Reducing Emissions in Plant Flaring Operations
The FGRS system significantly reduced the greenhouse gas emissions from the plant and the harmful impacts normally associated with flaring. By recovering the gases routinely sent to the flares, the plant
prevented 32.5 metric tons of NOx, 176.8 metric tons of CO and 67,000 metric tons of CO2 from being emitted into the atmosphere each year. Thermal radiation from the flames was greatly reduced,
which resulted in an increase in overall safety of the plant. Light and noise – two other objectionable side effects of flaring – were also greatly reduced.
Besides major reductions in emissions, light and noise, installation of the FGRS allows substantial cost savings because the recovered gases can be used as fuel or process feedstock. Assuming a fuel gas cost of US$5/MMBTU, the plant will save more than US$5,000,000 per year on fuel gas costs if the FGRSs operate at full capacity. With an expected operating cost of US$300,000 per year, the cost of the FGRS could be recouped in less than nine months.
Results Partnering with Callidus Technologies by Honeywell enabled this major corporation to achieve their corporate goals of improving energy efficiency, utilising the latest technologies and reducing emissions for the Dushanzi plant. The Green Team objectives of achieving zero injury, zero pollution and zero accidents were also met with the addition of the
1. PetroChina, 2008 Corporate Social Responsibility Report, Energy Conservation and Emission Reduction, 2008;30.
2. PetroChina, 2008 Corporate Social Responsibility Report, Refining & Chemicals, 2008;26.
3. PetroChina, 2008 Corporate Social Responsibility Report, Emission Reduction, 2008;8.
Liquid ring compressor and motor
M
Water and recovered hydrocarbon liquids
Operation liquid cooler Flare header Flare gas
Knockout vessel
Liquid seal in flare base or free standing
Figure 4: Schematic of Flare Gas Recovery System Spill back valve
Recovered gas
Separation vessel Existing flare
demountable stack flare systems and FGRSs. In addition to recouping the cost of the FGRSs during the first year of operation, the company will enjoy reduced maintenance costs of the flare due to the advanced flare design technology and material selection. They will continue to reduce their overall emissions and increase the operating efficiency of the plant. n
4. Mokhatab S, Vatani A, Zadakbar O, Gas refineries can benefit from installing a flare gas recovery system, Hydrocarb Proc, 2010;51.
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GEOPHYSICS • CONSTRUCTION • DRILLING • SUBSEA • NATURAL GAS
VOLUME 6 ISSUE 1
Logistics • Sulphur Management • LNG • Catalysts • Refining Assets Articles include:
BOEMRE’s New Regulatory Approach to Environmental and Safety Systems Management HA Tony Wood
Expanding Iraq’s Oil Production – Issues and Impediments Peter Robin Avent Wells
Enlightening Subsea Structures Marc Niklès and Fabien Ravet
Approach to Improve and Optimise Deepwater Waterflood Projects in 2011 Fady R Chaban and Grant T Gibson
Shale Gas Reservoirs in the Western Canadian Sedimentary Basin Daniel John Kerridge Ross
Greenhouse Gas Regulations – All Pain and No Gain Charles T Drevna
Refinery Energy Losses Due to Fouling in Heat Exchangers Francesco Coletti and Sandro Macchietto
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Process Simulation for Improved Energy Efficiency, Maximised Asset Utilisation and Increase in Feed Flexibility in a Crude Oil Refinery Zoltán Varga, István Rabi and Klára Kubovics Stocz
6 L
Emerging Markets in the Middle East for New and Existing Liquefied Natural Gas Projects Fereidun Fesharaki, Alexis Aik and Noelle Leonard
Corrosion – Issues and Solutions for Hydrocarbon Refineries François Ropital
T F
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A comprehensive resource for the global oil and gas community
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