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PM Controls in Refineries

This presentation by Henk Schipper, Technical Coordinator at CONCAWE, addresses the sources and control measures of particulate matter (PM) emissions in refinery operations. It covers PM generated from oil-fired equipment, Fluid Catalytic Cracking Units (FCCU), and catalyst regenerators. Key types of PM, including soot, cenospheres, and coke particles, are discussed, along with their formation and size. The presentation emphasizes the importance of correct operating conditions for emission control and details advanced systems like cyclones, electrostatic precipitators, and bag filters to improve air quality.

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PM Controls in Refineries

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  1. PM Controls in Refineries For IIASA workshop by Henk Schipper Technical Coordinator - CONCAWE CONCAWE presentation to IIASA workshop by Henk Schipper

  2. Sources of particulates in refineries • Oil fired equipment • process heaters • boilers (burning oil) • Fluids Catalytic Cracking Unit (FCCU) • catalyst regenerators of such units CONCAWE presentation to IIASA workshop by Henk Schipper

  3. PM from Oil fired Equipment • Types of PM in flue gases • soot, the particle size is below 1 µm – visible smoke from a stack is caused by all particles but mainly 0.5 to 5 µm • cenospheres : they originate from the liquid phase residues of combustion of heavy oil droplets, at relatively low temperature (< 700 °C), the size is equal to or larger than that of the original oil droplets • coke particles, formed through liquid phase cracking in combustion at high temperatures (> 700 °C). The particle size is generally from 1 to 10 µm. • fine particles (< 0,01 µm): their contribution to the total mass emission is negligible. CONCAWE presentation to IIASA workshop by Henk Schipper

  4. Catalyst Regeneration • Coke deposited on catalyst is passed through a regenerator, where it is burned off. The combustion gasses are passed through cyclones before disposal to the stack. About 90% is < 10 mm. The main control for PM emissions is correct operating conditions! Basic design includes 2 stage cyclones • Further improvements by (very site specific): • tertiary cyclones • multi cyclones • electrostatic precipitators • wet flue gas scrubbers CONCAWE presentation to IIASA workshop by Henk Schipper

  5. Coking Plants • Coking as described here is a severe thermal cracking process that maximises the severity to the extent that coke is formed while production of the more profitable light products is maximised • Unburnt gases from the calciner are burned in an incinerator, then passed through a waste heat boiler before being released to the atmosphere via a dust collection system • PM emissions from: • furnace flue gas; • coke fines (particulates) from handling of coke • the calciner. • Controls same as for Cat Cracker. In addition bag filters can be used for handling of coke fines at a Capex of about 5 M EUR. CONCAWE presentation to IIASA workshop by Henk Schipper

  6. Process Fired Heaters CONCAWE presentation to IIASA workshop by Henk Schipper

  7. BOILERS CONCAWE presentation to IIASA workshop by Henk Schipper

  8. Cat Cracker & Coker CONCAWE presentation to IIASA workshop by Henk Schipper

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