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Louisiana Refinery Accident Database

Placid Refining (2366), Port Allen

LDEQ Accident Report

Pollutants Released

Accident Classified As: Reportable Quantity

Cause of Problem: Instrument Failure

An electronic level indication in Placid's Sulfur Recovery Unit #3 (SRU #3) was faulty which caused excess sulfur carry over to Talk Gas Treatment Unit NO2 (TGTU #2). The carryover caused the TGTU #2 quench tower to plug. The plugging created excess pressure in SRU #3 and the TGTU#2 was bypassed lining up the SRU #3 off gas directly to the SRU #2 incinerator. The incinerator then shutdown due to the excess load and the acid gas stream going to the SRU #3 had to be flared. At this time operations began reducing rates to the FCC unit to bring the total refinery sulfur production down so SRU #2 could handle the load while trying to re-light and return SRU #3 to service. In approximately 30 minutes SRU #3 and the incinerator was back online and the acid gas stream was removed from the flare. Operations continued to reduce refinery charge rates to reduce sulfur production so SRU #3 and TGTU #2 could be shutdown to clean the plugged tower. During the shutdown of SRU #3 sweet natural gas is used to sweep the catalysts beds to keep the recovery catalyst from solidifying with sulfur. During this sweeping process excess sulfur dioxide emissions occur from the incinerator as the sulfur is swept off the catalyst. Placid is permitted to sweep the catalyst beds once per year to change the catalyst but that one event has already occurred this year. Placid opened the TGTU #2 quench column for inspection and cleaning prior to returning the SRU #3 and TGTU #2 back to service.

Discharge Preventable - Yes

Notes/Remedial Actions

Placid implemented the Preventative Maintenance and Operation Plan (PMO) and procedures to reduce the refinery sulfur production to reduce the duration and amount of excess emissions. Placid will conduct a formal Root Cause Analysis (RCA) and submit a separate report for this incident per a Settlement Agreement with the Louisiana Department of Environmental Quality (LDEQ). During this process procedures and measures to minimize and prevent recurrence of similar incidents will be evaluated, implemented and reported as required.