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Alon Refining (3116), Krotz Springs

Causal Factor: Maintenance/Procedures

LDEQ Accident Number
Accident Date
Point Source(s) Notes Amount of Release
No LDEQ Reported

FCC Flare EPN 5-85
Cause: Were emitted from the FCC Flare as a result of excess steam while steaming out a vessel.

Followup: Yes

Notes: Notified DEQ of potential for flaring gases during the shutdown of the FCC unit on 12/14/06. Release resulted in an odor in the nearby community. Offsite monitoring was conducted immediately and found no signs of pollutants. Report written before startup completed and the potential for excess emissions still existed. The final report with accurate quantities of pollutants may be in 2007.
Volatile Organic Compounds: 1,260.0 pounds

Cause: FCC unit started up after 2 weeks of planned maintenance. Relief valves opened to flare when weight gas compressor for FCCU malfunctioned. Two odor complaints received by LDEQ connected to this accident. Starting unit for the wet gas compressor on the FCCU malfunctioned. 2 Citizen Complaints included: 135203 and 135197

Followup: No

Notes: Report states that Title V permit limits were exceeded. A site visit was made on 11/15/2011. Unit started up after two weeks of maintenance. Unauthorized Discharge Notification Report received 11/22/11. Report states that the maximum hourly permit limit was exceeded for hexane but no reportable quantities were exceeded. they did not realize until the next morning that RQ was exceeded.
Sulfur Dioxide: 636.0 pounds
Nitric Oxide: 43.2 pounds
Carbon Monoxide: 234.9 pounds
Volatile Organic Compounds (VOCs): 497.9 pounds
Hexane: 30.9 pounds
Particulate Matter: 2.9 pounds
Ethylene: 26.8 pounds
Propylene: 114.1 pounds

Drain connect to heat exchanger
FCCU Unit Flare
Cause: On April 25, contractors were in the process of repairing a leak on a drain valve of a heat exchanger in the Reformer Unit. While placing a clamp on the heat exchanger to encase the valve and stop the leak, the point where the drain connects to the heat exchanger failed, releasing LPG (propane/butane mix). At about 8:14 am, the LPG ignited and a fire began. The fire was ultimately controlled, and remaining LPG was flared in a controlled manner until the damaged equipment was free of flammable gas.

Followup: Yes

Notes: The Refinery Emergency Response Team immediately responded to control and extinguish the fire. While fighting the fire, the entire refinery was shut down to mitigate additional danger from the fire. Upon and since emergency shutdown of the FCCU Regenerator, stack concentration limits for CO (500 ppm hourly average), SO2 (50 ppm 7-day rolling average), and Opacity (30% for 2 or more 6 min per hour) have been exceeded. While 7-day average SO2 concentration limits dictated by the Consent Decree were exceeded, permitted lb/hr limits were not. The Consent Decree exempts SO2 exceedances during times of SSM. The Complex II Fuel gas H2S 3-hr average limit of 161 ppm was exceeded due to forced shutdown of the H2S treatment system. Upon startup of the FCCU after the incident from May 6 through May 7, the FCCU stack concentration limits for CO were exceeded for 9 hours with the hourly pounds per hour limit for CO exceeded during 4 of those hours. CO will generally be high upon startup until temperatures become high enough to adequately combust the coke on catalyst. On April 29, the Complex 2 flare exceeded its Consent Decree 24-hr SO2 limit of 500 lbs/dy. However, no Title V hourly maximum permit limit was exceeded.
Volatile Organic Compounds (VOCs): 501.0 pounds
NOx: 9.2 pounds
Carbon Monoxide: 50.0 pounds
Volatile Organic Compounds (VOCs): 579.7 pounds
Hydrogen Sulfide: 27.6 pounds

Cause: On March 4, 2014, there was an air release caused by a flare flame-out at the ALON Krotz Springs Refinery. The release was caused by a loss of the FCCU flare flame for 6 minutes during the shutdown of Complex II/FCCU due to freezing conditions. Caused unburnt gas to be released to the atmosphere for 6 minutes.

Followup: No

Notes: Re-lit flare LDEQ incident report states that 7-day notification was received on March 13, 2014. Document did not exist in EDMS search.
Hydrogen Sulfide: 2.6 pounds
Particulate Matter: 0.0 pounds
NOx: 0.3 pounds
Carbon Monoxide: 1.6 pounds
Sulfur Dioxide: 4.8 pounds
Volatile Organic Compounds (VOCs): 27.2 pounds
Ammonia: 0.1 pounds
Mercaptan: 0.0 pounds
Carbon Disulfide: 0.0 pounds
Ethylene: 14.2 pounds
Propylene: 1.8 pounds
1,3-Butadiene: 0.0 pounds
n-Hexane: 0.2 pounds
Benzene: 0.0 pounds
Cyclohexane: 0.1 pounds
Toluene: 0.1 pounds
Ethylbenzene: 0.0 pounds
Xylene: 0.1 pounds