Kami Export - English - VRU - Evolution

Presentation of Vapour Recovery Systems
By Ties Mulder
Process and Implementation Consultant
June 2005
• History of Vapour Recovery & Technologies developed
• Worldwide Emission legislation
• Closed circuit European recovery system for truck
• Implementation of Vapour Recovery systems on terminals
• Recovery product, rate, tax refund
• Safety aspects, ATEX, SIL
2/64
Presentation VRU - June 2005
3/64
First Systems
First systems = thermal destruction (air assisted flare)
• Energy consumption : high

• Destruction : 97 % efficiency
• Maintenance : low
4/64
First Recovery Systems
First recovery systems installed in the United States

Flare gas recovery using compression and cooling
Outlet to Flare

• Emissions : 80 % efficiency
Vapour Inlet • Maintenance : medium
Cooler
Separator
Compressor Recovered Liquid
5/64
Adsorption systems
Early 70s : first activated carbon / vacuum system

(Rheem Brothers - USA)
Clean air outlet
Top product vented to atmosphere
• Energy consumption : low

• Emissions : 80 % efficiency
Glycol Separator
Gasoline supply
• Maintenance : high
Re-absorber
Vapour Inlet
Activated Carbon Filters
Vacuum Pump Gasoline return
6/64
Deep cooling systems
Deep cooling systems @ -35°C (Edwards - USA)
Clean Air Outlet
De-icing
heater • Emissions : < 80 g/m3
• Maintenance : very high
Cooling Chiller
Elements
Vapour Inlet
Pure Product
7/64
Evolution of Adsorption systems...
First patent by McGill in 1978 based on Rheem brothers with

recycling of absorber top
Clean air outlet

Top product returned to inlet • Emissions : 35 g/m3
Gasoline supply
Glycol Separator
Ö Replacement of deep cooling by

Vapour Inlet
Re-absorber adsorption systems in USA
Activated Carbon Filters
Vacuum Pump Gasoline return
8/64
Evolution of Adsorption systems
Since 1980 ’s : Activated carbon / Liquid ring vacuum systems

as known today
Clean Air Outlet
Purge

Adsorbers • Emissions : < 35 g/m3
Vapour Inlet
Ö Suppliers patents in several

Absorber
European countries
Absorbents EG Vacuum Pump

Separator
Cooler
9/64
Alternative solutions
Fear of patent infringement Ö Development of alternative

solutions in Europe
¾ Cold absorption system : Coolsorption / Kappagi
¾ Membrane system : Vaconocore / Preussag
¾ Activated carbon + cold re-absorption : Kaldair
¾ Cogeneration : Petro-Plus (Qlear) / Schwelm
¾ Absorption / Adsorption / Absorption : Mc Gill
Introduction by Germany and Switzerland of extremely low

emissions Ö Development of complex hydride systems
¾ Cold adsorption + Steam regenerated carbon : Coolsorption
¾ Membrane + Vacuum regenerated carbon : Vaconocore
¾ LRVP + Roots blowers : John Zink
¾ Thermal balance adsorption : Ties Mulder
10/64
Cold absorption system
Clean
Air
Outlet
Absorbents Inlet
Vapour Cooler
Inlet
Reabsorber
Heater
Absorber
Absorbents Return
Nonane Circuit Splitter
Chiller
11/64
Membrane system
Clean Air Outlet
Evnt. 2 nd Stage
Membrane
Separator
Vapour Inlet
Cooler
Vacuum Pump
Compressor
12/64
Thermal Balance Adsorption
Clean Air Outlet
Adsorption
Filters
Absorber
Vapour
Inlet
Condenser
Separator
Vac pump
Absorbents
Heat exchanger
13/64
Latest developments
Latest developments : Dry screw pumps systems by CarboVac
Outlet
• Emissions : < 10 g/m3
• Maintenance : low
Ö Replacement of glycol systems

by dry systems
Inlet
Dry Screw
Activated Carbon Beds Re-Absorber Absorbants Circulation
Vacuum Pump
P
14/64
Actual situation
Activated carbon = highly favourite solution since 1980

¾ More than 90% of all recovery systems in the world
In the USA, destruction by combustion still represents 40%

But restrictions are coming due to :
¾ New CO2 limitation policies (Kyoto protocol)
¾ Adoption by Petroleum Companies (BP, Shell) of internal green

policies (engagement to reduce 50% of CO2 emissions)
Î Replacement of destruction by recovery solutions
15/64
16/64
VOC effects
VOC emissions impact on the

human health (carcinogenic components)
pollution of the troposphere (ozone creation)
In Europe, 17 million tons /year of VOC released in the atmosphere

in 1990.
Î Implementation of legislation and several regulations

in particular on emissions in hydrocarbon storage and transfer terminals
17/64
USA 1st Clean Air Act
In the 80ies, 1st legislation : Clean Air Act on VOC

Î Emission limit : 80 g/m3 loaded
In 1982, emission limit reduced to 35 g/m3 loaded (general case)

and locally to 10 or 6 g/m3 loaded.
Complex control measurement method to prove compliance.

¾ First with balloons and mass balance
¾ Later by using CIM and CEM
18/64
European legislation
European Directive EC94/63

¾ 35 g / m3 of air emitted (often 10 g / m3 is desired - Oslo protocol)
¾ 3 phases :
Õ 1998 : a VRU for all new terminals + terminal > 150 000 tons/year of gasoline
Õ 2001 : a VRU for terminal > 25 000 tons/year
Õ 2004 : a VRU for terminal > 10 000 tons/year
¾ Application for fuels with RVP > 276 mbar
TA-Luft 01 in Germany, LRV in Switzerland

If emission mass flow > 3 kg/h :
¾ 150 mg HC/ m3 of air emitted (20. BImSchG)
¾ 5 mg / m3 for benzene
¾ Methane is excluded (difficult to recover, only destruction possible by

combustion with secondary emissions)
19/64
Emission control
In USA : emissions measured as a function of loaded gasoline

Î Complex system required for EPA compliance test
¾ Measurement of the entire volume during 6 hours
¾ Measurement of the average hydrocarbon concentration
¾ Measurement of the total volume of gasoline loaded during 6 hrs
¾ Calculation of the mass emitted/litre loaded averaged over 6 hrs
Continuous measuring system with complex and expensive

devices
¾ CIM : Control Inlet Monitoring
¾ CEM : Continuous Emissions Monitoring
In Europe : emissions measured as real emission concentration

Î Simple emissions monitor in the outlet line (infra-red detector)
20/64
Energy consumption versus emissions
0,3
Energy consumption (kWh/m3 treated)
TA-Luft Emissions
0,25
0,2
0,15 Israeli Emissions
0,1
EU Emissions
0,05
0
40 35 30 25 20 15 10 5 0
Emission limit (g/m3)

N.B : Data based on LRVP Systems
21/64
Recovery chain
Losses : 0,1 kg/m3

Emission reduction measures up to 99%
Refinery
Total efficiency of the recovery chain is never better

than the weakest link
Terminal Losses : 1 kg/m3
Service-station
Car filling
Losses : 1 kg/m3
Emission reduction measures up to 99,99 %
Losses : 1 kg/m3
22/64
23/64
EC Directive 94/63 Stage 1 and 2
for fuel distribution...
Stage 1 :
¾ Recovery of the vapour from the service-station ground tank to
the truck
¾ and Recovery of the vapours from truck loading on the
terminal.
Stage 2 :
¾ Recovery of the vapour from the car fuel tank to the ground
tank
Not ratified by some countries in Europe due to lack of
efficiency
24/64
EC Directive 94/63 Stage 1 and 2
for fuel distribution
At the Service Station Stage 2
Car
At the Terminal Stage 1
To VRU
25/64
Implementation of Stage 1...
Service-station :
¾ Pressure / vacuum relief valve to be installed in the ground tank
vent line
¾ Vapour return connection to be installed on the tank vent line
Truck
¾ Truck modified to bottom loading
¾ Overfill protection
¾ All compartments connected to a central vapour collecting line
equipped with 4" API coupler with check valve.
26/64
Implementation of Stage 1
Terminal :
¾ Modification from top loading to bottom loading

¾ Installation of a Vapour Recovery System
¾ Vapour collecting line to the Vapour Recovery System
¾ Use of a dedicated gasoline tank for recovered product
¾ Installation of floating roof in fixed roof type storage tanks or
complete balancing of the vapour space to the VRU
¾ Integration of a new process in the terminal and adaptation of
operating and safety procedures
27/64
Stage 1 example with fixed roof tanks
Pressure Vacuum
Valve
Vapours Detonation Arrestor
Emitted
Ventilator
P
PT
Tanks
Loading
Operation
Absorbents Vapour Recovery Unit
28/64
Implementation of Stage 2
Cars :
¾ Installation of small canister in gasoline cars (91/441/CEE)
¾ Installation of large canister resisted by automobile industry
Service-station
¾ Installation of vapour balance system between car fuel tank and
ground tank
Õ For every litre of gasoline filled into the tank, one litre of vapour
is returned to the ground tank
Efficiency not demonstrated Î Solutions not promoted by

Oil Companies
29/64
Typical vapour composition
(Truck loading)
During the loading of gasoline and diesel in trucks, the concentration of the vapours may vary
between 0 to 50 % Vol. depending of :
• the nature of the products previously loaded.
• the loading station (equipped or not acc. to Stage 1 and 2 of the EC Directive)
Theses hydrocarbons are generally composed of :

C1 0 - 0.2 % Vol.
C2 0 - 0.45
C3 1.5 - 3.8
C4 37 - 50
C5 22 - 43
C4 and C5 represent around 90% of the
C6 8 - 12
hydrocarbons at the inlet vapours
C7++ 1.7 - 5.4
Benzene 0.26 - 2.6
Toluene 0.36 - 1.8
30/64
31/64
How to size a VRU
Important data for VRU sizing for truck and rail car loading:
• Peak flow rate
= max. flow rate generated by the loading facility
(i.e max. number of loading points connected simultaneously x flow rate per point)
→ Determination of the pressure drop of the VRU and the vapour collecting system
→ Determination of the lines size, carbon bed diameter
All vapours have to pass through the VRU. Influence on price is small.
• Max. throughput per cycle

= max. vapour amount generated in 15 minutes (for truck loading)
(i.e number of loading bays x volume loaded per cycle or vessel capacity)
For continuous throughputs the cycle time is usually fixed at 12 minutes
→ Determination of the activated carbon volume in the beds
• Max. throughput per 4 hour period

= evaluation of the intensity of the activities at the terminal during the busiest period
→ Determination of the required vacuum capacity
→ Determination of the re-absorber and absorbents circulation pumps
• Max. daily throughput
= evaluation of the loading profile per day
→ Adjustment of the vacuum capacity
32/64
Typical compartment truck
Compartment cover serves as

pressure safety relief valve
Vapour Collector connected to each compartment
4” API Vapour Coupler
33/64
Vapour Collecting System
Truck loading Application
Pressure Vacuum
Safety Valve
Vapour Line
Detonation Arrestor
Vapour arm
Level Switch
Position Switch
Drain valve
VRU
34/64
35/64
36/64
37/64
Absorbent Circulation System
VRU
P501
P601
38/64
Civil works
39/64
Civil works
40/64
Electrical works : communication signals
Operations Room PC &

interactive keyboard
Gasoline
Cabling
out
in
Modem line
Control building Open/close Emergency Vent
Vapour pipe work Vapour
modem Emergency vent valve position
Recovery Cabling Power
Nitrogen Input (start/stop truck loading)
Unit Gasoline pump start /stop/running signal
Water Air Air Compressor Site ESD signal
(instrument quality) VRU running
VRU alarm
Foundation drainage
41/64
Electrical works
Safe Area Hazardous Area
Control Room
Cables
42/64
Electrical cables schematics
Electrical Room
VRU
PLC
I
Power feed cable

J M
Instrument cables
Power cables to Motors
PC
PC Monitoring
Customer signals
43/64
Operational connection schematic
Control Cabinet
CONTROL ROOM
Power Cabinet
Modem
VRU SUPPLIER
Instrumentations
Modem
E-Motors
LOCAL
REPRESENTATIVE
Modem
44/64
VRU Location
Important parameters :
¾ Pressure drop of the vapour line
- EU Directive : 55 mbar @ truck coupler
- Typical ΔP of a 4" API vapour coupler : 3 mbar
- Typical ΔP of a vapour arm + hose : 12 mbar
- Typical ΔP of an anti-deto FA : 5 mbar
- Typical ΔP of a VRU : 25 mbar
Î Max available ΔP of vapour line : 10 mbar
¾ Pressure drop of the gasoline circulation lines

- Supply pump : usually close to the tank or in the pump station
- Return pump : usually on the VRU foundation
¾ Accessibility for maintenance works

¾ Electrical cable routing
45/64
46/64
Quality of the recovered product
Gasoline Application
Recovered product mostly C4 and C5.
Õ Tendency to increase the absorbent ’s RVP

Õ Tendency to increase the absorbent ’s temperature
Î Selection of a absorbent tank with a reasonable throughput
47/64
Typical Recovered Product
Hypotheses :
Vapour inlet concentration : 40 % Volume
Average outlet concentration : 2g / Nm-3
Average MW : 65 (Gasoline vapours)
Calculation :
0.4 x 65
Mass of hydrocarbons at inlet per m-3 = = 1160,7 g / m-3
22.4 x 10 - 3
Masse of hydrocarbons in the outlet per m-3 inlet = 2 x (1 - 0.4) = 1.2 g / m-3
® Masse of hydrocarbons recovered 1159.5 g / m-3 of inlet vapour
The recovery rate :

§ The effective recovery rate is 1.49 litre per m3 Inlet vapour
§ Vapour recovery rate 99. 9 %.
48/64
Tax refund in Europe
Recovered product not easily measured
Õ Recovered product = only a small % of the return absorbent flow

Õ Accuracy of the metering devices not sufficient
Î Agreement between tax authorities and oil companies to

implement a fixed rate equal to 1.4 to 1.5 litre per m3 of gasoline
entering the terminal
Õ 1.4 litre/ m3 of the gasoline throughput exempted from taxes
49/64
50/64
VRU Safety
VRU are installed in environment containing combustible liquid and

explosive gases
¾ Risks of fire and explosion with toxic emissions

¾ Preventive measures and risk analysis have to be performed :
Õ HAZOP
Õ ATEX explosion protection document (EXDOC)
Õ SIL safety integrity level risk assessment
51/64
ATEX Philosophy
Four possible types of equipment :
Assemblies
¾ Assemblies with fully specified configuration of parts
¾ Assemblies with various configuration
Installations
Electrical equipment
Î VRU is an assembly with fully specified configuration of parts

(§ 3.7.1 of the ATEX guideline)
52/64
§ 3.7.1 Resume
VRU = assembly of two different pieces of equipment :

¾ Equipment with CE marking (ATEX) :
Õ Manufacturer may presume conformity of these pieces
¾ Equipment without CE marking :

Õ Manufacturer has to cover those parts with his own conformity
assessment of the whole assembly
EC declaration of conformity for the whole unit (§ 3.7.1.1)

¾ Manufacturer assumes responsibility for compliance with the directive
¾ Manufacturer should provide a conformity assessment of the whole
assembly
¾ Manufacturer provides clear instructions for assembly / installation /
operation / maintenance… in the operating manual.
53/64
VRU Safety features
Some of the VRU safety features
¾ The whole system is explosion pressure proof to 9 barg

¾ All valves with open / closed limit switches
¾ Gasoline pumps installed below liquid level
¾ High and low level switches on the re-absorber column
¾ Temperature monitoring in the activated carbon beds
¾ Outlet temperature of the vacuum pump < 50°C
¾ Detonation arrestor in the inlet
¾ Two positive closing valves in each gasoline circulation line
¾ etc...
54/64
VRU Explosion proof design
55/64
Detonation arrestor in inlet line and
Valves with limit switches
56/64
Gasoline return pump
57/64
Level control and switches
58/64
Temperature sensors and indicators
in carbon bed
59/64
Dry Vacuum Pump
Temperature Monitoring
60/64
Two safety valves
in each gasoline circulation line
61/64
Safety Integrity Level...
EN 61508‐5.2001
Safety integrity level risk assessment of a dry screw VRS :

4 elements to be assessed
¾ Consequence of the risk (C)

Õ Minor Injury
Õ Serious Injury or permanent incapacity
Õ Fatality or catastrophic incapacity
¾ Frequency of exposure (F)

Õ Rare to more often (0 - 10%)
Õ Frequent to permanent (10 - 100%)
62/64
Safety Integrity Level
EN 61508‐5.2001
¾ Possibility of avoidance of a hazardous event (P)

Õ Possible under certain conditions
Õ Almost impossible
¾ Demand rate (W)

Õ High W3
Õ Low W2
Õ Very low W1
Î Result of SIL risk assessment is Category a

Õ No special safety requirements
63/64
Result of SIL risk assessment
Consequence of Risk (C)

Minor Injury <1
Toxonomy Serious Injury or permanent incapacity <=1
Fatality or catastrophic incapacity 1 >1 >10
C1 C2 C3 C4
Frequency of Exposure (F)

Rare to more often ( 0 - 10% ) F1 F1 F1
Toxonomy
Frequent to permanent ( 10 - 100% ) F2 F2 F2
Possibility of avoidance of a hazardous event (P)

Possible under certain conditions P1 P1 P1 P1 P1 P1
Toxonomy
Almost impossible P2 P2 P2 P2 P2 P2
Demand Rate (W)

High W3 a 1 2 3 2 3 4 3 4 b
Toxonomy Low W2 a 1 2 1 2 3 2 3 4
Very Low W1 a 1 a 1 2 1 2 3
Result of the Risk Reduction Estimation = a, no special safety requirements
64/64

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Presentation of Vapour Recovery Systems

• Worldwide Emission legislation

• Closed circuit European recovery system for truck

• Implementation of Vapour Recovery systems on terminals

• Recovery product, rate, tax refund

• Safety aspects, ATEX, SIL

• Worldwide Emission legislation

• Closed circuit European recovery system for truck

• Implementation of Vapour Recovery systems on terminals

• Recovery product, rate, tax refund

• Safety aspects, ATEX, SIL

 First systems = thermal destruction (air assisted flare)

• Energy consumption : high

 First recovery systems installed in the United States

• Energy consumption : high

Compressor Recovered Liquid

 Early 70s : first activated carbon / vacuum system

Clean air outlet

Top product vented to atmosphere

• Energy consumption : low

Vacuum Pump Gasoline return

 Deep cooling systems @ -35°C (Edwards - USA)

Clean Air Outlet

 First patent by McGill in 1978 based on Rheem brothers with

Clean air outlet

• Energy consumption : low

Ö Replacement of deep cooling by

Vacuum Pump Gasoline return

 Since 1980 ’s : Activated carbon / Liquid ring vacuum systems

• Energy consumption : high

Ö Suppliers patents in several

Absorbents EG Vacuum Pump

 Fear of patent infringement Ö Development of alternative

 Introduction by Germany and Switzerland of extremely low

Nonane Circuit Splitter

Clean Air Outlet

Clean Air Outlet

 Latest developments : Dry screw pumps systems by CarboVac

Ö Replacement of glycol systems

 Activated carbon = highly favourite solution since 1980

 In the USA, destruction by combustion still represents 40%

¾ Adoption by Petroleum Companies (BP, Shell) of internal green

Î Replacement of destruction by recovery solutions

• Worldwide Emission legislation

• Closed circuit European recovery system for truck

• Implementation of Vapour Recovery systems on terminals

• Recovery product, rate, tax refund

• Safety aspects, ATEX, SIL

VOC emissions impact on the

In Europe, 17 million tons /year of VOC released in the atmosphere

Î Implementation of legislation and several regulations

 In the 80ies, 1st legislation : Clean Air Act on VOC

 In 1982, emission limit reduced to 35 g/m3 loaded (general case)

 Complex control measurement method to prove compliance.

¾ Later by using CIM and CEM

 European Directive EC94/63

 TA-Luft 01 in Germany, LRV in Switzerland

¾ Methane is excluded (difficult to recover, only destruction possible by

 In USA : emissions measured as a function of loaded gasoline

 Continuous measuring system with complex and expensive

 In Europe : emissions measured as real emission concentration

0,15 Israeli Emissions

Emission limit (g/m3)

First systems = thermal destruction (air assisted flare)

First recovery systems installed in the United States

Early 70s : first activated carbon / vacuum system

Deep cooling systems @ -35°C (Edwards - USA)

First patent by McGill in 1978 based on Rheem brothers with

Since 1980 ’s : Activated carbon / Liquid ring vacuum systems

Fear of patent infringement Ö Development of alternative

Introduction by Germany and Switzerland of extremely low

Latest developments : Dry screw pumps systems by CarboVac

Activated carbon = highly favourite solution since 1980

In the USA, destruction by combustion still represents 40%

In the 80ies, 1st legislation : Clean Air Act on VOC

In 1982, emission limit reduced to 35 g/m3 loaded (general case)

Complex control measurement method to prove compliance.

European Directive EC94/63

TA-Luft 01 in Germany, LRV in Switzerland

In USA : emissions measured as a function of loaded gasoline

Continuous measuring system with complex and expensive

In Europe : emissions measured as real emission concentration

VRU = assembly of two different pieces of equipment :

EC declaration of conformity for the whole unit (§ 3.7.1.1)

Some of the VRU safety features