i o n p l a t f o r m s a r e p r e s e n t e d i n Table 4-5.
As w i t h t h e m odel c o n d e n s a t e t a n k b a t t e r i e s processing plants
and n a t u r a l gas
p a r a m e t e r s f o r m odel g l y c o l d e h y d r a t i o n u n i t s
a t offshore production platforms are not presented in t h i s ta b le .
P a r a m e t e r s f o r m odel g l y c o l d e h y d r a t i o n u n i t s a r e p r e s e n t e d i n Section 4.2.1
a n d T a b l e s 4 - 1 a n d 4 - 2 o f t h i s BID.
T h e r e a r e a p p r o x i m a t e l y 300 o f f s h o r e p r o d u c t i o n p l a t f o r m s i n S t a t e w a t e r s t h a t a r e u n d e r t h e EPA s j u r i s d i c t i o n f o r a i r e m i s s i o n s r e g u l a t i o n . 22 To c h a r a c t e r i z e t h i s s e g m e n t o f t h e o i l
and n a t u r a l gas p r o d u c t i o n source c a t e g o r y
t h e EPA r e q u e s t e d
t e c h n i c a l d a t a f r o m members o f A P I • s CAIG t o a s s i s t
in developing
m odel o f f s h o r e p r o d u c t i o n p l a t f o r m s t h a t w o u l d b e r e p r e s e n t a t i v e of those
located in State waters.23
4-9
TABLE 4 - 4
MODEL N
TUR L
G S
PROCESSING PLANTS Model n a t u r a l g a s
Parameter
processing plant
A
B
c
<20
20 t o 100
>100
10
35
200
4
4
4
300
750
-1 800
Light l i qui d
60
150
360
H eavy l i q u i d
20
40
60
Light l i qui d
4
10
24
H eavy l i q u i d
2
4
6
4
10
24
10
24
54
1 200
3 200
12 000
N atur al gas I
I
C a p a c i t y (MMSCF/D) Throughput
(MMSCF/D)
Fixed-roof product s torage tanks 1 000 barrel capacity
Com ponents
Valves
Gas/vapor
Pump s e a l s
Compressor s e a l s Pressure r e l i e f valves
Flanges and co n n ect i o n s
4
10
24
8
1()
48
1 600
4 200
14 000
260
300
140
Sampling co n n ect i o n s Open-ended l i n e s Total
components
Estimated population
MMSCF/D - M i l l i o n o f s t a n d a r d c u b i c f e e t p e r d a y a -
P r i m a r y p r o d u c t s l o a d e d a r e n a t u r a l g a s o l i n e an d c o n d e n s a t e .
4-10
TABLE
4-5.
MODEL OFFSHORE
Parameter
PRODUCTION
PLATFORMS
Small
Medium
Number o f w e l l s l o t s
2
18
Production wells
1
8
1 000
5 000
200
2 000
10
20
5
10
Gas/vapor Light liquid
60 15
540 120
H eavy l i q u i d
2
8
Light l i q u i d
1
1
H eavy l i q u i d
1
Crude o i l c a p a c i t y
BOPD)
Crude o i l pr oduction
BOPD)
Natural gas capacity
MMSCF/D)
Natural gas production
MMSCF/D)
Com ponents
Valves
Pump s e a l s
7
Compressor s e a l s Pressure r e l i e f valves
Flanges and connections
2
16
500
4 000
Sampling connections
1
3
Open-ended l i n e s
2
2
T o t a l components
590
4 700
Estimated population
260
40
BOPD
- B a r r e l s o f o i l p e r day
MMSCF D
- M illio n o f s tan d ar d cu b i c f e e t p e r day
4-11
as o f t h e d a t e o f t h i s background inj:ormation
Ho we v e r,
document
{BID),
the requested technical
d a t a on S t a t e w a te r
o f f s h o r e p r o d u c t i o n p l a t f o r m s have not been r e c e i v e d from A P I s
CAIG.
Due t o t h i s ,
t h e EPA d e v e l o p e d i t s
characterization of
o f f s h o r e product i on pl at form s lo cated i n S t a t e wa te r s and e s t i m a t e d model p a r a m e t e r s b a s e d o n d a t a a p p e a r i n g i n a n U . S .
D e p a r t m e n t o f I n t e r i o r s M i n e r a l s Management S e r v i c e
MMS)
report
on F ederal o f f sh o r e s t a t i s t i c s . 2 4 4.2.5
N a t u r a l Gas T r a n s m i s s i o n a n d S t o r a g e
T h e o n l y HAP e m i s s i o n p o i n t o f c o n c e r n f o r t h e n a t i o n a l
emission standards for hazardous a i r pol l ut ant s n a t u r a l gas t r an s m i s s i o n and st o r a g e f a c i l i t i e s vent associ at ed with a glycol dehydration unit
facilities.
NESHAP)
i s any proces s at
these
According to i n d u s t r y r e p r e s e n t a t i v e s ,
dehydration u n i t s used in the natural
80 p e r c e n t o f
gas t rans m i s s i on and
s t o r a g e s o u r c e c a t e g o r y a r e TEG d e h y d r a t i o n u n i t s , desiccant
for
with solid
systems accounting f o r most o f t h e rem ain in g u n i t s . 2 5
T h e r e a r e few,
i
any,
EG d e h y d r a t i o n u n i t s
in t h i s
source
category.26,27
Thus,
a s w i t h t h e model c o n d e n s a t e t a n k b a t t e r i e s ,
gas processing plants,
natural
and o f f sh o r e product i on pl at form s l o c a t e d
in State waters,
p a r a m e t e r s f o r model TEG d e h y d r a t i o n u n i t s a t
n a t u r a l gas t r an s m i s s i o n and st o r a g e f a c i l i t i e s in this
s e c t i o n o f t h e BID.
dehydration units
are not presented
The p a r a m e t e r s f o r model TEG
a r e p r e s e n t e d in S ect i o n 4 . 2 . 1 and Table 4-1 o f
t h i s BID. 4.3 1.
REFERENCES Responses t o t h e U.S. Environmental P r o t e c t i o n Age nc y s A i r E m i s s i o n s S u r v e y Q u e s t i o n n a i r e s f o r t h e O i l a n d N a t u r a l Gas P r o d u c t i o n S o u r c e C a t e g o r y EPA A i r D o c k e t A-·94-04, I t e m s I I - D - 1 thr ough I I - D - 2 5 ) . 1993.
2.
S i t e V i s i t T r i p R e p o r t S e r i e s from V i c o n o v i c , G . , I n c o r p o r a t e d , t o S m i t h , M . E . , EPA/CPB EPA/WCPG). 1993, and 1996.
3.
Memorandum f r o m A k i n , T . , a n d G. V i c o n o v i c , EC/R I n c o r p o r a t e d , t o S m i t h , M . E . , EPA/CPB. A p r i l 2 1 , 1 9 9 3 .
EC/R
1992,
4-12
Summary o f t h e o i l a n d n a t u r a l g a s p r o d u c t i o n r o u n d t a b l e
workshop.
4.
L e t t e r . a n d a t t a c h m e n t from E v a n s , J . M . , Gas R e s e a r c h I n s t i t u t e , t o V i c o n o v i c , G . , EC/R I n c o r p o r a t e d . A p r i l 1 9 , TEX c o n t e n t . 1995. N a t u r a l gas
5.
American P etro leu m I n s t i t u t e . T r i e t h y l e n e Glycol D e hydr a tor O p e r a t i n g P a r a m e t e r s f o r E s t i m a t i n g TEX E m i s s i o n s ( P r e p u b l i c a t i o n D r a f t ) . W a s h i n g t o n , DC. F e b r u a r y 1 9 9 6 .
6.
Memorandum f r o m A k i n , T . , EC/R I n c o r p o r a t e d , t o S m i t h , M . E . , EPA/CPB. J u l y 3 0 , 1 9 9 3 . R e v i s e d p r e l i m i n a r y e s t i m a t e o f t h e num ber a n d s i z e r a n g e s o f t a n k b a t t e r i e s o n a n a t i o n a l basis.
7.
Reference 3.
8.
Memorandum from V i c o n o v i c , G . , EC/R I n c o r p o r a t e d , t o S m i t h , M . E . , EPA/CPB. A p r i l 8 , 1 9 9 3 . Summary o f m e e t i n g w i t h t h e G as R e s e a r c h I n s t i t u t e .
9.
Gas R e s e a r c h I n s t i t u t e . T e c h n i c a l R e f e r e n c e Manual f o r GRI GLYCalc™: A P r o g r a m f o r E s t i m a t i n g E m i s s i o n s from G l y c o l D e h y d r a t i o n o f N a t u r a l Gas, V e r s i o n 3 . 0 GRI-96/0091). C h i c a g o , I L . March 1 9 9 6 .
10.
GRID: Gas R e s e a r c h I n s t i t u t e D i g e s t Research I n s t i t u t e , Chicago, IL.
Summer 1 9 9 3 ) . G as
11.
C h e m i c a l E n g i n e e r i n g . Decem ber 1 9 9 3 . Company, H i g h t s t o w n , NJ.
McGraw H i l l P u b l i s h i n g
12.
Gas R e s e a r c h I n s t i t u t e . N a t u r a l Gas D e h y d r a t i o n : S t a t u s a n d Trends. F inal Report GRI-94/0099). Chicago, IL. J a n u a r y 1994.
13.
Memorandum from A k i n , T . , a n d G. V i c o n o v i c , EC/R I n c o r p o r a t e d , t o S m i t h , M.E., EPA/CPB. J u n e 2 3 , 1 9 9 4 . Summary o f t h e m e e t i n g w i t h t h e A m e r i c a n P e t r o l e u m I n s t i t u t e s C l e a n A i r I s s u e s Group o n May 1 7 t h , 1 9 9 4 .
14.
Reference 8.
15.
Reference 13.
16.
Memorandum a n d a t t a c h m e n t s from V i c o n o v i c , G . , EC/R I n c o r p o r a t e d , t o S m i t h , M.E., EPA/WCPG. J u n e 26, 1 9 9 5 . Summary o f t h e A p r i l 2 6 t h , 1995,. t e l e c o n f e r e n c e w i t h r e p r e s e n t a t i v e s o f t h e American Petroleum I n s t i t u t e .
17.
Reference 5. 4-13
18.
Refere nce 12.
19. 20.
Reference 1 . Reference 1.
21.
O i l a n d Gas J o u r n a l . Company, T u l s a , OK.
22.
U.S. Environmental P r o t e c t i o n Agency/Office o f Water. D e v e l o p m e n t Document f o r E f f l u e n t L i m i t a t i o n s G u i d e l i n e s a n d New S o u r c e P e r f o r m a n c e S t a n d a r d s f o r t h e O f f s h o r e S u b c a t e g o r y o f t h e O i l a n d Gas E x t r a c t i o n P o i n t S o u r c e Category: F inal EPA 8 2 1 - R - 9 3 - 0 0 3 . W a s h i n g t o n , DC. J a n u a r y 1993.
23.
Memorandum from A k i n ,
J u ly 12,
T.,
1993.
PennWel l P u b l i s h i n g
a n d G. V i c o n o v i c ,
EC/R
I n c o r p o ro a ft e M d , e ettoi n g EPA/CPB. S mwi tiht h , M , m 9 9t 4 Summary e r i c a n P eF n4s,t i 1 tu e. s t h.eE . A t reobl reuuamr y I 1 C l e a n A i r I s s u e s Group.
24.
D e p a r t m e n t o f t h e I n t e r i o r / M i n e r a l s Management S e r v i c e . F e d e r a l O f f s h o r e S t a t i s t i c s : 1993 OCS R eport. MMS 9 4 - 0 0 6 0 .
U.S.
Herndon,
VA.
1994.
25.
Memorandum from V i c o n o v i c , G . , EC/R I n c o r p o r a t e d , t o S m i t h , M . E . , EPA/WCPG. J u l y 1 0 , 1 9 9 6 . S i t e v i s i t r e p o r t T r a n s c o n t i n e n t a l Gas P i p e L i n e C o r p o r a t i o n , C o m p r e s s o r S t a t i o n , D i s t r i c t 160, R e i d s v i l l e , No r t h Ca rolina .
26.
R eferen ce 25.
27.
Memorandum from V i c o n o v i c , G . , EC/R I n c o r p o r a t e d , t o S m i t h , M . E . , EPA/WCPG. D ecem ber 7 , 1 9 9 5 . Summary o f November 9 t h , 1995, m eetin g w i t h r e p r e s e n t a t i v e s o f t h e n a t u r a l g as transmission industry.
4-14
5.0
5.1
ENVIRONMENTAL AND ENERGY IMPACTS OF CONTROL OPTIONS
INTRODUCTION
This chapter provides a d i sc u ssi o n of the environmental and energy impacts a s s o c i a t e d with the control options t h a t have been i d e n t i f i e d a s applicable to t h e i d e n t i f i e d hazardous a i r
HAP)
pollutant
emission p o i n t s in the o i l and n a t u r a l gas
p r o d u c t i o n and n a t u r a l gas t r a n sm i ssi o n and s t or a ge
categories.
source
The c o n t r o l o p t i o n s u n d e r e v a l u a t i o n f o r HAP
emission points i d e n t i f i e d in these source categories are l i s t e d in Table 3-1 of Chapter 3.0 of t h i s background information
document
BID) .
The c o n t r o l o p t i o n s a p p l i c a b l e t o t h e i d e n t i f i e d HAP
emission points include a variety of emission reduction techniques.
The c o n t r o l o p t i o n s i n c l u d e
1)
the.use of emissions
c o n t r o l equipment
for tanks) glycol
and
(e.g.,
i n s t a l l a t i o n of a cover o r fixed-roof
work s t a n d a r d s
2)
dehydration units
(e.g.,
system optimization f o r
and l e a k d e t e c t i o n and r e p a i r
LDAR)
programs for f u g i t i v e emission points) . Two c o n t r o l o p t i o n s b e i n g e v a l u a t e d f o r HAP e m i s s i o n p o i n t s i n t h e s e s o u r c e c a t e g o r i e s may h a v e s e c o n d a r y e n v i r o n m e n t a l
impacts o r energy-use impacts. use of
1)
a combustion system
f a c i l i t i e s and fixed-roof
These c o n t r o l o p t i o n s i n c l u d e t h e (flare)
for remotely located
a vapor c o l l e c t i o n and r e d i r e c t system f o r
2)
storage tanks.
The i m p a c t a n a l y s e s c o n s i d e r a f a c i l i t y s a b i l i t y t o h a n d l e collected vapors. Some r e m o t e l y l o c a t e d f a c i l i t i e s may n o t b e able to use co l l ect ed vapor for
fuel
or recycle
t
back in to the
5-1
process.
In addition
some f a c i l i t i e s
t
may n o t b e t e c h n i c a l ly ly f e a s i b l e
to utilize
for
the non-condensable vapor streams
condenser systems as an al t er n at i v e fuel source safely. o p t i o n f o r t h e s e f a c i l i t i e s i s t o com bust t h e s e v a p o r s b y
from
n
flaring.
These concerns a r e r e f l e c t e d i n t h e analyses conducted by t h e EPA. of all
In
ts
analyses
t h e EPA e s t i m a t e d t h a t
1)
45 p e r c e n t
impacted f a c i l i t i e s w i l l be able to use c o l l e c t e d vapors
as an alternative fuel
source f o r an o n - s i t e combustion device
such as a process he a t e r or the glycol dehydration uni t firebox 2)
4 5 p e r c e n t w i l l b e a b l e r e c y c l e c o l l e c t e d v a p o r s i n t o a low
p r e s s u r e header system f o r combination with o t h e r hydrocarbon streams handled a t
the facility
and
3)
10 p e r c e n t w i l l d i r e c t
a l l c o l l e c t e d vapor to an o n - s i t e f l a r e . 5.2
AIR POLLUTANT IMPACTS
Primary Air Po l l u t a n t Impacts
5.2.1
The p r ima r y a i r p o l l u t a n t impacts a r e b a s e d on t h e e s t i m a t e d c o n t r o l e f f i c i e n c y o f t h e c o n t r o l o p t i o n s l i s t e d :Ln T a b l e
S-1.
Emission reductions for control of the glycol
unit
r e b o i l e r vent a r e based on t h e a p p l i c a t i o n o f with a
flash tank in the design of the glycol
d e h ~ r d r
1)
t i o n
a condenser
d e ~ r d r
t i o n
system
or
2)
a n e q u i v a l e n t HAP c o n t r o l s y s t e m .
T h e c o n t r o l o p t i o n s t h a t a r e b e i n g e v a l u a t e d f o r HAP emission points
i n t h e s e s o u r c e c a t e g o r i e s a r e al:so e f f e c t i v e
t h e c o n t r o l o f v o l a t i l e o r g a n i c compound
VOC)
and methane
e m i s s i o n s f r o m t h e same i d e n t i f i e d e m i s s i o n p o i n t s .
Thus,
primary a i r pol l ut ant impacts associated with control emission points
emissions.
include reductions
VOC
the
o f HAP
i n a s s o c i a t e d VOC a n d m e t h a n e
The p ri m a ry n a t i o n w i d e a i r p o l l u t a n t imp a c ts ,
a r e r e d u c t i o n s i n HAP
which
and methane a i r e missio n s a s s o c i a t e d
w i t h m a j o r HAP e m i s s i o n p o i n t s i n t h e s e s o u r c e c a t e g o r i e s
p r e s e n t e d in Tables 5-1 and S-2.
pollutant
impacts associated with area source glycol dehydration
S-2
5 l.
NATIONAL PRIMARY AIR POLLUTANT IMPACTS MAJOR SOURCES I N THE OIL AND NATURAL GAS PRODUCTION SOURCE CATEGORY EXAMPLE
Emissions Emission point
Megagrams p e r y e a r )
HAP
voc
M e t ha ne
36,000
85,000
6,200
Storage vessels
2,100
6,900
3,900
Equipment l e a k s
470
1,500
1,100
39,000
94, o·oo
11,000
28,000
55,000
3,800
Storage vessels
1,500
4,800
2,700
Equipment leak s
230
730
540
30,000
61,000
7,000
8,000
30,000
2,400
Storage vessels
640
2,100
1,200
Equipment leak s
240
770
560
Baseline
Process v e n t s
Total baseline
Reduction
Process vents
Total
reduction
Controlleda
Process vents
are
The p r i m a r y . n a t i o n w i d e a i r
u n i t s a r e presented in Table 5-3.
TABLE
in
FOR
8,900
Total controlled a
4,200
33,000
Based on following c o n t r o l o p t i o n s :
Glycol dehydration uni t Condenser w i t h f l a s h t a n k i n d e s i g n Storage tanks V e n t t o 95 control device Equipment l e a k s 70 level of control
5-3
TABLE 5 - 2 .
EX MPLE
NATIONAL M
N
TUR
L
G
S
JOR
PRIM RY AIR POLLUT NT IMPACTS SOURCES I N THE ND STOR GE SOURCE C TEGORY
TRANSMISSION
Emissions
Emission p o i n t
(Megagrams p e r yE ar)
H P
voc
Methane
120
1,500
59
110
1,400
54
10
100
5
Baseline
Process vents Reduction
P r o c e ss v e n t s
Controlleda '
Process vents
a - Based on f o l l o w i n g c o n t r o l o p t i o n s : G ly co l d e h y d r a t i o n
un t
- Condenser w i t h f l a s h t a n k
n
design
FOR
5-4
T
BLE
EX MPLE N TION L PRIM RY AIR POLLUT NT IMPACTS RE SOURCE GLYCOL DEHYDR TION UNITS I N THE OIL ND N TUR L G S PRODUCTION SOURCE C TEGORY
5-3.
Emissions Emission poi nt
Megagrams p e r y e a r )
voc
M e t ha ne
19,000
43,000
9,600
3,300
7,200
1,500
16,000
36,000
8,100
H
P
FOR
Baseline
Process vents Reduction
Process vents Controlleda
Process vents a
Based on t h e a p p l i c a t i o n o f a condenser w i t h f l a s h t a n k i n d e s i g n t o a re a source glycol dehydration u n i t s . Of t h e e s t i m a t e d t o t a l p o p u l a t i o n o f approximately 37,000 area source g l y c o l d eh y d ratio n u n i t s a p p r o x i m a t e l y 520 u n i t s woul d b e r e q u i r e d t o i n s t a l l c o n t r o l s .
5-5
Secondary Air P o l l u t a n t Impacts
5.2.2
Secondary e m i s s i o n s o f a i r p o l l u t a n t s r e s u l t from t h e operation o f c e r ta in control devices
b e u s e d t o com ply w i t h a s t a n d a r d . estimated that
such as a f l a r e
t h a t may
For condenser systems,
it
is
45 p e r c e n t o f i m p a c t e d g l y c o l d e h y d r a t i o n u n i t s
w i l l use t h e non-condensable p o r t i o n o f th e e mission stream as a
supplemental fuel source for the glycol reboiler. no n e t change
n
Thus,
there
is
energy use associated with the application of
t hi s control option for those f aci l i t i es
that incorporate this
d e s i g n and no n e t change i n co mb u s t i o n -rel at ed
A p o r t i o n o f impacted f a c i l i t i e s
emissions.
10 p e r c e n t )
judged to
are
be remotely located or technically unable to u t i l i z e collected These f a c i l i t i e s f l a r e c o l l e c t e d e mission s t reams .
vapors.
Thus,
oxide
there w ill be an increase in s ul f ur dioxide
NOx) , a n d c a r b o n m onoxide
combustion.
CO)
5.3
e missions from t h i s
The e s t i m a t e d n a t i o n a l a n n u a l
i ncrease in secondary a i r emissions
Mg)
nitrogen
Table 5-4 pre se nt s th e secondary a i r p o l l u t a n t
impa c ts on a n a t i o n a l b a s i s . m egagr am
SOx),
o f SOx,
7 Mg o f NOx,
from f l a r i n g
~ i l l
b e <1
a n d 1 Mg o f CO.
WATER AND SOLID WASTE IMPACTS The c o n d e n s e d w a t e r c o l l e c t e d w i t h t h e h y d r o c a r b o n
condensate can be d i r e c t e d back i n t o the system f o r reprocessing w i t h t h e hydrocarbon· condensate o r ,
i f separated,
produced water for disposal by r e i n j e c t i o n .
combined w i t h
Thus,
the water
impact associated with i n s t a l l a t i o n of a condenser system for a g l y c o l d e h y d r a t i o n u n i t r e b o i l e r v e n t would b e m i n i m a l .
W a t e r v a p o r may b e c o l l e c t e d a l o n g w i t h h y d r o c a r b o n v a p o r s n
t h e vapor c o l l e c t i o n and r e d i r e c t system f o r fixed-roof
storage tanks.
systems.
The w a t e r v a p o r may c o n d e n s e i n t h e c o n t r o l
A knockout designed i n t o t h e system w i l l c o l l e c t any
condensable product
w a t e r a n d h y d ro c a rb o n s ) .
As w i t h t h e
c onde nse r system, t h i s wa te r can be d i r e c t e d back i n t o t h e s y s tem f o r rep r o cessin g wi t h t h e hydrocarbon condensate o r, separated,
i
combined w i t h produced w a te r f o r d i s p o s a l by 5-6
T
BLE
5-4.
EX MPLE NATIONAL SECOND RY AIR POLLUT NT IMPACTS FLARING FOR M JOR ND RE SOURCES IN THE OIL ND N TUR L G S PRODUCTION SOURCE C TEGORYa
DUE
TO
Model p l a n t a n d emission point
E s t i m a t e d num ber installing flare
Estimated emissions p e r flareb Kilograms per year)
Total
Megagrams
per year)
SOx
NOx
co
SOx
NOx
co
<1
48 48 48 52
10 10 10
<1
2
<1
2
<1 <1
<1 <1 <1
Stand alone glycol units B
52 34
c
4
D
2
<1 <1 <1
A
Tank b a t t e r y
<1 <1 <1
6
<1
<1 <1
<1
H
2
<1 <1
10 10 11
<1
4
48 48 52
<1
G
<1
<1
<1 <1
1
<1
48
10
<1
<1
<1
<1
7
1
Natural gas processing plants A
Total
a
No
major so u r c e s i n t h e n a t u r a l gas tr an s m is s io n and st o r a g e s our c e
category are anticipated to use b
SOx NOx
co
flares
Sulfur dioxide
Nitrogen oxides C a r b o n m onoxi de
5-7
reinjection.
Thus,
t h e water impact a sso c ia te d with i n s t a l l a t i o n
o f v a p o r c o n t r o l sy st e m s would be minimal.
There a r e no i d e n t i f i e d s o l i d was t es t h a t would be g e n e r a t e d
by i n s t a l l a t i o n of dehydration unit
1)
a condenser system f o r t h e 9 l y c o l
reboiler vent o r
r e d i r e c t system for fixed-roof
a vapor
2)
storage tanks.
o l l ~ ~
Thui3
t i o n
and
no s o l i d
waste impacts are a nt i c i pa t e d with the i n s t a l l a t i o n o f these
systems.
5.4
N RGY
IMPACTS
I f vapor c o l l e c t i o n and r e d i r e c t systems i s used f o r t h e c o n t r o l o f e m i s s i o n s from a f i x e d - r o o f
storage tank,
it
would
r e q u i r e e l e c t r i c i t y f o r o p e r a t i o n o f t h e p ri m a ry components o f t h e vapor c o l l e c t i o n / r e c o v e r y system. fans
These components i n c l u d e
and blowers f o r proper o p e r a t i o n o f t h e system. The a n n u a l e s t i m a t e d e n e rg y r e q u ir e me n ts
collection/recovery system i s hr/yr
.
t
for each vapor
300 k i l o w a t t h o u rs p e r y e a r
kw -
i s e s t i m a t e d t h a t a p p r o x i m a t e l y 125 f a c i l i t i e s w o u l d
i n s t a l l one o r more o f t h e s e c o n t r o i o p t i o n s . T h e n a t i o n a l e n e r g y demand i m p a c t i s p r e s e n t e d i n T a b l e 5 - 5 .
The e s t i m a t e d n a t i o n a l e l e c t r i c a l the operation of all
control
demand t h a t w o u l d r e s u l t
options
i s 38,000 kw-hr/yr.
from
5-8
T
BLE
S-5.
Emission point a n d m ode l p l a n t
EX
MPLE
NATIONAL
ENERGY
REQUIREMENTSE
E s t i m a t e d num ber
Energy
installing
requirement kw-hr/yr)
kw-hr/yr)
100
300
30,000
25
300
7,500
control
option
Total
Storage tanks Condensate t a n k batteries Natural gas processing
plants·
38,000
Total kw hr/yr
Kilowatt hours p er year
5-9
6.0 6.1
COSTS OF CONTROL OPTIONS
INTRODUCTION
This ch ap ter p r e s e n t s th e approach used to e s t i m a t e t h e c o s t impacts of the control options presented in Chapter 3.0 to i d e n t i f i e d hazardous a i r polluta nt
HAP)
emission points in the
o i l and n a t u r a l g as p r o d u c t i o n and n a t u r a l g as t r a n s m i s s i o n and storage source categories.
C o s t i m p a c t s a r e b a s e d o n t h e model
p l a n t s presented in Chapter 4.0.
The model p l a n t c o s t i m p a c t s w e r e e x t r a p o l a t e d t o e s t i m a t e the cost
and c o s t - e f f e c t i v e n e s s of the c o n t r o l options on a
national basis.
The m e t h o d o l o g y u s e d t o e s t i m a t e t h e c o s t
i m p a c t s o f a p p l y i n g c o n t r o l o p t i o n s 1 t o i d e n t i f i e d HAP e m i s s i o n points
in these source categories
i s d e s c r i b e d i n A ppendix B.
A d e t a i l e d e x a m p l e i s p r o v i d e d i n t h i s BID t o d e m o n s t r a t e
the methodology as the
a p p l i e d o n a model p l a n t b a s i s .
control options used in t h i s
The c o s t s o f
example c a s e a r e p r e s e n t e d i n
Reference 1.
6.2
SUMMARY OF COST METHODOLOGY
Gen eral Approach
6.2.1
Cost e s t i m a t e s were developed f o r t h e fol l owi ng c o n t r o l options
condenser systems,
1)
of a gas condensate glycol
tank)
w i t h and w i t h o u t t h e i n s t a l l a t i o n
separator
GCG s e p a r a t o r o r f l a s h
i n glycol dehydration system design,
systems f o r fixed-roof s torage ta nks
2)
and
3)
vapor c o l l e c t i o n a leak detection
LDAR) p r o g r a m f o r f u g i t i v e e m i s s i o n s . c o s t s w e r e u p d a t e d t o J u l y 1993 d o l l a r s u s i n g c o s t
and r e p a i r All
i n d i c e s o b t a i n e d from Chemical E n g i n e e r i n g . 2
In selected cases
6-1
s e p a r a t e c o s t s were e s t i m a t e d f o r applying c o n t r o l opt i ons
to
e x i s t i n g a n d new f a c i l i t i e s .
The d i f f e r e n c e i n c o s t s b e t w e e n a n e x i s t i n g f a c i l i t y a n d
a
new f a c i l i t y f o r t h e same c o n t r o l o p t i o n i s a r e t r o f i t f a c t o r t h a t accounts f o r space l i m i t a t i o n s and a ddi t i ona l engineering requirements.
of control
The r e t r o f i t f a c t o r i s a p p l i e d t o t h e c a p i t a l c o s t
options
installed at existing facilities.
The
r e t r o f i t cost adjustment factor i s estimated to be 1.15 that
was j u d g e d t h a t
t
t
will cost
(on a v e r a g e )
me a n in g
1 5 p e r c e n t mo r e
t o i n s t a l l a c o n t r o l o p t i o n a t a n e x i s t i n g f a c i l i t y a s c o mp a r e d w i t h i n s t a l l a t i o n o f t h e same c o n t r o l
option a t
a
similar size
new f a c i l i t y . 6.2.2
M o n i t o r i n g E q u i p me n t Cost e s t i m a t e s f o r monitoring equipment a s s o c i a t e d with
co n d en ser systems and v a p o r c o l l e c t i o n d e v i c e s were i n c l u d e d i n the capital cost estimates.
costs of
In addition
t h e m o n i t o r i n g equipment were
the annualized capital
included in the
annual
costs of these control options.
The c o s t o f mo n ito r in g equipment c o n s i s t s o f t h e i n s t a l l a t i o n of instrumentation to monitor the control device.
For purposes of t h i s analysis
o p e ~ r
t i o n
the cost
of
of
the
m o n i t o r i n g was e s t i m a t e d t o b e
instrumentation factor
equal to the c a p i t a l cost
for each control
option.
Product Recovery
6.2.3
Product recovery i s presented as an annual c r e d i t in each cost
table
Product r e c ove ry c r e d i t s were
where a p p l i c a b l e .
c a l c u l a t e d b y m u l t i p l y i n g t h e mass o f p r o d u c t r e c o v e r e d b y t h e product value for each control
option.
Recovered condensate and o t h e r l i q u i d hydrocarbons were assigned a value of
for crude o i l . 3
18.00 p e r b a r r e l
t h e a v e ra g ' e c u r r e n t p r i c e
For recovered gaseous products
different values
w e r e a s s i g n e d d e p e n d i n g o n how t h e r e c o v e r e d g a s a r e u s e d . Recovered gaseous hydrocarbons recycl ed f o r processi ng were assigned a value of
(mscf)
4
2.00 p e r thousand standard cubic fe e t
By a s s i g n i n g a v a l u e o f 1 , 0 0 0 B r i t i s h t h e r m a l u n i t s
6 -2
(BTUs}/mscf, fuel
recovered gaseous hydrocarbons used as supplemental
were va lue d a t
1.30/mscf.
Gaseous h y d r o c a r b o n s d i r e c t e d
t o a n i n c i n e r a t o r o r f l a r e h av e n o v a l u e f o r p r o d u c t r e c o v e r y . 6.2.4 M o n i t o r i n g . I n s p e c t i o n . R e c o r d k e e p i n g . an d R e p o r t i n g
The a n n u a l c o s t s a s s o c i a t e d w i t h m o n i t o r i n g ,
recordkeeping,
an d r e p o r t i n g
MIRR}
inspection,
w e re i n c l u d e d i n t h e t o t a l
a n n u a l c o s t s , b u t a r e p r e s e n t e d s e p a r a t e l y fro m t h e c o n t r o l option costs.
Appendix
C presents
t h e met h o d o l o g y an d e s t i m a t e d
e x a mp le
MIRR c o s t s
f o r e a c h m a j o r HAP e m i s s i o n p o i n t .
ex amp l e
MIRR c o s t s
a r e a l s o p r e s e n t e d i n A p p e n d ix C f o r g l y c o l
dehydration units
Estimated
that are classified as area sources.
C o s t s o f HAP E m i s s i o n C o n t r o l O p t i o n s
6.2.5
6.2.5.1
Process Vents.
The g l y c o l d e h y d r a t i o n u n i t
r e b o i l e r v e n t h a s b e e n i d e n t i f i e d i n t h i s BID a s t h e p r i m a r y HAP
e m i s s i o n p r o c e s s v e n t i n t h e o i l an d n a t u r a l g a s p r o d u c t i o n a n d natural
gas t r a n s m i s s i o n and s t o r a g e s o u rce c a t e g o r i e s .
effective control option identified for.reducing
the
The m o s t
level of
H
emis s io n s from t h e g l y c o l d eh y d ratio n u n i t r e b o i l e r v e n t i s a condenser operated in conjunction with
a
flash tank in a glycol
de hydra tion u n i t s system design. Additional control
can be achieved by re c yc l i ng t he non
P
c o n d e n s a b l e g a s s t r e a m i n t o t h e i n co mi n g n a t u r a l g a s l i n e . n o n - c o n d e n s a b l e g a s s t r e a m may a l s o b e d i r e c t e d t o i n c i n e r a t o r o r used as a supplemental fuel
flare or
a
source.
The
A
condenser
may b e o p e r a t e d a t a h i g h e n o u g h e f f i c i e n c y s u c h t h a t t h e r e s i d u a l n o n - c o n d e n s a b l e g a s s t r e a m may b e v e n t e d t o t h e
atmosphere.
with
a
C os t e s t i m a t e s w e re d e v e l o p e d f o r
condenser system
a
95 p e r c e n t HAP e m i s s i o n r e d u c t i o n e f f i c i e n c y .
n e c e s s a r y eq u i p men t
The
f o r a condenser system in clu d es a
condenser,
c o n d e n s a t e s t o r a g e v e s s e l , an d p i p i n g . S y st em o p t i m i z a t i o n i s a n o t h e r c o n t r o l o p t i o n t h a t may
be
a p p l i c a b l e t o t h i s HAP e m i s s i o n p o i n t . Costs for system o p t i m i z a t i o n a r e n o t p r e s e n t e d due t o · t h e v a r i a b i l i t y o f e f f o r t a s s o c i a t e d with implementing t h i s
In·addition,
option.
t h e HAP
6-3
r e d u c t i o n a n d t h e c o s t s o f i m p l e m e n t i n g t h i s o p t i o n may v a r y
s u b s t a n t i a l l y among f a c i l i t i e s b a s e d o n s i t e - s p e c i f i c
Storage Tanks.
6.2.5.2
Crude o i l and co n d en s ate a r e
typically stored in fixed-roof these tanks are too small to the control options
factors.
storage tanks.
Sin. ce m o s t o f
i n s t a l l an i n t e r n a l f loating ro o f
evaluated for
stora.ge tanks
fixed-roof
require col l ect i ng the vapor emitted with a closed-vent
system.
T h e v a p o r c o l l e c t e d b y t h e c l o s e d - v e n t s y s t e n l may b e processed for sale device.
used for fuel
For t h i s analysis
t
o r be d i r e c t e d t o a c o n t r o l
was e s t i m a t e d t h a t 4 5 p e r c e n t o f
a l l f a c i l i t i e s i m p l e m e n t i n g c o n t r o l s f o r s t o r a g e t : anks w i l l process the recovered gas recovered gas
for
fuel
for
o r fuel
sale
45 p e r c e n t w i l l u s e t h e
substitute
a n d 10 p e r c e n t w i l l
i n s t a l l f l a r e s to destroy the col l ect ed gas stream. The c a p i t a l c o s t f o r e a c h c l o s e d - v e n t s y s t e m i n c l u d e s t h e cost of a
fan
designed to
flame a r r e s t o r
and piping.
r e c o v e r v ap o r from four
storage
The e q u i p m e n t w as tanks.
Total
c o s t w as e s t i m a t e d t o b e t h e same f o r a l l m odel p l a n t configurations utilizing this
control
option.
C osts were a l s o e s t i m a t e d f o r f l a r e s .
Based on t h e
capital
recovered volumes o f gas
from t h e s t o r a g e t a n k s
w e r e d e v e l o p e d f o r tw o s i z e f l a r e s . include the costs
f o r a k n o c k o u t drum
costs
for
flares
and p i p i n g .
a flare
Control option costs for
Equipment Leaks.
6.2.5.3
Capital
costs estimates
equipment l e a k s a t n a t u r a l gas p ro ces s i n g p l a n t s a r e based on t h e m o d e l p l a n t com ponent c o u n t s f o r t h e f a c i l i t i e s presented in Chapter 4.0
that
are
a n d t h e u s e o f a LDAR p r o g r a m .
Cost
e s t i m a t e s w e r e t a b u l a t e d f o r a m o n t h l y LDAR p r o g r a m b a s e d o n t h e
New S o u r c e P e r f o r m a n c e S t a n d a r d s
NSPS)
f o r Equipment Leaks o f
VOC f r o m O n s h o r e N a t u r a l Gas P r o c e s s i n g P l a n t s
4:0 CFR,
Part
60
S u b p a r t KKK . 6 6.3
MODEL PLANT BASED CONTROL COSTS T h i s s e c t i o n p r o v i d e s a g e n e r a l d i s c u s s i o n o f how c o n t r o l
o p t i o n c o s t s w e r e e s t i m a t e d f o r t h e m odel p l a n t s . .
More d e t a i l e d
6-4
i n f o r m a t i o n o n t h e m e t h o d o l o g y a n d t h e a l g o r i t h m s u s e d may b e
found in Reference 1 . 6.3.1
Glycol Dehydration Units The c o s t s o f a p p l y i n g a c o n d e n s e r t o t h e r e b o i l e r v e n t o f
e a c h m odel g l y c o l d e h y d r a t i o n u n i t d e s c r i b e d i n C h a p t e r 4 . 0 w e r e estimated.
For t h i s a n a l y s i s
m odel t r i e t h y l e n e g l y c o l
t
was e s t i m a t e d t h a t a l l . e x i s t i n g
TEG}-D a n d TEG-E d e h y d r a t i o n u n i t s h a v e
f l a s h tanks in t h e i r system designs
see Chapter 2.0 for
I t was a l s o e s t i m a t e d t h a t 90
d i s c u s s i o n o f f l a s h t a n k use} .
p e r c e n t o f t h e m odel TEG-A d e h y d r a t i o n u n i t s
TEG-B d e h y d r a t i o n u n i t s dehydration units
designs.
60 p e r c e n t o f m odel
a n d 4 5 p e r c e n t o f m odel TEG-C
do n o t have f l a s h t a n k s i n t h e i r s y s t e m
T h e r e f o r e , c o s t s f o r f l a s h t an k s were added t o t h e
c o n d e n s e r c o s t e s t i m a t e s f o r t h o s e e x i s t i n g m odel g l y c o l dehydration units
6.3.2
not having flash tanks in the system design.
C o n d e n s a t e Tank B a t t e r i e s
F o r c o n d e n s a t e m odel t a n k b a t t e r i e s
control option costs
w e r e e s t i m a t e d f o r VRUs f o r f i x e d - r o o f s t o r a g e t a n k s . 6.3.3
N a t u r a l Gas P r o c e s s i n g
Plants
C o n t r o l o p t i o n c o s t s f o r m odel n a t u r a l g a s p r o c e s s i n g p l a n t s
w e r e d e v e l o p e d f o r VRUs f o r f i x e d - r o o f
monthly 6.4 EX
LD
R
MPLE
s t o r a g e t a n k s and a
program f o r c o n t r o l o f equipment l e a k s .
The f o l l o w i n g e x a m p l e i l l u s t r a t e s t h e a p p r o a c h u s e d t o estimate the cost
i m p a c t s o f c o n t r o l o p t i o n s o n a m odel p l a n t .
The m odel p l a n t s e l e c t e d f o r t h i s e x a m p l e i s m odel c o n d e n s a t e t a n k b a t t e r y G t h a t h a s a m odel TEG-C u n i t
battery.
co-located at
the tank
The m odel p l a n t c h a r a c t e r i s t i c s o f t h e s e f a c i l i t i e s
are
p r e s e n t e d i n Tables 4-1 and 4-3 o f Chapter 4 . 0 .
The a p p l i c a b l e c o n t r o l o p t i o n s f o r t h i s m odel p l a n t
combination include
1)
a condenser f o r the glycol dehydration
2) a c l o s e d - v e n t s y s t e m f o r t h e s t o r a g e u n i t r e b o i l e r v e n t and tanks. T h i s e x a m p l e m odel p l a n t c o m b i n a t i o n h a s a n o n - s i t e
combustion device required for
so i n s t a l l a t i o n o f a control device i s not
t h e va por c o l l e c t e d from s t o r a g e
tanks.
6-5
The s i z e o f t h e c onde ns e r i s d ep en d en t on t h e flow r a t e o f the glycol dehydration unit reboiler vent, stream to
the condenser.
which i s the i n l e t
The f l o w r a t e a n d
H
t h e g l y c o l d e h y d r a t i o n u n i t r e b o i l e r v e n t was parameters presented in Table 4-1
GRI-GLYCalcTM ( V e r s i o n 3 . 0 ) . 7
n
P
concentration of
e s t i n ~
t e d
using the
C h a p t e r 4 . 0 oj: t h i s BID a n d
The r e d u c t i o n o f
H
achieved by
P
t h e condenser i s b as ed on a H P em i s s i o n r e d u c t i o n e f f i c i e n c y o f
9 5 p e r c e n t a n d a n a v e r a g e i n l e t c o n c e n t r a t i o n o f 200 p a r t s p e r m i l l i o n b y v o l u me
mixed x y l en es
ppmv) b e n z e n e ,
toluene,
e t h y l benzene,
c o l l e c t i v e l y r e f e r r e d t o a s BTEX)
and
in the wet
n a t u r a l gas e n t e r i n g the glyc ol dehydration proces:s.
The d e s i g n c r i t e r i a and c o s t o f t h e c onde ns e r s ys t e m a r e presented
n
Table 6-1 and Table 6-2.
As shown,
t o t a l c a p i t a l investment of the condenser i s t o t a l net annual cost
s
the
estimated
11,000, while th e
( 940) .
A closed-vent system i s the control option applied to the fixed-roof
storage tanks
at this facility.
Emissions from t h e
s t o r a g e t a n k s a r e based on st a ndi ng and working l o s s e s .
p u r p o s e s o f t h i s e x a mp le , As shown
n
Table 6-3,
f l a s h e m i s s i o n s w e re n o t
the t o t a l
c a p i t a l investment
For
calculated.
is estimated
as
The v a p o r c o l l e c t e d i s d i r e c t e d t o the: o n - s i t e
3,600.
recovery
flare) . credit combustion device T h e r e f o r e , no p r o d u c t i s c l a i m e d n t h e t o t a l n e t a n n u a l c o s t shown i n T a b l e 6 - 4 .
T h e t o t a l e s t i m a t e d a n n u a l c o s t s f o r MIRR are; a p p r o x i m a t e l y The c o s t s a r e a d d e d t o t h e a n n u a l
5 , 7 0 0 f o r t h i s mo d e l p l a n t .
c o s t s f o r t h e c o n t r o l o p t i o n s f o r t h i s model p l a n t .
summation o f t h e s e annual c o s t s divide d by the annual emission reduction is
The H
P
equal to the cost e f f e c t i v e n e s s for
c o n t ro l l i n g the combination of H P emission points a t
t h i s mo d e l
plant.
The c o s t i m p a c t s o f i m p l e m e n t i n g t h e s e c o n t r o l o p t i o n s t o t h i s mo d e l p l a n t c o m b i n a t i o n a r e s u mma r i z e d i n T a b l e 6 - 5 . shown, t h e t o t a l c a p i t a l i n v e s t m e n t f o r t h i s model p l a n t
combination i s
14,600.
Total
net annual cost
As
i n c u r r e d by t h e
6-6
TABLE 6 1 .
EXAMPLE CONDENSER CAPITAL COSTSa FOR MODEL GLYCOL DEHYDRATION UNIT TEG-C
Equipment
Condenserl'
Description
Size
Condenser and
Factor/
Reference Ref.
All
8
Cost 6,800
piping
C o n d e n sa t e
s
gallons
storage tank Flash tank
125 p s i g
Low p r e s s u r e
2.72{V)+1,960 Ref. 9
R ef. 10
2,100 N.A.
separator
Purchased equipment c o st s
Enhanced m o n i t o r i n g equipment Total capital
cost
{TCC
8,900
{PEC) {EM
for existing unite
0.10*PE C 1.1S*{PEC+EM)
a -
J u l y 1993 d o l l a r s .
b -
Includes di r ect
c
R e t r o f i t facto r of 1.15x fo r ex istin g u n i t s .
-
N.A.
890
11,000
and i n d i r e c t c o s ts .
- Not a p p l i c a b l e t o u n i t s w i t h f l a s h t a n k i n e x i s t i n g s y s t e m d e s i g n .
N o t e : Numbers may v a r y d u e t o r o u n d i n g .
6-7
T
BLE
6-2.
EX MPLE
CONDENSER NNU L COST:Sa TION UNIT TEG C
FOR
MODEL GLYCOL DEHYDR
Cost category
Factor
Cost
Direct annual cost
Operating labor
(0.5 hr/8 hr)*(2,080 hr/yr)*(
1,700
13.20/hr)
Supervising labor
0.15*(0perating labor)
Operating materials
None r e q u i r e d
260 0
Maintenance Labor
(0.5 hr/8 hr)*(2,080 hr/yr)*(
Material
Utilities
1,900
14.50/hr)
0.5*(Maintenance labor) None r e q u i r e d
950 0
I n d i r e c t annual costs
2,300
OVerhead
0.60*(Maintenance t o t a l )
Administrative
0.02*(TCC)
230
Property taxes
0.01*(TCC)
110
Insurance
0.01*(TCC)
110
Capital recoveryh
0.1098*(T CC)
Recovery c r e d i t c /
1,500
condensate
(555 b b l / y r ) * (
(10,000)
18.00/bbl)
Total annual cost
( 940)
a
J u l y 1993 d o l l a r s .
b
B a s e d o n a n e q u i p m e n t l i f e o f 1 5 y e a r s and a n i n t e r e s t r a t e o f o v e r t h e l i f e o f t h e equipment.
c
Number i n p a r e n t h e s e s i n d i c a t e a s a v i n g s .
~
7 percent
Numbers may v a r y d u e t o r o u n d i n g .
6-8
TABLE 6 - 3 .
EXAMPLE CLOSED VENT SYSTEM CAPITAL COSTSa FOR MODEL CONDENSATE TANK BATTERY TB-G
Equipment Fan
FRP,
Motor
w/Belt
Piping
2
Galv. s t e e l
Fl ame arrestor
2
dia.
Equipment c os t s
centrifugal
starter
Purchased equipment c o s t
(PEC)
Direct installation cost
DC)
-
dia.
42.3*(D)1. 2 Ref. 11
capital cost
Cost $750
7 . 5 hp
235*(hp)0.256 Ref. 11
410
200 f t
R e f . 12
830
Ref.
110
12
$2,100
Indirect installation cost
a
10.5
Factor/
Reference
(EC)
Enhanced m o n i t o r i n g equipment
Total
Size
Description
EM)
(IC)
(TCC)
J u l y 1993 d o l l a r s .
N o t e : Numbers may v a r y d u e t o r o u n d i n g .
0.10*(EC) 1.08*(EC+EM)
Ref.
12
0 . 20* (PEC) (PEC+DC+IC)
210
2,500 580 500
$3,600
6 9
T
BLE
6-4.
EX MPLE CLOSED VENT SYSTEM NNU L MODEL CONDENS TE T NK B TTERY TB-G Factor
Cost category
COSTSa FOR Cost
D i r ect annual co st
Maintenance Labozl>
(1 h r / y r ) * (
Material
1.0*(Maintenance labor)
14.50/hr)
0.0509/kW-hr
Utilities
15 15 20
In d ire c t annual costs
OVerhead
0.60*(Maintenance t ot al )
18
Administrative
0.02*(TCC)
72
Property taxes
0.01*(TCC)
36
Insurance
0 . 01* TCC)
36
Capital r e c o v e ~
c
T ot a l annual co st
a
-
0.1098*(TCC)
400 610
J u l y 1993 d o l l a r s .
b -
Reference 12.
c
B a s e d on a n equipment l i f e o f 15 y e a r s and a n i n t e r e s t r a t e o f 7 p e r c e n t
-
over t h e l i f e o f the equipment.
N.A.
- Not a p p l i c a b l e .
~
Numbers may v a r y due t o r o u n d i n g .
6-10
T
BLE
6-5.
EX MPLE
MODEL
PL
NT
COST
IMPACTSa
H P
H
emission point
P
Glycol r e b o i l e r vent
Storage tanks
Control
reduction
Total
option
(Megagrams
capital cost
p e r year)
Condenser
60
Closed vent system
0.2
annual cost
11,000
3,600
( 940)b 610
5,700
MIRR c o s t s c Total
Total net
60
14,600
5,370
a
-
e x i s t ignl g fa l ihtyyd rraetp T hn e sdee ncsoa st et ti a mnpka cbt sa t at ep rpyl yGt oand a n model b y model co yco l cdi e un ntiet d TEG-C. i or en s e
b
-
Pa r e n t h e se s r e p r e se n t a c o s t s av i n g s due to product recovery.
c -
M o n i t o r i n g , i n s p e c t i o n r e c o r d k e e p i n g , a n d r e p o r t i n g MIRR) c o s t s includes 3,400 f o r g l y c o l d e h y d r a t i o n u n i t and 2,300 f o r s t o r a g e tanks.
6-11
mo d e l p l a n t c o m b i n a t i o n i s MIRR.
Total
annual reduction of hazardous a i r p o l l u t a n t s i s
megagrams p e r y e a r these control
megagram
Mg)
5,370, which includes the c o s t o f
(Mg/yr) .
options
Therefore,
the cost effectiveness of
on t h i s model p l a n t co mb i n at i o n i s
90 p e r
o f HAP r e d u c e d .
References
used i n th e development of the t a b l e s in t h i s
chapterB,9,10,11,12,13
are l i s t e d in Section 6.5 of t h i s
chapter.
6.5
REFERENCES
1.
U . s . En v i r o n men t al P r o t e c t i o n Agency Economic Impact A n a l y s i s o f t h e P r o p o s e d O i l a n d N a t u r a l Gas NESHAPs. F i n a l R e p o r t ( E P A - 4 5 3 / R - 9 6 - 0 1 6 ) . R e s e a r c h T r i a n g l e P a r k , NC.
November 1 9 9 6 .
2.
Chemical Engineering. P u b l i s h i n g . New York,
3.
O i l a n d Gas J o u r n a l . S t a t i s t i c s . P u b l i s h i n g Company. T u l s a , OK.
4.
Reference 3.
5.
Gas R e s e a r c h I n s t i t u t e . P r o c e e d i n g s o f t h e 1992 Gas R e s e a r c h I n s t i t u t e Glycol Dehydrator Air Emissions Conference. Chicago, IL. September 1992.
E q u i p me n t I n d i c e s . M c G r a w - H i l l NY. V a r i o u s I s s u e s .
June 21,
19:93.
PennWell
6.
S t a n d a r d s o f P e r f o r m a n c e f o r E q u i p me n t L e a k s o f VOC f r o m O n s h o r e N a t u r a l Gas P r o c e s s i n g P l a n t s . Code o f F e d e r a l R e g u l a t i o n s , T i t l e 40, P a r t 60, S u b p a r t KKK J u l y 1 , 1 9 9 2 . U . S . G o v e r n me n t P r i n t i n g O f f i c e , W a s h in g to n , DC.
7.
G a s R e s e a r c h I n s t i t u t e . T e c h n i c a l R e f e r e n c e Manual f o r GRI GLYCalc™: A P r o g r a m f o r E s t i m a t i n g E m i s s i o n s f r o m G l y c o l D e h y d r a t i o n o f N a t u r a l Gas, V e r s i o n 3 . 0 ( G R I - 9 6 / 0 0 9 1 ) . Chicago, IL. March 1996
B.
California). Ventura County A i r P o l l u t i o n C ontrol D i s t r i c t Rule 71.5, Glycol Dehydrators (Draft S t a f f Report). E x e c u t i v e Summary. V e n t u r a , CA. A u g u s t 8 , 1 9 9 4 .
9.
U . S . E n v i r o n m e n t a l P r o t e c t i o n Agency. OAQPS C o n t r o l C o s t Manual ( F o u r t h E d i t i o n , EPA 4 5 0 / 3 - 9 0 - 0 0 6 ) . R e s e a r c h T r i a n g l e P a r k , NC. J a n u a r y 1 9 9 0 .
10.
Owens, A . S . BTEX E m i s s i o n s f r o m G a s / G l y c o l D e h y d r a t o r s : A i r · Q u a l i t y C a s e H i s t o r i e s . P r o c e e d i n g s o f t h e 1994 GRI G l y c o l D e h y d r a t o r / G a s P r o c e s s i n g A i r T o x i c s Conferl:mce (J u n e 1 9 9 4 ) . Gas R e s e a r c h I n s t i t u t e , Chicago, IL .
.6 - 1 2
11.
12.
13.
E n v i r o n m e n t a l P r o t e c t i o n Agency. C o n t r o l T e c h n o l o g i e s f o r Hazardous A i r P o l l u t a n t s EPA 6 2 5 / 6 - 9 1 / 0 1 4 . W a s h i n g t o n ,
U.S.
DC. J u n e 1 9 9 1 . U . S . E n v i r o n m e n t a l P r o t e c t i o n Agency. H a z a r d o u s W a s t e T S D F B a c k g r o u n d I n f o r m a t i o n f o r P r o p o s e d RCRA A i r E m i s s i o n S t a n d a r d s - Volume I I I EPA 4 5 0 / 3 - 8 9 - 0 2 3 c . R e s e a r c h T r i a n g l e P a r k , NC. J u n e 1 9 9 1 . N a t i o n a l Emissions S ta nda r ds f o r Hazardous A i r P o l l u t a n t s ; Announcem ent o f N e g o t i a t e d R e g u l a t i o n s f o r E q u i p m e n t L e a k s F e d e r a l R e g i s t e r V o l . 5 6 , No. 4 4 , p p . 9 3 1 5 - 9 3 3 9 . Mar ch 6 , 1 9 9 1 . O f f i c e o f t h e F e d e r a l R e g i s t e r Wa s h i n g t o n , DC.
6-13
APPENDIX A. EVOLUTION
OF
THE
B
CKGROUND
INFORMATION
The p r i m a r y o b j e c t i v e o f t h i s p r o j e c t for
DOCUMENT
i s to develop a b a s i s
supporting proposed nat i onal emissions standards f o r
h a z a r d o u s a i r p o l l u t a n t s NESHAP) f o r t h e o i l a n d n a t u r a l g a s production and n a t u r a l gas transmission and s t o r a g e source categories.
To a c c o m p l i s h t h i s o b j e c t i v e ,
acq u ir ed on th e
1)
technical
d a t a were
f o l l o w i n g a s p e c t s o f t h e s e two s o u r c e c a t e g o r i e s
p r o c e s s o p e r a t i o n s and equipment,
e x t r a c t e d and recovered products,
3)
2)
the characteristics of
identified potential
em i ssi on p o i n t s where h azard o u s a i r p o l l u t a n t s
HAP)
are released
i n c l u d i n g t h e magnitude and co mp o sitio n o f H P e m i s s i o n s ) ,
and
4)
t h e t y p e s and c o s t s o f c o n t r o l
o p t i o n s t h a t may b e a p p l i e d t o
identified potential H P emissions. The b u l k o f t h e i n f o r m a t i o n was g a t h e r e d f r o m t h e f o l l o w i n g sources 1.
Technical l i t e r a t u r e ,
2.
Federal,
Regional,
State,
and l o c a l r e g u l a t o r y
agencies, 3.
Site visits,
4.
Industry representatives,
5.
Equipment ve ndor s.
and
Significant events relating to the evolution of the
b a c k g r o u n d i n f o r m a t i o n document
BID)
f o r t h e o i l and n a t u r a l gas
p r o d u c t i o n a n d n a t u r a l g a s t r a n s m i s s i o n a n d s t o r a g e NESHAPs a r e i t em i zed i n Table A-1.
A-1
TABLE
A-1.
EVOLUTION OF
Date
Company
06/22/92
U.S.
~ 0
0 7
9 2
THE
BACKGROUND
INFORMATION DOCUMENT
or agency/location
consultant
E n v ir o n m en tal P r o t e c t i o n Agency and
industry representatives/RTP
Nature o f a c t i o n I n d u s·t.r y m e e t i n g
NC
Amoco P r o d u c t i o n Co.
S e c t i • o n 114
Gas Co. Chevron U.S.A. I n c . Ex x o n Company U . S . A .
l e t t e r for plant visits
ARCO
i n f o ~ m
Oil
t i o n
request
Conoco Inc. Texaco E xpl or a t i on and Producing Inc Mobil E x p l o r a t i o n P r o d u c i n g u.s. I n c . ~ 0
1 2
9 2
Amoco P r o d u c t i o n C o .
Zachary
LA
Plant v i s i t
to gather
b ack g ·r o u n d
i n f o r m a t i o n on t h e methcds used to p ro d u . c e o i l a n d natur al gas
10/12/92
ARCO
Oil
Gas C o .
Lafayette
LA
Plant v i s i t
to gather
b ack sr r o u n d
on the methe>ds u s e d t o produce o i l and natur al gas i n f o i ~
t i o n
1 0
~ 3
9 2
Chevron
U.S.A.
Inc.
Thompson
TX
Plant v i s i t
to gather
backHround information on the methods u s e d t o produce o i l and natuJral gas
10/13/92
Ex x o n Company
U.S.A.
Katy
Plant v i s i t
TX
to gather
back9round information on the
methods u s e d t o p r o d ·u ce o i l a n d n a t u r a l gas
10/14/92
Conoco
Inc.
Benavides
Plant v i s i t
TX
to gather
background on the methods u s e d t o produce o i l and . na tur a l gas i n f o ~
t i o n
A 2
T
BLE
A-1.
EVOLUTION
OF
THE
B CKGROUND
Continued)
consultant, o r agency/location
Date
Company
10/15/92
Texaco E x p l o r a t i o n and Producing I n c . Midland, TX
03/17/93
04/06/93 04/07/93 04/29/93
05/27/93
INFORMATION
u.s. Environmental P r o t e c t i o n Agency·and Gas Res ear ch I n s t i t u t e / R T P ,
DOCUMENT
N atu r e o f a c t i o n
Plant v i s i t to gather
background inf or m a tion on t h e methods u s e d t o p r o d u ce o i l and n a t u r a l gas
I n d u s t r y m eetin g
NC
U.S. Environmental P r o t e c t i o n Agency and i n d u s t r y r e pr e s e nta tive s /R TP, NC
I n d u s t r y m eetin g
U.S. Environmental P r o t e c t i o n Agency/RTP, NC and Washington,
Work group m eetin g
Marathon O i l Co. Oxy US I n c . S h e l l O i l Co. Lomack P etr o leu m , I n c . Maxus Energy Corp.
DC
A i r e m i ssi o n s su r v e y questionnaires mailout
M i t c h e l l Energy Co. P h i l l i p s P etr o leu m Co.
Amerada Hess Corp.
Amoco P r o d u c t i o n Co. Conoco, I nc . Oryx Energy Co. Texaco, I nc . Unoc Uno cal Mesa P etr o leu m Union P a c i f i c Environmental S e r v i c e s Enron Corp.
A t l a n t i c R i c h f i e l d Co. BP E x p l o r a t i o n A las k a, I n c . Chevron US P r o d u c t i o n Co. Exxon US P r o d u c t i o n Dept. Mobil O i l Corp. Kerr McGee Pogo P r o d u c t i o n Co. Arch P etr o leu m
A 3
TABLE A - 1 .
EVOLUTION OF THE B CKGROUND I N F O R M
(Continued)
Date
Company,
07/27/93
Ex x o n Company U . S . A . Chevron U.S .A., I nc. Shell western E P Inc.
consultant,
or agency/location
N a,tur e o f a c t i o n
i n f o i ~ a t i o n
request
lettE r for p l a n t
visit:s
08/03/93
Texaco E x p l o r a t i o n and Pro d u ct i o n I n c . , O f f s h o r e o f S a n t a B a r b a r a C o u n t y , CA
08/04/93
Mobil E x p l o r a t i o n and Producing Goleta,
DOCUMENT
S e c t i o n 114
T e x a c o US
Inc.,
~ r i O N
u.s.
CA
Plant: v i s i t t o g a t h e r back9round infoJ::1llation o n t h e methods use d t o produce o i l and natu:r :al g a s Plan·t v i s i t to g a t h e r back ::Jround inf or ma tion on t h e
methods use d to produce o i l and n at u r al gas
08/04/93
Ex x o n Company,
B arb ara County,
U.S.A., Offshore of Santa CA
Plant v i s i t
to g ath er
background information on the
methods use d to
\
produce o i l and n at u r al gas
08/03/93
Chevron U.S.A. I n c . , O f f s h o r e o f S a n t a B a r b a r a C o u n t y a n d V e n t u r a C o u n t y , CA
08/05/93
08/09/93
Plant v i s i t s to g ath er background inf or ma tion on t h e
methods use d to produce o i l and n at u r al gas S t a t e o f Kansas,
Various s i t e s
through
08/ll/93
Plant v i s i t s to g ath er background infc,rmation on th e
methods use d t o produce o i l and n a t ~ r a l gas
A 4
TABLE
A-1.
EVOLUTION OF THE BACKGROUND INFORMATION DOCUMENT Continued)
Date
Company,
08/10/93
Wallace Energy,
consultant
o r agency/location
Inc.
Plainville
KS
Nature o f action Plant v i s i t
to gather
background information on the
methods u s ed to produce o i l and n a t u r a l gas
08/10/93
O i l R e c l a i m i n g Company,
Limited,
Seward,
Plant v i s i t
to gather
background
KS
information on the
methods u s ed to produce o i l and n a tu r a l gas
08/10/93
H W
Oil
Company,
Ha ys,
KS
Plant v i s i t to gather background inf or ma tion on t h e methods u s ed to produce o i l and n a t u r a l gas
08/11/93
T r i d e n t NGL
Inc.
Cheney,
Plant v i s i t to gather background i n f o r m a t i o n on t h e
KS
methods u s ed t o produce o i l and n a t u r a l gas
Transmission Corp.
Air emissions survey questionnaire mailout
09/15/93
CNG
02/01/94
U . S . E n v i r o n m e n t a l P r o t e c t i o n A gency a n d industry representatives/RTP
I ndus tr y meeting
NC
02/01/94
D i s t r i b u t i o n o f d r a f t BID C h a p t e r s 2 . 0 3.0 and 4. 0 to i n d u s t r y
BID c h a p t e r distribution
04/12/94
u.s.
Work g r o u p m e e t i n g
04/26/94
Environmental P r o t e c t i o n A gency/RTP , NC a n d w a s h i n g t o n , U.S.
DC
E n v i r o n m e n t a l P r o t e c t i o n A gency a n d
industry representatives/RTP
I ndus tr y meeting
NC
A 5
T BLE
A-1.
EVOLUTION OF
THE
B
CKGROUND
{Continued)
INFORM TION DOCUMENT
Nature o f a c t i o n
Date
Company,
04/26/94
D i s t r i b u t i o n o f d r a f t BID C h a p t e r s 2 . 0 3.0 and 4.0 t o i n d u s t r y
BID c h a p t e r distribution
05/17/94
u.s.
Industry meeting
consultant
or agency/location
E n v iro n m en tal P r o t e c t i o n Agency and
indus try representatives/RTP
05/23/94
u.s.
E n v iro n m en tal P r o t e c t i o n Agency and
indus try representatives/RTP
08/26/94
NC
Industry meeting
NC
D i s t r i b u t i o n o f complete preliminary
BID d i s t r i b u t i o n
d r a f t BID t o i n t e r e s t e d p a r t i e s
u.s.
E n v iro n m en tal P r o t e c t i o n Agency and indus try representatives/RTP NC
Industry
12/08/94
u.s.
E n v iro n m en tal P r o t e c t i o n Agency and indus try representatives/RTP NC
Indu ;try meeting
04/26/95
u.s.
Indu1;try tele1::onference
10/13/94
E n v iro n m en tal P r o t e c t i o n Agency and
indus try representatives/RTP
NC
telec:onference
05/08/95
u.s.
E n v iro n m en tal P r o t e c t i o n Agency and indus try representatives/RTP NC
I ndus t r y meeting
05/25/95
u.s.
Industry teleconference
11/02/95
U.S.
E n v iro n m en tal P r o t e c t i o n Agency and NC industry representatives/RTP E n v i r o n m e n t a l P r o t e c t i o n A g e n c y a nd
indus try representatives/RTP
11/09/95
u.s.
NC
E n v iro n m en tal P r o t e c t i o n Agency and
indus try representatives/RTP
Industry meeting
Industry meeting
NC
12/14/95
u.s.
E n v iro n m en tal P r o t e c t i o n Agency and indus try representatives/RTP NC
Industry meeting
03/21/96
u.s.
Industry meeting
E n v iro n m en tal P r o t e c t i o n Agency and industry representatives/RTP NC
A 6
T
BLE
A-1.
EVOLUTION OF
THE
B
CKGROUND
Continued)
Date
Company,
04/04/96
T r a n s c o n t i n e n t a l Gas P i p e L i n e corporation Reidsville NC
consultant
INFORM TION DOCUMENT
or agency/location
Nature of a c tion Plant v i s i t
to gather
background information on the
methods u s e d i n n a t u r a l gas transmission 05/09/96
u.s.
E n v i r o n m e n t a l P r o t e c t i o n A g en cy . a nd
industry representatives/RTP
07/30/96
u.s.
08/28/96
10/17/96
10/31/96
NC
E n v i r o n m e n t a l P r o t e c t i o n A g en cy a n d
industry representatives/RTP
NC
u.s.
Environmental P r o t e c t i o n Agency/RTP, NC a n d W a s h i n g t o n ,
DC
u.s. E n v i r o n m e n t a l P r o t e c t i o n Agency/RTP, NC a n d W a s h i n g t o n ,
DC
Industry teleconference Work g r o u p m e e t i n g
Work g r o u p m e e t i n g
u.s.
Environmental P r o t e c t i o n Agency/RTP, NC a n d W a s h i n g t o n ,
In d u st ry meeting
Work g r o u p m e e t i n g DC
11/07/96
u.s.
E n v i r o n m e n t a l P r o t e c t i o n A g en cy a n d industry representatives/RTP NC
A
7
I n d u s t r y meeting and teleconference
APPENDIX B . N
B.1
TION
L
IMPACTS
METHODOLOGY
INTRODUCTION
This appendix d e s c r i b e s t h e g e n e ra l methodology u s e d t o e s t i m a t e t h e nationwide impacts o f the proposed n a t i o n a l emission standards f o r hazardous a i r p o l l u t a n t s NESHAP) t h a t a r e b e i n g
developed f o r t h e o i l and n a t u r a l gas p ro d u c t i o n and n a t u r a l gas transmission and storage source c a t e g o r i e s .
results
in
1)
estimates of baseline
i m p l e m e n t a t i o n o f NESHAP) HAP)
emissions and
estimated
2)
i.e.,
This methodology before
the
and c o n t r o l l e d hazardous a i r p o l l u t a n t
the
impacts of control options.
include H P emission reduction,
Impacts
t o t a l c a p i t a l and n e t
annual c o s t s , B.2
and se c onda r y e nvir onme nta l and e ne r gy i mp act s .
OVERVIEW OF
METHODOLOGY
The b a s i c e l e m e n t s o f t h e m e t h o d o l o g y u s e d i n e s t i m a t i n g impacts f o r the o i l and n a t u r a l gas produc tion and n a t u r a l g as t r a n s m i s s i o n a n d s t o r a g e NESHAPs a r e a s
follows
1)
development
o f m odel p l a n t s ,
2)
i d e n t i f i c a t i o n o f H P emission p o i n t s and
control options,
3)
application of H P emission control options
to
identified emission points,
impacts,
and
national
impacts.
B.3
MODEL
5)
4)
e s t i m a t i o n o f m odel p l a n t
e x t r a p o l a t i o n f r o m m odel p l a n t
impacts to
Each o f t h e above e le me n ts i s d i s c u s s e d below.
PL NT DEVELOPMENT
Due t o t h e l a r g e num ber o f f a c i l i t i e s
in these source
c a t e g o r i e s and t h e tim e and r e s o u r c e s t h a t would have b een required, standards
t
was n o t f e a s i b l e
to simulate the impacts o f
on each a c t u a l impacted f a c i l i t y .
Instead,
a m odel
p l a n t a p p r o a c h was u s e d .
B- 1
First, identified
d i s t i n c t s e c t o r s o f t h e s o u r c e c a t e g o r i e s were n
terms of operation,
equipment,
and emissions.
Then
a s u f f i c i e n t n u mb e r o f mo d e l p l a n t s w e r e d e v e l o p e d t o r e p r e s e n t
each indus try sector.
The s e c t o r s i d e n t i f i e d i n c l u d e
dehydration units,
(2)
condensate tank b a t t e r i e s ,
processing plants,
(4)
offshore production p l
waters,
and
5)
(3)
t f o ~ m s
glycol
natural gas n
ie S , n a t u r a l g a s t r a n s m i s s i o n f a c i l i t ie
underground storage operations.
(1)
State
including
Since the primary i d e n t i f i e d
emission point o f concern a t n a t u r a l gas
H
transmission f a c i l i t i e s
i s t h e c o - l o c a t i o n o f any t r i e t h y l e n e g l y c o l
TEG)
dehydration
unit a t these fa c ilitie s ,
s e p a r a t e mo d e l p l a n t s w e r e n o t
developed f o r f a c i l i t i e s gas industry.
n
t h i s s e c t o r of the o i l and n a t u r a l
The p r i m a r y i n f o r m a t i o n s o u r c e s u s e d t o d e v e 1 o p t h e model p l a n t s a n d model p l a n t p a r a m e t e r s i n c l u d e d
U.S.
Environmental P r o t e c t i o n Agency s
Survey Questionnaires,1 {3)
discussions
representatives,
(2)
(1)
(E P A s)
re1:1ponses t o
the
A ir Emissions
s i t e vi s i t s to operating facilities,
and meetings with i n d u s t r y and t r a d e a s s o c i a t i o n and
(4)
available
literature.
P
In addition,
a d a t a b a s e f r o m t h e Gas R e s e a r c h I n s t i t u t e
c o n t a i n i n g n a t u r a l gas an aly s es 2 and a d a t a b as e provided
(GRI)
b y t h e A m e r i c a n P e t r o l e u m I n s t i t u t e (API) 3 w e r e u s e d , i n conjunction with industry survey responses, to develop n a t u r a l gas compositions. H
P
Composition o f p ro ces s streams,
i s a k e y p a r a m e t e r i n t h e mo d e l p l a n t a n a l y s i s .
constituents,
The c o n c e n t r a t i o n o f direct
H
constituents in ~ h e s e
P
i m p a c t o n e s t i m a t e d mo d e l p l a n t
The p r i m a r y
particularly
H
P
H
P
streams has a
emissions.
constituents of the process streams
a s s o c i a t e d w i t h t h e o i l and n a t u r a l gas p ro d u ct i o n and n a t u r a l
ga s t r a n s m i s s i o n and stora ge s o u rce c a t e g o r i e s inc lude benzene toluene,
e t h y l benzene,
and mixed x y l e n e s
(collectively referred
t o a s BTEX), a n d n - h e x a n e . Process stream c onc e ntra tions of t h e s e H P a r e l i s t e d i n T a b l e 2 - 1 o f C h a p t e r 2 . 0 o f t h i s BID. As i n d i c a t e d i n T abl e 2 - 1 ,
t h e EPA e s t i m a t e d t h r e e n a t i o n a l
a v e r a g e BTEX c o n c e n t r a t i o n s f o r n a t u r a l g a s o f 2 0 0 ,
160,
a n d 13
B-2
p a r t s p e r m i l l i o n volum e
ppmv) .
These v a l u e s a r e r e f l e c t i v e o f
t h e t h r e e s e c t o r s i n t h e s e s o u r c e c a t e g o r i e s o f (1) p r o d u c t i o n , (2) p r o c e s s i n g , a n d (3) t r a n s m i s s i o n a n d u n d e r g r o u n d s t o r a g e ,
which h an d l e n a t u r a l ga s s t reams .
The EPA h a s a n a l y z e d BTEX
values within ranges of e i t h e r side of these average values
in an
e f f o r t t o b e t t e r d e t e r m i n e t h e i m p a c t s o f t h e p r o p o s e d NESHAPs.
Initially,
t h e EPA e s t i m a t e d a p r o d u c t i o n BTEX c o n c e n t r a t i o n
o f 550 ppmv b a s e d o n t h e d a t a r e c e i v e d i n com pany r e s p o n s e s t o t h e A i r Emissions Survey Qu es t i o n n ai res
( R e f e r e n c e 1) .
The EPA
r e v i s e d t h i s e s t i m a t e t o 440 ppmv b y i n c o r p o r a t i n g BTEX d a t a s u p p l i e d b y GRI
(Reference 2 ).
The EPA r e v i s e d i t s e s t i m a t e
May 1996)
t o 200 ppmv a f t e r i n c o r p o r a t i n g a d d i t i o n a l new BTEX d a t a s u p p l i e d b y API ( R e f e r e n c e 3 ) . again
The p r o d u c t i o n e s t i m a t e i n f l u e n c e s t h e c a l c u l a t i o n o f HAP concentrations for the processing sector in th e .o il
gas production source category. concentration for
The r e v i s i o n o f t h e HAP
t h e production s e c t or has
r e d u c t i o n in the EPA s i n i t i a l
and n a t u r a l
c a u s e d a 75 p e r c e n t
(December 1993)
estimate of
n a t i o n w i d e HAP e m i s s i o n s f r o m g l y c o l d e h y d r a t i o n u n i t s ,
the
p r i m a r y i d e n t i f i e d HAP e m i s s i o n p o i n t i n t h e s e s o u r c e c a t e g o r i e s . E a c h m odel p l a n t was c h a r a c t e r i z e d b a s e d o n t h e s p e c i f i c
parameters necessary to calculate impacts. (1)
product and o t h e r throughputs, i.e.,
vessels
storage tanks),
com ponent e q u i p m e n t
i.e.,
and
Parameters include
(2)
num ber a n d t y p e o f p r o c e s s
(3)
num ber a n d t y p e o f p r o c e s s
C h a p t e r 4 . 0 o f t h i s BID
valves).
p r o v i d e s d e t a i l e d d e s c r i p t i o n s o f t h e m odel p l a n t s .
B.4
CONTROL OPTIONS
C o n t r o l o p t i o n s w e r e i d e n t i f i e d t h a t r e d u c e HAP e m i s s i o n s f r o m HAP e m i s s i o n p o i n t s i n t h e o i l a n d n a t u r a l g a s p r o d u c t i o n These c o n t r o l o p t i o n s a r e d i s c u s s e d i n d e t a i l i n
industry.
C h a p t e r 3 . 0 o f t h i s BID.
C o n t r o l o p t i o n s t h a t a r e a p p l i c a b l e t o HAP e m i s s i o n p o i n t s in t h e o i l and n a t u r a l gas production i n d u s t r y w i l l a l s o a c hie ve c o - c o n t r o l o f v o l a t i l e o r g a n i c compound
emissions.
Due t o
VOC)
and methane
in the emission c h a r a c t e r i s t i c s
similarities
B -3
o f HAP, VOC,
and methane from t h e em is s io n p o i n t s i n t h i s H
P
control options for industry were j udge d to be e q u a l l y in terms of emission reduction efficiency f o r HAP, effective
and methane.
VOC,
The e f f i c i e n c i e s u s e d i n t h e a n a l y s i s f o r e a c h
c o n t r o l o p t i o n c a n b e f o u n d i n T a b l e 3 - 1 o f t h i s BID.
B.S
MODEL
PLANT IMPACTS
Impa c t s o f t h e c o n t r o l o p t i o n s were pl ant s using available information.
(1)
H
P
c a l c u l a t E ~ d
Model p l a n t
e m i s s i o n r e d u c t i o n p e r mo d e l p l a n t
(2)
f o r model
impacts include t o t a l c a p i t a l and
n e t a n n u a l c o s t s a n d c o s t - e f f e c t i v e n e s s p e r megagram o f a n n u a l H
P
emission reduction
and
3)
secondary environmental impacts
and energy requirements. B.S.l Emissions
E mi ssi ons were e s t i m a t e d u s i n g emissio n f a c t o r s and e m i s s i o n estimation tools.
Emissions from g l y c o l d e h y d r a t i o n u n i t s were
e s t i m a t e d u s i n g GRI-GLYCalc™
(Version 3 . 0 ) .4
Emissions from
s t o r a g e t a n k s r e s u l t i n g from s t a n d i n g and working l o s s e s were e s t i m a t e d u s i n g t h e E P A s T NKS p r o g r a m . s s t o r a g e t a n k s were e s t i m a t e d u s i n g a
Flash emissions
separate algorithm
from
s p e c i f i c a l l y d e v e l o p e d b y t h e EPA f o r e s t i m a t i n g . f l a s h e m i s s i o n s
from s t o r a g e tanks i n t h e o i l and n a t u r a l gas production industry.6 Emissions from components were e s t i m a t e d u s i n g e m i s s i o n f a c t o r s d e v e l o p e d f o r equipment l e a k s . ?
E m i s s i o n s b a s e d o n t h e mo d e l p l a n t s w e r e f i r s t baseline.
B a s e l i n e was e s t a b l i s h e d b y a s s i g n i n g
l e v e l o f c o n t r o l t o e a c h mo d e l p l a n t c a t e g o r y .
estimated a t
an es t i m at ed Therefore
b a s e l i n e e s t i m a t e s have taken i n t o account those emission p o i n t s already controlled.
E m i s s i o n s w e r e t h e n e s t i m a t e d f o r e a c h mo d e l p l a n t w i t h t h e or a f t e r implementation of
application of controls
difference of these estimates
is the emissions
N E S H
P ~
The
impact
r e ~ d u c t i o n
t h a t t h e NESHAP w o u l d h a v e o n e a c h mo d e l p l a n t . B.5.2
CoS tS C a p i t a l c o s t s and n e t annual
control option.
Capital costs
c o s t s were c a l c u l a t e d f o r e a c h
include the cost of the B
control
4
equipment and t h e c o s t s a s s o c i a t e d with i n s t a l l i n g t h e equipment. Net a nnua l c o s t s account f o r t h e o p e r a t i o n and m ain ten an ce c o s t s
and monitoring,
i n s p e c t i o n , .recordkeeping,
and re c o rd i n g
MIRR)
costs.
Where a v a i l a b l e ,
s t
n d
~ d i z e d
costing methodologies,
p r e s e n t e d i n t h e O QPS C o n t r o l C o s t M a n u a l ,
such as
were use d t o e s t i m a t e
A p r o d u c t r e c o v e r y c r e d i t was
c a p i t a l and annual costs.B
included in the annual costs,
where judged a p p r o p r i a t e .
Exam pl e
m odel p l a n t c o n t r o l o p t i o n c o s t s a r e d i s c u s s e d i n C h a p t e r 6 . 0 a n d
e x a m p l e MIRR c o s t s a r e d i s c u s s e d i n A p p e n d i x C o f t h i s BID. The i m p a c t a n a l y s e s c o n s i d e r a f a c i l i t y s
a b i l i t y to handle
collected vapors. Some r e m o t e l y l o c a t e d f a c i l i t i e s may n o t b e able to use c o l l e c t e d vapor f o r f u e l o r recycle it back i n t o t h e process.
In addition ,
some f a c i l i t i e s
it
may n o t b e t e c h n i c a l l y f e a s i b l e
for
to u t i l i z e t h e non-condensable va por s t r e a m s from
condenser systems as an a l t e r n a t i v e fuel source s a f e l y. option for these f aci l i t i es
n
i s t o com bust t h e s e v a p o r s b y
flaring.
These c onc e r ns a r e r e f l e c t e d i n t h e a n a l y s e s c onduc te d by