Chennai Petroleum Corporation Limited(A Group company of IndianOil)

WATER

MANAGEMENTMANAGEMENT

AT CPCL

Slide 1

February 18-20, 2015

FrameworkCPCL O er ie CPCL- Overview

Water Management : Water Management :

-- Overview

--- History

--- Facilities

-- Present status / Areas of improvement

W f d Slide 2

-- Way forward

CPCL (erstwhile MRL) wasInception

CPCL (erstwhile MRL) wasestablished in 1965 as a JV - PSU with• GOI - 74 %• NIOC, Iran - 13 %• AMOCO, USA - 13 %

AMOCO disinvested in 1985.

GOI disinvested to IOC in March 2001

CPCL is a group company of IOCLwith shareholding as follows:

IOC ……………. 51.89 %NIOC ………….. 15.40 %FII ……………… 14.73 %

Slide 3

Public ………… 4.46 %Others ………… 13.52 %

CPCL Refinery Locations

ManaliManali10.5 MMTPA

Nagapattinam1.0 MMTPA

Slide 444

Process Units – Manali (Fuel & Lube Refinery)

PRIMARY UNITS (MMTPA)

• CDU I 2.8• CDU-II 3.7• CDU-III 4.0

OTHERS (TMTPA)

Wa 30SECONDARY UNITS

(MMTPA) • Wax 30• Propylene 30

H 25

(MMTPA)• FCCU 0.78• OHCU 1.80

• Hexane 25• Lube 235

• VBU 1.15• CCR 0.30• DHDS 1 80

Slide 5

• DHDS 1.80• DHDT 1.80

Manali Refinery as Mother Industry Kothari

POLY BUTYLENEKothari

Petrochemicals(PBFS)

POLYOLPROPYLENE GLYCOL

Manali Petrochemicals

(Propylene)

LINEAR ALKYL BENZENECPCL

(Propylene)

Tamil Nadu Petro-Products

FERTILISERS

(LABFS)

Madras Fertilizers( )

MEK

(Naphtha)

CetexP t h i l

Slide 6

Petrochemicals (MEKFS)

REFINERY PROCESS  FLOW DIAGRAM

Water Management-Overview contd.

• Any petroleum refinery requires water under the following headsy p y q g1. Drinking /canteen /sanitary2. Cooling water for cooling /condensingg g g3. Boiler feed water for steam/power generation.4. Service water / fire fighting water/Green belt/gardening

• The quality of each type/category is different• Each category has its own supply & distribution system• Item 1 is met by fresh water presently• Items 2-4 are met by treated wastewater

---Refinery waste water,

Slide 8

--- Sewage and--- Seawater

Water Management-Overview contd.

SOURCES:1. Fresh water : unreliable ,cost prohibitive

2. City sewage : reliable source, but difficult to reuse, processing cost

3. Sea water : reliable source, processing cost, transportation

4. Refinery waste water : Mandatory to reprocess , & reuseThree types: Process waste water (Oil contaminated)Three types: Process waste water (Oil contaminated)

Refinery toilet /canteen waste waterSpill off/ collections in storm water system

Slide 9

Spill off/ collections in storm water system

Water Management –overview contd.

Desalination PlantSewage Reclamation Plants

SRP-1 : 1990 SRP-2 : 2007 2009SRP 1 : 1990 SRP 2 : 2007 20095.8 MGD2.5  MGD              2.5 MGD

Refinery‐ I  Refinery II  Refinery III 1969 1984 2004 Wastewater Reclamation

Total Capability 13 5 MGD2.8   6.5    10.5  MMTPAWater requirement : 10.00 MGD

Total Capability  :  13.5 MGD

Effluent Treatment Plants I, II & III

Zero Discharge Plants4.00 MGD

Slide 10

Zero Discharge Plants ZDP-1 :2002 ZDP-2 :20050.7 MGD            0.8 MGD

Water supply system –overview contd,

Fresh water Reservoir Refinery unitsCooling TowersCooling TowersWork stationsCanteen DM l

ETP feed tanks

Desal plantDM water plantsFire water pondsFire water network

ETPsesa p a

Sewage Reservoir Green Belt

ZDPsSRPsReservoir

Storm water canals & Storm water ponds

Slide 11Out fall Buckingham canal

Water Management -History

• Water consumption at CPCL was 3.5 MGD during 1969 and currently it isin the order of 7 0 MGDin the order of 7.0 MGD.

• Restricted water supply at Chennai• Restricted water supply at Chennai• Rapid industrialization and urbanization• Depletion of water resources• Depletion of water resources• Restricted municipal reservoir capacities

• These necessitated CPCL to go on water conservation and identifyalternate water resources for sustenance of refining operations.

Slide 12

Water Management -HistoryMid 80’ (1984 / 1987) Thi it ti h k d CPCL t fMid 80’s (1984 / 1987)(Acute water shortage was experienced in

This situation has provoked CPCL to go foralternate sources. CPCL’s first SewageReclamation Plant was envisaged in the yearwas experienced in

Chennai City. Industries in Manali were shutdown)

g y1987 and was commissioned in the year 1991.

were shutdown) April-1996 to Sept-1997 Substantial quantity of 53.7 MG of Treated

effluent was used in Cooling Towers.gAug-2001 to Nov-2001 47.5 MG of Chengleput lake water was brought

from a distance of 55 kms by 200-500 tankers /d/day.68.0 MG of Treated sewage / Treated effluent was used in cooling towers.was used in cooling towers.

2003-2004 Arranged Tankers from Poonamalle borewells.Slide14

Water Management -History

Year Cost of Fresh Water (Rs / m3) Cost of Sewage (Rs / m3)

1991-92 8.40 0.90

1994-95 25.00 3.00

1998-99 40.00 5.40

2010 60.00 10.20

2014 60.00 11.852014 60.00 11.85

Slide 15

Water Management Initiatives

Facility Year Rs.Cr.

Effluent Treatment Plant-I 1969 1.0

Effluent Treatment Plant-II 1983 5.0

Sewage Reclamation Plant -I 1991 24.5

Ref-I ETP Modernisation 1992 13.5

Ref-II ETP Modernisation 1993 6.7

Zero Discharge Plant -I 2001 4.6

Effluent Treatment Plant-III 2004 23.0Z Di h Pl t II 2005 10 5Zero Discharge Plant-II 2005 10.5RO Reject Recovery Plant 2006 2.0Sewage Reclamation Plant-II 2006 55.0

Slide 15

g5.8 MGD Sea Water Desalination Plant 2009 234.0

FRESH WATER / RAW WATER CONSUMPTION DETAILS

5.006.00

on M

GD

2.003.004.00

onsu

mpt

io

0.001.00

w w

ater

co

Raw

Year

Effluent Treatment Plants (ETPs)F dFeed:• Waste water from Refinery process units

Features of ETPs:• Gravity separation for removal of free oil & oily particulate matter.

F i Chl id f l i & i i i f lfid• Ferric Chloride for coagulation & precipitation of sulfides• Dissolved air floatation to remove emulsified oil, clarification• Biological process (Trickling filter Activated sludge with surface AerationBiological process, (Trickling filter Activated sludge, with surface Aeration,

Diffuser type )• Sand filter and activated carbon filter

Slide 17

ETP- flow sheet

API Oil Flash mixer- Dissolved Air Flotation unit

Ferric & PECaustic

Separator Flotation unit

ClarifierTrickling filterAeration tank

Clarifier PSF & ACF Treated water pond

Slide 18

Sewage Reclamation PlantsF dFeed:• Primary & secondary treated city sewage from CMWSSB.• Primary treatment : Floating mass removal.y g• Secondary treatment : Organic substance removal through

biological process.

Features of SRPs:• Biological process, (Activated sludge, Sequencing Batchg p , ( g , q g

Reactors)with surface Aeration, Diffuser type

• Coagulation flocculation clarification filtration disinfection• Coagulation, flocculation, clarification,filtration,disinfection,

• Ultrafiltration & two-stage RO process

Slide 19

g p

FeCl3 & Secondary

Sewage Reclamation Plant - II (SRP-II)

ClarifierSequencing Pressure Flash Mixer

Anionic Poly dosing

treated sewage

ClarifierSequencing Batch

Reactorsand filter

Flash Mixer Flocculator

475 KL/hr

Ultra-Filtration Break point

chlorinationReverse Osmosis I stage

DegasserI stage .

Chemical dosing Rejects

Reverse RO permeate44 KL/hr

SBS, HCl, Antiscallant

Osmosis II stage

RO permeate tank

396 KL/h 44 KL/h

Rejects

DM Plant feed

396 KL/hrWash Water

44 KL/hr

UF & RO process Ult filt ti M bUltra filtration Membranes

– To remove suspended / colloidal particles and microorganisms to avoid particulate & biological fouling

– Up to 0.01micron size particles will be filtered.– Material: (Poly Ether Sulfone) Membrane– Type : Hollow FiberType : Hollow Fiber

RO Membranes :- To remove dissolved solids to reduce the load on

DM water unit-- 80 % Recovery & 97 5 % salt rejection80 % Recovery & 97.5 % salt rejection– Material : Polyamide Membrane– Type : Spiral wound.

Slide 21

Zero Discharge Plants (ZDPs)

Feed : Treated Refinery waste water

Objectivesj– To maximize reuse of treated Refinery wastewater– To make it suitable for DM water Plant feed

Processing steps in ZDP:Coagulation

Suspended Particle Removal by Pressure Sand Filterp yUltra-FiltrationRO

Slide 22

RO

ZERO DISCHARGE SCHEME

From ETPCoagulant

Equilization

Upflow Filters )

Equilization pond

Coagulation

RO SYSTEM Permeate

UF SKID

Backwash pump

Backwash sump

Water Management Projects

Zero Discharge Plant-2g• Capacity: 1.05 MGD• Project cost : Rs. 10.6 Cr• Commissioning : 2005

Additional Sewage Treatment Project• Capacity: 2 5 MGD• Capacity: 2.5 MGD• Project cost : Rs. 46.68 Cr• Commissioned : Dec ’06

Slide 24

Sewage Reclamation Plant-1 RO skidsSewage Reclamation Plant-1 RO skids

Slide 25

Zero Discharge Plant-2

Slide 26

Desal Plant - Inlet & Outlet Quality

PARAMETERS UNIT SEAWATER

PRODUCTWATERWATER WATER

Fl M3 / H 3284 1100Flow M3 / Hr 3284 1100

pH 8.2 5.0-7.0

TDS ppm 38762 < 350

Turbidity NTU 25-50 < 1

Sodium ppm 12082 < 150

Chlorides ppm 21199 < 220

Slide 27

Chlorides ppm 21199 < 220

Desal RO Plant - Flow Chart

A) PRETREATMENT

Flash mixer

Flocculation tank

Lamella Clarifier

Gravity Sand Filtermixer tank Clarifier Sand Filter

Filter Water Cartridge Filter Cartridge Filter Storage TanksFeed Pumpswith chemical

dosing system

B) RO PLANTB) RO PLANT

High Pressure Feed Pumps

Polyamide Membrane

Energy Recovery Device (Turbo)

C) CHLORINATION SYSTEM

pAssembly Units

( )

Slide 28

Chlorination system for Pretreatment, Post treatment and Seawater intake system.

Sea Water Desalination Plant

To overcome dependency on highcost Metro Water, CPCL hascommissioned a Sea Watercommissioned a Sea WaterDesalination Plant of 5.8 MGDcapacity at Ennore.The plant is based on ReverseThe plant is based on ReverseOsmosis technology.Spiral wound Polyaminemembranes sedmembranes used.Water recovery is 35%Expandable to 10 MGD forpcatering to water requirement offuture projects.Cost of water produced from

Slide 29

pDesalination Plant is Rs.60 / m3.

Aerial View of 2.5 MGD SRP-II

Slide 30

Cost of water produced from Sewage Reclamation Plants – Rs.40 / KL

Desalination PlantIntake well & Pump House

Investment : ` 243.9 Cr. Capacity : 5.8 MGDp y

Desalination Plant dedicated to Nation on 4.7.2009

Intake well & Pump House for Sea Intake well & Pump House for Sea water

Slide 3131 of 48 31

Sea Water Intake SystemSea Water Intake System

• To overcome dependency on high costt t CPCL h i i dmetro water, CPCL has commissioned

Sea Water Desalination Plant of 5.8MGD capacity.

• The plant is based on ReverseOsmosis technology

• Expandable to 10 MGD for catering towater requirement of future projects.

Slide 32

Details of water consumption Figs in MGD

Details 10-11 11-12 12-13 13-14 14-15Fresh water consumption 1.78 0.93 2.56 0.89 0.70Fresh water consumption 1.78 0.93 2.56 0.89 0.70

Desalinated water 0.93 3.37 1.86 2.43 2.30RO permeate- sewage 3.29 2.23 2.05 1.82 2.20Bio treated filtered -Se age

1.05 0.90 1.06 1.10 1.10:

SewageRO Permeate, Refinery waste water

0.65 0.34 0.50 1.07 0.40

Bio treated Filtered Refinery waste water

2.23 2.38 2.24 2.11 2.20

Total water consumption 9.92 10.14 10.26 9.42 8.90Total water consumption 9.92 10.14 10.26 9.42 8.90

Cost of Production Figs in Rs/KL

S.No Details Cost Remarks 1 Fresh water 60 Purchase from

CMWSSB2 Secondary treated sewage 11.853 Desalinated water 76 Average of

past two years 12 13 & 13 144 RO permeate- sewage, Refinery waste water 52

:

12-13 & 13-145 Bio treated filtered -Sewage 26

6 Bio treated Filtered Refinery waste water 15

Power, chemicals, R&M, Employee cost insurance

Refinery waste water treatment & reusePhysical/chemical/biological treatment with /tertiary treatment Treated water from ETPs used for

(i) Full requirement of Fire water system makeup (ii) Full requirement of Service water & Green Belt

Wastewater treatment & reuse

(ii) Full requirement of Service water & Green Belt (iii) Balance /excess quantity as Boiler feed water after processing thro

a. Ultra filtration (UF) to remove submicron particlesb Reverse Osmosis(RO) to remove TDSWastewater treatment & reuseb. Reverse Osmosis(RO) to remove TDSc. Permeate processed thro DM water plant

Fire water network Green beltService water

ETPs Guard Pond

CT Make up

Slide 35

UF/RO/BFW

Refinery waste water treatment & reuseProbable solutionProbable solution

Fire water network Green beltService water

ETPs Guard Pond

Service water

CT Make up Pond CT Make up

UF/RO DMP/BFWMaximize

Maximize RO permeateand blend in FW/ CW systemTo avoid corrosion of pipelines

Slide 36

To avoid corrosion of pipelines

Reclamation of Secondary Treated Sewage Physical/chemical/biological treatment with /tertiary treatment

CT make up

SRPs

UF/RO/DMP/BFW

SRP : Sewage Reclamation PlantCT : Cooling tower:

Slide 37

DMP: De-Mineralisation PlantBFW: Boiler Feed Water

Desalination of Sea-Water Physical/chemical treatment/RO process D li d W d fDesalinated Water used for(i) 60% requirement of Cooling water make up (ii) As Boiler feed water after processing thro DM water plants if required( ) p g p q

CT make up

Desal

CT make upOil Contaminated sea waterFouling & failure RO membranes

DMP/BFW Excess effluent generation due to High

CT : Cooling tower:DMP: De-Mineralisation Plant

g gTDS Desalinated water

Slide 38

BFW: Boiler Feed Water

Performance of Reclamation facilities• Dependence on CMWSSB is not totally eliminated • Dependence on CMWSSB is not totally eliminated • Cost of Reclaimed water almost nearing that of CMWSSB

supply, in case of desal plant, it is higherpp y, p , gAreas that need to be focussed1 Enhance UF/RO membrane useful life1. Enhance UF/RO membrane useful life2. Maximize permeate recovery 3 Reduce lead time for Membrane procurement3. Reduce lead time for Membrane procurementEnabling actions Improve Pre-treatment effectiveness to reduce load on UF & Improve Pre treatment effectiveness to reduce load on UF & RO membranesPre-treatment for RO feed at 2nd /3rd stage

Slide 39

Pre treatment for RO feed at 2 /3 stage Always have stock of UF & RO membranes

Limitations UF membraneUF b tli d t RO bUF membrane costlier compared to RO membraneUF membrane is not an ultimate barrierF d t UF h ld t b i i tFeed to UF should meet some basic requirementUF membrane quality, characteristics very importantM b li ith t f i t d tMembrane suppliers either not aware of or intend to keep users in dark about the limitations of UF 

bmembraneStringent guarantee /warranty conditions by OEMsI I di tl d l ith t d ithIn India mostly we deal with  traders with poor understanding of Ultrafiltration technology

Slide 4040 of 62

Limitations of UF membraneb d d d• UF membranes are not standardized

• Once a system is finalized, suitable to specific type the same has to continue throughout the life timehas to continue throughout the life time.

• If the UF membrane fails to perform, switch over to othermembrane calls for total system change y g

No standard procedure/test method for  t facceptance of 

(i) UF/RO membranes,(ii) Micron ‐Cartridge filters (iii)Anti‐scalants/ coagulant aids

Slide 41

Effectiveness of Pre-treatment Activated Sludge Process problemsActivated Sludge Process -problems• Carry over of MLSS from Clarifier of ASP is one of problems

P ttli f MLSS i l ifi t b d• Proper settling of MLSS in clarifier to be ensured

P i i f i t ASP t i fl • Provision of anoxic zone at ASP aerator improves floc. characteristics which settles better at clarifierO d fi i t l ifi b tt l di d it ifi ti i • Oxygen deficiency at clarifier bottom leading de-nitrification is another reason for MLSS carryover.

Slide 42

EFFECTIVENESS OF PRE -TREATMENTBio treatment introd ces man organic imp rities hich are• Bio treatment introduces many organic impurities which are sub‐micron particles, due to carry over of MLSS.

• Organic impurities causing fouling of membranesOrganic impurities causing fouling of membranesEfOM, EPS, Humic acid, proteins polysaccharides etc., Presently not monitored,   UF membrane suppliers also               not demanding such characteristics 

For Removal the above organic impurities the following are theFor Removal the above organic impurities  the following are the treatment facilities:• Coagulation /flocculation/sedimentation• Adsorption• Wet air oxidation

E h i i & d i

Slide 43

Every process has its own merits & demerits

Effectiveness of Pre-treatment R l f i i iti Removal of organic impurities Presently coagulation /filtration being usedOptimum dosage by Jar test which is time consumingOptimum dosage by Jar test, which is time consumingFor varying incoming quality it is difficultImprovement in NTU is being monitored in jar testp g jImprovement in NTU does not reflect improvement in organic impurities Organic impurities measurement is the basic requirement in jar test .

No reputed laboratory in city is capable of doing such testIITM & CLRI Chennai have requisite facility and awareness & their

Slide 4444 of 62

IITM & CLRI Chennai have requisite facility and awareness & their services are being utilized

Environment Management : Way forward

Wastewater recycleWastewater recycleMaximizing recycle is possible only by TDS reduction/RO processingprocessingStrengthen pre-treatment so that operation can be sustained with out UF membranewith out UF membraneCost benefit analysis for justifying UF membrane installation.Development of cost effective wet air oxidation process preferably at ambient conditions

Slide 45

p y

PROCESS FLOW CHART

Coagulant & aids dosedDosing of Chlorine

(0 5 TO 1 0 )

Sea Water 5.8 MGD DESALINATION PLANT

Stilling Chamber

(0.5 ppm TO 1.0 ppm)

Flash Mixer Flocculator

Pump House to DesalPlant – 16 Kms.Travel time – 1 Hr.

Sea Water Pump House

Lamella Type clarifier

14 Nos. Gravity Sand Filters

Filter Water Storage Tank

Cartridge Filters

Dosing of Anti -Scalant

Degasser Tank

Filters(4 Nos.)

Sludge bed

110 KV Yard

Dosing of NaOH & Chlorination for pH correction

Feed To Refinery - 17 Kms.Tank

Permeate Tank

RO Banks(2324 Membranes(4x275 m3/hr.)

RO High Pressure Pumps

Slide 4646