Reducing fugitive emissions remains a substantial priority for many industries worldwide. It is essential to develop a deeper understanding and take actions to capture the obvious benefits while also uncovering and exploring options to capture the hidden or latent benefits. Bottom line – “Recovering” process material by preventing it from leaking from pipes, valves and fittings adds revenue to the business.
Refresher: What Are Fugitive Emissions?
Fugitive emissions are the unintended and uncontrolled release of gases, often from leaks of industrial equipment such as valves, pumps, and connectors. In petroleum refineries, these emissions can include methane, ethane, propane, and sometimes more harmful substances like benzene. In chemical plants, these emissions can include 1,3 butadiene, ethylene oxide, ethylene dichloride, and vinyl chloride. While these volatile organic compounds (VOCs) have a short atmospheric lifespan, they tend to have lasting adverse effects on the environment.
What are the Value Drivers?
Most Obvious – Reduced leaks lead to reduced pollutants released to the air (VALUE)
- Improved gaskets and valve packing reduces fugitive emissions helping facilities comply with increasingly strict environmental regulations.
- With reduced emissions, companies reduce the risk of incurring fines, legal penalties, or other costs associated with non-compliance.
- Reducing emissions can qualify facilities for reduced emission fees and possibly emission credits (GHG and other pollutants).
Obvious – Reduced leaks lead to more product for sale and revenue (VALUE)
- When fugitive leaks are minimized with improved gaskets and valve packing, the facility retains more of its valuable products for sales.
- This not only boosts revenue but also enhances overall process efficiency.
- When leakage is reduced the energy needed to compensate for lost (leaked) material is lessened, leading to a more energy-efficient operation.
- Product loss due to leaks represents a significant economic cost. Reducing fugitive emissions is, therefore, often considered not only an environmental necessity but also a financial imperative.
Latent – Reduced leaks lead to lower maintenance, repair and planning / scheduling costs
(VALUE)
- Leaks contribute to equipment degradation, leading to increased maintenance & cost, more frequent repairs & cost, and premature replacement of components & cost.
- Proactively using low emission gaskets and valve packing meeting Industry standards – API 622, 624, 641; and ISO 15848 – extend the operational life of critical infrastructure by reducing exposure to aggressive process vapors, thus reducing corrosion and wear.
- Reduced leaks and repairs lead to reduced equipment environmental monitoring (LDAR) costs.
- These savings on maintenance and repair expenses translate into lower operating costs and reduced capital expenditures over time.
Case Study
A mid-sized refining facility with 30,000 valves and 105,000 connectors can significantly cut emissions by upgrading its sealing components. By replacing 90,000 flange connections with ASME B16.20 low-emission spiral wound gaskets and repacking 5,000 valves with API 622-compliant low-emission packing, emissions can drop from 635 tons to just under 10 tons per year. Based on EPA emission calculations, this upgrade translates to an annual savings of $900,000. This example highlights the immense potential for cost savings and environmental benefits through strategic upgrades and maintenance.
The ‘Take Away’
The implementation of low emission gaskets and valve packing presents a compelling economic advantage for industries seeking to mitigate fugitive emission leaks. Addressing fugitive emissions through the Total Cost of Ownership (TOC) lens, evaluating ‘obvious’ and ‘latent’ costs & benefits, to reduce fugitive emissions underscores the importance of a holistic approach that considers both financial and environmental impacts. Investing in advanced low emission technologies and adhering to gasket & valve best practices significantly reduces fugitive emissions, generates a financial return, and positions companies for the future while complying with current regulations.
