Featured Project: Permanent Fugitive Emissions Elimination on Aging DAF Cell Lids – Automated Thermal Oxidizer & LDAR Compliance
With LDAR enforcement intensifying nationwide (e.g., SCAQMD Rule 1173, BAAQMD Reg 8-18, TCEQ HRVOC, Colorado Reg 7), even low-pressure sources like Dissolved Air Flotation (DAF) cell lids on oil-water separators are now monitored via Method 21 and optical gas imaging. Aged fiberglass or steel lids routinely leak 500–5,000 ppmv VOCs, triggering mandatory repairs, root-cause analysis, and potential $25,000+/day fines.
This facility chose to get ahead of regulators with a permanent, automated vapor control system instead of endless repairs.
The Challenge: Fugitive VOCs from Old DAF Cell Lids
- Aging lids on multiple DAF cells leaking detectable hydrocarbons
- Method 21 readings routinely >500 ppmv (some >10,000 ppmv)
- Risk of major LDAR violations and consent decree exposure
- Manual venting or carbon cans were temporary and ineffective
Envent’s Permanent Solution: Custom Automated Thermal Oxidizer System
Envent designed, fabricated, and installed a fully automated, plant-integrated thermal oxidizer system that maintains a slight negative pressure inside every DAF cell — ensuring zero fugitive emissions at the lid seals.
Key System Features
- Selective Vacuum Control: Motorized dampers automatically cycle between cells to maintain −0.1 to −0.5 in. w.c. on each lid
- Dedicated Thermal Oxidizer: 500–1,000 scfm enclosed unit with >99.9% DRE at 1,600 °F
- Plant Utility Integration: Uses site natural gas and electricity — no diesel generator or supplemental fuel fuel costs
- Full Automation: PLC + HMI with remote monitoring — runs 24/7 without operator attendance
- Safety: Flame arrestors, LEL monitoring, auto-shutdown, and explosion vents
Post-installation Method 21 surveys: 0 ppmv detectable on every lid.
Proven Benefits – Permanent LDAR Compliance
| Benefit | Delivered Outcome |
|---|---|
| Fugitive Emissions | 100% eliminated — zero leaks above 500 ppmv |
| LDAR Compliance | Removed DAF cells from future Method 21 monitoring |
| Regulatory Satisfaction | Passed air district inspection with flying colors |
| Operating Cost | Uses plant utilities — no generator/fuel expense |
| Labor Savings | Fully automated — no daily operator required |
| Longevity | Permanent stainless steel system built for 20+ years |
This system has become the gold standard for oil recovery units, API separators, and wastewater tanks in strict LDAR jurisdictions.
Tired of endless DAF lid repairs and LDAR violations? Get your Free Permanent Fugitive Control Design & Quote today. Call Envent at 888-997-9465 or email [email protected] — we make fugitive emissions disappear for good.
