Table of Contents

1 Executive Summary
    1.1 Basis of Study
    1.2 Limitations of Study Results
    1.3 Pollution Prevention Ideas for Model New Crude Unit
    1.4 Pollution Prevention Ideas for Revamp of
         Conventional Crude Unit
    1.5 Summary of Findings
2 Introduction
    2.1 Background
    2.2 Statement of Objective
    2.3 Study Plan
    2.4 Usefulness of Results
    2.5 Limitations of Study Results
    2.6 Physical Boundaries and Study Limits
    2.7 Future Studies
    2.8 Overview of This Report
3 Regulatory Issues
    3.1 General Issues
    3.2 Air Emissions
    3.3 Wastewater Treatment and Discharges
    3.4 RCRA Hazardous Waste
    3.5 The Pollution Prevention Act
    3.6 New Economic Justification for Waste Reduction
4 Methodology
    4.1 Introduction
    4.2 Generic Methodology for Pollution Prevention Studies
    4.3 Pollution Prevention Methodology Applied to Crude
         Oil Units
5 Conventional Crude Unit (Base Case)
    5.1 Introduction
    5.2 Design Basis
    5.3 Process Description
    5.4 Chemical & Utility Requirements
    5.5 Inventory of Emissions & Effluents
    5.6 Cost Estimate
    5.7 Summary & Conclusions
    Tables
6 Model New Crude Unit (Case 1)
    6.1 Introduction
    6.2 Design Basis
    6.3 Process Description
    6.4 Chemical & Utility Requirements
    6.5 Inventory of Emissions & Effluents
    6.6 Cost Estimate
    6.7 Comparison with Base Case
    6.8 Cost/Benefit Analysis
    6.9 Summary & Conclusions
         Tables
7 Revamp of Conventional Crude Unit (Case 2)
    7.1 Introduction
    7.2 Design Basis
    7.3 Process Description
    7.4 Chemical & Utility Requirements
    7.5 Inventory of Emissions & Effluents
    7.6 Cost Estimate
    7.7 Comparison with Base Case
    7.8 Cost/Benefit Analysis
    7.9 Summary & Conclusions
         Tables
Appendices
A Summary of Pollution Prevention Ideas: Brainstorm List
B Process Flow Diagrams for Base Case
C Process Flow Diagrams for Case 1
D Process Flow Diagrams for Case 2
E Major Equipment List - Base Case
F Major Equipment list - Case 1
G Major Equipment List - Case 2
H Product Stream Characteristics
I Crude Preheat Train Pinch Analysis
J Economic Analysis
K Other Studies
L List of Acronyms
M Bibliography
LIST OF TABLES
1.1 Summary of findings
5.1 State of Products for All Cases
5.2 Base Case - Chemical Requirements
5.3 Base Case - Utility Requirements
5.4 Base Case - Emission Point Source Inventory
5.5 Base Case - Air Emissions (Fuel Gas Case)
5.6 Base Case - Air Emissions (0.2% Fuel Oil Case)
5.7 Base Case - Air Emissions (1.0% Fuel Oil Case)
5.8 Base Case - Air Emissions (3.34% Fuel Oil Case)
5.9a Base Case - Fugitive VOC Emissions Calculations
5.9b Base Case - SARA Constituents in Fugitive VOC Emissions
5.10 Base Case - Benzene NRSHAP Emissions Estimate
5.11 Base Case - Wastewater Inventory
5.12 Base Case - Solid and Hazardous Waste Inventory
5.13 Base Case - Summary of Air Emissions
6.1 Case 1 - Chemical Requirements
6.2 Case 1 - Utility Requirements
6.3 Case 1 - Air Emissions (Fuel Gas Case)
6.4 Case 1 - Air Emissions (0.2% Fuel Oil Case)
6.5 Case 1 - Air Emissions (1.0% Fuel Oil case)
6.6 Case 1 - Air Emissions (3.34% Fuel Oil Case)
6.7 Case 1 - Fugitive Emissions Calculations
6.8 Cases 1 and 2 - Benzene NESHAP Emissions Estimate
6.9 Case 1 - Wastewater Inventory
6.10 Case 1 - Solid and Hazardous Waste Inventory
6.11 Case 1 - Net Emission Reduction Annualized Cost
               Analysis
6.12 Case 1 - Heat Integration of Crude Preheat
6.13 Case 1 - Steam Jet Ejectors, Vs. Steam Jets (2 Stages)
               and Liquid Ring Vacuum Pump (3rd Stage)
6.14 Case 1 - Summary of Air Emissions
7.1 Case 2 - Chemical Requirements
7.2 Case 2 - Utility Requirements
7.3 Case 2 - Air Emissions (Fuel Gas Case)
7.4 Case 2 - Air Emissions (0.2% Fuel Oil Case)
7.5 Case 2 - Air Emissions (1.0% Fuel Oil Case)
7.6 Case 2 - Air Emissions (3.34% Fuel Oil Case)
7.7a Case 2 - Fugitive VOC Emissions Calculations
7.7b Case 2 - Fugitive VOC Emissions Calculations
7.7c Case 2 - Fugitive VOC Emissions Calculations
7.7d Case 2 - SARA Constituents in Fugitive VOC Emissions
7.8 Case 2 - Wastewater Inventory
7.9 Case 2 - Inventory of Solids and Hazardous Waste
               Production
7.10 Case 2 - Net Emission Reduction Annualized Cost
               Analysis
7.11 Case 2 - Heat Integration of Crude Preheat
7.12 Case 2 - Summary of Air Emissions
Figure 1.1 Air Emissions from 175,000 BPSD Crude Unit
               (Atmospheric Crude Heater Firing 1 wt1%
               Sulfur Fuel Oil)
Figure 1.2 Air Emissions from 175,000 BPSD Crude Unit
               (Atmospheric Crude Heater Firing 1 wt%
               Sulfur Fuel Oil)
Figure 1.3 Wastewater Loads from 175,000 BPSD Crude Unit
Figure 1.4 Solid Waste Generation from 175,000 BPSD
               Crude Unit
Figure 4.1 Pollution Prevention Methodology
Drawing No. P-7001-D Process Flow Diagram Crude Tower &
                       Sidestrippers (Base Case)
Drawing No. P-7002-D Process Flow Diagram Crude Preheat
                       Train (Base Case)
Drawing No. P-7003-D Process Flow Diagram Vacuum Tower
                       (Base Case)
Drawing No. P-7004-D Process Flow Diagram Crude Tower &
                       Sidestrippers (Case 1)
Drawing No. P-7005-D Process Flow Diagram Crude Preheat
                       Train (Case 1)
Drawing No. P-7006-D Process Flow Diagram Vacuum Tower
                       (Case 1)
Drawing No. P-7007-D Process Flow Diagram Crude Tower &
                       Sidestrippers (Case 2)
Drawing No. P-7008-D Process Flow Diagram Crude Preheat
                       Train (Case 2)
Drawing No. P-7009-D Process Flow Diagram Vacuum Tower
                       (Case 2)
Drawing No. P-7010-D Schematic Diagrams A and B
Drawing No. P-7011-D Schematic Diagrams C and D
Drawing No. P-7012 Process Simulation Diagram
Figure I-1 Heat Composite Curves

Abstract

This report demonstrates the application of pollution prevention concepts in the design of a refinery crude processing unit. Included are realistic waste and emission reduction changes that would be economically and technically attractive to refiners. The document is intended to serve as a reference for refinery designers during the preliminary design phase of building a new crude unit or revamping an existing crude unit.

General Product Information

Published
Document Type	Standard
Status	Current
Publisher	American Petroleum Institute
Pages
ISBN