“Controlling Refinery emission &

Effluent Management ”

GM (HSE), Haldia Refinery Indian Oil Corporation Limited

Date: 18-04-2015

Presentation Structure /Outline:

► Information on Refining Sector

► Refinery Process Emissions

► GHG Emission/Information

► Health Effects

► Environmental Acts/

Regulations/Notifications

► Emission Control in Refinery

► Effluent Water Management

The Refining Sector :

India's oil refining capacity amounted to 215 MMTPA in Apr

2014 placing India in the fifth position in the world after the

United States, China, Russia and Japan.

Crude Oil imports constitute over 75% of India’s total domestic

oil consumption.

Today, India is the fifth largest energy consumer in the world.

Oil and gas contribute around 40% to primary energy

consumption.

The total primary energy consumption from crude oil , natural

gas , coal , nuclear energy , hydro electricity , wind

power, and solar power etc.

Indian Crude oil overview

Crude imports (volume) – increased by double since 2005-06

• Import dependency about 75%

Domestic oil production stagnant at ~38 MMT

4

Petroleum refining - physical,

thermal and chemical separation

of crude oil

Refinery produce different type of

products for vehicles, homes, and

different industries

These products can be broadly

grouped into three main areas:

1. Fuels (such as LPG, gasoline, diesel

, ATF, light and heavy fuel oil),

2. Non-fuel products (such as lubricating

oils and greases, asphalt)

3. Raw materials (Naphtha for

petrochemical , Sulphur for pharmaceutical &

Acid industry etc.) for the chemical

industry.

The Refinery Sector

The refinement of fossil fuels involves

a number of steps including: distillation &

separation; conversion or upgrading,

desulphurization etc.

Different petroleum refineries use

different refining techniques and

technologies.

Refineries have hundreds of

emission points

Second largest industrial source

of GHGs .

The Refinery Sector

Typical Block Flow Diagram-Refinery C

rud

e

HSD (E-III ,E-IV, Export)

FO (2 GRADES)

Bitumen(3GRADES)

CDU

Fuel Gas LPG

SRN

Kero Cut St.Run G.O

JBO

RCO

ATU&ARU

Sweet Fuel Gas

SRU Sulphur

LPG Naphtha

NHDT&CRU MS(E-III/IV, Export)

KHDS

MTO

RTF/ATF

Kerosene

DHDS

HGU-I

H2

JBO(P)/(C)

VDU

IFO

GO SO

LO / IO / HO

SR

PDA

DAO

FEU

NMP SDU HFU

FCCU

Extract

Slack Wax

LO

Asphalt

VBU

BTU

CBFS

MCW MCW

CDWU

MSQ

FCC Gasoline

H2

H2

H2

Reformate

HC

N

Off Gas

H2

100N/150N/500N/850N/

150BN GR-I LOBS

DC

O

Extr

act

70N/100N/150N/500N/

850N/150BN GR-II LOBS

H2

Bitumen Emulsion Bitumen Emulsion

VB Tar

Raffinate

Raffinate DWO

OHCU OHCU Bottoms

HGU-II

H2

FG Sulphur

LPG

LC

N

Kero

HSD

ATU&SRU

HC

N

► Common Air Pollutants

Sulfur dioxide SO2

Oxides of Nitrogen NO X

Carbon Monoxide CO

Particulate Matter (PM)

► Other Air Pollutants

Carcinogenic air pollutant, including benzene, naphthalene,

Non-carcinogenic AP, including Hydrogen Sulfide (H2S),Hydrogen Fluoride (HF) and Hydrogen Cyanide (HCN) etc.

► Volatile Organic Compounds (VOC)

Light Organic compounds having high vapor pressure

► GHG

Greenhouse Gases (GHG) –( CH4, CO2, N2O, Ozone (O3),CFC etc.)

Refineries Emit a Wide Variety of Pollutants

Global Greenhouse Gas Emissions

The most common F-gases are hydrofluorocarbons (HFCs),

which contain hydrogen, fluorine, and carbon

Typical GHG emission sources in

Refinery

Health Effects of Refinery Emissions

Compound Health Effect

Sulfur Dioxide (SO2) and

Oxides of Nitrogen (Nox)

Adverse respiratory effects,

airway inflammation ,

increased respiratory symptoms in people with

asthma

Carbon monoxide (CO) Harmful health effects associated with the reduction

of oxygen delivery to the body’s organs (heart and

brain ) and tissues

Particulate Matter Increased respiratory symptoms,

irritation of the airways,

coughing , or

difficult breathing ,

decreased lung function;

aggravated heartbeat;

nonfatal heart attacks;

Health Effects of Refinery Emissions

Compound Health Effects

Volatile Organic

Compounds (VOC)

Significantly reduce lung function

and induce respiratory inflammation ,

chest pain , coughing, nausea etc.

Green House

Gases(GHGs)

Increase in average temperatures of earth, increased

drought , harm to water resources , ecosystems and

wild life , health risk to sensitive populations

Compound Health Effect

Benzene Irritation of the eye , skin and respiratory track

Blood disorders (reduced number of red blood

cells and anemia) , cancer

Naphthalene Skin disorders ,

depression of the immune system , damage of

the cataracts, cancer

Environmental Acts/ Regulations

• The Water (Prevention and Control of Pollution) Act, 1974 and rules,

1975.

An act to provide for prevention and control of water pollution).

• The Water (Prevention and Control of Pollution) Cess Act, 1997 and

Rule, 1997.

An Act to provide for levy and collection of cess on water used by

industries.

• The Air (Prevention and Control of Pollution) Act, 1981, including

Rules 1982 &1983.

An act to provide for prevention and control of Pollution).

• The Environment Protection Act, 1986 including rules, 1986

An act providing for the protection and improvement of the environment.

• The Hazardous Wastes (Management & Handling) Rules, 1989

An act providing safeguards on handling and disposal of hazardous

wastes.

• The Environmental Appellate Authority Act, 1997

An act providing the details about constitution and functioning of a national

environmental appellate authority to hear and disburse all cases filed by

any person likely or to be affected by environmental clearance of any

project.

Environmental Acts/ Regulations

• Biomedical Waste (Management & Handling, 1998)

These rules framed under EP Act provide for proper methodology to be adopted in collection, receipt, storage, transport, treatment and disposal of bio-medical wastes generated from hospitals, nursing homes etc.

• The Environmental Impact Assessment Notification, 1994 with amendments under EP Act, 1986.

A notification providing requirements and procedures for taking environmental clearance for Expansion/Modernisation or grassroots projects costing more than Rs. 50 crores.

Supply of New Generation Auto Fuels

S.

No

Property BS I BS II BS III BS IV

A Petrol

1. Sulphur, (PPM) Max 500-1000 500 150 50

2. Benzene (% Vol) Max 1-3 1 1 1

3. RON (Octane no )

Min.

88 88 91 91

4. Lead (PPM) Max. 130 130 50 50

5. Aromatics (% Vol.)

Max

NA NA 42 35

6. Olefin (% Vol. ) Max NA NA 21 18

B Diesel

1. Cetane Number, Min 46 46 51 51

2. Sulphur, (PPM) Max

500-2500 500 350 50

Environment Management in Refinery

Water Pollution Monitoring and Control.

Air Pollution Monitoring and Control.

Noise Pollution Monitoring and Control

Green Belts and Eco Parks.

Carbon Management.

Renewable and Alternate Energy.

New Generation Auto Fuels.

Solid Waste Management.

E-Waste Management

Air Pollution Monitoring and Control

Pollutants Sources

Sulphur

Dioxide

• Boilers, Process Heaters, FCCU Re-generator, Sulphur

Recovery Unit, Flares

Oxides Of

Nitrogen

• Process Heaters, Boilers, Catalyst Re-generator, Flares

Particulate

Matter

• Catalyst Re-generator, Decoking Operations, Incinerators

Carbon

Monoxide

• Catalyst Re-generators, Incinerators

Hydrocarbons

• Loading Facilities, Turn Arounds, Storage Tanks,

Sampling, During maintenance

Hydrogen

Sulphide

• Sour Water from Condensers, Sour Gas, Sulphur

Recovery Unit

Main Air Pollutants from Oil and Gas Installations

Air Pollution Monitoring Monitoring of emission from Process stacks , attached to

process Heater/ furnaces in various units.

Ambient Air Quality Monitoring Stations having dedicated continuous analyzers for monitoring of following parameters in ambient air:

• Sulphur Dioxide (SO2)

• Nitrogen Dioxide (NO2)

• Hydrocarbon (HC)

• Carbon Monoxide (CO)

• Particulate Matter – size less than 10 µm (PM10)

• Particulate Matter – size less than 2.5 µm (PM2.5)

• Ozone (O3)

• Meteorological Instruments (Wind Speed, Wind Direction etc)

Air Pollution Monitoring

Manual monitoring of Ambient Air Quality by High Volume

Sampler.

On line continuous analyzers (SO2 & NOX) are installed in

flue gas stacks of major furnaces / Boilers.

Manual monitoring of stack emissions by Stack Monitoring

Kit / through SPCB accredited environment auditors

Leak Detection and Repair (LDAR) programme to monitor

and control fugitive emissions.

Air Pollution Control Measures

Stack Emissions control

Use of low sulphur fuel oil/ natural gas/ de-sulphurised gas

in boilers and heaters to minimize SO2 emission.

High Efficiency Heaters with low excess air consumption.

De-sulphurisation of Fuel Gas.

Production of elemental sulphur in SRU from H2S, generated

during de-sulphurisation of refinery Fuel

Sulphur dioxide emissions from Catalytic Crackers are

controlled by effective feed sulphur management.

Reduction in fuel consumption by adopting Energy

Conservation measures.

Air Pollution Control Measures

Stack Emissions control (contd.)

Use of Flue gas scrubbing at FCCU for

arresting emission of sulphur dioxide

and particulate matters.

Use of Tall stacks in Captive Power

Plant, Process units and flare system.

Use of Low NOx burners in heaters

and boilers.

Tall Stacks at Refinery

Provision of cyclone separators in

FCCU.

Air Pollution Control Measures

Fugitive Emissions control

Use of floating roof tanks for crude and light product

services & provision of primary and secondary seals.

Double mechanical seals in pumps.

Use of closed blow down system to arrest hydrocarbon

release.

Intermediate storage of effluent in closed tanks in Effluent

Treatment Plants (ETPs).

Covered Tilted Plate Interceptor (TPI) Oil Separators in ETPs.

Vapour Recovery System.

Flares

Combustion control device used to burn waste gases

from units in both normal and process upset conditions

Scrubbers

Removal of material from the gas phase to the liquid

phase

SO 2 removal from stack removal from stack

gases

removal of organics from vent gases

Steam Strippers

A distillation process whereby gases and other whereby

gases and other unwanted organics are removed from

water

H2S, NH3 removal from wastewater

removal of other organics from water

Controls of Air pollution from Refinery

Process Unit

Electrostatic Precipitators (ESP)

PM control device that uses an

induced

electrostatic charge to remove small

particles from gases (similar to static

electricity)

Refinery Process Unit Controls

Refinery Emission Standard

National Ambient Air Quality Standards (notified by Govt. of India on 18.11.09)

S.

No

Pollutant Time Weighted

Average

Industrial, Residential,

Rural and Other Area

1 SO2 , µg/m3 Annual 50

24 hours 80

2 NO2 , µg/m3 Annual 40

24 hours 80

3 Particulate Matter (size less

than 10µm) or PM10 µg/m3

Annual 60

24 hours 100

4 Particulate Matter (size less

than 2.5µm) or PM2.5 µg/m3

Annual 40

24 hours 60

5 Ozone (O3) , µg/m3 8 hours 100

1 hour 180

National Ambient Air Quality Standards

(notified by Govt. of India on 18.11.09)

S.

No

Pollutant Time Weighted

Average

Industrial, Residential,

Rural and Other Area

6 Lead (Pb), µg/m3

Annual 0.5

24 hours 1.0

7 CO , mg/m3 8 hours 02

1 hour 04

8 Ammonia (NH3) , µg/m3 Annual 100

24 hours 400

9 Benzene (C6H6) µg/m3 Annual 05

10 Benzo(a)Pyrene (BaP) -

Particulate phase only, ng/m3

Annual 01

11 Arsenic (As), ng/m3 Annual 06

12 Nickel (Ni), ng/m3 Annual 20

Water Management

Water – Primary Utility Item for Refining Process Units & Treating Units

Utility Facilities:

o Cooling water

◦ Cooling water for Coolers /Condensers

◦ Cooling water for pump glands

◦ Cooling Tower & Cooling Tower make up

o Steam & power Generation

◦ Steam Generation for Power Generation

◦ Steam for process heating (heat exchangers)

◦ Steam for stripping operations

o Service application (Fire water, Floor washing, chemical

solution preparation, construction)

Drinking, Sanitation etc.

Effluent Water Management

Sources of Waste / Effluent Water

Process Waste water Characteristics

Crude Desalting Wash water thru

Pretreatment to remove

salts

Free/emulsified oil, ammonia,

phenols, sulphides, SS, DS, trace

metals

Crude distillation Sour water thru stripping

steam of distillates

Foul (sulphides, mercaptans,

thiophenols), ammonia, chlorides

Oil & organics

Cracking Sour water thru stripping

steam of cracked

distillate

Coke Chamber

blowdown

Oil, sulphides, phenols, ammonia,

BOD, COD, Cyanide

Coke fines, oil contamination

Isomerisation/Re

forming

Alkaline water from

desulphurisation as

pretreatment of feed

Sulphides, mercaptans, ammonia,

oil

Sources of Waste / Effluent Water

Process Waste water Characteristics

Hydrotreating /

Hydrodesulphurisatio

n

Sour water Sulphur, nitrogen, metals

compounds

Asphalt production Stripped sour water Viscous oil, BOD, sulphur

compounds

Solvent Extraction Leaky solvent

contaminated water

Solvent, oil

Acid gas treatment Waste water from

ATU

Hydrogen sulphide

Sulphur Recovery Sour water from

SWS

Hydrogen sulphide

Storage tanks Tank drain water Oil, phenols, sulphides etc

Blending/dispatch Waste water with

Leaky equipment

Oil

Utilities DM regenerants, Blr

B/down, CT B/down

Acid, alkali, TDS, silica, oil, BOD,

COD, Treatment chemicals

Sources of Waste / Effluent Water

Process Waste water Characteristics

Contamination of

rain

Contaminated storm Oil, SS

Sanitation Sanitary water SS, BOD

Effluent Management in

Refineries Segregation ◦ Storm Water Management System (SWMS)

◦ Contaminated Rain Water (CRWS)

◦ Oily Water Sewer (OWS)

Storm Water Management System:

◦ All tank dyke areas, pavements, roads, building roofs etc are connected to SWMS

◦ Storm water is collected in a large guard basin.

◦ Storm water is pre-treated in Storm water management system.

◦ Pre-treated water is fed to ETP for further treatment and reuse.

Contaminated Rain Water (CRWS)

o Contaminated rain water is generate during rain and it is routed to OWS for 1st 15-20 min and then to SWMS.

Oily Water Sewer (OWS) : Underground drainage system for all the plants to the Centralized Effluent Treatment Plant.

35

Treated Effluent

Tank

Effluent

Oil to Slop

Holding

Tank (T-103/104)

Flocculator

Flash Mixer

PAC + H2O2 DOPE

Influent

Sump

TPI

Separator

Oily

Sludge

Equalization

Pond

DAF

Sa

tura

tio

n

Ve

ss

el

Bio-

Tower

Sump

H2SO4

NaoH

Nutrients

pH

Adjustment

Tank Bio Tower

Aeratio

n

Tank

Clarifier

Treated Effluent

to TTP

Sludge HRSCC

Alum

Dolomite

Soda Ash

Refinery Effluent (MINAS) Standard

37

Effluent Treatment Plant

1 2 3 4 5 6 7 8 9 10 11 12 13

Flow-

m3/hr 600 600 600 600 600 300 300 600 900 300 600 900 600

pH 6-10.5 6-10.5 6-8 6-8 6-8 7-8 7-8 7-8 7-8 7-8 7-8 7-8 7-8

Phenol 80 80 80 80 80 80 80 68 68 47.6 47.6 0.3 0.3

Sulfide 30 30 30 30 30 30 30 9 9 4.5 4.5 0.45 0.45

Free

O&G

760 76 61 60 60 60 60 10 3 - - - 2

Emul.

O&G

200 200 200 200 200 200 200 2 1 - - - -

BOD 500 425 425 425 425 425 425 400 400 200 200 10 10

COD 4500 3600 3600 3600 3600 3600 3600 2700 2700 1080 162 60

TSS 350 150 150 150 150 150 150 30 30 30 30 30 10

38

Tertiary Treatment Plant

DMF Sump

DMF

Basket

Strainer

Ultra

Filtration

H2SO4 +

NaOH + NaOCl

Antiscalant +

SMBS + H2SO4

Micro

Cartridge

Filter

Static Mixer

RO Feed

Tank

RO

Module-1

RO

Module-2

RO Permeate

Tank

Degasser

Tower

Reject

Cooling Tower

Micro

Cartridge

Filter Reject

MB Feed

Tank

Ai

r

DM Water RO

Module-3

Mixed Bed

B/W Line

39

Tertiary Treatment Plant

DMF UF

Ai

r

Reject

MCF

RO-II

RO-I

DGT

MCF RO-III

MB

1

Reject

2 3

4

5

6 7

8

Parameter Unit 1 2 3 4 5 6 7

Flow m3/hr 1379 1379 1252 1127 177 154 150

Total Hardness

(ion) ppm 170 132 132 1.58 2.04 0.02 0.02

Pressure kg/cm2 5.0 3 - 4 2 - 3 < 1.73 5.0 atm 2.5 - 3

pH - 6.0 - 8.5 6.0 - 8.5 6.0 - 8.5 5.35 - 5.92 7.2 – 8.7 5.3 – 5.5 6.5 – 6.9

TDS ppm 2470 2470 2470 85 277 7.76 0.50

Conductivity µS/cm 3800 3800 3800 100 426 12 0.20

Silica (SiO2) ppm < 18 32 >0.1µ 0.24 0.31 0.01 0.01

Chloride (Cl) ppm 530 530 530 23 30.02 1.38 -

Renewable and Alternative Energy

In order to reduce consumption of fossil fuels, which are more

polluting and whose reserves are finite, IOC is investing in

various renewable and non polluting energy sources as

under:

Wind Energy

Solar Energy

Bio-Fuels

Nuclear Energy

Ethanol blending in gasoline

Renewable and Alternative Energy

Indian Oil has forayed into alternative energy

options such as wind, solar, bio-fuels and

nuclear power.

21 MW wind energy farm in operation

since January 2009 at Kachchh, Gujarat.

Additionally, 48 MW capacity wind power

projects in Andhra Pradesh

- 42 MW capacity already commissioned .

Solar lanterns are being

sold through retail and LPG network .

First 5 MW Solar Photo Voltaic (PV)

Power Plant in operation at Village Rawra

in Jodhpur district of Rajasthan

Renewable and Alternate Energy

Our R&D Centre is taking a number of initiatives for promotion of

Bio- Diesel and other alternate energy sources in the country.

IndianOil’s two nuclear power units of 700 MW capacity each

are up-coming at Rawatbhata Atomic Power Project, Rajasthan

through a Joint Venture company with M/s Nuclear Power

corporation of India Limited (NPCIL). It is expected to start

commercial production from the year 2017.

Environment Management– Future Outlook

Higher efficiency furnaces

Better NOX burners

Reduction in Sulphur dioxide by:

Increasing the use of natural gas as fuel in furnaces

Increasing the efficiency of Amine Absorption Unit to

get more elemental sulphur at SRU.

Exploring the technology for de-sulphurisation of Fuel

oil

Environment Management– Future Outlook

Finding out the possibilities of further treating the

concentrates of DM / RO / UF Plant or releasing them to

a safer place / pit.

Promotion of clean technology to reduce generation of

hazardous wastes

Co-incineration of compatible Hazardous Waste in

Cement Kiln

To explore the possibilities of using solid waste for

making bricks, building material, road material etc.

Thank You