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FLUID CATALYTIC CRACKER LAKE CHARLES REFINERY STACK TEST FEBRUARY 2, 3, 1981 CONOCO INC. P. 0. BOX 37 WESTLAKE, LA 70669 T. J. Mihalcik Senior Process Engineer Refinery Technical Services A. J. Nash Environmental Engineer Refinery Technical Services p \)hyL^ J. B. Blazek Staff Process Engineer Refinery Technical Services Approved by: I. F. Wagner Plant. Manager Lake Charles Refinery SHE000000567 TABLE OF CONTENTS INTRODUCTION ................................................................ 1 SUMMARY ........................................................................ 5 PROCEDURE.................................................................... 10 ANALYTICAL TECHNIQUE ............................................... 12 CHAIN OF CUSTODY....................................................... 13 TEST DATA AND CALCULATIONS.................................. 14 APPENDICES.................................................................... 43 1. Calibration Worksheets 2. Qualifications of Lab Personnel 3. Continuous Monitoring Systems 4. Kemron Report SHZ000000568 INTRODUCTION On February 2, and 3, 1981 Kemron Environmental services and Conoco personnel conducted stack emission tests for particulate emissions, carbon monoxide emissions, and stack opacity on the Fluid Catalytic Cracker (FCC) at the Lake Charles Refinery, as required by CFR 40, part 60,8 "Performance Tests" for New Stationary Source Pollution Standards. The FCC unit consists of a 30,600 BPSD Pullman-Kellogg Orthoflow "F" Riser Catalytic Cracker, a product fractionation section, an energy recovery sec tion, and an emission control section. On the following page there is a process flow diagram for the FCC. The catalytic cracker is comprised of three main vessels: the riser, the disengager, and the regenerator. Hot regenerated catalyst flows from the regenerator to the feed injection nozzle. The liquid feed is contacted with the hot catalyst, and it is instantly vaporized. The expanding vapors drive the catalyst up the riser. It is in the riser itself that the cracking reaction takes place. As a byproduct of the cracking reaction, coke is formed on the surface of and in the pores of the catalyst particles. The reaction is quenched by sepa rating the product vapors from catalyst particles in the disengager. The product vapors go to the product fractionation section while the catalyst flows through the stripper and drops into the standpipe. The weight of catalyst in the standpipe overcomes the pressure differential between the disengager (low) and the regenerator (high). Spent catalyst from the standpipe is distributed on top of the fluidized bed in the regenerator. -1- SHE000000569 SHE000000570 INTRODUCTION (continued) Combustiort air is supplied by three air distributors (95%) and three fluffing air rings (5%). The coke is burned off the catalyst, heating and regenera ting it. The hot regenerated catalyst flows out the bottom of the regenera tor, completing the catalyst circulation loop. The flue gas exits the regenerator through the regenerator cyclones and enters the doughnut-shaped plenum. From there the flue gas goes to the catalyst separator which removes the catalyst fines from the bulk of the flue gas. The flue gas then goes to the energy recovery section where the expander recovers power from the hot gas to drive the combustion air canpressor, then to the waste heat boiler. The catalyst fines and underflow gas leaves the bottom of the catalyst separator and flows to the flue gas cooler, X-362, where the gas is cooled to protect the bag filter fabric. In the bag filter, catalyst fines are recovered from the underflow and are disposed of into a dump box. The underflow gas passes through the bag and rejoins the flue gas leaving the waste heat boiler. The flue gas is then emitted out of the flue gas stack. On the following page is a drawing of the stack cross section at the sample port. -3- SHE000000571 D-r-#At///-> ACCORD/H6. TO Mfr///?> Of/S. (,??FR mmrffoo otte seenon iv or xemron xswxr) BRUNING 40-53* CONTINENTAL Oil COMPANY -4- | No. SHE000000572 SUMMARY Emissions: A summary of emission rates, Table 1, is located on the following page. Particulate emissions exceeded the performance standard. Carbon monoxide emissions and stack opacity were within the performance standards. Stack opacity was measured with our continuous monitoring system. The stack was also visually monitored by a trained observer, Mr. Robert A. Ressl of the PEDCo Group. Mr. Ressl was under contract with Region 6 of The Environmental Protection Agency. His two sets of opacity readings averaged 16 and 15. A copy of his Visible Emission Observation Form is on page 41. The test runs were made at a feed rate of 29,050 BPD, measured with flow recorder FR-404. The design and normal maximum operating level is 30,600 BPD of feed. Air Pollution Control Equipment: Carbon monoxide emissions are minimized by operating the regenerator under 3% excess oxygen and using a CO combustion promoted catalyst. This causes complete combustion of carbon monoxide to carbon dioxide, without any after burning. The regenerator cyclones are the first level of particulate emissions con trol . They are meant to minimize catalyst losses from the converter. There are six first stage cyclones, Emtrol Corp. model number 46B055, and six second stage cyclones, Emtrol Corp. model number 48A033. Each first stage cyclone is paired with a second stage cyclone, with the discharge of the first stage going directly into the entrance of the second stage. -5- SHE000000573 TABLE 1: A summary of emission rates for particulates and carbon monoxide* and stack opacity. EMISSION Particulates, Ib/hr Particulates, lb/1000 lb of coke burn-off Percentage of isokinetic sampling rate, % Carbon Monoxide, ppm, run average Opacity, % RUN # PERFORMANCE I 1 3 AVE. STANDARD 37.6 28.7 31.4 32.6 2.20 1.65 1.85 1.90 1.00 95.1 94.6 94.1 94.6 100 + 10 40.3 13.4 67.3 13.6 59.7 13.1 55.8 13.4 500 30 JBB:jw 6- - SHE000000574 SUMMARY Air Pollution Control Equipment: (continued) The discharge from the second stage cyclones goes into a common plenum. The recovered catalyst is returned to the regenerator through six first stage and six second stage diplegs. The next level of particulate emissions control is given by the catalyst separator. The catalyst separator, often referred to as the "Shell separator" was manufactured under a licensing agreement with the developers. Shell Oil Co. It is meant to remove catalyst fines from the bulk of the flue gas stream prior to the expander and waste heat boiler. It has 55 separator tubes. Figure 3, on the following page, shows a typical separator tube. Catalyst fines and flue gas pass down the outside of the tubes and across swirl vanes which impart a spin to the stream and throw the denser catalyst particles to the outside. The gas makes a turn at the bottom of a tube and flows up the inside of the tube and then out of the separator. The catalyst falls to the bottom of the separator vessel and is drawn out in a fluid flow using about three percent of the incoming flue gas as the carrier. The bottoms stream passes through critical flow nozzles (between the flue gas cooler and the bag filters). Flow through these nozzles is at sonic velocity and is there fore relatively constant and does not vary with FCC charge rate. The temperature of the bottoms stream is 1300F. The flue gas cooler, X-362, reduces this to 375F, the maximum continuous operating temperature the Huyck felt bags in the bag filters can withstand, by producing steam. The final level of particulate emissions control is given by the bag filters -7- SHE000000575 BRUNING 40-534 32957 SHS000000576 BRUNING 40-534 32957 SHE000000577 SUMMARY Air Pollution Control Equipment: (continued) which recover the catalyst fines. The underflow gas is returned to the main flue gas stream leaving the waste heat boiler. The two bag filters, American Air Filter Co. Pulse-Oet Fabric Dust Collectors, type 12-48-770, are in stalled in parallel. Each will handle the full gas stream, and normally only one is on stream. During the test one was on stream. Each filter has 48 Huyck felted bags, fabric weight 16 oz. The "pulse jet" type periodically uses a back flow pulse of compressed air to shake the bags to remove the recovered catalyst. The catalyst drops into a hopper at the bottom of the collector. Four gate valves remove the fines to a dump box for dis posal. Only twelve of the bags are pulsed at a time, the rest remain in ser vice. A solid state local control panel allows variation of pulse duration (0.010 - 0.500 sec.) and interval (10 - 240 sec.). During the test the pulse duration was 0.100 seconds and the interval was 1 minute. The flue gas leaving the waste heat blower passes by the opacity monitor located in a horizontal section of pipe before exiting out the flue gas stack. -9- SHE000000578 PROCEDURE Particulate Emissions: The test methods and procedures given in CFR 40 part 60.106(a) were used to determine particulate emissions. One deviation from the special procedure was used: Paragraph (1) specifies making a determination of the volumetric flow rates for gases released to the atmosphere; paragraph (2) specifies making a separate determination of the volumetric flow rates for exhaust gases prior to the emission control system. Only one measurement of volu metric flow rates (of gases released to the atmosphere) was made. Because of the configuration of the emission control system, with no afterburning and return of the underflow gas from the catalyst separator to the main flue gas stream, no additions to or deletions from the flue gas stream occur in the control system. Therefore, only one determination of volumetric flow rate is needed. It is much more practical to measure the flue gases after they have been cooled from 1300F to 480F. Because measurements are made in standard cubic feet per minute, the change in temperature will make no difference in the numerical answer. Method 1 was used to determine the number and location of sample and velocity traverses. The calculations are found in Test Data and Calculations, pages 22-24. Method 1 is described in Appendix 4, KEMRON Report, Section IV. Method 2, used to measure velocity and volumetric flow rate, is described in Appendix 4, KEMRON Report, Section V. Method 5, used to measure concentration of particulate matter and moisture -10- SHE000000579 PROCEDURE Particulate Emissions: The test methods and procedures given in CFR 40 part 60.106(a) were used to determine particulate emissions. One deviation from the special procedure was used: Paragraph (1) specifies making a determination of the volumetric flow rates for gases released to the atmosphere; paragraph (2) specifies making a separate determination of the volumetric flow rates for exhaust gases prior to the emission control system. Only one measurement of volu metric flow rates (of gases released to the atmosphere) was made. Because of the configuration of the emission control system, with no afterburning and return of the underflow gas from the catalyst separator to the main flue gas stream, no additions to or deletions from the flue gas stream occur in the control system. Therefore, only one determination of volumetric flow rate is needed. It is much more practical to measure the flue gases after they have been cooled from 1300F to 480F. Because measurements are made in standard cubic feet per minute, the change in temperature will make no difference in the numerical answer. Method 1 was used to determine the number and location of sample and velocity traverses. The calculations are found in Test Data and Calculations, pages 22-24. Method I is described in Appendix 4, KEMRON Report, Section IV. Method 2, used to measure velocity and volumetric flow rate, is described in Appendix 4, KEMRON Report, Section V. Method 5, used to measure concentration of particulate matter and moisture -10- SHE000000580 PROCEDURE Particulate Emissions: (continued) content, is described in Appendix 4, KEMRON Report, Section VI. The total particulate catch was adjusted for sulfate concentration. Sulfates are in the vapor phase at stack conditions. Method 5 sampling results in them being reported as particulates. This inconsistency was corrected by analyzing the particulates for sulfates and taking an offset for any sulfates found. Sulfate emissions are shown in Appendix 4, KEMRON Report. Carbon Monoxide; The test methods and procedures given in CFR 40 part 60.106(b) were used to determine carbon monoxide concentration in the flue gas emitted to the atmosphere. Method 10, used to measure emissions of carbon monoxide, is described in Appendix 4, KEMRON Report, Section VII. Opacity; Stack opacity was measured using our continuous monitoring system. A trained observer also made visual observations in accordance with CFR 40 part 60.11(b). -11- SHE0Q0000581 ANALYTICAL TECHNIQUE A description of the analytical technique can be found in Appendix 4, the KEMRON Report, Section II. -12- SHE000000582 CHAIN OF CUSTODY The Chain of Custody is described in Appendix 4, the KEMRON Report, Section II. -13- SHE000000583 TEST DATA AND CALCULATIONS a) Field Data Sheets b) Process Operations Log c) Laboratory Data d) Emissions Calculations -14- SHE000000584  r^id. Sc, , 9;^ ` 9: is " Jy.'O" - fX - oo*i $\e.e> A > *i f fc. 72 1.1 r :a f ^. 1 '* if i. (a S 3 ^ tt1 To4 . & lUti ^ <o. 5f 11^-5 " ,n:\t" to 5To- FX-<70*r ^ . od. Hii 1 / ='; *T' C-' .IS i*. Si' :3i o: '* fc-3<? Y ; 1 -1 &.3D .30 /ljjf l: 15 r . 1:,3. * .. &o ,t.50 6=30 .&.2.T 3 /i 3-LJ V_>J G l: ^ |. M5f . t"Ai .6-.^5:. * 6.SO 2:35 f . 2:^5 p U.5 5 . .30 rx-00& Kf 0 J. t *1 (-.3 0 0 is t.,3 X fe.90 . 5<r 6. 3x .. t.'ir 2 -T 6r 3i~ {..39 Utt Si* At Dr-j ' 5L> ? 1 *- / 2? 3X 31 37 3? 3? 3? J? 3| 10 Hi Vi 5-3 Vtl % *7 ^7 ip To i? V ._ X/ o i 1 4 j. li '> i /.' * ( F c c. r- >. rjs -r> - t r t tPVi: _. /?>/= SHE000000585 Further field data sheets for particulate and carbon monoxide emissions can be found in Appendix 4, the KEMRON Report, Section VIII, appendix. -16- SHE000000586 It* mi** 4c *h : if a** tl is i? i' t!i i>l! _ L*a?** -W- Wl_ t : -*K r|J 8? r" ~vj Vi 'S I bK I! 1 silN y S3 \u 1:.. I it! o O'! Ufc y* !M f-1? 5 g :lll; . , K*V 5 \ 't* il I ; : W/h7/v/l t twt * MW IUMt (T (Hcavv W CONTINENTAL OIL COMPANY CCOnOCO) iniNin enccmumg cintu 1 CONTROL ROOM CHARTS FCC REGENERATOR Ni.P.l EMISSION TEST ! CONOCO INC. .LAKE CHARLES REFINERY i VU* Mm |noJC-BSOi'tt -ii-tA-C SHE000000587 c) LABORATORY DATA PARTICULATE 1. Filter Weights 2. Probe Residues 3. 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