waste water treatment plant- bpcl
TRANSCRIPT
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BPCL KR , Ambalamugal
WASTE WATER TREATMENT PLANT
BYTEAM INNOVATORS
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INTRODUCTION
• Cochin Refineries Limited was incorporated in the joint sector as a Public Limited Company in September 1963.
• The Refinery was commissioned in 1966 with a crude processing capacity of 2.5 Million Metric Tons per Annum (MMTPA).
• The name of the Company:-– Kochi Refineries Limited (KRL) in May 2000. – Pursuant to Order dated 18th August 2006 issued by
Ministry of Company Affairs the refinery has been amalgamated with Bharat Petroleum Corporation to form BPCL Kochi Refinery.
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• Presently its having a crude oil refining capacity of 9.5 Million Metric Tonnes per Annum (MMTPA).
• The product portfolio of the 190,000 barrels per day refinery today includes petrochemical feedstocks and specialty products in addition to its range of quality fuels.
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• Environmental care and protection. • Anti-pollution measures• BPCL-KR is an ISO 14001 company
– KR’s Environment Management Systems conform to international standards.
– Kochi Refinery is the first organization in Kerala to receive the ISO 14001 certification.
• The design of the effluent water treatment system– The water discharged from the treatment unit is well within the
quality levels prescribed by the State Pollution Control Board and the national standards.
• Kochi Refinery is the first industrial unit in Kerala permitted by the State Pollution Control Board, to discharge treated water into inland rivers.
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PETROLEUM PRODUCTS
• • Liquefied Petroleum Gas (LPG) and Superior Kerosene Oil (SKO) for households and industrial uses
• • Motor Spirit (MS/ Petrol) and Hi-speed Diesel (HSD) for automobiles
• • Naphtha, the major raw material for fertilizer and petrochemical industries
• • Furnace Oil (FO), Light Diesel Oil (LDO) and Low Sulphur Heavy Stock (LSHS) as fuel for industries
• • Aviation Turbine Fuel (ATF) for aircrafts
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SPECIALTY PRODUCTS
• Benzene for manufacture of caprolactum, phenol, insecticides and other chemicals
• Special Boiling Point Spirit (SBPS) used as solvent in tyre industry
• Toluene for manufacture of solvents and insecticides, pharmaceuticals and paint
• Mineral Turpentine Oil (MTO) for use in textile and paint industry
• Sulphur for use in fertilizer, sugar, chemicals and tyre industry
• Poly Isobutene (PIB) for manufacture of lubricants and cable jelly
• Propylene as a feedstock for various petrochemicals
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EXCLUSIVE PRODUCTS • Natural Rubber Modified Bitumen or Rubberised Bitumen:
Natural Rubber Modified Bitumen (NRMB) is one of Kochi Refinery’s premium products that revolutionized road development. NRMB has been on a fast track since its introduction in 1999.
• Bitumen, which is derived from petroleum, is a critical component in road building. Polymer added to Bitumen enhances both quality and longevity of roads. Kochi Refinery in association with leading research institutes made an in-depth study on feasibility of using natural rubber available in abundance in Kerala, to develop the premium product, NRMB.
• NRMB has improved many roads throughout the region. Its success track is evident from the smooth Seaport-Airport road in Cochin.
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BITUMEN EMULSION • This eco-friendly product was launched by the refinery in June 2005.
Bitumen in different grades is used for road maintenance and construction. Bitumen requires heating for the temporary reduction of viscosity.
• Bitumen Emulsion, which is a ready to use product, there is no need for the preliminary heating. Reduced road maintenance cost, energy savers, economical, longer service life for roads and reduced atmospheric pollution during road laying/ maintenance are some of the advantages of Bitumen Emulsion.
• The following grades of Bitumen Emulsion are produced in Kochi Refinery meeting IS 8887:2004 specifications: – Bitumen Emulsion Rapid Setting-1 (BERS-1) – Bitumen Emulsion Rapid Setting-2 (BERS-2) – Bitumen Emulsion MediumSetting-1 (BEMS-1) – Bitumen Emulsion Slow Setting-1 (BESS-1) – Bitumen Emulsion Slow Setting-2 (BESS-2)
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BPCL-KR solution to dispose of
waste plastics
• Solution for the disposal of waste plastics without causing any disturbance to the eco-system.
• up to 3 % of waste plastics could be added to the bitumen and beyond this level, the waste plastics tend to separate
• on re-heating the waste plastic bitumen blends prior to laying- – solu:- ‘onsite’ mixing of waste plastics along with the
aggregates prior to laying of bitumen– It is possible to incorporate clean shredded waste plastic in the
bitumen while road paving. The Karnataka PWD has laid about 40 km of waste plastic modified bitumen in and around Bangalore
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HAZARDOUS EFFECT OF OIL SPILS ON ENVIRONMENT
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Oil Extraction
• 0.75-1.8 billion gallons of crude oil wasted annually• Occupational hazards • Chronic diseases cadmium , arsenic , cyanide• Offshore rigs contaminate sediments , fish and fish
consumers• Spills, explosions and fires have mu;ti[;e effects on
environment• Marine life• Drilling harms sensitive eco systems
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Oil transport
• Spills and leaks from transport of petroleum• Many leaks occur in developing nations• Marine mammals are affected by the oiling of
their fur and skin
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Oil Refining
• chemical, thermal, and noise pollution.• affects the health and safety of refinery
workers• health hazards for human communities• Regulations on labor, safety, emission
standards and environmental protection are often inadequate
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Gasoline
• Its additives cause acute and chronic toxicity• Victims are: employees, people living near
refinerys, gas station workers• Lead poisoning in developing nations
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Combustion: Air Pollution
• Gas flaring at the point of extraction• The additives and products of oil combustion,
VOCs, NOxs, SOxs, CO, CO2, PM-10s, PM-2.5s and Pb
• Chemical and particulate air pollution are related to heart and lung disease
• NOxs and VOCs combine to form ground level ozone
• formation of photochemical smog
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Combustion: Acid Rain
• Acids formed from oxides of nitrogen (NOxs) and sulfur (SOxs) acidify all forms of precipitation
• The anticipated recovery of acidified soils• Calcium and magnesium deficiencies in soils harm
plants and animals.• Acidification leaches lead, copper and aluminum
into drinking water.• NOxs from oil combustion) cause eutrophication of
lakes, estuaries and marine coasts lrsfd to biological red zones.
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Combustion: Climate Change
• altered the levels of atmospheric greenhouse gases
• Land surfaces and the deep ocean are warming
• Droughts are becoming more severe and persistent
• Melting of permafrost threatens the integrity of northern latitude pipelines
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BPCL - Initiative
• Carbon disclosure project• Corporate sustainability report• Adopted norms of GRI• Systems to arrest/ monitor emission• Bio-remediation of sludge• CDM opportunities
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Continuation………
• Benzene vapour recovery system• Rain water harvesting • Waste water recycling and reuse• Biogas plant from canteen waste• Solar heating, wind mill, solar cell power for
lighting• bio- disel and hydrogen fuel cell plant
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Energy Consumption
• The two major indices of energy consumption for a petroleum refinery are:- – Plant fuel and loss (% of crude oil processed)– specific energy consumption (MBTU/Bbl/NRGF).
The company have been able to reduce their energy consumption by adopting energy efficient practices and implementing innovative process schemes for improving the energy efficiency of process units.
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Energy Consumption
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Plant Fuel & Loss
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Energy Cost as % of Manufacturing Cost
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Specific Thermal Energy Consumption
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Specific Electrical Energy Consumption
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Key points to be noted
• As seen from the graphics above, last three years have witnessed tremendous improvement in their energy efficiency.
• Apart from creating records in crude processing and production of various fuels, a number of energy conservation activities were taken up resulting in annual fuel savings of more than 27,000 Metric Tonnes.
• Reduction in green house gas emissions close to 1,00,000 tonnes were also achieved as a result of these efforts.
• Such impressive improvement in energy efficiency was made possible by the synergistic
• efforts of our Energy Group, Process Engineering, Other technical groups and operations groups
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OBJECTIVE– Is to analyse the waste water treatment
mechanisms in BPCL KR– Analyse optimum utilisation of resources– To analyse whether BPCL KR has undertaken the
responsibility of managing the waste and does not bring harm to the environment
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• Oily water is harmful to plant and animal life and therefore it is very important that all traces of oily contaminants are removed before the effluent is routed to the paddy fields. The system also provides for proper treatment of sanitary sewage from the installation and the Housing Colony.
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TREATMENT SECTIONS
• The system consists of five sections:-1. The API Seperator2. The Equalization Pond3. Flocculation/Floatation Unit4. Biological Treatment Unit
There are also two sludge ponds, No.1 and No.2
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SURGE POND
API
SEPERATOR
API
SEPERATOR
FLASH MIXER
FLOCCULATOR/FLOTATION
PH ADJUSTMENT
TRICKLING
FILTER
RE-CIRCULATION SUMP
AERATOR
FINAL CLARIFIER
OIL SUMPHAY FILTER
FIRE POND
SLUDGE POND
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SOURCES OF OILY WATER
• Primary process area• Truck loading gantry• Wagon loading gantry• Pump houses
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WASTE WATER TREATMENT PLANT NO-1
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API SEPERATOR
• Two compartments-east bay and west bay• Uses specific gravity difference between oil and
water• Oil skimmer handle takes off oil at top layer to
sump• Flight scraper removes oil of the skimmer(inlet
to outlet valve)• Prevent water from entering sump(over
skimmer movement)
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• Oil pumped from sump to slop(crude tank)• Strainers prevent solid substance entry into
API and out from API• Water moves to equalisation pond
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EQUALISATION POND
• Two inlet valves lead to primary basin• Skims off over carried oil from previous stage• Two compartments(removes most of effluents)
lead to final compartment• Has inlet fro storm water from dyke and process
area(pen stock valve open)• When storm water has less oil -penstock closed-
so water moves directly to fire water pond
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• Primary basin having oil-carried to API –Skimmed and moved to sump
• Sludge dumped in asphalt quarry• Final compartment has 3 valves-top, middle,
bottom• Top valve->flocculation or floatation unit• Control level using valve in this outlet• If heavy rain ->open bottom valve to maintain
level• water directly to fire pond from bottom valve
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FLOCCULATION/FLOTATION UNIT
• 3 Sections- fast mix, flocculation and flotation chamber
• Sources of entry- equalization pond, (boiler blow down, cooling water blow down-add caustic lime for later stages)
• Fast mix chamber-mix using electric motor driven mixer->add lime to increase Ph->help flocs formation
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• Flocculation chamber->has slow mixer with wooden paddles->help flocs to grow in size(increase surface area) ->collect oil traces ->Skim flocs and oil floating matter using side pump
• Flotation chamber->through perforation between both chamber walls->skim top layer to sump using flight scrapers
• Sump->sludge pond->using bucket pump• Oil free water moves to biological treatment
unit
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BIOLOGICAL TREATMENT UNIT
• Two compartments- aeration basin, clarifier• Aeration basin-large concrete tanks wit 3
“Yeo” cone aerators• Sources-Flotation unit, sanitary sewage from
buildings and cafeteria and housing colony• Mixture is drawn through draft tube of cones
and thrown out by spinning action of blades• Catches oxygen using contact with air
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• Sludge mixture->consist of living and dead microorganism->promote bacteria growth->helps to purify sewage
• So water when contact with sludge assimilate absorb and multiply organic matter
• Oxygen is collected for the aerobic bacteria(using “Yeo” cone aerators)
• Indicated by brown flocculation sludge on mixer in the aeration pond
• Water overflows to the clarifier
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CLARIFIER
• Sludge settles with organic matter leaving behind pure water
• Method->mixture enters through circumference of tank->inlet hole in circular baffle->around and in to the overflow weir at the centre of tank
• Overflow weir velocity ->in order to settle solid and give way to pure water->fire water pond
• Settled sludge->bottom sump->using motor driven scraper->send to aeration basin
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• Sludge at periphery to sump->using scraper• Recycling and removal of large amount of
accumulated sludge to sludge pond->done by pump at clarifier side
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WASTE WATER TREATMENT PLANT NO-2
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FEATURES• Better designed due to nature of effluent• Done for secondary processing facilities• Same principle as plant no:1
IMPURITIES• Oil • Organic compounds (phenol, mercaptans)• Inorganic compounds (cyanides, sulphides)
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SYSTEM
• Sources: merox wash from merox unit effluent stream of SPF unit• Two large 3000KL Capacity surge ponds
->collect water for treatment• Surge pond 1: collect contaminated rain water
and floor washings->from 360 RCC pipe• RCC tank 2:collect spent caustic drained from
LPG and naphtha caustic wash in primary unit
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• RCC tank 2 content is added to effluent at a rate of 1KL/day
• After flow equalization the matter is taken to API seperator
• De –oiled storm water->hay filter chamber if no oil content ….Else to API seperator
• Gooseneck outlets->prevent water spill during heavy rain from surge pond to fie water pond
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API separator
• Two compartments divided using cylindrical concrete blocks: pre-separator channel and main separator channel
• Pipe with cup type valves->draw sludge from floor to sludge lagoons
• Both section has slotted skimmer• Main section has flight scrapper->free oil to
sump• Tank 1 can use either one of compartments
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• Oil free water->flash mixer->agitator for chemical treatment
• To precipitate sulphides and cyanides->ferrous sulphate and chlorine solution is added
• Ferrous sulphate 10%->to make chlorinated copper as solution
• liquid chlorine(.14 to .16)->to destroy sulphides and cyanides in flash mixer
• Correct Ph to 9 by adding basic alkali using Ph indicator, recorder and controlled system(if acid-10% sulphuric acid,base-caustic soda)
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• Chemical treated mixture ->clariflocculator->Ph adjustment tank
• Under sludge of clariflocculator ->chemical sludge
• Rake mechanism thickens sludge->sludge lagoon
• Oil of skimmer->scum trough arrangement->slop oil sump
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Ph adjustment tank
• Range to be 6.8-7.5• To nurture and sustain micro-organism used to
degrade organics• Adjust Ph using acid/alkali using automatic ph
controller and recorder(caustic soda used)• Ph adjustment tank->biological treatment unit
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BIOLOGICAL TREATMENT UNIT• 2 Stages• Trickling filter: mix stream of water
with recycling sump that contains bacteria
• Di ammonium sulphate and urea(80% siluted to 10%) is added
• Mixture->crushed granite(increased surface area to stabilize waste)
• Semi stabilized waste->for recirculation cum effluent transfer path-> as it has bacteria
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• Sanitary waste and treated effluent also enter sump for re-circulation
• Aeration tank(with 2 surface agitators) ->provide max O2 dissolution and keeps biomass developed in unit suspension
• Aeration tank and trickling filter avoided when water does not require treatment
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• Stabilised waste of aeration pond->final clarifier by gravity
• Flocs settle-> collect using rake arm->remove through gate valve
• Overflow of final clarifier ->hay filter
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HAY FILTER
• Consist of hay basket filled with hay effluent from final clarifier and rain water surge pond
• Remove last free oil • water->fire pond
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SLUDGE• Final clarifier sludge-> biosludge
sump->aeration pond/ sludge drying beds(based on concentration)(use pumps)
• SLUDGE DRYING BEDS: shallow gravel beds encase the pipes underneath
• Biosludge water-> percolates sand-> open drains-> recycled to bio treatment plant
• Slurry remaining on sand is dried for disposal
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NOTE
• Got in concentrated forms• Diluted to required strength on a day to day
basis based on requirement
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SPECIAL THANKS TO
Mr. BALAKRISHNAN(Employee of BPCL KR,S&OM Dept.)
Mr. P VELAYUDHAN(Retired BPCL KR Employee, S&OM Dept.)
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THANK YOU