1、API PUBL*3LL 93 / i. Desi 4 Considerations 1 Petrbleu- I. for - Refining . Grude , Processing Units W O732290 05LL22L 945 W , i f - -* API PUBLw3LL 93 0732270 05Ll1222 81 Environmental Design Considerations for Petroleum Refining Crude Processing Units Health and Environmental Affairs Department API
2、 PUBLICATION NUMBER 31 1 FEBRUARY 1993 PREPARED UNDER CONTRACT BY: THE M.W. KELLOGG COMPANY HOUSTON, TEXAS American Petroleum Institute API PUBL*3LL 93 0732290 0511223 7LB FOREWORD API PUBLICATIONS NECESSARILY ADDRESS PROBLEMS OF A GENERAL NATURE. WITH RESPECT TO PARTICULAR CIRCUMSTANCES, LOCAL, STA
3、TE, AND FEDERAL LAWS AND REGULATIONS SHOULD BE REVIEWED. API IS NOT UNDERTAKING TO MEET THE DUTIES OF EMFLOYERS, MANUFAC- TURERS, OR SUPPLIERS To WARN AND PROPERLY TRAIN AND EQUIP THEIR EMPLOYEES, AND OTHERS EXPOSED, CONCERNING HEALTH AND SAFETY RISKS AND PRECAUTIONS, NOR UNDERTAKING THEIR OBLIGATIO
4、NS UNDER LOCAL, STATE, OR FEDERAL LAWS. NOTHING CONTAINED IN ANY API PUBLICATION IS TO BE CONSTRUED AS GRANTING ANY RIGHT, BY IMPLICATION OR OTHERWISE, FOR THE MANU- FACTURE, SALE, OR USE OF ANY METHOD, APPARATUS, OR PRODUCT COV- ERED BY LETTERS PATENT. NEITHER SHOULD ANYTHING CONTAINED IN ITY FOR I
5、NFRINGEMENT OF LETTERS PATENT. THE PUBLICATION BE CONSTRUED AS INSURING ANYONE AGAINST LIABIL- Copyright O 1993 American Petroleum Institute i API PUBLI3LL 93 0732290 05LL224 654 = ACKNOWLEDGMENTS THE FOLLOWING PEOPLE ARE RECOGNIZED FOR THEIR CONTRIBUTIONS OF TIME AND EXPERTISE DURING THIS STUDY AND
6、 IN THE PREPARATION OF THIS REPORT AFI STAFF CO NTACTs) Barbara Bush, Health and Environmental Affairs Department Genevieve Laffly, Manufacturing, Dishbution a dry operation to reduce the quantity of sour condensate; o use of vacuum pumps to replace all or part of the steam jet ejector system to pro
7、vide the vacuum for the vacuum tower; o use of reboiled sidestrippers on the atmospheric tower rather than open steam stripping to reduce the quantity of sour condensate; replacement of frst generation low NO, burners with new generation low NO, burners in furnaces; o use of catalytic and non-cataly
8、tic processes for the selective reduction of NO,; reuse of stripped sour water to replace clean process water as desalter water; and 2 API PUBL*3LL 93 0732290 05LL233 667 = heat integration for maximum energy utilization (commonly referred to as pinch analysis). 1.2 Limitations of Study Results Nume
9、rous pollution prevention concepts have been evaluated and reported in this study, but no optimum or ttbest“ design is implied. This study was as comprehensive as time allowed, but doubtlessly there are other pollution prevention measures that have potential application to crude units. Each refiner
10、will need to make an assessment of his refinerys requirements and then consider the ideas that best suit those needs. Corporate planning, engineering, regulatory, and operations personnel will be able to use the ideas and techniques reported in this study as an initial step toward a more thorough ca
11、se-by-case evaluation of pollution prevention for the crude units at individual refineries. 1.3 For a model new crude unit (Case l), the following pollution prevention ideas may be considered in the design stage and are reported in Section 6: Pollution Prevention Ideas for Model New Crude Unit Apply
12、 pinch analysis to the crude preheat train heat integration (refer to Appendix I). Increase crude preheat temperature and minimize heat losses to air and cooling water. Increase crude distillation column pumparounds from two to four. Reboil sidestrippers with a heat transfer oil rather than by steam
13、 stripping. Lower vacuum column flash zone pressure from 35 to 20 mmHgabs. This will lower furnace fired duty and reduce cracking of the feed to lighter products and wet oivrecovered oil. 3 Use a liquid ring vacuum pump in place of the third stage steam jet ejector on the vacuum tower overhead. Stri
14、p desalter brine for benzene removal before sending brine to wastewater treatment. Send recovered benzene to gasoline blending. Install new generation low NO, burners. Use selective catalytic reduction (SCR) to reduce NO, in furnace flue gas. Scrub furnace flue gas for removal of SO, when fdng high
15、sulfur fuel oil. Optimize water reuse by application of sidestream softening to blowdown streams. Apply advanced process control to optimize energy utilization. Install analyzers to provide continuous pollutant monitoring. Employ specialized hardware and inspection and from the point of view of reva
16、mping a conventional existing crude unit (referred to as Case 2). 14 API PUBL*311 93 0732290 0511245 389 To serve as a reference point or Base Case, a typical ten-year-old U.S. Gulf Coast crude unit of 175,000 BPSD feed rate was chosen. 2.4 Usefulness of Results The primary result of this study is a
17、 technical assessment of alternative pollution prevention concepts applicable to a refinery crude unit and how these concepts could be incorporated into a new or revamp crude unit. A secondary product of the study is the methodology that was developed for the systematic analysis of pollution prevent
18、ion. This methodology is applicable to the evaluation of other refinery processes and to individual pollution prevention projects. Some caveats apply to this study. This study should not be regarded as a recommendation for the process design of a crude unit. Only one type of crude and one set of pro
19、duct specifications were considered in this study. This does not form an adequate design basis for a process study. Multiple Cnide feedstocks and a range of product specifications would normally be considered in the design of a crude unit. 2.5 Limitations of Study Results No optimum or “best“ design
20、 is to be implied from this study. Numerous pollution prevention concepts have been evaluated and reported in this study. Other pollution prevention measures have potential application to crude units. Each refiner will need to make an assessment of requirements and utilize the ideas and concepts tha
21、t best fit the needs of the individual refinery and situation. Corporate planning, engineering, regulatory, and operations personnel will be able to use the ideas and techniques developed by this study as an initial step toward a more thorough case-by-case evaluation of pollution prevention at indiv
22、idual refineries. There is considerable difference between a conceptual study and the actual implementation of pollution prevention systems. For many of the ideas that appear to be promising for an individual refinery, it may be necessary to conduct laboratory studies or field demonstrations before
23、implementing the project. API PUBt311 93 m 0732290 05112Yb 215 W Laboratory studies are useful to verify the technical feasibility of the proposed design and operating changes, to confirm that the process will still produce products that meet customer requirements, to develop a basis for investment
24、estimates, and to identify safety and logistic concerns prior to field implementation. Plant field demonstrations prove the technology on a larger scale. 2.6 The scope and content of this study was limited to the crude unit and subject to the boundaries and exclusions explained below: Physical Bound
25、aries and Study Limits 2.6.1 unit, including: The study addressed equipment and processes Inside Battery Limits (ISBL) of the crude - crude oil desalter - crude oil preheat exchangers - vacuum-producing equipment - atmospheric distillation tower and its heater - vacuum distillation tower and its hea
26、ter. 2.6.2 A single sour crude feedstock was chosen: Light Arabian Crude. 2.6.3 the battery limits. Compression of overhead vapors from the atmospheric tower was accomplished within 2.6.4 The stabilizer was not within the study scope. 2.6.5 Unstabilized naphtha was routed to the battery limits for f
27、urther processing. 2.6.6 The study investigated in detail the following methods of pollution prevention: 16 API PUBLX311 93 0732290 0511247 151 modification of vacuum tower to dry operation and reduced flash zone pressure to minimize cracking of feed, dry operation to reduce the quantity of sour con
28、densate; use of vacuum pumps to replace all or part of the steam jet ejector system used to create the vacuum for the vacuum tower; use of reboiled side strippers on the atmospheric tower rather than open steam stripping to reduce the quantity of sour condensate; replacement of conventional burners
29、with low NO, burners in furnaces; use of catalytic and non-catalytic processes for the selective reduction of NO,; reuse of sttipped sour water to replace clean steam condensate as desalter water, and heat integration for maximum energy utilization. Other methods for pollution prevention were subseq
30、uently added or substituted for the ones mentioned above as the study evolved. 2.7 Future Studies During the execution of this study, several areas were identified as worthy of further analysis in a future study: Analysis of interfaces with other refinery process units for downstream impacts Evaluat
31、ion of alternate crude and product slates 17 API PUBL*311 93 O732290 0511248 098 W O Sensitivity analysis of other engineering ant Evaluation of cooling tower system O 2.8 Overview of This Report Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 financial parameters Executive Summary This
32、section summarizes the findings of the study. Introduction This section previews the contents of this report and explains the basis for the study. Regulatory Issues This section discusses the environmental regulations currently driving refineries and their influence on pollution prevention. Methodol
33、ogy This section describes a generic methodology for conducting pollution prevention studies and how this methodology was applied to the pollutiom prevention study for crude oil units. Conventional Crude Unit (Base Case) This section presents the results of a process and environmental audit of a con
34、ventional existing crude unit, referred to as the Base Case. Model New Crude Unit (Case 1) This section describes a conceptual design for a model new crude unit which incorporates practicable pollution prevention ideas. The Model New Crude Unit is referred to as Case 1. 18 API PUBL*3LL 73 m O732290
35、0511249 T24 Section 7 Revamp of Conventional Crude Unit (Case 2) This section describes how the Base Case crude unit can be revamped to incorporate pollution prevention ideas. The revamp of the conventional crude unit is referred to as Case 2. Appendices A through M contain the collected information
36、 referenced in the text of the report. 19 API PUBL*3LL 93 W 0732290 05LL250 74b Section 3: REGULATORY ISSUES 3.1 General Issues Environmental regulatory compliance for todays petroleum refinery is an ever-increasing economic, technical, and operational challenge. Some of the most important environme
37、ntal statutes that apply to U.S. refineries are: O The Clean Air Act (CAA) The Clean Water Act (CWA) The Resource Conservation and Recovery Act (RCRA) The Pollution Prevention Act of 1990 (PPA) o o The Superfund Amendments and Reauthorization Act (SARA) o Several of these statutes that have been ena
38、cted or amended in the recent past contain various components of pollution prevention. Moreover, the Clinton administration has indicated that pollution prevention will continue to be a priority of the Environmental Protection Agency in its future activities. In addition to traditional regulatory in
39、itiatives, pollution prevention (and energy efficiency) have also become the focus of many non-regulatory initiatives such as the 33/50 Program and the Green Lights Program. A common element of these programs seeks to engage facilities and individual companies in determining their own levels of part
40、icipation in such programs and in finding the most cost-efficient method of attaining broad environmental goals set by the Agency. Other voluntary efforts by industry trade associations (e.g., Responsible Care and STEP), independent organizations (GEMI), and company programs (e.g., SMART and WOW) ar
41、e yet another method of instilling the pollution prevention principles into industry operations. The result of the coupling of the traditional regulatory compliance activities and the numerous voluntary initiatives result in a very complex system and a close linkage between normal daily production operations and those systems installed to eliminate, separate, purify, recycle, and reuse 20
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