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Petroleum refining water/wastewater management

Petroleum refiningwater/wastewateruse and managementOperationsBest global oil and gas industry association for environmental and social issues5th Floor, 209 215 Blackfriars Road, London SE1 8NL, United KingdomTelephone: +44 (0)20 7633 2388 Facsimile: +44 (0)20 7633 2389E-mail: Internet: IPIECA 2010 All rights part of this publication may be reproduced, stored in a retrieval system, or transmitted in anyform or by any means, electronic, mechanical, photocopying, recording or otherwise, without theprior consent of publication is printed on paper manufactured from fibre obtained from sustainably grownsoftwood forests and bleached without any damage to the refiningwater/wastewateruse and managementIPIECA Operations Best Practice SeriesThis document was prepared by AECOM.

Cooling tower makeup water 43 Utility water 43 Boiler feedwater makeup 43 Technologies for upgrade of refinery wastewater 43 Basic media/sand filtration 44 Microfiltration or ultrafiltration 45 Microfiltration or ultrafiltration, with reverse osmosis 47 Microfiltration or ultrafiltration, with nanofiltration 48 Ion exchange 48

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Transcription of Petroleum refining water/wastewater management

1 Petroleum refiningwater/wastewateruse and managementOperationsBest global oil and gas industry association for environmental and social issues5th Floor, 209 215 Blackfriars Road, London SE1 8NL, United KingdomTelephone: +44 (0)20 7633 2388 Facsimile: +44 (0)20 7633 2389E-mail: Internet: IPIECA 2010 All rights part of this publication may be reproduced, stored in a retrieval system, or transmitted in anyform or by any means, electronic, mechanical, photocopying, recording or otherwise, without theprior consent of publication is printed on paper manufactured from fibre obtained from sustainably grownsoftwood forests and bleached without any damage to the refiningwater/wastewateruse and managementIPIECA Operations Best Practice SeriesThis document was prepared by AECOM, Inc.

2 On behalf of the IPIECA Refinery water management Task Force. The assistance of M. Venkatesh of ENSR AECOM is gratefully photographs reproduced courtesy of the following (clockwise from top left): ExxonMobil; Nexen; Photodisc Inc.;iStockphoto; Corbis; water overview3 Overall refinery water balance3 Sources of water3 water leaving the refinery4 Raw water treatment:5 Use of raw water in refineries5 Wastewater8 Process water8 Desalter effluent8 Sour water11 Tank bottom draws13 Spent caustic14 Cooling water16 Cooling tower blowdown best practices18 Condensate blowdown18 Boiler blowdown18 Steam generator blowdown18 Unrecovered condensate18 Condensate blowdown best practices20 Raw water treatment20 Raw water treatment best practices20 Miscellaneous discharges best practices20 Miscellaneous discharges minimization21 Laboratory wastewater21 Spent/unused hydrocarbons samples best practices21

3 Spent/unused wastewater samples best practices21 Discharges from laboratory sinks best practices21 Discharges from bottle washing systems best practices21 Stormwater and sewerage22 Stormwater segregation and management22 Contaminated stormwater22 Non-contaminated stormwater23 Sewerage management24 Effluent treatment25 Process wastewater pretreatment25 Desalter effluent treatment25 wastewater segregation27 Primary treatment28 First stage: separation (oil/ water separators, API separators)28 Secondary oil/ water separation29 Equalization system30 Location of the equalization system31 Secondary treatment31 Suspended growth processes31 Attached growth processes35 Tertiary treatment38 Sand filtration38 Activated carbon38 Chemical oxidation39 Treatment of sludges40 API separator bottom sludge40 DGF/IGF float and sludge40 Waste biological sludge41 Recycle and reuse issues42Re-use of non-contaminated stormwater43 Fire water43 Cooling tower makeup water43 Utility water43 Boiler feedwater makeup43 Technologies for upgrade

4 Of refinery wastewater43 Basic media/sand filtration44 Microfiltration or ultrafiltration45 Microfiltration or ultrafiltration, with reverse osmosis47 Microfiltration or ultrafiltration, with nanofiltration48 Ion exchange48 Technology summary refinery wastewater reuse50 Reuse of municipal wastewater50 Media filtration51 Microfiltration or ultrafiltration511 Petroleum refining water / wastewater USE AND MANAGEMENTM icrofiltration or ultrafiltration, plus reverse osmosis52 Microfiltration or ultrafiltration, plusnanofiltration53 Ion exchange53 Zero liquid discharge53 References55 List of TablesTable 1 Typical sources of water4 Table 2 Contaminants in raw water7 Table 3 Sources of wash water9 Table 4 Desalter effluent contaminants10 Table 5 Sour water producers12 Table 6 Stripped sour water contaminants12 Table 7 Crude tank bottom sediment andwater contaminants14 Table 8 Intermediate product stream caustic treated14 Table 9 Cooling tower blowdown contaminants18 Table 10 Contaminant specification for reuse water 42 Table 11

5 Refinery wastewater reuse summary50 List of FiguresFigure 1 Refinery water balance3 Figure 2 Typical desalter configuration8 Figure 3 Sour water stripper configuration11 Figure 4 Crude tank water draw13 Figure 5 Typical distillation system16 Figure 6 Once-through cooling water system17 Figure 7 Closed loop cooling system18 Figure 8 Evaporative cooling water system19 Figure 9 Boiler blowdown typical19 Figure 10 Steam generator blowdown typical19 Figure 11 Typical refinery wastewater treatment25 Figure 12 Desalter oil/ water separation26 Figure 13 Desalter effluent stripper26 Figure 14 Segregated wastewater treatment27 Figure 15 API separator28 Figure 16 Dissolved air flotation a typical DAF unit29 Figure 17 Induced air flotation (IAF) unit30 Figure 18 Activated sludge system32 Figure 19 The PACT (Powdered ActivatedCarbon Treatment)

6 System33 Figure 20 Sequencing batch reactor system34 Figure 21 Membrane bioreactor system34 Figure 22 Aerated lagoon system35 Figure 23 Trickling filters36 Figure 24 Rotating biological contractor system36 Figure 25 Nitrification/denitrification system37 Figure 26 Sand filtration38 Figure 27 Activated carbon system39 Figure 28 Chemical oxidation system39 Figure 29 API sludge treatment system40 Figure 30 DGF/IGF float treatment41 Figure 31 Biological sludge treatment41 Figure 32 Contaminant removal for different types of filtration processes44 Figure 33 Media filtration45 Figure 34 Microfiltration or ultrafiltration46 Figure 35 Microfiltration or ultrafiltration, with reverse osmosis47 Figure 36 Microfiltration or ultrafiltration, with nanofiltration48 Figure 37 Ion exchange treatment49 Figure 38 Media filtration51 Figure 39 Microfiltration/ultrafiltration52 Figure 40 Microfiltration/ultrafiltration, plus reverse osmosis52 Figure 41 Microfiltration/ultrafiltration.

7 Plusnanofiltration53 Figure 42 Zero liquid discharge53 IPIECA2 This manual describes typical best practices andstrategies used in Petroleum refineries to managewater, including ways to reduce water water management in a petroleumrefinery can potentially reduce the volume and costof raw water used in refinery , improved water management mayresult in reductions in wastewater flow orcontaminant load or both. Lower flow andcontaminant load may result in lower wastewatertreatment operating and maintenance water management may also reduce themass of contaminants in the treated effluent, thusimproving the quality of a wastewater dischargeand ultimately the environmental impact of arefinery s practices are a collection of operational,equipment and procedural actions related to watermanagement in a refinery.

8 Since each refinery isuniquely configured, some of these practices may ormay not be applicable based on the complexity ofthe refining operations, type of wastewatertreatment operations available at a particular site,availability of raw water sources, dischargeconfiguration and type of receiving water body. Thismanual will enable a refiner to compare theiroperations with typical industry practices anddevelop a plan for optimizing water management inthe manual is organized as follows: Introduction Refinery water overview wastewater Stormwater and sewerage Effluent treatment Recycle and reuse issuesIntroductionPetroleum refineries are complex systems of multipleoperations that depend on the type of crude refinedand the desired products.

9 For these reasons, no tworefineries are alike. Depending on the size, crude,products and complexity of operations, a petroleumrefinery can be a large consumer of water , relativeto other industries and users in a given a refinery, the water network is as unique tothe refinery as its processes. This section describesthe typical sources of water supplied to a refineryand the typical discharges of water from a also provides an overview of the types ofcontaminants contained in the raw water and themethods used to remove these refinery water balanceMany of the processes in a Petroleum refinery usewater, however, not each process needs raw ortreated water , and water can be cascaded or reusedin many places.

10 A large portion of the water usedin a Petroleum refinery can be continually recycledwith in a refinery. There are losses to theatmosphere, i


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