Insights from passive FTIR flare performance testing

In s ig h ts F T IR fr o m F la r e P a s s iv e P e rfo rm a n c e T e s tin g Scott Evans Clean A ir Engineering Saturday, September 17, 11 A c k n o w le d g e m e n ts Ruth Cade • Marathon Petroleum Bob Spellicy • IMACC Brian Dickens • US EPA The Zink Boys... Scott Fox Jim Franklin Zach Kodesh Saturday, September 17, 11 Hydrogen Effects' | The Propylene Hypothesis Saturday, September 17, 11 Correlating Operating Parameters Conclusions T h e P F T IR M e th o d I N T o ta l ra d ia n c e c o n s is ts F la r e o f t o m a n y ra d ia n c e s ig n a l o f t h e in s tr u m e n t c o m p o n e n ts . is t h e o n ly c o n c e r n . P a s s iv e N o Saturday, September 17, 11 A c tiv e F T IR IR S o u rc e Passive FTIR Extractive - TCEQ MPC - Texas City Ineos - Addystown MPC - D e tro it Shell - D e e r Park Flint Hills - Port A rth u r Saturday, September 17, 11 T K. Dual Detector for improved sensitivity for a wider range of compounds Saturday, September 17, 11 Not So Good PFTIR Alignment Good PFTIR Alignment *5 9i [11085] Aiming - Saturday, September 17, 11 Saa-Can 201 0-1 0-28 I 0:04:36 P ic tu r e o f H o r s e 's H e a d Note: Suspicious Data. Camera may not be at optimum angle Saturday, September 17, 11 Dual Instrument Deployment lol ol lllolltfiflfflll oolli AU Flare LOU Flare PFTIR Location PFTIR Viewing Angle L.O.U. ELEVATED FLARE 19G -101.19G -104 STA. 6 + 50.0' A.E. 14 + 50.0' A.N \ 37°-7' < Saturday, September 17, 11 Poor Alignment Window Good Day Saturday, September 17, 11 Bad Day C a m e ra s PFTIR Aiming Cam era (IR) MRN F OC U S RNGE FLIR Camera (IR) 1 $ F L IR ~ I MW: 25 S/VG: 1.25 I V tfH V :9 2 0 S/HC: 2.06 Visible Camera Saturday, September 17, 11 9 /1 5 /0 9 CZ HV: 397 S/S521: 2.81 LO O F F _______ A U T O H IS T BL 1 .1 3 .5 8 P M Steam Rate: 2,576 Exit Vel: 2.79 VE Rating 6.0 FLIR GasFind Cam era (IR) Saturday, September 17, 11 Saturday, September 17, 11 Saturday, September 17, 11 Saturday, September 17, 11 f F T X R TX& * A w a L ^ s L s A lg o n t K w A a a 1 W £ N ‘ / } Al i ^ A C t r occtiRS I Saturday, September 17, 11 D£>N'T K N £ W , B ^ B - t>£> Y O U T H IN K 5 P A VUIUL, B U Y IT ? EPA began work on a PFTIR Test Method in 2010 ASTM Task Group formed to develop a PFTIR Test Method EPA has not decided yet whether they will participate in the ASTM effort Saturday, September 17, 11 W h y N o t? Q u b ^ tita tiv e S p e c ia '- 'o n Units are in concentration x pathlength In order to quantify, you must know plume depth What is the depth of the flare plume at the point of measurement? Saturday, September 17, 11 Methane inAir Saturday, September 17, 11 Methane inAir lOOr 90 80 fe z 70 UJ u x UJ Cl u - 60 50 z I 40 o 3 O c <U ■M O c 3 CD u o ,0 UJ ^ 30 20 10 0 No Combustion Combustion Saturday, September 17, 11 Saturday, September 17, 11 Methane inAir Saturday, September 17, 11 Methane inAir 100r 90 80 fe z 70 UJ u x _ Cl u - 60 50 z = 40 H £ 30 P No Combustion Combustion Saturday, September 17, 11 Methane inAir 100r Upper Flammability Limit 90 80 fe z 70 UJ u x _ Cl u - 60 50 z I 40 H ^ 30 20 10 Lower Flammability Limit 0 No Combustion Combustion Saturday, September 17, 11 Methane inAir 10 IS 20 25 30 35 40 45 G A SES IN O R IG IN A L A T M O S P H E R E , P E R C E N T Combustion Saturday, September 17, 11 Methane inAir Combustion Saturday, September 17, 11 Methane inAir Combustion Saturday, September 17, 11 Methane inAir 10 IS 20 25 30 35 40 45 G A SES IN O R IG IN A L A T M O S P H E R E , P E R C E N T Combustion Saturday, September 17, 11 F o llo w in g a V o lu m e Pre-Combustion (Fuel Rich) Combustion Post-Combustion (Fuel Lean) Source: Brian Dickens, US EPA Saturday, September 17, 11 o f V e n t G a s T h r o u g h T im e F o llo w in g a V o lu m e Pre-Combustion (Fuel Rich) Combustion Post-Combustion (Fuel Lean) Source: Brian Dickens, US EPA Saturday, September 17, 11 o f V e n t G a s T h r o u g h T im e F o llo w in g a V o lu m e Pre-Combustion (Fuel Rich) Combustion Post-Combustion (Fuel Lean) Source: Brian Dickens, US EPA Saturday, September 17, 11 o f V e n t G a s T h r o u g h T im e F o llo w in g a V o lu m e Pre-Combustion (Fuel Rich) Combustion Post-Combustion (Fuel Lean) Source: Brian Dickens, US EPA Saturday, September 17, 11 o f V e n t G a s T h r o u g h T im e F o llo w in g a V o lu m e Pre-Combustion (Fuel Rich) Combustion Post-Combustion (Fuel Lean) Source: Brian Dickens, US EPA Saturday, September 17, 11 o f V e n t G a s T h r o u g h T im e F o llo w in g a V o lu m e o f V e n t G a s T h r o u g h JO Pre-Combustion (Fuel Rich) Combustion Post-Combustion (Fuel Lean) Source: Brian Dickens, US EPA Saturday, September 17, 11 10 15 20 25 30 35 ¥ 45 G A SES IN O R IG IN A L A T M O S P H E R E , P E R C E N T T im e LOU-A: Traditional Steam Injection For Various Vent Gas Compositions and Assist Media Flows ■Vent Gas Flammability in H20 In Flare Header ‘ Vent Gas Flammability in N2 'Traditional Steam Injection: LOU-A Center Steam Added 0 10 15 20 25 30 35 40 45 50 55 D ilu e n t P e rc e n t Saturday, September 17, 11 60 65 70 75 80 85 90 95 100 LOU-A: Traditional Steam Injection For Various Vent Gas Compositions and Assist Media Flows c <u u i- QJ Q_ "o5 D 10 15 20 25 D ilu e n t P e rc e n t Saturday, September 17, 11 30 35 40 45 50 Saturday, September 17, 11 W a t e r a n d F ir e •K w ' V/ .) ^-* Steam Effects % . A m Saturday, September 17, 11 m A Few O b s e r v a tio n s on T C E Q / U T T e s ts Saturday, September 17, 11 th e Saturday, September 17, 11 Saturday, September 17, 11 Saturday, September 17, 11 CE vs. NHVcz (i CleanAir All TCEQ Steam vs Base Loads 100 % 90% 80% Co 70% r >* u C QJ 'u 60% •$ £ UJ C 50% # o s 3 -Q 40% E o u • TCEQ B - Vary Steam (S3, 4, 5, 6) 30% TCEQ C- Vary VG (S7, 8, 9, 10, 11) • TCEQ D - Vary VG, Propane (S12, 13,14) 20 % O FHR AU A - Base, 38% H2, 830 lb/hr o FHR LOU A - Base, 28% H2, 2900 lb/hr 10 % OTXC A l l - Base, 15% H 2 ,1100 lb.hr 0% □ DET A - Base, 20% H2, 550 lb/hr o 200 400 600 800 1,000 1,200 1,400 Combustion Zone Gas Net Heating Value (H 2 = 1 2 1 2 BTU/scf) (BTU/scf) Saturday, September 17, 11 1,600 1,800 Saturday, September 17, 11 Saturday, September 17, 11 E ffe c t o f In c r e a s in g S te a m Saturday, September 17, 11 U p p e r 20 % Saturday, September 17, 11 Saturday, September 17, 11 E ffe c t o f S h iftin g C e n t e r S te a m Saturday, September 17, 11 to U p p e r S te a m Saturday, September 17, 11 Saturday, September 17, 11 E ffe c t o f In c r e a s in g T ip V e lo c ity Saturday, September 17, 11 Saturday, September 17, 11 Saturday, September 17, 11 W in d Saturday, September 17, 11 E ffe c ts M o m e n t u m W in d V G M F R MFR < F lu x R a tio M o m e n t u m = W in d M o m e n t u m MFR = I MFR « o A W Inage: Phil Smth, University of Utah Red = High CE MFR > Saturday, September 17, 11 a k e S ta b iliz e d I Same MFR and Wind Speed Saturday, September 17, 11 Same MFR and Wind Speed LOU B 3.0(1) MFR = 0.084 Wind = 9 mph CE = 98% % Less Upper Steam Saturday, September 17, 11 S Same MFR and Wind Speed LOU B Min(1) MFR = 0.087 Wind = 9 mph CE = 98% + Even Less Upper Steam Saturday, September 17, 11 Same Conditions Different Wind Speed LOU B 3.0(1) MFR = 0.084 Wind = 9 mph CE = 98% + A 35° [1 1 0 8 5 ] A i m in g - S e a - C a n 2 0 1 0 - 1 1 - 0 1 LOU B 3.0(2) MFR = 0.032 Wind = 14 mph CE = 99% 1 6:1 9 : 2 5 + 30* |11 066j Aiming - S ea-C an 201 0-11 -0 B 1 0:39:31 Saturday, September 17, 11 Illustration courtesy John Zink Saturday, September 17, 11 Saturday, September 17, 11 ydrogen is a great fuel, but... It is not a hydrocarbon and does not have the same flammability characteristics as a hydrocarbon H2: 270 Btu/scf HC: 1000 - 4000 Btu/scf When burning hydrogen, the NHV is diluted even though combustion is good. This may be confusing. Saturday, September 17, 11 To provide a more consistent view of NHV regardless of the hydrogen content of the vent gas, a hydrogen adjustment factor may be used. H2: 10.8 Btu/scf @ LFL HC: 48.5 Btu/scf @ LFL 48.5 0.8 = 4.49 270 Btu/scf x 4.49 = 1212 Btu/scf Saturday, September 17, 11 CleanAir C E v s . A ll T C E Q U n a d ju s te d S te a m w it h N H V c z F H R a n d M P C 100 % p *fp* +%i' 95% 90% 8 5 % E > c W C 1 75% • • TCEQ 20:80 TNG to Propane (S12,S13,S14) ^ o o o§ % • FHR AU-A: Base Load • FHR AU-B: <15% Hydrogen • FHRAU-C: 25-35% Hydrogen • FHRAU-D: 40-50% Hydrogen O FHR LOU A: Base Load O FHR LOU-B: Base Load + 5,000 lb/hr 70% op E o u • TCEQ 100% Propylene (S1,S2) • TCEQ 20:80 TNG to Propylene (53,54,55,56) o U) 3 -Q .1 ® . ° * ♦ 80% 4> u £ o o * o> TCEQ 20:80 TNG to Propylene (S7,S8,S9,S10,S11) ^ u °D ° * y 65% • FHR LOU-C: Base Load + 10,000 lb/hr • TXC A ll: Base Load • TXCA19: Base Load o O TXC B: Base Load + Added RFG 0 60% 55% OTXC D: Propylene Low Flow % • TXC E: Propylene High Flow ■ Detroit A: Base Load □ Detroit B: Base Load + Added RFG □ Detroit C: Propylene 50% 100 200 300 400 500 600 Actual Combustion Zone Gas Net Heating Value (BTU/scf) Saturday, September 17, 11 700 800 CleanAir C E A ll T C E Q v s . A d ju s te d S te a m w it h N H V c z F H R a n d M P C 100 % 95% 90% • TCEQ 100% Propylene (S1,S2) • TCEQ 20:80 TNG to Propylene (S3,S4,S5,S6) 8 5 % E > TCEQ 20:80 TNG to Propylene (S7,S8,S9,S10,S11) ^ u c • TCEQ 20:80 TNG to Propane (S12.S13.S14) o o 80% 4> u £ W C • FHR AU-A: Base Load • FHR AU-B: <15% Hydrogen • FHRAU-C: 25-35% Hydrogen 75% • FHRAU-D: 40-50% Hydrogen o U) 3 -Q O FHR LOU A: Base Load 70% O FHR LOU-B: Base Load + 5,000 Ib/hr © E o u • FHR LOU-C: Base Load + 10,000 Ib/hr • TXC A ll: Base Load 65% o • TXCA19: Base Load O TXC B: Base Load + Added RFG 60% 55% OTXC D: Propylene Low Flow % • TXC E: Propylene High Flow ■ Detroit A: Base Load □ Detroit B: Base Load + Added RFG □ Detroit C: Propylene 50% 100 200 300 400 500 600 Combustion Zone Gas Net Heating Value (H2==1212 BTU/scf) (BTU/scf) Saturday, September 17, 11 700 800 CE CleanAir A ll T C E Q vs. N H V c z S te a m a n d F H R A U 100% o <9 1 ° ° ° 90% 0 o 80% s r 70% > VJ C 0J A ♦ * * 60% £ LU C 50% o co 3 _Q 40% E o u • • 30% TCEQ B - Vary Steam (S3, 4, 5,6) • 20% TCEQ C - Vary VG (S7, 8, 9,10, 11) TCEQ D - Vary VG. Propane (S12, 13,14) 10% O FHR AU A - Base, 38% H2, 830 Ib/hr 0% * IP 200 I---------------------1---------------------1---------------------1------------400 600 800 1,000 1,200 1,400 Combustion Zone Gas Net Heating Value (H2=1212 BTU/scf) (BTU/scf) Saturday, September 17, 11 1,600 1,800 Saturday, September 17, 11 Saturday, September 17, 11 Saturday, September 17, 11 C E v s . CleanAir 100% 90% 80% A ll T C E Q S te a m N H V c z a n d F H R A U + D E T D j 4 Jf <?° a * s r 70% > VJ C 0J 60% w* £ LU C 50% o co 3 _Q 40% E o u • TCEQ B - Vary Steam (S3, 4, 5, 6) • TCEQ C - Vary VG (S7,8, 9,10,11) 30% TCEQ D - Vary VG, Propane (S12,13,14) • 20% OFHR AU B - 13% H2, 2100 Ib/hr VG O FHR AU C - 28% H2, 1600 Ib/hr VG 10% OFHR AU D - 41% H2, 1560 Ib/hr VG • DETD- Vary H2, 950 Ib/hr 0% 200 400 600 800 1,000 1,200 1,400 Combustion Zone Gas Net Heating Value (H2=1212 BTU/scf) (BTU/scf) Saturday, September 17, 11 1,600 1,800 T h e Saturday, September 17, 11 N itr o g e n D e b a te Saturday, September 17, 11 CLAIM All inerts are not created equal. W e must distinguish between water and nitrogen as vent gas diluents when predicting flare performance using LFL. The Zabatakis nose plots show this difference. Saturday, September 17, 11 CLAIM All inerts are not created equal. W e must distinguish between water and nitrogen as vent gas diluents when predicting flare performance using LFL. The Zabatakis nose plots show this difference. RESPONSE The data show that for actual vent gas, LFL is constant with increased diluent concentration regardless of the diluent. For our purposes, all diluents ARE created equal. Saturday, September 17, 11 O XYG EN IN O R IG IN A L ATM O SPHERE, PERCENT GASES IN O R IG IN A L ATM O SPHERE, PERCENT Source: Coward and Jones Saturday, September 17, 11 O X Y G E N 19 IN 18 10 O R IG IN A L A T M O S P H E R E , P E R C E N T 17 15 16 20 15 25 14 30 13 35 12 40 45 GASES IN O R IG IN A L ATM O SPHERE, PERCENT Source: Coward and Jones Saturday, September 17, 11 O X Y G E N 19 IN O R IG IN A L A T M O S P H E R E , P E R C E N T 18 17 16 15 14 13 10 12 r F o r to s o m e in d iv id u a l in c re a s e d ilu e n t w ith a n d th e 15 20 25 s p e c ie s , L F L in c re a s e d ra te d e p e n d 10 gas o n 30 c o n c e n tra tio n s o f in c re a s e th e 35 a p p e a rs s e e m s o f t o d ilu e n t. 40 45 GASES IN O R IG IN A L ATM O SPHERE, PERCENT Source: Coward and Jones Saturday, September 17, 11 O X Y G E N 19 IN O R IG IN A L A T M O S P H E R E , P E R C E N T 18 17 16 15 14 13 10 12 r F o r to s o m e in d iv id u a l in c re a s e d ilu e n t w ith a n d th e 15 20 25 s p e c ie s , L F L in c re a s e d ra te d e p e n d 10 gas o n 30 c o n c e n tra tio n s o f in c re a s e th e 35 a p p e a rs s e e m s o f t o d ilu e n t. 40 45 GASES IN O R IG IN A L ATM O SPHERE, PERCENT Source: Coward and Jones Saturday, September 17, 11 O X Y G E N 19 IN O R IG IN A L A T M O S P H E R E , P E R C E N T 18 17 16 15 14 13 10 12 T F o r to s o m e in d iv id u a l in c re a s e d ilu e n t w ith a n d th e gas s p e c ie s , L F L in c re a s e d ra te d e p e n d o n c o n c e n tra tio n s o f in c re a s e th e a p p e a rs s e e m s o f t o d ilu e n t. = LFL with no added inerts '- ______ 1______ 1_______1______ 1------ 10 15 20 i 25 I 30 i i 35 40 "«* ___1______JL_____ 4! 50 55 GASES IN O R IG IN A L ATM O SPHERE, PERCENT Source: Coward and Jones Saturday, September 17, 11 O XYG EN IN O R IG IN A L ATM O SPHERE, PERCENT 19 18 17 16 15 14 13 12 11 r T F o r to s o m e in d iv id u a l in c re a s e d ilu e n t w ith a n d th e gas s p e c ie s , L F L in c re a s e d ra te d e p e n d o n c o n c e n tra tio n s o f in c re a s e th e a p p e a rs s e e m s o f t o d ilu e n t. 1= LFL with no added inerts '- ______ 1______ 1_______1______ 1------ 10 15 20 i 25 I 30 i i 35 40 "«* ___1______JL_____ 4! 50 55 GASES IN O R IG IN A L ATM O SPHERE, PERCENT Source: Coward and Jones Saturday, September 17, 11 O X Y G E N 19 IN O R IG IN A L A T M O S P H E R E , P E R C E N T 18 17 16 15 14 13 10 12 T F o r to s o m e in d iv id u a l in c re a s e d ilu e n t w ith a n d th e gas s p e c ie s , L F L in c re a s e d ra te d e p e n d o n c o n c e n tra tio n s o f in c re a s e th e a p p e a rs s e e m s o f t o d ilu e n t. 1= LFL with no added inerts '- ______ 1______ 1_______1______ 1------ 10 15 20 i 25 I 30 i i 35 40 "N ___1______JL_____ 4! 50 55 GASES IN O R IG IN A L ATM O SPHERE, PERCENT Source: Coward and Jones Saturday, September 17, 11 O X Y G E N 19 IN O R IG IN A L A T M O S P H E R E , P E R C E N T 18 17 16 15 14 13 10 12 T F o r to s o m e in d iv id u a l in c re a s e d ilu e n t w ith a n d th e gas s p e c ie s , L F L in c re a s e d ra te d e p e n d o n c o n c e n tra tio n s o f in c re a s e th e a p p e a rs s e e m s o f t o d ilu e n t. However... 1= LFL with no added inerts '- ______ 1______ 1_______1______ 1------ 10 15 20 i 25 I 30 i i 35 40 "N ___1______JL_____ 4! 50 55 GASES IN O R IG IN A L ATM O SPHERE, PERCENT Source: Coward and Jones Saturday, September 17, 11 H o w e v e r . . . for the gas mixtures typical of vent gas we find Flat Bottom Noses Saturday, September 17, 11 H o w e v e r . . . for the gas mixtures typical of vent gas we find Flat Bottom Noses Saturday, September 17, 11 N o s e P lo t f o r C o m b u s t ib le s in In e r t s H o w e v e r . . . for the gas mixtures typical of vent gas we find (%Air ■ 100% • %Combustibles - %lnerts) so% N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s (%Air ■ 100% - ^Combustibles - %lnerts) 45% X O > 45% a 35 % z + £"30% * 40% O > a ii s 'C VI 3 ■g £ o O ~ 01 Q w * Flat Bottom Noses 50% 40% 25% 35% z + -T* 30% 20% 15% 10% 5% VI $ s 25% Xj 3 ■e 20% £ 0 O D etroit B 8-2 Nose Plot ~ 15% c u 51 10% 0% Nitrogen Nos 5% 0% 0% 5% 10% 15% 20% 25% 30% 35% Percent Inerts ( V G * ,* , ♦ Steam ) (vol%) Saturday, September 17, 11 40% 45% 50% Saturday, September 17, 11 N o s e P lo t f o r C o m b u s t ib le s in In e r t s H o w e v e r . . . for the gas mixtures typical of vent gas we find (%Air ■ 100% • %Combustibles - %lnerts) 50 ,, N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s (%Air ■ 100% - %Combustibles - %lnerts) 45% O > a X + N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s % S0% 40% -T" 30% j» s 25% 'C </l o - 15% 0u1 «j 10% 5% o% N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s o > 35% so% '30% 3-O 25% ■C M 3 -Q E 0 a c 4) u C (%Air ■ 100% - %Combustibles - %lnerts) 45% X + >1 20% 0 (%Air ■ 100% - %Combustibles - %lnerts) 45% 35 Flat Bottom Noses 50% X 4U% 20% 15% * 4U:.. o > u 35% T ♦ 01 10% c£ 40% 30% VI JO 25% 'C *i 3 a. -O E 20% 0 0% c - O > a 35 % X + V 30% S 25% 0 5% 45% 15% 'C p t- TXC A l l 14-1 01 10% a. Nose Plot 5% 0% aL 10% C Nitrogen Note 0% ■«-' 0% 5% 10% 15% 20% 2S% 30% 35% Percent Inerts (V G ,*.*, + Steam) (vol%) Saturday, September 17, 11 40% 45% 50% N o s e P lo t f o r C o m b u s t ib le s in In e r t s H o w e v e r . . . for the gas mixtures typical of vent gas we find (%Air ■ 100% • %Combustibles - %lnerts) 50 ,, N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s (%Air ■ 100% - %Combustibles - %lnerts) 45% Flat Bottom Noses 50% X 40% O > a 35 N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s (%Air ■ 100% - %Combustibles - %lnerts) 45% % 50% Z + -T" 30% s 'C 25% * 40% o 0 - 35% 50 ' 30% S 25% 0u1 * 10% 'C - | 20% Q 0 ~ 15% 5% o% „ J * 4U % £> 15% (%Air ■ 100% - %Combustibles - %lnerts) 45% X + >1 20% o N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s > 0o1 * 10% 5% 0% N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s O X -T* 30% O VI a» 5 25% ■C 50% > a 40% 45% 35 % Z + v» 3 £ 20% - u S 25% ~ 15% 'C M E o (%Air ■ 100% - %Combustibles - %lnerts) 45% CT 35% X ♦ -T* 30% ^ 40% O > CT 35% Al 3 I 10% - 5% 0% -T* 30% 20% O 0 z + s 15% 3 0u1 A 10% 25% Shell EP A 12,500 ■c E o (1) Nose Plot 20% 0 ~ 15% 0u1 0% io% 5% 0% 0% 5% 10% 15% 20% 25% 30% 35% Percent Inerts (VG,„#m ♦ Steam ) (vol%) Saturday, September 17, 11 40% 45% 50% N o s e P lo t f o r C o m b u s t ib le s in In e r t s H o w e v e r . . . for the gas mixtures typical of vent gas we find (%Air ■ 100% • %Combustibles - %lnerts) 50 ,, N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s (%Air ■ 100% - %Combustibles - %lnerts) 45% Flat Bottom Noses 50% X 40% N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s O > (%Air ■ 100% - %Combustibles - %lnerts) 45% a 35% Z 50% + S* 40% -T" 30% s 'C 25% > O - 35% 50 „ '30% ai u * 10% o% N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s 'C ♦ X 40% -T* 30% O V) - | 20% Q o ao £ 10% 5% 0% (%Air ■ 100% - %Combustibles - %lnerts) 45% cr 35% ~ 15% 5% J* 4U% O £> S 25% 15% (%Air ■ 100% - %Combustibles - %lnerts) 45% X ■f >1 20% o N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s o Z 5 0' „ O) 25% ■C S0% Z + v» 3 £ 20% E o u - ~ 15% 'C M 01 40% -T* 30% 5% 0% O 45% a 35% S 25% 3 I 10% (%Air ■ 100% - %Combustibles - %lnerts) 45% a 35% VI 5 N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s > Z + J* 40% -1*30% J3 20% E o 0 ~ 15% - £> s 25% •c a01 OJ C L 10% ■g 20% Q O > a 35% z '30% o ~ 15% FHR L O U A 8 .5 (2) ao 0% Nose Plot £ 10% 5% ii o% a. 10% 5% 0% 0% 5% 10% 15% 20% Percent Inerts Saturday, September 17, 11 25% 30% 35% + Steam ) (vol%) 40% 45% 50% H o w e v e r . . . for the gas mixtures typical of vent gas we find Flat Bottom Noses Saturday, September 17, 11 N o s e P lo t f o r C o m b u s t ib le s in In e r t s H o w e v e r . . . for the gas mixtures typical of vent gas we find (%Air ■ 100% • %Combustibles - %lnerts) 50 ,, N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s (%Air ■ 100% - %Combustibles - %lnerts) 45% Flat Bottom Noses 50% X 40% N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s O > Z + 25% 'C </l >1 20% o 0 - 50% S* 4 0 % -T" 30% s (%Air ■ 100% - %Combustibles - %lnerts) 45% a 35% 15% 0u1 * 10% 5% o% N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s o > X ■f (%Air ■ 100% - %Combustibles - %lnerts) 45% 35% 50', J* 4U% '30% N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s O (%Air ■ 100% - %Combustibles - %lnerts) 45% £> S 25% 'C V) - | 20% Q o CT 35% z 5 0' „ ♦ X 40% -T* 30% O VI a» ■C Z + ao * 10% 3 £ 20% - 5% 0% 25% v» E o (%Air ■ 100% - %Combustibles - %lnerts) 45% a 35% ~ 15% 5 N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s > 50% 40% -tT* 30% N o s e P l o t f o r C o m b u s t i b l e s in I n e r t s O u S 25% ~ 15% 'C M 01 I 10% 3 -1*30% O £> CT 35% >| 20% ~ 15% 0% 50% J* 4U% O 2, 0 5% Z + 0u1 10% S 25% •c V) ■g 20% Q o ~ 15% ao 0% (%Air ■ 100% • %Combustibles - %lnerts) 45% a 35% z ♦ V* 30% X O > v\ at a 35% 'C v» + ft 25% 3 £ 10% £ 20% 0% 40% L F L z fo r ty p ic a l e s s e n tia lly fla re gas c o n s ta n t cases E o ~ 15% re g a rd le s s ■c c o n c e n tra tio n o r s p e c ie s S 25% 01 3 -Cl £ 10% 5% 0% E 0 u c FHR AU-A 5 .0 (2 ) Nose Plot 20% 15% 0u1 w E Q. 10% Nrtroge<i Nose 5% 0% 0% 5% 10% 15% 20% 2S% 30% 35% Percent Inerts (VG*,,,,, + Steam) (vol%) Saturday, September 17, 11 re m a in s o f V* 30% - j» u 5% 45% 40% 45% 50% o f in e rt LFL for typical flare gas cases remains essentially constant regardless of concentration or species of inert Saturday, September 17, 11 LFL for typical flare gas cases remains essentially constant regardless of concentration or species of inert Therefore... W e o n ly w ith a n e e d s in g le w ith n o Saturday, September 17, 11 c o n c e rn L F L o u rs e lv e s v a lu e ... t h e in e rts a d d e d . L F L LFL for typical flare gas cases remains essentially constant regardless of concentration or species of inert Therefore... W e o n ly w ith a n e e d s in g le w ith T h is c h e m ic a l s u ch L F L n o v a lu e c o n c e rn v a lu e ... t h e in e rts is f o u n d Saturday, September 17, 11 C R C o r L F L a d d e d . in e n g in e e rin g as o u rs e lv e s c o m m o n re fe re n c e s P e r r y 's LFL for typical flare gas cases remains essentially constant regardless of concentration or species of inert Therefore... W e o n ly w ith a n e e d s in g le w ith T h is c h e m ic a l s u ch L F L n o v a lu e c o n c e rn v a lu e ... t h e in e rts is f o u n d C R C A n d Saturday, September 17, 11 o r s o ... L F L a d d e d . in e n g in e e rin g as o u rs e lv e s c o m m o n re fe re n c e s P e r r y 's Saturday, September 17, 11 r T h e P r o p y le n e H y p o th e s is r Saturday, September 17, 11 (1 CE vs. NHVcz All TCEQ Steam and Texas City Base and Olefins CleanAir |-»0e° 100% i* of o\p 0V• o o >• 90% 80% 1 70% 1 > u c v oo c ®°o°o 00 o -m i 60% o o» u £ LU c o v> 3 -Q 50% • 40% E o TCEQ B - Vary Steam (S3,4, 5, 6) • u TCEQ C - Vary VG (S7, 8, 9, 10, 11) 30% TCEQ D - Vary VG, Propane (S12,13,14) • O TXC A l l - Base, 15% H 2 ,1100 lb.hr 20% OTXC D - 25% Propylene, 4000 Ib/hr 10% OTXC E - 28% Propylene, 9000 Ib/hr OTXC A19 - Base, 15% H2, 1850 Ib/hr 0% -m *- # T T I 200 400 600 800 ................. T------------------1,000 1,200 1,400 Combustion Zone Gas Net Heating Value (H2=1212 BTU/scf) (BTU/scf) Saturday, September 17, 11 1,600 1,800 Saturday, September 17, 11 TCEQ Test - PFTIR Saturday, September 17, 11 1 9 8 7 u 6 1st Data Submission (with Error) T5 CD CO 03 -Q □ < a Saturday, September 17, 11 i- 100%TNG - 100%Propane CD - 80%Propane/20%TNG P ro p e n e /2 0 % T N G 0%Propene i 8 1 ARI based DRE % 1 8 7 u 6/2011 submission, CEpropane bug isfixed T5 CD CO 03 JD < 100%TNG 100%Propane 80%Propane/20%TNG 8 0 % P ro p e n e /2 0 % T N G 100%Propene 8 ARI based DRE Saturday, September 17, 11 I 1 A p o s s ib le e x p la n a t io n ... Propylene gives up hydrogen atoms to free radicals (hydrogen abstraction) The reaction product is stable. It does not contribute to furthering the reaction. T h e r e fo r e ... When hydrogen is present in high propylene gas streams the combustion process is inhibited Saturday, September 17, 11 Sa/oo/a K "r~ «<*»«,0 ^ d r o c a r b o n C o m ,,? S a lo o ja S tu d y , " Studl' « o f O f e f probab/y ^ f ? da(,on fess readiWth ynde^°cs Effect of Olefins on HC Combustion Soing n L ^ . 15 Partly d u e /n ^ thanethylene. ^^ogen-ahS *ditioS^**<Kftion re­ ^*onsrath!!?!uantly the **n radical fornLd ** abs*rat*ed 0 0 6 u n d c r ' rcarfinf' * ! though tt S ^ s S r1 ® Pr0dUMS c U ^ n' 3 Ethylene Produces another radical Propylene Produces a stable compound ------------- 'fc> ( W XI> iih „liyi m i r ^ .-r -r -S ^ C 0" ^ We molecular SDecfe oni P™l*nc produws >2+X CH2X Ths is consistent with some observations that adding hydrogen to a propylene gas stream will cause smoking H o w e v e r ... Saturday, September 17, 11 H o w e v e r ... Salooja did not look at gas mixtures that include H2 Others* have postulated different reaction mechanisms No specific research on H2 and propylene More Work to be Done *Tully, F. "Kinetic Study of the Hydroxyl Radical-Propene Reaction," Chemical Physics Letters, Vol. 116, No. 4, May 10, 1985 Saturday, September 17, 11 C o r r e la tin g O p e r a tin g P a ra m e te rs Saturday, September 17, 11 (1 CE vs. NHVcz All TCEQ Steam vs Base Loads CleanAir 100% 90% '- ' o 80% C7T 70% O' >* o c QJ U 60% ® tl The Reason This Method is Possible 8 o. £ LU C 50% 3 -Q 40% o *.p co E o u TCEQ B - Vary Steam (S3, 4, 5, 6) 30% TCEQ C-Vary VG (S7, 8, 9, 10, 11) TCEQ D - Vary VG, Propane (S12, 13,14) 20% ♦ FHR AU A - Base, 38% H2, 830 Ib/hr ♦ FHR LOU A - Base, 28% H2, 2900 Ib/hr 10% OTXC A ll - Base, 15% H2, 1100 lb.hr □ DET A - Base, 20% H2, 550 Ib/hr 0% 200 400 600 800 1.000 1,200 1,400 Combustion Zone Gas Net Heating Value (H2=1212 BTU/scf) (BTU/scf) Saturday, September 17, 11 1,600 1,800 (i CE vs. NHVcz DET and TXC Base Loads (zoomed) CleanAir 100% o o o >* QJ o 8 o u c o° o o 94% o o r? o 96% ° O ° o ° o O o o 98% 92% 'u £ LU C s 90% o o 3 -Q o 88% o E o u 86% 84% ® TXC A l l - Base, 15% H 2 ,1100 lb.hr 82% O DET A - Base, 20% H2, 550 Ib/hr ® TXC A19 - Base, 15% H 2 ,1850 Ib/hr 80% 100 200 300 400 500 Combustion Zone Gas Net Heating Value (H2=1212 BTU/scf) (BTU/scf) Saturday, September 17, 11 600 (1 CE vs. NHVcz DET and TXC Base Loads (zoomed) CleanAir 100% O ° o 98% • Efficient Combustion • • • • . • ...........o c 96% o o 3* 8 94% >• § £ LU C 90% 3 -Q 88% o *.p M E o u 86% 84% OTXC A l l - Base, 15% H 2 ,1100 lb.hr 82% O DET A - Base, 20% H2, 550 Ib/hr • TXC A19 - Base, 15% H 2 ,1850 Ib/hr 80% 100 200 300 400 500 Combustion Zone Gas Net Heating Value (H2=1212 BTU/scf) (BTU/scf) Saturday, September 17, 11 600 (1 CE vs. NHVcz DET and TXC Base Loads (zoomed) CleanAir 100% O ° o 98% • Efficient Combustion • • • • . • ...........o c 96% o o 3* 8 94% >• g 92% £ LU C 90% 3 -Q 88% o *.p M E o u 86% 84% OTXC A l l - Base, 15% H 2 ,1100 lb.hr 82% O DET A - Base, 20% H2, 550 Ib/hr 80% ' • TXC A19 - Base, 15% H 2 ,1850 Ib/hr 4 100 V NHVvg-LFL DET = 47 Btu/scf TXC = 48 Btu/scf Saturday, September 17, 11 200 300 400 500 Combustion Zone Gas Net Heating Value (H2=1212 BTU/scf) (BTU/scf) 600 F a c to rs CE vs. NHVcz DET and TXC Base Loads (zoomed) CleanAir A =6 B=3 100% o 98% 96% 3* O' 94% >* u C QJ O 92% o O 0 o ° ° " ^ T i ---------------------------------------------Efficient Combustion 0 o° ...................................................................................o.................................................. ° oo 8 o o O ~9~ £ LU C o *.p co 3 JD 90% O O 88% O E o u NHVcz-limit y D E T = 298 Btu/scf / T X C = 303 Btu/scf 86% 84% OTXC A l l - Base, 15% H 2 ,1100 lb.hr 82% O DET A - Base, 20% H2, 550 Ib/hr 80% y OTXC A19 - Base, 15% H 2 ,1850 Ib/hr 100 200 300 400 500 Combustion Zone Gas Net Heating Value (H2=1212 BTU/scf) (BTU/scf) NHVvg-LFL DET = 47 Btu/scf TXC = 48 Btu/scf Saturday, September 17, 11 600 F a c to rs (1 CE vs. NHVcz DET and TXC Base Loads (zoomed) CleanAir A =6 B=3 100% O° o 98% Efficient Combustion o o • • • CM 96% o o 3* O' 8 94% >* u c QJ U 92% £ LU C 90% 3 JD 88% o *.p co E o u NHVcz-limit DET = 298 Btu/scf T X C = 303 Btu/scf 86% 84% OTXC A l l - Base, 15% H 2 ,1100 lb.hr 82% O DET A - Base, 20% H2, 550 lb/hr 80% OTXC A19 - Base, 15% H 2 ,1850 lb/hr ( wm 100 V NHVvg-LFL DET = 47 Btu/scf TXC = 48 Btu/scf Saturday, September 17, 11 200 300 ---------- 400 500 Combustion Zone Gas Net Heating Value (H2=1212 BTU/scf) (BTU/scf) 600 F a c to rs (1 CE vs. NHVcz DET and TXC Base Loads (zoomed) CleanAir A =6 B=3 100% O ° o 98% o Efficient Combustion o • • • CM 96% o o 3* O' 8 94% >* u c QJ U 92% £ LU C 90% 3 JD 88% o *.p co E o u NHVcz-limit DET = 298 Btu/scf T X C = 303 Btu/scf 86% 84% OTXC A l l - Base, 15% H 2 , 1100 lb.hr 82% O DET A - Base, 20% H2, 550 Ib/hr OTXC A19 - Base, 15% H 2 , 1850 Ib/hr 80% ( wm 100 V NHVvg-LFL DET = 47 Btu/scf TXC = 48 Btu/scf Saturday, September 17, 11 200 300 ---------400 500 Combustion Zone Gas Net Heating Value (H2=1212 BTU/scf) (BTU/scf) 600 F a c to rs (1 CE vs. NHVcz DET and TXC Base Loads (zoomed) CleanAir A =6 B=3 100% O ° o 98% o Efficient Combustion o • • • CM 96% o o 8 3* 94% O' >* u c QJ U 92% £ LU C 90% 3 JD 88% o *.p cn E o u NHVcz-limit DET = 298 Btu/scf T X C = 303 Btu/scf 86% 84% OTXC A l l - Base, 15% H 2 ,1100 lb.hr 82% O DET A - Base, 20% H2, 550 Ib/hr 80% OTXC A19 - Base, 15% H 2 ,1850 Ib/hr ( wm 100 200 300 ---------- 400 500 Combustion Zone Gas Net Heating Value (H2=1212 BTU/scf) (BTU/scf) NHVvg-LFL DET = 47 Btu/scf TXC = 48 Btu/scf Saturday, September 17, 11 600 F a c to rs (1 CE vs. NHVcz DET and TXC Base Loads (zoomed) CleanAir A =6 B=3 100% O ° o 98% o Efficient Combustion o • • • CM 96% o o 3* 8 94% Goal: Keep actual NHVcz above the limit >• g 92% £ LU C 90% 3 -Q 88% o *.p M E o u NHVcz-limit DET = 298 Btu/scf T X C = 303 Btu/scf 86% 84% OTXC A l l - Base, 15% H 2 , 1100 lb.hr 82% O DET A - Base, 20% H2, 550 lb/hr OTXC A19 - Base, 15% H 2 , 1850 lb/hr 80% ( wm 100 V NHVvg-LFL DET = 47 Btu/scf TXC = 48 Btu/scf Saturday, September 17, 11 200 300 ---------400 500 Combustion Zone Gas Net Heating Value (H2=1212 BTU/scf) (BTU/scf) 600 RSVF v vs CE 2 100 o 90 80 70 ^ £ u>* c aj u £ ** c °° ° 8& 60 -------------- C 0 50 o 0 cP 1 1 o 40 u RSVF Objective: Snuff Point = 1 30 ° Detroit OTXC _ oo 20 o FHR AU Actual Snuff Points o FHR LOU - 10 ° S Series 'A A o 0 .0 0 0 .2 0 0.40 0.60 0.80 ATS A AA£> 1.00 RSVF [~] Saturday, September 17, 11 1.40 v i 1.60 1.80 C o n c lu s io n s A Ik? Saturday, September 17, 11 C o n c lu s io n s Oversteaming will cause a decline in combustion efficiency. By carefully monitoring vent gas composition and steam flow, it is possible for refinery flares to consistently achieve high combustion efficiency. Saturday, September 17, 11 C o n c lu s io n s Based on testing conducted at six refinery flares along with the validation testing conducted by TCEQ, we can conclude that the PFTIR test method is capable of accurately characterizing flare performance over a wide range of tip types and vent gas compositions Saturday, September 17, 11 C o n c lu s io n s Steam-assisted flare performance is reasonably consistent over a wide range of tips and vent gas streams Wind does not significantly degrade combustion efficiency on steamassisted flares r , l Saturday, September 17, 11 C o n c lu s io n s Flammability nose tips are not predicitive of flare snuffing It is unlikely that steam-assisted flares will experience wake dominated flow at less than hurricane conditions Saturday, September 17, 11 C o n c lu s io n s Since data show that flare performance is reasonably consistent across flare types and compositions, it is possible to develop an LFL based compliance parameter that can be generally applied to a wide range of flares. te? Saturday, September 17, 11 C o n c lu s io n s The hydrogen content of the vent gas has no appreciable effect on flare performance. Nitrogen in the vent gas may be treated the same as steam. Saturday, September 17, 11 C o n c lu s io n s Propylene appears to adversely affect flare combustion efficiency but the mechanisms must be further investigated. NHV is a more useful regulatory parameter than a ratio or a steambased parameter Saturday, September 17, 11 C o n c lu s io n s There is little evidence to suggest that IR cameras can reliably distinguish hydrocarbon emissions from other combustion products such as smoke or water vapor. te? Saturday, September 17, 11 Saturday, September 17, 11 F IN I [e-mail] C le a n A in Saturday, September 17, 11