BPCL KR , Ambalamugal

WASTE WATER TREATMENT PLANT

BYTEAM INNOVATORS

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.

• 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.

• 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.

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

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

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.

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)

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

HAZARDOUS EFFECT OF OIL SPILS ON ENVIRONMENT

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

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

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

Gasoline

• Its additives cause acute and chronic toxicity• Victims are: employees, people living near

refinerys, gas station workers• Lead poisoning in developing nations

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

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.

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

BPCL - Initiative

• Carbon disclosure project• Corporate sustainability report• Adopted norms of GRI• Systems to arrest/ monitor emission• Bio-remediation of sludge• CDM opportunities

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

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.

Energy Consumption

Plant Fuel & Loss

Energy Cost as % of Manufacturing Cost

Specific Thermal Energy Consumption

Specific Electrical Energy Consumption

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

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

• 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.

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

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

SOURCES OF OILY WATER

• Primary process area• Truck loading gantry• Wagon loading gantry• Pump houses

WASTE WATER TREATMENT PLANT NO-1

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)

• Oil pumped from sump to slop(crude tank)• Strainers prevent solid substance entry into

API and out from API• Water moves to equalisation pond

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

• 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

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

• 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

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

• 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

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

• 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

WASTE WATER TREATMENT PLANT NO-2

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)

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

• 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

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

• 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)

• 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

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

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

• 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

• 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

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

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

NOTE

• Got in concentrated forms• Diluted to required strength on a day to day

basis based on requirement

SPECIAL THANKS TO

Mr. BALAKRISHNAN(Employee of BPCL KR,S&OM Dept.)

Mr. P VELAYUDHAN(Retired BPCL KR Employee, S&OM Dept.)

THANK YOU