PERMIT MEMORANDUM 2003-105-TVR DRAFT 18
OKLAHOMA DEPARTMENT OF ENVIRONMENTAL QUALITY
AIR QUALITY DIVISION
MEMORANDUM August 20, 2007
TO: Phillip Fielder, P.E., Permits and Engineering Group Manager, Air Quality Division
THROUGH: Matt Paque, Supervising Attorney, Air Quality Division
THROUGH: Kendal Stegmann, Senior Environmental Manager, Compliance and Enforcement
THROUGH: Grover Campbell, P.E., Existing Source Permits Section
THROUGH: Phil Martin, P.E., Engineering Section
THROUGH: Peer Review
FROM: John Howell, P.E., Existing Source Permits Section
SUBJECT: Evaluation of Permit Application No. 2003-105-TVR
Atlas Pipeline Mid-Continent WestOK, LLC.
Chaney Dell Gas Plant
NW/4 of Section 35, T23N, R10W, (Lat. 36.432º; Long. -98.246º)
Major County, Oklahoma
Located 3 ½ miles north of Ringwood on SH 58
SECTION I. INTRODUCTION
Western Gas Resources, Inc. has submitted an application for renewal of the current Title V permit [Permit No. 97-133-TV (M-1), issued October 11, 1999] for the Chaney Dell Gas Plant. The applicant has requested that this permit incorporate the following changes in equipment and operations:
· Turbines C-3 and C-6 have been dismantled and removed from the permit.
· Incorporation of CAM plans for three engines equipped with catalytic converters.
· Replacement of Unit C-24, a [grandfathered] 818-hp uncontrolled rich-burn engine, with Unit C-16, a lean-burn engine with lower emissions of all criteria polutants. The replacement will be a permitted engine with emission limitations and operating requirements.
· Removal of [grandfathered] engine C-15.
· Correct rated size of emission unit H-1 from 35.1 MMBTUH to 8.9 MMBTUH.
· The emission estimates for the glycol dehydration units have been adjusted based on a new rich/lean glycol analysis.
· Incorporate emission limits and operating requirements for glycol dehydrator V-1, a previously grandfathered unit.
· Authorize continued operation of additional equipment [a 1,340-hp Caterpillar G3516LE engine [designated Unit C-15] and a dehydration unit with a BTEX eliminator] installed under authority of Permit No. 97-133-C (M-2), issued June 12, 2006.
· Re-estimate emission levels based on updated emission factors.
· Discussion of state and federal rule applicability will be updated to the current AQD boilerplate. Emission limitations of NOx and CO expressed in ppm are no longer used by AQD and were removed.
SECTION II. FACILITY DESCRIPTION
The facility (SIC 1321) operates a refrigerated lean oil absorption process at a capacity of approximately 125 MMSCF/day and a skid mounted cryogenic unit at a capacity of approximately 22 MMSCF/day. Other equipment currently at the facility includes eleven 1,035-hp Solar Saturn turbines, five stationary internal combustion engines in compressor service [two Caterpillar G3516LE compressor engines equipped with catalytic converters, and three 1,478-hp Waukesha L7042 GSIU engines with catalytic converters], a 8.9 MMBTUH oil regenerator, a 0.6 MMBTUH condensate tank heater, an 0.8 MMBTUH cryogenic system regenerative gas heater, a 3 MMBTUH condensate line heater, an amine unit with a flare for control of emissions of hydrogen sulfide, and a ground flare for the control of emergency upsets and blowdowns.
The plant currently has four main high pressure inlet gas streams and four low pressure inlet gas streams that feed the cryogenic gas plant. The inlet gas flows through a slug catcher where liquids are removed. The gas is then transferred through several other vessels to lower the pressure. Next, the gas stream is routed through the molecular sieve to remove water before the gas enters the cryogenic unit. The cryogenic unit liquefies the ethane and heavier gas components. The remaining gas is recompressed to 650 psig and delivered to a pipeline. The recovered liquids are exposed to the amine system for removal of CO2 and trace amounts of H2S and then pumped to a pipeline.
The lean oil process involves dehydration of the gas using an ethylene glycol unit, gas refrigeration, and natural gas liquid (NGL) absorption by the lean oil. NGLs are then recovered from the lean oil by heating. Some of the lean oil overhead gas is recompressed and sent to the cryogenic unit. The cryogenic expander process involves dehydration of the gas using a molecular sieve, chilling using exchangers, and removal of NGLs after passing through the turbo expander.
The facility is currently operating under Permit No. 97-133-TV (M-1), issued October 21, 1999. The facility emits more than 100 TPY of a regulated pollutant and is subject to Title V permitting requirements. Emission units (EUs) have been arranged into Emission Unit Groups (EUGs) in the following outline. Pipeline-grade natural gas is the primary fuel with the turbines, engines, reboilers, and heaters being operated continuously.
SECTION III. EQUIPMENT
EUG 1 Grandfathered Turbines/Internal Combustion EnginesEU / Point / Make/Model / hp / Serial # / Const. Date
C-1 / 1 / Solar Saturn (K1A) / 1,035 / 20138 / 1966
C-4 / 4 / Solar Saturn (K2A) / 1,035 / 20134 / 1966
C-5 / 5 / Solar Saturn (K2B) / 1,035 / 20143 / 1966
C-7 / 7 / Solar Saturn (K3A) / 1,035 / 301202 / 1966
C-8 / 8 / Solar Saturn (K3B) / 1,035 / 200983 / 1966
C-9 / 9 / Solar Saturn (K3C) / 1,035 / 20144 / 1966
C-10 / 10 / Solar Saturn (G1) / 1,035 / 20731 / 1967
C-11 / 11 / Solar Saturn (G2) / 1,035 / 20840 / 1967
EUG 2 Non-Grandfathered Turbines/Internal Combustion Engines
EU / Point / Make/Model / hp / Serial # / Const. Date
C-2 / 13 / Solar Saturn (K1B) / 1,035 / 0201S21 / 19801
C-12 / 14 / Waukesha L7042 GSIU
w/Catalytic Converter / 1,478 / 369735 / 1997
C-13 / 15 / Waukesha L7042 GSIU
w/Catalytic Converter / 1,478 / 338536 / 1997
C-14 / 16 / Waukesha L7042 GSIU
w/Catalytic Converter / 1,478 / 243442 / 1997
C-15 / 20 / Caterpillar G3516LE w/Catalytic Converter / 1,340 / 4EK04629 / 2006
C-16 / 28 / Caterpillar G3516LE w/Catalytic Converter / 1,340 / 4EK04248 / 2006
C-20 / 17 / Solar Saturn (K3D) / 1,035 / 212393 / 1981
C-21 / 18 / Solar Saturn (G3) / 1,035 / 20466 / 1981
1 Moved to this location on April 3, 1998
EUG 3 Heaters/Regenerators/Vents/Flares
Insignificant Emission Units.
EU / Point / Make/Model / MMBTU/hr / Const. DateH-2 / 22 / Condensate Heater/Treater / 0.6 / 1983
H-3 / 23 / Cryo Regenerator Heater / 0.8 / 1979
G-1 / G-1 / Ground Flare / 1.7 / 1965
H-401 / 27 / Glycol Dehydrator Reboiler / 0.5 / 2006
Grandfathered Emission Units
EU / Point / Make/Model / MMBTU/hr / Construction DateH-1 / 21 / Oil Regenerator / 8.9 / 1965
H-4 / 24 / Line Heater / 3.0 / 1965
Non-Grandfathered Emission Units
EU / Point / Make/Model / MMBTU/hr / Const / Modification DateV-1 / 25 / Glycol Regenerator/Still Vent / N/A / 1966 / 2007
V-2 / 26 / Amine Unit Flare / 2.0 / 1965
H-401-Vent / H-401-Vent / Glycol Dehydrator Still Vent / N/A / 2006
EUG 4 Tanks
EU / Point / Contents / Barrels / GallonsTanks / V-81 / Condensate / 400 / 16,800
V-82 / Condensate / 400 / 16,800
V-83 / Condensate / 400 / 16,800
V-84 / Condensate / 400 / 16,800
V-89 / Condensate / 400 / 16,800
V-90 / Condensate / 400 / 16,800
V-86 / Methanol / 285 / 11,970
V-87 / Methanol / 285 / 11,970
V-88 / Methanol / 210 / 8,820
V-28 / Ethylene Glycol / 210 / 8,820
T-10 / Ethylene Glycol/Water / 210 / 8,820
T-11 / Di-ethanol Amine / 24 / 1,000
T-12 / Di-ethanol Amine / 24 / 1,000
T-13 / Lube Oil (horizontal) / 24 / 1,000
T-14 / Lube Oil (horizontal) / 24 / 1,000
T-15 / Lube Oil (horizontal) / 380 / 15,960
T-16 / Lube Oil (horizontal) / 24 / 1,000
T-17 / Gasoline / 210 / 8,820
T-18 / Bio-degradable Solvent / 13 / 550
T-19 / Diesel Fuel / 12 / 500
T-20 / Kerosene Fuel / 12 / 500
T-21 / Lean Oil / 210 / 8,820
T-22 / Ethylene Glycol / 24 / 1,000
T-23 / Ethylene Glycol / 24 / 1,000
T-24 / Ethylene Glycol / 24 / 1,000
T-25 / Natural Gasoline (pressurized) / 2,143 / 90,000
T-26 / Propane (pressurized) / 286 / 12,000
EUG 5 Fugitives
EU / Number Items / Type of EquipmentFugitives / 1,495 / Valves
3,988 / Connectors
1,994 / Flanges
231 / Open Ended Lines
116 / Other
52 / Pumps
Engine/Turbine Parameters
EU / Source(make/model) / Height
(feet) / Diameter
(inches) / Flow
(ACFM) / Fuel
(SCFH) / Temp.
(°F) /
C-1 / Solar Saturn1 / 42 / 102 / 23,174 / 12,524 / 620
C-2 / Solar Saturn1 / 42 / 102 / 23,174 / 12,524 / 620
C-4 / Solar Saturn1 / 42 / 102 / 23,174 / 12,524 / 620
C-5 / Solar Saturn1 / 42 / 102 / 23,174 / 12,524 / 620
C-7 / Solar Saturn1 / 42 / 102 / 23,174 / 12,524 / 620
C-8 / Solar Saturn1 / 42 / 102 / 23,174 / 12,524 / 620
C-9 / Solar Saturn1 / 42 / 102 / 23,174 / 12,524 / 620
C-10 / Solar Saturn / 15 / 18 / 23,037 / 12,524 / 800
C-11 / Solar Saturn / 15 / 18 / 23,037 / 12,524 / 800
C-15 / Caterpillar G3516LE / 23 / 14 / 7,685 / 10,112 / 855
C-16 / Caterpillar G3516LE / 23 / 14 / 7,685 / 10,112 / 855
C-12 / Waukesha L7042 GSIU / 24 / 14 / 6,970 / 11,205 / 1,150
C-13 / Waukesha L7042 GSIU / 23 / 14 / 6,970 / 11,205 / 1,150
C-14 / Waukesha L7042 GSIU / 23 / 14 / 6,970 / 11,205 / 1,150
C-20 / Solar Saturn1 / 42 / 102 / 23,174 / 12,524 / 620
C-21 / Solar Saturn / 15 / 18 / 23,037 / 12,524 / 800
1All emissions from these units are discharged through two stacks that are 42 feet high and have inside diameters of 102 inches.
SECTION IV. EMISSIONS
Emission estimates for the turbines and engines are based on continuous operation and manufacturers’ emission data as shown below. Emission estimates for the heaters and regenerators are based on AP-42 (7/98), Chapter 1.4. Emissions from the existing glycol regenerator still vent V-1 are based upon GRI Gly-Calc Version 4.0, a recent gas analysis analysis, gas throughput of 60.0 MMSCFD, glycol recirculation rate of 10.0 gpm, recompression of flash tank off-gas, operation with a condenser on the still vent stream, and combustion of noncondensibles. Emissions from the new dehydration unit H-401 with a BTEX eliminator and a flash tank are based on GRI Gly-Calc Version 4.0, a natural gas flow rate of 5.5 MMSCFD, a recent gas analysis, the maximum lean glycol recirculation rate of 1.5 gpm, and the flash tank being recycled/recompressed to the inlet. The BTEX eliminator consists of a condenser with combustion of the uncondensed vapors in the reboiler firebox. Emission estimates for the amine flare are based on AP-42 (3/98), Chapter 1.4, a gas analysis, and a mass balance calculation. Estimated working and breathing losses for the tanks are based on AP-42 (1/95) Chapter 7.1. Emissions from loading operations are based upon AP-42 (1/95), Chapter 5.2, a throughput of 168,480 barrels/year, and a 90% control efficiency based on operation with a VRU that meets the requirements of OAC 252:100-37-16 to control VOC emissions. Fugitive VOC emissions are based on EPA’s “1995 Protocol for Equipment Leak Estimates” (EPA-453/R-95-017). Flashing losses/emissions from the condensate tanks are based on the Vasquez-Beggs Gas-Oil correlation. Based on an inlet gas analysis, a fuel gas analysis, and a condensate analysis total HAP emissions do not exceed the 10/25 TPY major source threshold.
Engine Emission Factors
Make/Model / NOX(g/hp-hr) / CO
(g/hp-hr) / VOC
(g/hp-hr)
1,035-hp Solar Saturn / 1.485 / 2.761 / 1.123
1,478-hp Waukesha L7042GSI w/CC / 2.5 / 2.5 / 1.0
1,340-hp Caterpillar G3516LE w/CC / 2.0 / 1.0 / 0.5
The turbines and reciprocating internal combustion engines have emissions of HAP, the most significant being formaldehyde. Formaldehyde emission estimates are based on continuous operation and the emission factors shown in the following table.
Fomaldehyde Emissions from the Engines
Make/Model / Numberof Units / MMBTUH or hp / Factor / Emissions
lb/MMBTU / lb/hr / TPY
Solar Saturn / 11 / 12.524 / 0.00463 / 0.638 / 2.794
Waukesha L7042 GSIU w/CC / 3 / 11.205 / 0.00505 / 0.170 / 0.744
Caterpillar G3516LE w/Oxidation CC / 2 / 1,340-hp / 0.15 g-hp-hr / 0.89 / 3.88
Totals
/ 1.70 / 7.42The dehydration units using a glycol desiccant will emit benzene, toluene, ethyl benzene, xylene, (BTEX) and n-hexane from the still vent stack. These compounds are regulated as HAP. The applicant has analyzed the inlet gas for concentrations of BTEX and n-hexane and estimated the emissions using GRI-GLYCalc™ and the controls previously discussed.
EU V-1 HAP Emissions From Dehydration Unit V-1
Estimated EmissionsPollutant / CAS # / lb/hr / TPY
Benzene / 71432 / 0.14 / 0.64
Toluene / 108883 / 0.09 / 0.39
Ethyl benzene / 100414 / 0.01 / 0.02
Xylene / 1330207 / 0.02 / 0.06
n-Hexane / 110543 / 0.03 / 0.13
Total / 0.30 / 1.24
EU H-401 HAP Emissions From Dehydration Unit H-401
Potential Emissions / Controlled EmissionsPollutant / CAS # / lb/hr / TPY / lb/hr / TPY
Benzene / 71432 / 0.9575 / 4.1940 / 0.0023 / 0.0101
Toluene / 108883 / 0.9327 / 4.0850 / 0.0008 / 0.0034
Ethyl benzene / 100414 / 0.0603 / 0.2643 / <0.0001 / 0.0001
Xylene / 1330207 / 0.2773 / 1.2144 / <0.0001 / 0.0001
n-Hexane / 110543 / 0.1918 / 0.8402 / 0.0007 / 0.0032
Total / 2.4196 / 10.5979 / 0.0040 / 0.0169
Facility Wide Emissions
NOx / CO / VOC / SO2EU / lb/hr / TPY / lb/hr / TPY / lb/hr / TPY / lb/hr / TPY
C-1 / 3.39 / 11.87 / 6.30 / 7.88 / 2.56 / 11.22 / 0.005 / 0.02
C-2 / 3.39 / 11.87 / 6.30 / 7.88 / 2.56 / 11.22 / 0.005 / 0.02
C-4 / 3.39 / 11.87 / 6.30 / 7.88 / 2.56 / 11.22 / 0.005 / 0.02
C-5 / 3.39 / 11.87 / 6.30 / 7.88 / 2.56 / 11.22 / 0.005 / 0.02
C-7 / 3.39 / 11.87 / 6.30 / 7.88 / 2.56 / 11.22 / 0.005 / 0.02
C-8 / 3.39 / 11.87 / 6.30 / 7.88 / 2.56 / 11.22 / 0.005 / 0.02
C-9 / 3.39 / 11.87 / 6.30 / 7.88 / 2.56 / 11.22 / 0.005 / 0.02
C-10 / 3.39 / 11.87 / 6.30 / 7.88 / 2.56 / 11.22 / 0.005 / 0.02
C-11 / 3.39 / 11.87 / 6.30 / 7.88 / 2.56 / 11.22 / 0.005 / 0.02
C-15 / 5.91 / 25.88 / 2.96 / 12.96 / 1.48 / 6.47 / 0.006 / 1.05
C-16 / 5.91 / 25.88 / 2.96 / 12.96 / 1.48 / 6.47 / 0.006 / 0.03
C-12 / 8.15 / 35.69 / 8.15 / 35.69 / 3.26 / 14.27 / 0.007 / 0.03
C-13 / 8.15 / 35.69 / 8.15 / 35.69 / 3.26 / 14.27 / 0.007 / 0.03
C-14 / 8.15 / 35.69 / 8.15 / 35.69 / 3.26 / 14.27 / 0.007 / 0.03
C-20 / 3.39 / 11.87 / 6.30 / 7.88 / 2.56 / 11.22 / 0.71 / 3.13
C-21 / 3.39 / 11.87 / 6.30 / 7.88 / 2.56 / 11.22 / 0.71 / 3.13
H-1 / 1.03 / 4.50 / 0.86 / 3.78 / 0.06 / 0.25 / 0.01 / 2.53
H-2 / 0.07 / 0.30 / 0.06 / 0.25 / 0.01 / 0.02 / 0.00 / 0.00
H-3 / 0.09 / 0.40 / 0.08 / 0.34 / 0.01 / 0.02 / 0.00 / 0.00
H-4 / 0.37 / 1.61 / 0.31 / 1.35 / 0.02 / 0.09 / 0.00 / 0.01
V-1 / 0.0 / 0.0 / 0.0 / 0.0 / 0.54 / 2.35 / 0.0 / 0.0
V-2 / 0.23 / 1.03 / 1.27 / 5.58 / 0.00 / 0.00 / 1.03 / 4.53
H-401 / 0.06 / 0.27 / 0.05 / 0.23 / 0.15 / 0.66 / 0.03 / 0.12
G-Flare / 0.10 / 0.45 / 0.56 / 2.46 / 0.00 / 0.00 / 0.00 / 0.00
Tanks / 0.0 / 0.0 / 0.0 / 0.0 / 0.0 / 19.6 / 0.0 / 0.0
Fugitive / 0.0 / 0.0 / 0.0 / 0.0 / 0.0 / 16.22 / 0.0 / 0.0
Totals / 75.5 / 298.0 / 102.9 / 233.7 / 41.7 / 218.4 / 2.6 / 14.8
SECTION V. INSIGNIFICANT ACTIVITIES