Rule Particulate Control Environmental Considerations in Today’s Projects

Agenda  ConocoPhillips  Los Angeles Refinery  Environmental Regulations  What does an Environmental Department do ?  General Project Considerations  Case Study – Rule

Who is ConocoPhillips ?  Large Integrated Oil Company  Does business in over 40 countries  Familiar brands – 76, Phillips 66, Conoco  Sustainable Development –Ethical Standards –Environmental Improvements –Community –Energy

Los Angeles Refinery  Mid-sized, about 140,000 bbls/day  Worst Crude/Cleanest Products –Mostly cracking heavy material distillation –Distillation –Treating/removing impurities  Start 1918, Runs 24/7  About 660 Employees  One of 6 major refineries in South Coast

Environmental Regulations  Clean Air Act  Clean Water Act  RCRA – Waste  Emergency Release Regulations  Toxic Regulations  Multi-Agency Complex Regulations  3 rd -Party Intervention

What Does An Environmental Department Do ?  Regulation expertise – air, water, waste  Advocate on new legislation/regulation  Help facility implement new regulations  Obtain environmental permits  Compliance assurance/continuous improvement management system approach  Maintain reporting/recordkeeping  Staff of 7 professionals, 6 air emphasis

General Project Considerations  Safety – First Priority  Environmental Considerations –Compliance, permitting, scope  Community Impact  Schedule (Timing with Outages)  Quality – Will it work when done  Cost – differentiate alternatives, cost as budgeted

Why Rule Project ?  SCAQMD Regulation –Control solid particle emissions –Control ammonia (precursor)  Impacts the Fluid Catalytic Cracking Unit (FCCu)  Particulate limit, 30 lbs/hour to about 6 lbs/hour  Ammonia, no limit to 10 ppm

What does an FCCu look like ?

Project History  Rule passed 12/2003  Began meeting vendors and setting design parameters  Determined early need for ‘pre-treatment’ –3 rd /4 th -stage separators  Determined early need for schedule adjustment  Installed 3 rd /4 th stage separators in November  Performing Testing

New 3 rd -Stage Separator

New Flue Gas Train

Technology Choices  Dry Electrostatic precipitators (ESPs)  Wet gas scrubber  Wet gas scrubber/Wet ESP

ESP

SCRUBBER EEE NaOH / Na 2 CO 3 Effluent Process Water FCCU Off-Gas WESP Section Stack Absorber Section OxidationAir Sump

Safety Considerations  All technologies selected can and have operated safely. –Dry ESPs in FCCu service (CO on start-up) –Wet ESPs ? –‘Batch’ mode operational factors  ESPs  Wet Solids handling

Community Impact  Steam Plume for wet systems (aesthetics) –Perception vs. Reality –Environmental Justice  Traffic –Construction –Operation  Who is the community ?

Schedule  Outages (turnarounds) approximately every 4 years –Tie-ins are possible  Long lead equipment –Steel –Vessels  Competing Orders  Permitting

Quality  Dry ESPs have most applications  Wet ESPs have least  Limits are pushing the edge of technology –Lack of vendor guarantees –Test method issues  Transient Conditions (start-ups/upsets)  Sparing Philosophy

Costs  Capital Costs –Sparing Philosophy  Operational Costs –Energy –Water/Waste Processing

Environmental Considerations  Test method reliability –EPA vs. SCAQMD method  Future regulation uncertainty –PM 2.5 ( ) –Secondary Pollutants (Precursors)  NOx/SOx/NH3 –PM (New EPA effort, state ?)

Environmental Considerations  Selective Catalytic Reduction (SCR) for NOx –Other regulations –Unit Expansion (Best available Control Technology) –Installation  Temperature/energy considerations  SO2 – SO3 conversion (dry vs. wet)  Fouling  Construction (leaving room)

Environmental Considerations  SOx controls –Other regulations –FCCu expansion – What is BACT ? –Wet systems have a clear advantage

Environmental Considerations  Wastewater treatment - Scrubbers –Purge for solids and chloride control –Removal for solids  Settling/Filter Press (messy Operation)  Allow settling in existing refinery sewer system – Sulfite (oxidation)  Can POTW take it ? (test method)  Adequate aeration in existing system ?

Environmental Considerations  Electrical (ESP vs. Scrubber) –Offset by restarting power recover turbine ?  Energy Profile (waste heat recovery)  Permitting Complexity (12-18 months) –California Environmental Quality Act (CEQA) –Agency experience with ESPs

Environmental Considerations  3 rd -Party Involvement  FCCu Start-Up/Upset Considerations  Plume Mitigation ?

Plume Mitigation

WHAT WOULD YOU DO ?