Adsorption-type Loading Platform Vapor Recovery Device

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The adsorption-type Vapor recovery unit for loading platforms is a highly efficient and environmentally friendly device designed to address the issue of Vapor volatilization during the loading process of tank trucks and train tank cars in refined oil depots, refining enterprises, and chemical terminals. This product employs activated carbon adsorption + vacuum desorption technology. It utilizes the difference in adsorption capacity between Vapor components and air components by porous adsorbents such as activated carbon, achieving selective separation of Vapor from air. The enriched Vapor is recovered to storage tanks or absorption towers for further treatment, and the treated exhaust gas meets emission standards.

This product complies with the requirements of the "Technical Standard for Vapor Recovery and Treatment Facilities" (GB/T 50759-2022) and the "Emission Standard of Air Pollutants for Oil Storage Depots" (GB 20950). The treatment efficiency is ≥95%, and the emission concentration is ≤25g/m³ (some advanced processes can achieve ≤10g/m³). It is a reliable choice for refined oil depots and refining enterprises to achieve a win-win situation of environmental compliance and resource recovery at loading platforms.

For gasoline loading at refined oil depots, due to the large loading volume and high Vapor concentration (inlet concentration can reach 300-1300 g/m³), adsorption is one of the industry's recommended preferred solutions, featuring high operational flexibility, adaptability to fluctuations in operating conditions, and mature and stable technology. Complete sets of adsorption-based Vapor recovery technologies have been promoted and applied in 200 oil depots in Beijing, Hebei, Shanghai, Zhejiang, and Guangdong, forming a series of products with processing capacities ranging from 200 m³/h to 1200 m³/h, with overall performance reaching a leading level in China. A technological achievement in Sichuan shows that using a combined adsorption and absorption process to treat Vapor during loading, the inlet non-methane total hydrocarbon concentration is approximately 300-1300 g/m³, the outlet emission index can be <10 g/m³, and the treatment efficiency is ≥98%.

2.1 Core Technical Principles

Adsorption-based Vapor recovery technology utilizes the differences in the binding forces between various components in the Vapor and the adsorbent (such as activated carbon, silica gel, molecular sieves, etc.) to achieve the separation of difficult-to-adsorb components from easily adsorbed components. Porous materials such as activated carbon have a strong adsorption capacity for hydrocarbon molecules in Vapor , but a very weak adsorption capacity for air, thus achieving selective separation of Vapor from air.

The adsorption + absorption combined process is currently the mainstream technology route for oil depot loading platforms. This technology route uses a combination of adsorption and absorption to collect and treat Vapor during the loading process at oil depots. It has good technical applicability, is easy to scale up, has good safety, is simple to operate, easy to maintain, produces clean production, has no secondary pollution, and has a long service life.

The Vapor generated at the loading platform is transported to the boundary of the unit by an exhaust fan, and then enters the absorption tower. The Vapor enter from the bottom, and the tower is filled with high-efficiency packing. Mass and heat transfer occurs between gasoline and VOCs in the Vapor on the surface of the packing. VOCs dissolve into the gasoline, and the low-concentration Vapor rises and exits from the top of the tower to enter the coalescing unit for treatment. In the high-efficiency coalescer, mist, droplets, etc., entrained in the gas at the top of the tower can be intercepted, and then the gas enters the adsorption tank for Vapor adsorption. The adsorption tank adopts a dual-tank design: one tank for adsorption and the other for regeneration. All switching is automatically controlled by electric valves, and the treated exhaust gas is discharged through the emission pipe.

The unit contains two carbon beds, which alternately operate and perform an adsorption-desorption-regeneration process, thus forming a continuous Vapor recovery capacity.

A low vacuum generated by a vacuum pump is used to desorb saturated Vapor from the activated carbon in the carbon bed and push it to the absorption tower, while the activated carbon recovers its original adsorption capacity.

2.2 Dual-Tank Alternating Operation Process

Based on the PAC (Purge Air Control) control method and the principle of Vapor adsorption technology, the working pressure and temperature signals are controlled by the control system to control the Vapor treatment and operation process. The specific process is as follows:

• Adsorption Stage: Vapor generated during loading enters adsorption tank A through the collection system. The activated carbon in the adsorption tank selectively adsorbs hydrocarbon components in the Vapor , and the clean air is discharged in compliance with standards.
• Switching and Regeneration Stage: When adsorption tank A becomes saturated, the PLC control system automatically switches to adsorption tank B for adsorption, while simultaneously desorbing and regenerating adsorption tank A.
• Vacuum Desorption: The vacuum pump is activated to perform vacuum desorption on the saturated adsorption tank (vacuum level can reach below -0.095 MPa), releasing the adsorbed hydrocarbons to form high-concentration Vapor .
• Vapor Recovery: The desorbed high-concentration Vapor enters the absorption tower (or is directly returned to the storage tank), where it is absorbed by the absorbent (such as gasoline or diesel), and the rich oil is returned to the tank area.
• Circulation Operation: The two adsorption tanks alternate between adsorption and desorption, ensuring continuous 24-hour operation of the unit.

The on-site equipment and facilities for Vapor recovery are mainly divided into three components: adsorption, desorption (regeneration), and recovery. These include: adsorption tanks, activated carbon beds, absorption towers, inlet and return oil pumps, dry screw vacuum pumps, filters, variable frequency motors, Vapor inlet valves, inlet and return oil valves, vent valves, regeneration valves, and purging solenoid valves. The entire system consists of a host computer operating platform, PLC and power control cabinet, and on-site equipment and facilities.

This product mainly consists of the following core components:

4.1 Standard Model Parameters

Taking an oil depot with a processing capacity of 700 m³/h as an example, by optimizing the activated carbon bed adsorption setpoints, the high and low liquid level protection setpoints of the absorption tower, the activated carbon high temperature alarm value, and the inlet oil flow rate, the Vapor recovery efficiency can be effectively improved.

4.2 Core Component Technical Standards (Based on GB/T 50759-2022)

According to the national standard "Technical Standard for Vapor Recovery and Treatment Facilities" (GB/T 50759-2022), the core components of the adsorption-type loading platform Vapor recovery device should meet the following technical requirements:

• Activated carbon performance: Specific surface area should not be less than 1000 m²/g; apparent density should not be less than 0.4 g/mL; water content should not be higher than 5%; adsorption capacity for n-butane should not be less than 0.1 g/mL; designed service life of activated carbon should not be less than 4 years.
• Adsorption Tank Design: There should be no fewer than two adsorption tanks; the total amount of adsorbent in the tanks should meet the design scale and the Vapor adsorption capacity for 20 minutes at the design Vapor concentration; when using granular adsorbent, the filling height should not exceed 2/3 of the total height; the adsorption operating temperature of the adsorption tank bed should not exceed 60℃; the leakage of the switching valve of the adsorption tank should not exceed 5×10⁻¹²m³/(s·bar·mm).
• Absorption Tower Design: The absorption tower should preferably be a packed tower; the packing should preferably be low-pressure-drop, structured packing, with a pressure drop not exceeding 1kPa; pressure gauges should be installed at the upper and lower sections of the packing layer, and the liquid section at the bottom of the tower should be equipped with local liquid level indicators and remote transmission instruments; the design pressure of the absorption tower should not be lower than 0.35MPa.

4.3 Activated Carbon Performance Requirements:

The performance of activated carbon used in Vapor recovery directly affects the adsorption efficiency and service life of the device. Key indicators are as follows:：

The specific surface area of ​​activated carbon for Vapor recovery determines the total number of adsorption sites and is positively correlated with the Vapor adsorption capacity. An iodine adsorption value ≥800 mg/g (GB/T7702.7) reflects the microporous adsorption capacity. Selecting a high-performance adsorbent is fundamental to the efficient operation of the unit, and selecting and adjusting operating parameters based on the adsorption-desorption characteristic curves of the adsorbent is a necessary condition for efficient operation. The application of the 400# benzene loading Vapor recovery technology at Qilu Petrochemical Company's storage and transportation plant demonstrates that selecting a high-performance adsorbent is fundamental to the efficient operation of the unit.

5.1 Mature and Reliable, Stable Performance

Widely Used in the Industry: The complete set of adsorption-based Vapor recovery technology has been promoted and applied in 200 oil depots nationwide, forming a series of products with processing capacities ranging from 200 m³/h to 1200 m³/h, with overall performance reaching the leading level in China. It can reduce Vapor emissions by hundreds of millions of cubic meters annually and recover more than 15,000 tons of gasoline.

Mature Technology: Adsorption methods have been proven effective in high-turnover oil products and, when combined with absorption methods, are the mainstream technology for oil depot loading platforms.

Adaptability to Fluctuating Operating Conditions: Loading operations are intermittent, resulting in significant variations and fluctuations in Vapor emissions and concentrations. This unit employs a dual-tank alternating design, adaptable to operating load variations from 0-100%. Operation should be adapted to changes and fluctuations in Vapor emissions and concentrations.

5.2 High-Efficiency Recovery, Ultra-Low Emissions

High Treatment Efficiency: Vapor recovery treatment efficiency ≥99%, far exceeding the national standard requirement of ≥95%.

Excellent Emission Indicators: Emission concentration can be ≤10g/m³, better than the GB20950-2020 air pollutant emission standard for oil storage depots. Some advanced technologies can achieve emission concentrations as low as ≤60mg/m³ (non-methane total hydrocarbons), meeting the highest emission standards for petrochemical enterprises.

Advantages of Combined Process: The combination of low-temperature absorption and high-efficiency coalescing components significantly extends the lifespan of activated carbon and reduces solid waste generation.

5.3 Dual-Tank Alternating Design for Continuous Operation

24-Hour Uninterrupted Operation: Two or more adsorption tanks alternate between adsorption and desorption, allowing for continuous equipment operation.

Automatic Switching Control: PLC automatically controls the switching sequence, using electric control valves, eliminating the need for manual intervention.

Intelligent Start-Stop Energy Saving: The operating mode automatically adjusts according to changes in adsorption capacity. The vacuum pump automatically stops operating when there is no work or low workload, reducing idling losses.

High-Efficiency Activated Carbon Regeneration: The dry vacuum pump uses segmented frequency conversion regeneration, offering advantages over similar products both domestically and internationally, including lower emissions, lower energy consumption, lower maintenance costs, simpler operation, and higher safety.

5.4 Safe and Reliable Design

Explosion-Proof Certification: Ex d IIB T4 explosion-proof rating, suitable for flammable and explosive environments.

High-Temperature Monitoring Interlock: Temperature gauges are installed at the top, middle, and bottom of the adsorption tanks, with temperature control interlock measures in place; the adsorption operating temperature of the adsorption tank bed should not exceed 60℃.

Flame Arrestor Protection: Flame arresters are installed on the exhaust pipes and gas collection system to prevent flame spread.

Multiple Safety Interlocks: Comprehensive safety protection functions including overpressure protection, temperature protection, and vacuum interlock.

Long Service Life: Utilizing hybrid adsorption technology and dry vacuum pump segmented frequency conversion regeneration technology, the equipment is designed for a service life of ≥10 years.

5.5 Intelligent Control System

PLC Fully Automatic Control: One-button start/stop, all-weather automatic operation, enabling 24-hour unattended operation.

Online Monitoring: An advanced online monitoring and control system is installed on the Vapor recovery unit to monitor unit operating data and emission gas concentration in real time.

Remote Data Transmission: Supports fully automatic control via a background monitoring platform and can be integrated into an enterprise's DCS system.

Parameter Optimization: Operating parameters such as activated carbon bed adsorption value, absorber high and low liquid level protection values, and activated carbon high temperature alarm values ​​can be set for refined operation management.

Self-Diagnosis of Faults: The system has automatic fault detection and alarm functions to ensure safe operation.

Application cases cover the recovery and treatment of Vapor generated during oil depot operations at companies such as CNPC, Sinopec, Sinochem, CNOOC, and China Aviation Oil, including those related to highway oil delivery, breathing gases from storage tanks, train loading and unloading, and dock loading and unloading.

While a single adsorption process can meet basic emission requirements, the Vapor generated at loading platforms is characterized by "large volumes, high concentrations, and intermittent emissions." Therefore, the combined absorption and adsorption process has become the mainstream solution for oil depot loading platforms and is internationally recognized as the recommended approach.

The combined absorption and adsorption process effectively treats high-concentration Vapor generated during vehicle loading. Vapor enter from the bottom of the absorption tower, which is filled with high-efficiency packing material. VOCs dissolve into the gasoline, while low-concentration Vapor , after being intercepted by a coalescer, enters the adsorption tank for further purification. The modified activated carbon adsorption and lean oil absorption combined Vapor recovery process has a processing capacity of 100~2500 m³/h, an Vapor emission concentration ≤10 g/m³, an Vapor recovery efficiency ≥99%, and a service life ≥10 years. It is included in the Ministry of Industry and Information Technology's recommended energy-saving technology catalog.

When using the above combined process route, selecting a high-performance adsorbent is fundamental to the efficient operation of the unit. Selecting and adjusting operating parameters based on the adsorption-desorption characteristic curves of the adsorbent is a necessary condition for efficient operation.

The economic benefits of the adsorption-type loading platform Vapor recovery unit are mainly reflected in the following aspects:

Taking the Shenzhen Meishi Oil Depot renovation project as an example: A modified activated carbon adsorption + lean oil absorption combined Vapor recovery process was adopted, with a processing capacity of 500 m³/h. After the renovation, the power consumption for processing 500 m³ of Vapor decreased from 2500 kWh to 700 kWh, and 400 tons of oil can be recovered annually. The project's comprehensive annual benefit totals 2.16 million yuan, with a total investment of 6 million yuan and a payback period of 2.78 years.

Shandong Port Qingdao Port Shihua Company's loading dock has 51 loading and unloading positions for refined oil (gasoline and diesel), equipped with multiple condensation + adsorption Vapor recovery devices. The renovation design of the loading dock's Vapor recovery devices was carried out according to the latest specifications. Kangqiao Oil Depot, considering the intermittent nature of highway oil dispensing operations, adopted an operating mode based on changes in the amount of Vapor adsorbed by the carbon canisters, reducing vacuum pump idling losses and expected to save the oil depot 100,000 yuan in electricity annually.

9.1 Recommendations for Processing Capacity Selection

The design capacity should be 100% to 110% of the maximum simultaneous Vapor emissions from the storage or loading facilities, and the maximum operating load should not exceed 110% of the design capacity. The operation of the unit should be adapted to changes and fluctuations in Vapor emissions and concentrations.

9.2 Process Route Selection

9.3 Selection Considerations

Selection of a system requires comprehensive consideration of factors such as gasoline outflow (loading capacity), number of loading arms, and peak-hour concurrent operations. The Vapor processing capacity should be calculated and determined. For example, a certain refined oil depot (designed capacity 140,000 m³) has a maximum hourly gasoline loading capacity of 800 m³/h. The local environmental protection department explicitly requires that gasoline loading must be equipped with an Vapor recovery system with a recovery efficiency of no less than 90%. Furthermore, the selection of the absorbent also requires attention: when absorbing a single type of Vapor , the absorbent should preferably be made of the same material; when absorbing mixed Vapor , the absorbent should preferably be low-grade diesel or a specialized absorbent. Lowering the absorbent temperature can further improve the absorption effect.

10.1 Installation Conditions
Install near the loading platform, meeting fire safety distance requirements.

A foundation must be reserved for the equipment. Install in a well-ventilated, dedicated area away from fire sources.

A 380V/50Hz three-phase power supply is required; power output depends on the processing capacity.

Gas connection: DN100～DN300 flange connection (depending on processing capacity).

The exhaust pipe outlet should be at least 15 meters above ground level, meeting environmental monitoring requirements.

10.2 Installation Precautions
The device should preferably be installed near the loading platform to shorten the length of the Vapor collection pipeline.

Electrical wiring must comply with GB 3836 series explosion-proof area construction specifications.

The connecting pipeline between the adsorption tank and the absorption tower must be airtight.

The distance between the absorbent storage tank and the Vapor recovery device should not be less than 8m.

Flame arresters must be correctly installed on the gas collection pipeline and the exhaust pipeline.

System airtightness is the primary inspection item; an inert gas pressure test should be performed on the entire system.

10.3 Piping and Gas Gathering System Design

Connect the oil/gas gathering pipeline to the gas phase outlet flange of the loading arm.

The pipeline slope should be no less than 2‰ to prevent liquid accumulation.

Install a pressure transmitter linked to the loading arm to ensure the gas gathering pressure is within a safe range.

All flange connections must undergo airtightness testing.

11.2 Regular maintenance

Activated carbon and other adsorbents will gradually become saturated after a period of use, requiring regeneration or replacement. Activated carbon replacement should be performed by professionals, and spent activated carbon should be treated as hazardous waste (HW49 category). The designed service life of activated carbon should not be less than 4 years.

11.3 Operational Optimization

When the temperature of the upper, middle, or lower parts of the adsorption tank exceeds the set value (e.g., 75℃), temperature interlock measures should be activated. Optimizing the set values ​​for the carbon bed adsorption, the high and low liquid level protection settings of the absorption tower, and the high temperature alarm value for activated carbon can improve Vapor recovery efficiency. Beijing Yanshan Petrochemical has achieved good treatment results by using vacuum desorption to regenerate activated carbon and by using absorption processes to recover Vapor during the loading process.

Trends Adsorption-based Vapor recovery technology has undergone many years of development in the oil depot loading platform field:

Maturation of Dual-Tank Alternating Adsorption: The traditional dual-tank alternating adsorption process technology is mature and stable, and remains the main solution for oil depot loading platforms.

Mainstream Combined Processes: The combination of absorption and adsorption has become the mainstream technology for oil depot loading platforms. The absorption tower and adsorption tanks are combined to achieve a balance between high efficiency and adaptability to a wide range of operating conditions.

Stricter Emission Standards: Emission concentration requirements have been reduced from ≤25g/m³ to ≤10g/m³ (strictly controlled areas), with some advanced combined processes achieving levels as low as ≤60mg/m³.

Intelligent Upgrades: New equipment supports fully automatic PLC control, online monitoring, and environmental data uploading, enabling remote monitoring and data recording via a host computer.

Energy-Saving Design: Intelligent start-stop technology that automatically adjusts the operating mode based on changes in the amount of Vapor adsorbed in the carbon tank significantly reduces the power consumption of the vacuum pump during idling, extending equipment lifespan.

Green Requirements: Minimizing solid waste generation, the use of hybrid adsorption technology and dry vacuum pump segmented frequency conversion regeneration technology results in lower emissions, lower energy consumption, and lower maintenance costs compared to similar products both domestically and internationally.

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