Integrated Data (i-Data), Mining and Utilization Approach for Effective Flare Management Strategies

Dynamic simulation for flare minimization in chemical process industry under abnormal operations

This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper SPE 166584, ’Abnormal-Situation Management and Its Relevance to Process Safety for Offshore Operations,’ by Dal Vernon Reising and Peter Bullemer, Human Centered Solutions, and Bruce Colgate (retired), prepared for the 2013 SPE Offshore Europe Oil and Gas Conference and Exhibition, Aberdeen, 3-6 September. The paper has not been peer reviewed. The Abnormal Situation Management (ASM) Consortium performed a root-cause analysis on 32 incident reports gathered from public documents and member companies. The analysis identified common failure categories and manifestations in these incidents. Consequently, the consortium completed three case studies on potential deployment solutions: one supporting better shift-handover communication, a second supporting better alarm-flood situations, and a third supporting better situation awareness by use of overview displays using qualitative gauges. Introduction The ASM Consortium has been working for almost 20 years with an emphasis on human-factor engineering to address process-safety and operational challenges for downstream hydrocarbon-processing and petrochemicals companies. These consortium members have jointly invested in research and development to create knowledge, tools, and products designed to prevent, detect, and mitigate abnormal situations that affect process safety in the control/operations environment. The consortium has placed a continual emphasis on the humans that use automation and technology to operate the production processes, focusing extensively on human factors, human reliability, and process safety. Recently, the consortium has expanded its focus to upstream enterprises, with many of the operating company members having extensive oil and gas businesses. What Are Abnormal Situations? The ASM Consortium has defined abnormal situations as “undesired plant disturbances or incidents with which the control system is not able to cope, requiring a human to intervene to supplement the actions of the control system.” An abnormal situation could be a simple upset condition quickly recognized and rectified by operator action, or an abnormal situation could escalate to a critical process-safety incident, where a safety system must be engaged for an emergency shutdown and evacuation is required. The objective of ASM is to bring the process back to normal before safety-shutdown-control systems or other safety-protection systems are engaged. This definition is specifically used to distinguish between normal, abnormal, and emergency situations from the perspective of console operations. Often, operator error is blamed for causing incidents, and companies rush to increase training as a panacea. The work of the consortium has shown that incidents are caused by a multitude of factors, and solutions to address incidents need to consider the human operator’s role, the technology involved, and the system design, as well as the environment.

Flare minimization under normal and abnormal operating conditions in large-scale industrial processes, especially for refineries and petrochemical plants, is a double-win practice, which simultaneously benefits industrial and environmental sustainability. Unfortunately, proactive and cost-effective flare minimization (PCFM) approaches under abnormal situations are still lacking. In this study, a PCFM approach for an ethylene plant is presented for its start-up operations. This approach employs rigorous steady-state and dynamic models of a front-end deethanizer ethylene plant to serve as a foundation to explore flare root causes during plant start-ups and subsequently a test bed to support both design and operational strategies for start-up flare minimizations. It has been demonstrated that the charge gas compressor (CGC) start-up is the most critical operation, which results in the largest amount of flaring sources. Several start-up strategies at different CGC feed rates and compositions, including scenarios recycling off-spec C 2s and C 3s from downstream recovery units to the CGC inlet as a substitute of a portion of charge gas, are virtually examined to identify the least flaring one. This work contributes to evaluating new start-up strategies, predicting abnormal process dynamic behaviors, and acquiring more precise estimation of flare emission sources. The study shows that the plant flaring can be significantly reduced, while the start-up time is shortened.

Abnormal Situations comprise a range of process disruptions in which petrochemical plant personnel must intervene to correct problems with which the control systems can not cope. Preventable losses from abnormal situations cost the U.S. economy at least $20B annually. The Abnormal Situation Management (ASM) Joint Research and Development Consortium (Honeywell, the seven largest U.S. petrochemical companies, and two software companies) was formed to develop the technologies needed to allow plant personnel to control and prevent abnormal situations. The Consortium is working on a NIST-funded, 3.5-year, $16.6 million program to demonstrate the technical feasibility of a collaborative decision support system (called AEGIS) for helping operations personnel deal with abnormal situations. Many of the issues faced in the development of AEGIS have also been faced in the research and development of associate systems for military aviation domains, especially the U.S. Air Force's Pilot's Associate (PA) and the U.S. Army's Rotorcraft Pilot's Associate (RPA). Honeywell intends to apply associate technologies as vigorously as possible to the ASM problem. The two domains have a number of features in common, which we hope will permit significant technology transfer in both directions. This paper describes the similarities of and differences between the technical and organizational domains in which Abnormal Situation Management and the PA and RPA systems must operate, and assesses the issues thus raised. Finally, we describe our approach to resolving these issues and assuring successful demonstration of the feasibility of associate technology in this new domain.

Volatile organic compounds (VOCs)are important air pollutants in China, and control of their emission is an important subject of air pollution prevention and control.Architectural coatings play a significant role as sources of atmospheric VOCs in China.Due to recent economic development and increase in the levels of urbanization, the building of residences and other buildings is ongoing all the time, which results in increasing demand for architectural coatings and the VOCs pollution caused by painting operations.However, there are few studies of the VOCs emission factors and VOCs emissions due to architectural coatings.In this paper, a set of bottom-up VOCs emission inventory estimation methods for architectural coatings in China was established.The architectural coatings VOCs emission factors were gotten by actual measurement of VOCs in architectural coatings and by summarizing studies of VOCs contents in architectural coatings.Combining these results with the consumption of architectural coating sources, a VOCs emission inventory of architectural coatings in China from 2013 to 2016 was established.The results showed the following.① VOCs emission factors were 24.63 g·kg-1 for water-based interior wall coatings; 17.5 g·kg-1 and 298.8 g·kg-1 for water-based and solvent-based exterior wall coatings, respectively. They were 2.75, 87.86, and 400 g·kg-1 for water-based, reaction-type, and solvent-based waterproof coatings, respectively. For water-based, solventless, and solvent-based floor coatings, they were 86.2, 25.24, and 317 g·kg-1, respectively; and 31.95 g·kg-1 and 464.61 g·kg-1 for water-based and solvent-based anticorrosive coatings respectively. The emission factors were 59.7 g·kg-1 and 347.2 g·kg-1 for water-based and solvent-based fire retardant coatings, respectively. ② VOCs emissions from the use of architectural coatings were 255900 t, 287500 t, 319700 t, and 348000 t from 2013 to 2016 in China, with an upward trend. ③ Total VOCs emissions from architectural coatings was 348000 t in 2016, and the VOCs emissions from floor coatings was 78700 t, accounting for 22.61% with the maximum contribution rate. The VOCs emissions from exterior wall coatings were 64900 t, accounting for 18.65% (second place), and the VOCs emissions from fire retardant coatings and anticorrosive coatings (functional coatings) were 64500 t and 50800 t, accounting for 18.53% and 14.6% respectively. The VOCs emissions from waterproof coatings and interior wall coatings were 46100 t and 43000 t, accounting for 13.25% and 12.36%, respectively. ④ The consumption of water-based architectural coatings reached a total of 4889400 t in 2016 with VOCs emissions of 97900 t and average VOCs emissions factor of 20.02 g·kg-1; however, the consumption of solvent-based architectural coatings totaled 636500 t with VOCs emissions of 227200 t and average VOCs emission factor of 356.95 g·kg-1. Reducing the consumption of solvent-based coatings would be favorable for reduction of VOCs emissions. ⑤ As for the spatial distribution, architectural coating-related VOCs emissions were mainly concentrated in Shandong, Jiangsu, Zhejiang, Henan, Sichuan, Guangdong, and Hebei provinces, which have large populations. The province with the highest VOCs emissions was Shandong, with a percentage of 9.36%, and the second was Jiangsu, with a percentage of 8.54%.

Rising temperatures amplify biogenic volatile organic compound (VOC) emissions from Arctic vegetation, causing feedbacks to the climate system. Changes in climate also alter plant physiology and vegetation composition, all of which can influence VOC emissions. Moreover, leaf development and biotic stresses cause highly variable emissions during the growing season. Therefore, linking VOC emissions with plant traits and tracking responses to climate change might provide better understanding of VOC emission regulation under future conditions. We measured VOC emissions and other plant traits in dwarf birch (Betula glandulosa) at two elevations in Narsarsuaq, South Greenland. The measurements were performed in warming experiments that have run since 2016. We collected VOCs using the branch enclosure method from early June until late July 2019 (n = 200). Emissions of green leaf volatiles (GLVs), oxygenated monoterpenes (oMTs), and homoterpenes followed a seasonal trend. VOC emission rates and the diversity of the VOC blend decreased at the end of the measurement period. Differences in VOC emission rates between elevations were pronounced early in the season. Majority of the traits did not explain the variation in VOC emissions. We show strong seasonal variability in VOC emissions within the growing season, which is likely driven by leaf phenology. While the diversity of VOCs was greater at the milder low‐elevation site, VOC emission rates were higher or similar at the harsher high‐elevation site, showing stronger VOC emission potentials than previously assumed. Seasonal variations in the emissions of VOCs are crucial for accurate predictions of current and future VOC emissions from arctic ecosystems.

Volatile organic compound emissions from an engine fueled with an ethanol-biodiesel-diesel blend

Plant volatile organic compound (VOC) emissions can drive important climate feedbacks. Although mosses and lichens are important components of plant communities, their VOC emissions are poorly understood. It is crucial to obtain more knowledge on moss and lichen VOCs to improve ecosystem VOC emission models. This is especially relevant at high latitudes, where mosses and lichens are abundant and VOC emissions are expected to increase in response to climate change. In this study, we examined VOC emissions from four common moss (Hylocomium splendens, Pleurozium schreberi, Sphagnum warnstorfii, and Tomentypnum nitens) and lichen (Cladonia arbuscula, Cladonia mitis, Cladonia pleurota, and Nephroma arcticum) species in the Subarctic using gas chromatography-mass spectrometry (GC-MS) and proton-transfer-reaction time-of-flight mass spectrometry. Moss and lichen VOC emissions were dominated by low molecular weight (LMW) VOCs, such as acetone and acetaldehyde, as well as hydrocarbons (HCs) and oxygenated VOCs (oVOCs). Of the studied mosses, S. warnstrofii had the highest and H. splendens had the lowest total VOC emission rates. The VOC emission blends of P. schreberi, S. warnstrofii, and T. nitens were clearly distinct from one another. Of the lichens, N. arcticum had a different VOC blend than the Cladonia spp. N. arcticum also had higher emission rates of HCs, oVOCs, and other GC-MS-based VOCs, but lower LMW VOC emission rates than the other lichen species. Our study demonstrates that mosses and lichens emit considerable amounts of various VOCs and that these emissions are species dependent.

Characterizing VOCs emissions of five packaging and printing enterprises in China and the emission reduction potential of this industry

As part of an effort to assess the potential impacts associated with global climate change, the U.S. Environmental Protection Agency's Office of Research and Development is supporting global atmospheric chemistry research by developing global scale estimates of volatile organic compound (VOC) emissions (excluding methane). Atmospheric chemistry models require, as one input, an emissions inventory of VOCs. Consequently, a global inventory of anthropogenic VOC emissions has been developed. The inventory includes VOC estimates for seven classes of VOCs: paraffins, olefins, aromatics (benzene, toluene, xylene), formaldehyde, other aldehydes, other aromatics, and marginally reactive compounds. These classes represent general classes of VOC compounds which possess different chemical reactivities in the atmosphere. The technical approach used to develop this inventory involved four major steps. The first step was to identify the major anthropogenic sources of VOC emissions in the United States and to group these sources into 28 general source groups. Source groups were developed to represent general categories such as “sources associated with oil and natural gas production” and more specific categories such as savanna buming. Emission factors for these source groups were then developed using different techniques and data bases. For example, emission factors for oil and natural gas production were estimated by dividing the United States' emissions from oil and gas production operations by the amount of oil and natural gas produced in the United States. Multiplication of these emission factors by production/consumption statistics for other countries yielded global VOC emission estimates for specific source groups within those countries. The final step in development of the VOC inventory was to distribute emissions into 10° by 10° grid cells using detailed maps of population and industrial activity. The results of this study show total global anthropogenic VOC emissions of about 110,000 Gg/yr. This estimate is about 10% lower than global VOC inventories developed by other researchers. The study identifies the United States as the largest emitter (21% of the total global VOC), followed by the (former) USSR, China, India, and Japan. Globally, fuel wood combustion and savanna burning were among the largest VOC emission sources, accounting for over 35% of the total global VOC emissions. The production and use of gasoline, refuse disposal activities, and organic chemical and rubber manufacturing were also found to be significant sources of VOC emissions.

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Improving VOC control strategies in industrial parks based on emission behavior, environmental effects, and health risks: A case study through atmospheric measurement and emission inventory

Bioremediation processes have been credited for reducing high levels of organic contaminants from soils. However, during the bioremediation of soils contaminated with diesel, the conversion of heavy molecules to volatile organic compounds (VOCs) and greenhouse gases (GHGs) and the volatilization of light molecules can occur. The ongoing construction of a large petrochemical complex in Rio de Janeiro (COMPERJ) and the transportation of large volumes of oil by-products have raised serious concerns regarding accidents that may result in soil contamination. Bioremediation is a potential technique that can be applied to minimize damage from such contamination. The objective of this study was to characterize the emission of GHGs and VOCs during the bioremediation of soils contaminated with diesel oil. Soil samples contaminated with 0.5, 2.0, and 4.0 w/w% diesel oil were kept in glass rectors (2 L internal volume) for 3 months under anaerobic/anoxic conditions. The soil moisture was kept at 80 % of the field capacity. Bioremediation processes were investigated in regard to nutrient adjustment (biostimulation), no adjustment (natural attenuation), and sterilized soil (abiotic process). The gases emitted from various reactors were collected with coconut shell charcoal cartridges, and the GHGs were collected in Tedlar bags. The chemical analyses of GHGs and VOCs were performed using gas chromatography. The results indicated that air samples contained high concentrations of CO2, but low concentrations of CH4. Differences in the composition of the gas emitted, regarding CO2, were not statistically significant. Regarding VOC emissions, such as alkanes and alkenes (both branched), cycloalkanes, and aromatic-substituted compounds, the compounds with higher emissions were cycloalkanes and branched alkanes.

BackgroundThree-dimensional (3D) printing is a technique by which materials are continually added in layers to form structures. The technique has grown in popularity over the past decade and affordable desktop 3D printers are now widely used in schools, universities, businesses, and hospitals.ObjectiveUnderstanding the types of chemical emissions from these 3D printers and their potential health effects is essential to safely use this technology.MethodsA scoping literature review on volatile organic compound (VOC) emissions from resin-bed and filament 3D printers has been conducted. Most of the published research has focused on emissions from filament 3D printers.ResultsVOC emissions from resin 3D printers have been reported mostly as carbonyl compounds or methacrylate monomers. Filament VOC emissions are more varied in composition reflecting the constituents in the filaments used in this printer. The published research reported that the airborne concentrations of specific VOCs from 3D desktop printers fell below the HSE British workplace exposure limits (WELs). This may suggest that VOC emissions from these printers do not present a risk to occupational health. However, caution is required in reaching this conclusion because most of these studies quantified specific VOC emissions using methods different to those required by workplace regulatory standards. Other exposure circumstances, such as the effect of total VOC emissions, need to be considered, particularly for vulnerable groups, including individuals with respiratory disease, the elderly, or young children. Variables that could increase exposure and risks to health include long print times, multiple 3D printers, and poor ventilation. Research on the VOC emissions from resin 3D printers is required using experimental emission chambers.ImpactThe research discussed in this review focused on VOC emissions from desktop 3D printers and the potential health impacts associated with exposure to these compounds. The review identifies circumstances when people may be exposed to 3D printer emissions for which no regulatory exposure limits apply. This circumstance is especially relevant to people working in small businesses and organisations and to vulnerable people, such as the young, elderly and those with pre-existing lung disease. Raising awareness of these potential health concerns from 3D printer emissions can help to inform actions to mitigate exposure, through policy and behavioural changes, as well as engineering control measures. To our knowledge, this is the first review discussing studies of VOC emission from resin and popular filament 3D printers, including exposure risks and health outcomes.

Livestock manure is one of the major sources of volatile organic compound (VOC) emissions; however, characteristics of VOCs emitted from biogas digestate (BD) storage, which is a common manure practice, remain unclear. The objective of this study was to characterize VOC emissions during BD storage through the dynamic emission vessel method, to identify the VOC emissions that have potential odor and/or toxic effects. The results revealed the detection of 49 VOCs with seven classes, whose total concentration varied from 171.35 to 523.71 μg m−3. The key classes of the 49 VOCs included Oxygenated VOCs (OVOCs), olefins and halogenated hydrocarbons. The top four compositions, accounting for 74.38% of total VOCs (TVOCs), included ethanol, propylene, acetone and 2-butanone. The top four odorous VOCs, accounting for only 5.15% of the TVOCs, were toluene, carbon disulfide, ethyl acetate and methyl sulfide, with the concentration ranging from 13.25 to 18.06 μg m−3. Finally, 11 main hazardous air pollutant VOCs, accounting for 32.77% of the TVOCs, were propylene, 2-butanone, toluene, methyl methacrylate, etc., with the concentration ranging from 81.05 to 116.96 μg m−3. Results could contribute to filling the knowledge gaps in the characteristics of VOC emissions from biogas digestate (BD), and provide a basis for exploring mitigation strategies on odor and hazardous air pollutions.