ANALYSIS OF THE FCCU EMISSIONS SOURCES

FERREIRA LEMOS, S., S., Petrobras S. A. Catalytic process Technology Group, Headquarters; MANSUR L, A., Petrobras S.A. Catalytic Process Technology Group, Headquarters; STELLING R., R., G., Petrobras S.A. Fuels Combustion and Emissions Group, Headquarters Abstract
The environmental problem is a priority for Petrobras that has established an ambitious program to reduce the emissions from its refineries. Petrobras owns 12 refineries operating 13 Fluid Catalytic Cracking Units. This report identifies Petrobrass best practices in the managing of environmental issues. Potential sources of environmental impact were analyzed in the majority of the existing cracking units in normal operation and in startups and shutdowns. Some of the analyzed sources are: Particulate, sulphur and nitrogen oxides emissions from the CO boiler or recovery boiler stack. Particulate emissions in unit startups. Equilibrium catalyst. Ash content in fuel oil. Sour water streams. Spent amines. Procedures prior to Equipment liberation for cleaning.

Introduction
In October of 2000 a work group was created with the task of identifying the best methodologies, technologies and Prevention Practices to Control of Emissions. These procedures will be the base for a Manual of the Best Practices to be adopted for each emission source identified and of an Action Plan for the refineries. Twenty-six key points were identified with strong environmental impact potential, generating recommendations for the Action Plan to be elaborated by the refineries, as summarized below.

Recommendations for the Refinery Action Plan

Impact 1) Particulate emission from the boiler stack

Particulate Emissions should be controlled by Operational Management CO boiler substitute fuel oil for gas burning Use of state of the art Cyclones Evaluation of catalyst losses through the main fractionator by measuring
content in the decanted oil

the ash

Definition of clear operational limits of variables that can influence catalyst losses

IMPACT 2) Catalyst emissions in FCC start-ups

Use of minimum air flow rates in catalyst loading Definition of the injected steam flow rate to the converter Definition of operational conditions to reduce catalyst
fractionator

losses through the main

DCS display of the converter variable limits to control catalyst entrainment

IMPACT 3) Particulate emissions from the catalyst storage drum

Use of sleeve filters in the ejectors suction Use of silencer in the ejectors exhaust line If possible all catalyst handling procedures
ejector the catalyst storage drum

should be carried out without using the

All the catalyst gathered from the sleeve filter and the ejectors cyclone has to return to
IMPACT 4) E-CAT destination

Prioritize E-Cat use as flushing Evaluate new options for E-cat use Residual catalyst from sampling must be transferred to the storage drum Make a check-list for E-cat transportation to cement industries Avoid using landfills Adjust the regenerator bottom configuration to optimize the discharge
IMPACT 5) Particulates in the decanted oil

Studies of ashes reduction technologies Decanted oil slurry, including that from
should be sent to the cement industry

storage tanks, heat exchangers and towers

IMPACT 6) Emission control during boiler maintenance shut-down

Use of CO combustion promoter to reduce emissions

IMPACTS 7/8) SOX and NOX emissions on the boiler stack

Monitor emissions every month from the mass balance measuring SOx and NOx concentrations in the stack gas twice a year
IMPACT 9) Smoke emissions from furnaces and boiler stacks

Improve burning control minimizing smoke emission Substitute fuel oil for gas
IMPACT 10) Effluents from CO-boilers seal drum

Refineries with seal drums must send its effluent to the Waste Water Treatment Plant
IMPACT 11) Sour Water Treatment

Use of two-tower processes Avoid sending hydrocarbons to Sour Water Treatment Install oil detector and removal systems in the Sour Water current Prioritize projects for rectified water recycle. Ex: Wet gas washing
IMPACT 12) Spent DEA destination

Segregate DEA discharge and washing water inventories

When

conditioning equipment for maintenance, use chemical product to reduce the generated inventory

IMPACT 13) Spent Soda destination

Inject spent phenolic soda in the sour water tower When conditioning equipment for maintenance, use
generated inventory

chemical product to reduce the

Prioritize draining during the daytime

IMPACT 14) Liquid and Gaseous Disulfide destination

Evaluate the possibility of liquid disulfides sale Study of the liquid disulfide displacement line to stainless steel containers Use Light Cycle Oil when conditioning equipment containing disulfide The gaseous disulfide must be sent to the Sulphur Recovery Unity
IMPACT 15) Destination of Washing Water from equipment in the Gas Recovery Plant commissioning

The initial draining must be sent to a tank, and then to the Sour Water Unit After pH adjustment and visual inspection, send it to the Waste Water Treatment Plant When commissioning equipment should be completely filled up with washing water Send the Recovery Unity gas to the Fuel Gas system and then to the flare
IMPACT 16) Fugitive Emissions

Make a Fugitive Emissions survey in all FCC units

IMPACT 17) SOX emissions from the Sulphur Recovery Unit Stack

Install on-line monitoring to SO2/H2S Install ammonia incinerator Elaborate process and procedure standards specifically for SOx emission control For the refineries without on-line monitoring, reevaluate gas analysis periodicity The unity operations manager should be in charge of all the analysis information
IMPACT 18) Clearing equipment contaminated with hydrocarbons

Avoid hydrocarbon drainage to the Waste Water Treatment Plant Use water to displace light products to the main fractionator upper drum Use steam to displace heavy products to the bottom of the main fractionator Coke from the equipments must be sent to the coke pile
IMPACT 19) Clearing equipment contaminated with chemical products

Avoid the product drainage to the Waste Water Treatment Plant

as hazardous

Build ceramics lined leak containment barriers with drain valves Attach the dosing pump directly to the chemical container Clean the plastic recipients where chemicals were stored, so that they are not labeled Measure noise inside and outside the Refinery Install silencers on the turbine vents Install silencers or open the converters upper manhole during the refractory drying

IMPACT: 20) Noise control during routine and clearing procedures

Install silencers in the end of the catalyst storage drums ejector

IMPACT 21) Particulates at the catalyst house

Minimize the use of catalyst big-bags Use uniforms (IPE) specified by the safety crew
IMPACT 22) Rotating equipment lube oil

Zero draining to the Waste Water Treatment Plant The oil must be recovered
IMPACT 23) Optimization of Utilities/Fuel consumption

Install and maintain utility and fuel gauges Measure the plants energy intensity index (EII) online, if possible Minimize fresh water consumption, checking all possibilities for recycle Measure combustion efficiencies not only in furnaces, but also in the CO-boilers
IMPACT 24) Cyanide in the Sour Water

Use of the Petrobras process for cyanide reduction

IMPACT 25) Entrained water in Naphta and LPG tanks

Study and apply systems/equipments capable of minimizing water entrainment to the

tanks

Analyze the entrained water quality, specifically its pH, sulfide and COD content Send the water to the Sour Water Unit - if phenolic, just drain to the Waste Water
Treatment Plant IMPACT 26) Sending gases to flare during compressor trips

In

case of two-compressors units, the immediate feed throughput reduction is recommended up to the capacity of the remaining compressors operation limit

For one-compressor unit, feed reduction is recommended up to the flare smoke limit
Conclusion
Each Refinery should analyze these recommendations considering its particularity. Pro-active procedures should be kept in the refineries, in order to solve these impacts. The environment impact must be introduced as one of the managerial control items. An Environmental Impact Evaluation shall be elaborated after the plant maintenance shutdown. Elaborate guidelines based on the best practices, establishing operational control items. The FCC units are great utilities and fuel consumers. The Energy Intensity Index and water consumption must be checked in a routine basis. Elaboration of ambient impact report in the shutdown must be one practical adopted. Therefore PETROBRAS aims at implementing in its catalytic cracking units the best techniques for emissions reduction. The matching with the best international standards of quality (benchmarking) will be searched in order to contribute to the goal of the PETROBRAS Environmental Excellency Program.