Mr. Tom McQueary - President ZymeFlow Decon Technology

TAR Vessel Entry Best Practices: Decrease Costs and Increase Safety

Evolution of decontamination

Best practices for vessel entry

Case study

Conclusion

Brief company introduction

Q&A

Agenda

Most basic method to prepare equipment for entry

Steam hardens deposits creating more mechanical work

Tower bottoms and trays many times require several shifts to break up hydrogen deficient deposits

Pyrophorics hidden under hardened deposits

Steam Out

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Typical refinery cleaning: remove organic scale, de-oil, passivate, and/or remove sludge

Chemicals and/or manual cleaning with equipment

Additional equipment required for setup, effluent treatment, and disposal

Secondary step required to decontaminate (LEL/VOC, benzene, H2S, FeS)

Traditional Chemical Cleaning

Traditional cleaning example

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Long maintenance outages reducing refinery margins

Increasing environmental and safety regulations

Unexpected fouling/coking from spot market feedstock

Emergency shutdowns

Pyrophorics risks

Unanticipated contaminants

Evolution of Decon: Forces of Change

State of the industry requires more efficient and safe technologies including turnarounds and maintenance

Decontamination

Making industrial equipment safe for entry by destroying, neutralizing, making harmless, or removing hazardous unwanted contaminants

ALL refineries and petrochemical plants must perform some form of decontamination every time a unit is brought down for personnel entry, hot work, and inspection

Hydrogen Sulfide

Harmful Gases (LEL/VOC)

Benzene Pyrophoric iron sulfide

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ZymeFlow Decontamination

H2S

Removed

Residual

Oil

0 ppm

LEL

FeS

0% Neutralized

Benzene

0 ppm

Preparing process units for safe entry in 8-12 hours.

Simultaneous Treatment

Residual Solids

Conditioned

Distillation Cleaning

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Oxidation

Zyme-Flow UN657 proprietary chemistry blend including surfactant and mild oxidizer

Vapour-Phase® patented method adding Zyme-Flow chemistry with steam to simultaneously eliminate contaminants

Penetrates sludge, scale, and surfaces to free hydrocarbon, benzene, and LEL

Oxidizes hydrogen sulfide (H2S) and pyrophoric iron sulfide (FeS)

Contaminants and chemistry measurable throughout the process

Evolution of Decon: Zyme-Flow Process

Time/Resources Simultaneous treatment of

contaminants

8-12 hours Minimum equipment footprint No secondary treatment needed

for effluent Safety Non exothermic Non reversible oxidation of H2S

and pyrophoric iron sulfide No exposure or corrosion

concerns

Environment Effluent can be sent directly to

oily water sewer Open to atmosphere much

faster No bi-products

Evolution of Decon: Zyme-Flow Process

• Water is added to tower bottom (about 20% level)

• Steam injected into the bottom drain, or as close as possible

STE

AM

• Zyme-Flow® and Rezyd-X® added to water and temperature raised to above 100°C

Zyme-Flow® Rezyd-X®

STEAM

Best Practice H2S Benzene Pyrophoric Scale LEL

Boil Out with Vapour-Phase®

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100°C

STEAM Zyme-Flow®

Rezyd-X®

• Solution continues to boil in the bottom of the tower during Vapour-Phase

• Injection of Zyme-Flow during the steaming phase will last 8-12 hours

STE

AM

Best Practice H2S Benzene Pyrophoric Scale LEL

Boil Out with Vapour-Phase®

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Full PetroChemical Turnaround Kuwait

Case Study

Kuwait Petrochem Plant Decon

• Vapour-Phase and Boil-Out applications used in combination with Zyme-Flow UN657 as

the main chemistry and Rezyd-X on areas containing heavy sludge • Critical path quench water column prepared for entry with a Vapour-Phase application

using Zyme-Flow UN657 • Combination of Zyme-Flow UN657 and Rezyd-X in a Boil Out application used on bottom

section of quench water column

Engineered Solution

• Attempted to circulate an alternate chemical which failed to fully decontaminate the units and produced large amounts of liquid waste

Past Procedure

• Previous shutdown produced large amounts of liquid waste and sludge • Kuwait’s new regulations do not allow liquid waste to be taken off site

Concern

• Decontaminate 42 pieces of equipment in 5 days, including critical path quench water

system

Challenge

Benzene, LEL, and H2S in all units reached zero

No pyrophoric activity

Critical path quench system decontaminated in less than 12 hours

Significantly reduced steam and effluent disposal

Plant implementing the procedure as a Best Practice for preparing process equipment and tanks for entry

Kuwait Petrochem Plant Results

“This is an excellent and unique performance, not only did ZymeFlow® help to enter the vessel safely, but also reduced the waste significantly.” -Turnaround Team

Click to edit Master title style New regulations forced the change to more efficient technology, ZymeFlow Decon tested and proven

Results beyond regulation compliance

Saved time including five (5) days off critical path

Greatly improved personnel safety

Significantly reduced water and waste/effluent disposal

Zero pyrophorics or gas incidents

Achieved full TAR in 30 days

Kuwait Petrochem Plant Summary

Using steam only methods continue to pose safety risk and extend turnaround time

Many chemical treatment options are available but must be evaluated carefully

Indirect and opportunity costs need to be considered

Proper selection of the decontamination method can directly affect turnaround success

Conclusion

Decontamination specialists for over 25 years

200+ TAR and emergency outage projects/year

Experience in over 50 countries

Wide range of specialty blended chemistries

Various application options including Vapour-Phase®

Zero recordable injuries in 25 year history

Worldwide Leader in Decontamination

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www.ZymeFlow.com

© 2016 United Laboratories International, LLC. All Rights Reserved.

Conclusion & Questions

Please contact: Meghan Kidwell Global Marketing Manager

Meghan.Kidwell@zymeflow.com