OPW Total Vapour Solution Business Case © OPW Fueling Components 2009
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Lifetime savings (15 years) 148 500 € Lifetime savings (15 years) 247 500 €
OPW Total Vapour Solution Business Case © OPW Fueling Components 2009
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Annual losses in litres 24 500 Annual losses in litres 17 500 Stage II Vapor Recovery
Losses after TVS installed 0,05% Losses after TVS installed 0,05% Stage II Vapor Recovery Systems collect gasoline vapors from vehicles’ fuel tanks while customers
dispense gasoline products into their vehicles at gasoline dispensing facilities. The Stage II system consists
Annual losses in litres after TVS 3 500 Annual losses in litres after TVS 2 500 of special nozzles and coaxial hoses at each gasoline pump that captures vapors from the vehicle’s fuel
tank and routes them to the station’s underground or aboveground storage tank(s) during the refueling
Saved gasoline in litres 21 000 Saved gasoline in litres 15 000
process.
Saved gasoline in euros 23 100 € Saved gasoline in euros 22 500 € Environmental Benefits: When using Stage II Vapor Recovery equipment, the escape of gasoline vapors
is held to a minimum, helping to protect the customers from the harmful effects of gasoline fumes as
Maintanance annually including Maintanance annually including well as minimizing the escape of pollutants that contribute to air pollution.
amortized cost of membrane and amortized cost of membrane and
1 000 € 1 000 € (Source: Illinois Environmental Protection Agency)
compressor replacement after 9 compressor replacement after 9
and 10 years respectively and 10 years respectively
Cost of TVS 50 000 € Cost of TVS 50 000 € The harmful petrol vapour which escapes during the refuelling of cars at service stations will have to be
captured according to a deal reached with the Council, which has been confirmed today by the European
Return on Investment (ROI) in Return on Investment (ROI) in Parliament. Petrol vapour contains benzene, which is known to cause cancer, and contributes to the
2,51 2,58
years years formation of groundlevel ozone (‘smog’), one of the air pollutants most damaging to human health and
the environment.
The European Parliament today confirmed a first-reading agreement reached in informal negotiations
Lifetime savings (15 years) 346 500 € Lifetime savings (15 years) 337 500 €
with Council which demands that stage II petrol vapour recovery technologies will become compulsory
Lifetime cost 78 340 € Lifetime cost 78 340 € at new or renovated service stations with large throughput as of 1 January 2012. Almost all service
stations (small ones will be exempted) will be obliged to install these new technologies by 2018, 2 years
Lifetime profit 268 160 € Lifetime profit 259 160 €
earlier than proposed by the Commission. An exception exists also for service stations used exclusively
in association with the construction and delivery of new motor vehicles.
The Member States will draw drivers’ attention to the recovery systems by appropriate labeling of petrol
pumps.
OPW Total Vapour Solution Business Case © OPW Fueling Components 2009
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There are 4 main components of the Petroman Total Processing, each playing an integral part in the total
processing of the stages 1B and stage 2 vapour, as well as the natural venting of the product.
On the forecourt vapour is generated through natural venting during the quieter period, further vapour
is produced during the delivery process by the effect of the liquid passing into the tank and on sites with
Stage 2 systems the vapour being recovered from the pumps is returned to the underground tank. The delivery process causes turbulence in the tanks through the liquid passing down the drop tube
On a normal site this vapour would be recovered by the delivery tanker during the fill process by virtue and exiting through the orifice directly into the tank. In order to control the delivery of the liquid the first
of the vacuum created in the tanker as the liquid is delivered. It is not always understood that even component used is the Softfill system.
when the delivery tanker is delivering diesel the tanker is connected to the vapour recovery system and This is basically a beam which is attached to the bottom of the drop tube and this allows the liquid to
therefore vapour is drawn from the sites tanks. feed along the base of the tank and is delivered through a large number of small holes (having a total
TVS is designed to maintain the vapour, produced by these various processes, underground in the sites surface area much greater than the normal 4” orifice). The effect of this is to calm the delivery and thus
tank farm and then to process the vapour back to liquid which is returned to the underground tanks reduce the vapour generation caused by the delivery.
(UST). The effect of this system is to reduce the wet stock losses normally associated with deliveries and The secondary action of the Softfill is to introduce the vapour mixture being returned into the liquid flow
provide the vapour as a saleable product. by the Accumulus valve, back into the product within the tank in a controlled manner to aid the vapour
introduction back into the liquid.
There are 4 main components of the system, each playing an integral part in the total processing of
This is retrofitted through the existing 4” tee on top of the tank and can be easily removed for
Stages 1B and 2 vapour and vapour produced by natural venting, which are:
maintenance.
1. Softfill
2. Accumulus
3. Vapour Management Panel
4. Processing Unit - vaporsaver
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During the delivery the vapour generation occurs within the spirit tanks and this passes from tank to
tank through the vapour recovery manifold.
The vapour air mixture that is generated is rich in hydrocarbons and the Accumulus valves works to reduce
the pressure in the tank and to introduce the vapour back into the liquid flow, causing the hydrocarbon On a normal delivery the delivery tanker would connect up to the vapour recovery point when offloading
component of the mixture to be entrained back into the liquid. diesel and petrol. The effect of the tanker is to pull the vapour from the underground tanks, back into the
tanker. Even when diesel is being offloaded, with the vapour recovery hose connected, the tanker pulls
The valve itself is positioned at the top of the drop tube, in the tank, in the vapour space. The valve forms
the petrol vapour from the UST. The effect of this is a loss in vapour that can equate to 20 – 30 liters of
part of the drop tube and is positioned below the overfill prevention valve.
fuel per delivery.
The design of the valve utilises the liquid flow to create a vacuum, this is done by passing the liquid
The vapour management panel is positioned on the vapour recovery manifold between the UST and the
being delivered to the tank through a venturi which creates a vacuum at the centre. This area of vacuum
vapour recover hook up point. The panel contains two sets of valves, the primary valves are for vapour
is linked to the vapour space in the tank by a tube and this vacuum pulls the vapour air mixture being
management and these valves are inserted into the panel and control the vapour allowed from the UST
generated back into the liquid flow from the tanker, thus entraining the hydrocarbons back into the
to the tanker.
liquid.
The valves are weighted to lift when the pressure in the UST reach 34 mbar, the effect of these valves is
The effect of this is to reduce the generated pressure during the delivery.
to prevent vapour from returning to the tanker when diesel is being offloaded. The valves will remain
closed during this process and the tanker will pull air into the tanker through its own vent system.
Once the delivery of spirit is started the pressure will start to build up in the UST, but to a lesser extent
than on a normal site because of the above components, as the pressure increases this is held back by
the valves and the processing unit start to work (this is explained below).
The valves will not lift until a pressure of 34mbar is reached and with the other components operating
this pressure may not be reached at all throughout the delivery process, thus meaning no return of
vapour to the delivery tanker.
Once the tanker has finished its delivery, the valves close and trap the vapour in the UST, this vapour is
then processed back to liquid.
The secondary valves in the panel are the PV valves which are normally positioned at the top of the vent
stack. These have been brought down to low level for ease of maintenance and weather caps put onto
the vent stacks.
The benefit of the vapour management panel is to reduce or eliminate the vapour going back to the
tanker and to trap the vapour in the UST, so that it can be processed back to liquid.
OPW Total Vapour Solution Business Case © OPW Fueling Components 2009
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1. The feed pump draws the vapour/air (saturated vapour) mixture from the storage tank.
2. The vapour/air flow is pressurised.
3. Increasing pressure within the same volume causes the vapour stream temperature to rise.
4. The heated vapour stream passes through a cooler.
5. The cooler reduces the vapour stream to ambient temperature.
6. The cooling process causes liquid gasoline to condense.
7. The vapour/air mixture and liquid gasoline go to a separator.
8. The liquid gasoline is separated, removed from the vapour/air mixture, and stored for later
removal and return to the storage tank.
9. The remaining vapour/air flow proceeds to the membrane.
10. The membrane material has two sides, a pressure (feed) side, and a vacuum (permeate) side.
11. As hydrocarbon molecules pass along the membrane pressure side, they are attracted and bond
to the membrane material.
12. Air molecules are repelled by the membrane surface on the pressure side, and continue on until
released from the Control System as clean air (residue).
13. The pressure differential between the pressure side and the vacuum side cause the hydrocarbon
molecules to be drawn through the membrane material.
As explained above the effect of the vapour management panel is to retain the vapour in the UST.
In addition to this, vapour is returned to the tanks by the Stage 2 system on the pumps and also through 14. The vacuum pump returns the supersaturated gasoline vapour (permeate) to the storage tank
natural venting during quieter times on the forecourt. where some of it will condense into liquid gasoline.
The OPW processing unit is provided to process the vapour back to liquid and thus a saleable product. 15. When the pressure in the storage tank is reduced a preset level, the Control System is shut down
The OPW processor consists of a vacuum pump, compressor and membrane system and is an ATEX and put into stand-by mode waiting for the pressure to rise again.
approved system. The processor is linked into the vapour recovery manifold and a pressure switch built 16. The separator valve is then opened, and the stored gasoline liquid in the separator is released to
into the system monitors the pressure in the UST. the UST.
When the pressure increases to more than 2mbar, the processor automatically starts and the vapour/
The principle of the membrane separation is called selective permeability or molecular selectivity. The
air mixture is passed through the membrane. The membrane allows the hydrocarbon element to pass
membrane allows the hydrocarbon molecules to readily pass through while the air (oxygen and nitrogen)
through but prevents the air from exiting.
molecules are less permeable and are vented to the atmosphere.
This effect allows the air to be split from the hydrocarbon; the air which is clean can then be passed out
to atmosphere through a vent system. The hydrocarbon element is pumped back into the UST and this
liquid stream is run through an inner pipe contained within one of the existing vent lines. This allows the The Overall Effect of OPW TVS
liquid to be returned directly to the tank. The overall effect is the storing of the vapour produced during a delivery, thus reducing the vapour
The vaporsaver is controlled from through various pressure switches and timers to allow it to run being returned to the tanker, the processing of all stored and Stage 2 vapour and the conversion of the
only when needed. The main bulk of the processing will be done during and after a delivery with the vapour back to liquid.
processor then being utilised at other times to process the Stage 2 vapour and natural venting as and The benefits of the system are that it offers a financial payback because of the liquid recovered from the
when required. system which would normally be returned to the tanker with a higher vapour content.
Each of the components compliments each other in reducing the pressure, maintaining the vapour in the
UST and processing this vapour back to liquid.
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30th June 2008 to 30th June 2009 Two Sites - One with T. V. S one without
Station
Period Gasoline Sales Loss/Gain in Liters Variance in % Glendhow SS Sales Losses % Loss Litrs Corrected % A.T.C % A.T.C Losses
Losses
1st January to 31st March 2009 2,967,833 -1,007 -0.03% November 113489 0,11 128 -0,10 366,33 -0,210 -238,33
Deliveries 24000
Savings 72.76%
OPW Total Vapour Solution Business Case © OPW Fueling Components 2009
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U.S. Based cost per year @ .04 USD/kWh (Peak) 8 Total $ 480.00
28 Total $ 1,680.00
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$ 3,250.00
$ 5,825.00
$ 9,000.00
Compressor
Vac Pump
Membrane
1
1
$ 60.00
$ 120.00
$ 60.00
P rocedure
OPW instructs user on choosing
a proper site for TVS
$ 45.00 Vac Belt 1 $ 60.00
Simplified
$ 45.00
$ 18,165.00
Compressor Belt
Totals
1
6
$ 60.00
$ 360.00
F or
OPW instructs user to fill in the site
survey form and provides photos
of the site or layout
Procedure
$ 1,211 Adjusted cost per Year Based on Third Party Requirements for Replacement Interval
For
NOTE: Replacement based on an expected life of 9.5 years of the membrane, vacuum pump and compressor.
Vaporsaver expected life is 15 years, so maintenance cost is put in relation with that number of years.
Installing
Following approval of the site,
OPW tests the site for vappour
tightness
Installing
O PW TVS
Component parts price shown is LIST PRICE. Actual price will vary.
Actual cash outflow will only follow once the components need replacing, so for the first 9 years there is no
expected cash outflow, apart from possible vac and compressor belt replacement. After site passes the test, OPW
OPW TVS
provides a drawing proposal
and installation procedure,
together with commercial offer
At
At
Following acceptance of the user,
parties agree on date
Your
of installation
Petrol
Your
User sends in official purchase
order, with OPW returning
acknowledgement with
Station
agreed terms
P etrol
Following successful installation,
OPW stays in contact with user
to track performance
and regular service