BP-Lingen - Erdöl-Raffinerie Emsland Environmental Statement 2010

Erdöl-Raffinerie Emsland (BP-Lingen)
BP-Lingen - Erdöl-Raffinerie Emsland

ENVIRONMENTAL STATEMENT 2010
Introduction ............................................................................................................................................ 2
Environmental policy and management.............................................................................................. 2
Main principles..................................................................................................................................... 2
Health, safety, security, environment and quality (HSSEQ) tracking .................................................. 2
Environmental management................................................................................................................ 3
The refinery ............................................................................................................................................ 4
Areas of activity ................................................................................................................................... 5
Refinery power plant............................................................................................................................ 6
The refinery’s environmental impact ................................................................................................... 6
Scope of the investigation ................................................................................................................... 6
Environmental impact factors .............................................................................................................. 6
Weighting............................................................................................................................................. 7
Frequency............................................................................................................................................ 7
Compliance with legal regulations ....................................................................................................... 7
Communication...................................................................................................................................... 8
Key environmental factors ................................................................................................................... 8
Environmental quality ........................................................................................................................... 9
Emission protection ............................................................................................................................. 9
Sulphur dioxide emissions................................................................................................................... 9
Carbon dioxide (CO2).......................................................................................................................... 9
Nitrogen dioxide emissions.................................................................................................................. 9
Volatile hydrocarbons ........................................................................................................................ 10
Smoke, noise and unpleasant odours ............................................................................................... 10
Wastewater treatment ....................................................................................................................... 10
Waste................................................................................................................................................. 11
Soil..................................................................................................................................................... 11
Natural resources .............................................................................................................................. 11
Corporate citizenship......................................................................................................................... 11
Objectives for the coming year .......................................................................................................... 12
Additional information......................................................................................................................... 14
Appendix............................................................................................................................................... 14
Umweltbericht EnvironmentReport 2010.doc page 1 of 14 Issued: March 03rd, 2010

Introduction
This document is the 2010 environmental report of Erdöl-Raffinerie Emsland (BP-Lingen), a Deutsche
BP AG production facility. The report is based on data from our 2009 environmental balance sheet.
Reporting on our activities and their environmental impact is an integral component of our company
philosophy. All of our activities are carried out with a strong awareness of our responsibility as a
corporation to avoid harming human beings and the environment.
We have been particularly successful in keeping the channels of communication open with
governmental organizations, the local communities and people who live near our production facilities.
Our activities reflect our commitment to good corporate citizenship and promoting the common good in
the Emsland region in the area of social life, culture and sports.
Environmental policy and management

Main principles
Our health, safety and environmental policy is based on BP’s HSE policy. Our goals in this realm are
clear and unmistakable:
No accidents, no harm to human beings, no environmental damage.

All BP employees are responsible for the successful implementation of these goals.
Health, safety, security, environment and quality (HSSEQ) tracking
All of our activities are conducted on the basis of specific policies and principles pertaining to health
protection, workplace safety, facility security, environmental protection and quality control of our
products and services with a view to improving them continuously. This entails the following:
Fig. 1: OMS Performance Improvement Cycle

Avoid all accidents and injuries;

Avoid all harm to human beings;
Avoid all environmental damage to the air, soil and waterways;
Maintain a high level of customer satisfaction with our products and services;
Provide our employees with continuous workplace safety training;
Handle and process hazardous materials in a responsible manner that safeguards the health of all
concerned;
Repair any operational malfunctions immediately. Announce a turn around in advance and avoid
placing unnecessary strain on neighbours;
Devise and expand the emergency response plan and exercise it on a regular basis;
Implement changes in machinery and equipment in accordance with all applicable legal
regulations emphasizing the improvement of environmental quality and reducing energy
consumption.
We are committed to evolving and improving all of our spheres of activity and to identifying, analyzing
and avoiding risk.
Organizational measures implemented by senior and middle level management at the refinery ensure
that our employees know and comply with our environmental policies and objectives.
Environmental management
Monitoring and tracking HSSEQ related matters for the environment is a top organizational priority.
This is clearly visible by the fact that our facility has been granted ISO 14001 and ISO 9001
certification.

The refinery
Our production facility is located in southwest Lower Saxony and has extensive storage and shipping
facilities for the transport of oil to and from the refinery via rail, water, road and pipeline. The refinery,
which was constructed close to the Emsland oilfields, was commissioned in 1953. With the NWO
pipeline which went into operation in 1958, the refinery was gradually extended with additional
processing capacity for imported crude oils.
Formerly owned by Wintershall AG (BASF), Erdöl-Raffinerie Emsland was acquired by Veba Oel AG
in late 1999 and in 2000 it was integrated into the production processes of Veba Oil Refining &
Petrochemicals. With BP plc London’s purchase in 2002 of Veba Oel and Aral, Erdöl-Raffinerie
Emsland became a wholly owned subsidiary of Deutsche BP Aktiengesellschaft.
Fig. 2: Production facilities in Germany
The refinery, which belongs to a group of fuel refineries with substantial processing depth, makes
petroleum products from crude oil and other feed stocks. Additionally the modern refinery has been
configurated to be well suited for the production of petrochemical intermediate products.
Thanks to the refinery’s thermal and catalytic cracking units (cokers and hydrocrackers), it is
considered one of Europe’s leading conversion refineries. The refinery’s nominal crude oil processing
capacity is approximately four million tons annually, of which approximately one-fourth is German
crude, mainly from the oilfields in the surrounding Emsland region. After being shipped to
Wilhelmshaven, the imported crude oils are transported to the production facility through the NWO-
pipeline, which is operated by Nord West Oelleitung GmbH.
Crude oil feed
5
1000 kt p.a.
4
3
2
1
0
1995 2000 2005 2008 2009
Year

Fig. 3: Crude oil feed to refinery
Products of Erdöl-Raffinerie Emsland (BP-Lingen):
LPG (propane, butane)

Gasoline
Jet fuels
Diesel fuel
Light heating oil
Heavy heating oil (as needed)
Petroleum coke and calcinated petroleum coke
Sulphur
Cyclohexane
Normal paraffins
Electrical power
In keeping with our efforts to protect the environment, all of our gasoline and diesel fuels are free of
sulphur (max. 10 ppm sulphur).
Areas of activity
The crude oils processed by BP-Lingen contain more than 98% hydrocarbons (so called “sweet
crudes”). A Crude oil is composed of hydrocarbons and varying amounts of other compounds such as
oxygen, nitrogen and sulphur, as well as traces of organometallic compounds. Sediments and water
from the field and transportation form deposits, these are removed in the refinery.
Fig. 4: Processing
In refinery processing, crude oil is separated into fractions consisting of gases, naphthas and middle
distillates through a process known as fractional distillation. Residues and heavy distillates are
converted into distillate products through catalytic cracking (hydrocracker) and thermal cracking
(coker). The distillates are desulphurised separately and the resulting hydrogen sulfide is converted
into odourless primary sulphur. The naphthas are reformed and isomerized so as to increase their
octane numbers to meet the Mogas specifications.
The most important petrochemical intermediate products are normal paraffin, which is extracted from
kerosene distillates, and cyclohexane, which is a product of benzene hydrogenation.
The petroleum coke from the coker unit is converted by a thermal process (calciner unit) into nearly
pure carbon for industrial applications (see simplified flowchart in the appendix).

Refinery power plant

The refinery uses electricity from its own power plant whose emissions are continuously monitored.
This facility, which supplies the refinery with all of its electrical power and steam, is fitted with modern
natural gas turbines, a heavy oil-fired boiler plant as well as a fuel-gas powered boiler plant that can
be put online as needed. The gas turbines, which generate heat and electricity concurrently, have an
effectiveness gradient of more than 80 percent. They also supply power for the public grid.
The refinery’s total sulphur emissions have been reduced even further by switching the power plant
from heavy fuel oil to natural gas.
Total SO 2 em issions for the refinery
5
4
1000 t
3
2
1
0
1995 2000 2005 2008 2009
Year
Fig.5: SO2-Emission
The refinery’s environmental impact

Scope of the investigation
The following factors were assessed to analyze the potential environmental impact of the refinery’s
activities.
Environmental impact factors

All environmental impact factors were identified and are illustrated in Fig. 6 (below).
Emissions Noise
Air, N2
Energy Odours
Refinery activities
Water (own, outsourced), Visual
production,
handling and storage
Raw materials maintenance and turn arounds, Wastewater
Chemicals Waste
Misc. Products Leakages

Fig. 6: Environmental impact factors
Weighting
The environmental sustainability investigation (UVU) gives equal weight to the impact of our activities
on fauna and flora as well as on the greenhouse effect. We analyze our carbon dioxide (greenhouse
gas) output resulting from the energy input needed to operate the refinery. The findings obtained from
this analysis will be used to achieve our goal of further optimizing future performance.
Frequency
It is important for the study to identify the frequency and duration of the pollution. We identified the
following categories:
Normal operations
Short-term limit violations due to unforeseeable failures
Commissioning and turnarounds necessitated by maintenance and inspection activities
Compliance with legal regulations

Our integrated HSSEQ management system helps us to ensure that we comply with all legal
regulations. This system comprises the following elements:
Records of all refinery related legal requirements

at the local, state, federal and corporate level.
Continuous monitoring of rules and regulations
pertaining to proper operating procedures.
Preventive measures and emergency procedures
to safeguard against anomalies.
Compliance with BP standards.
Continuous monitoring enables us to ascertain

whether we are complying with applicable
environmental regulations and norms.
Fig. 7: The refinery and its environs

Communication
It is important for the company to communicate openly and in this way establish an atmosphere of
trust. It is of prime importance to us that residents of the Emsland region hold our economic and
ecological activities in high regard and that our neighbours are provided with information about these
activities. Although emissions of noise, smoke and offensive odours are to some extent unavoidable,
we are committed by public rules to undertake organizationally and technically feasible measures.
Key environmental factors

Data regarding key environmental factors are methodically recorded (a process that is supported by
environmental management in accordance with ISO 14001 standards) and these factors are optimized
continuously (see table below).
Key environmental factors
SO2; volatile hydrocarbons (VOC),

smoke, NOX, CO2, dust, sources of
Emission offensive odours, hydrogen sulfide,
protection noise pollution
Hydrocarbons (oil), ammonia,

Water alkalis, suspended particles, salts
Waste that does not require
monitoring (household waste),
Waste waste that does require monitoring
(industrial/hazardous waste)
Leaks, spills of petroleum products
Soil and crude oil
Natural resources Water and energy consumption
Fig. 8: Environmental factors

Environmental quality
Emission protection
Air quality in the environs of the refinery is affected by the rural structure of the Emsland region. It is
monitored through measurements that are undertaken continuously at the refinery’s production
facilities, and is also monitored remotely and continuously by environmental agencies. Following is an
overview of refinery emissions data from selected years.
Substance Unit 1995 2000 2005 2008 2009
SO2 kt 4.3 3.5 2.0 2.2 1.5

NOX kt 1.5 1.2 1.3 1.4 1.3
VOC kt 1.3 1.2 0.7 0.8 0.8
Dust t 70 67 36* 39* 46*
CO2 mio t 1.3 1.3 1.3 1.3 1.3
* New calculation basis from 2005
Fig. 9: Refinery emissions
Sulphur dioxide emissions

Due to our plant modernization and replacement program starting in 1995, we have mainly been using
fuel gas and natural gas in our power plant furnaces instead of heavy fuel oil. This has resulted in a
steady decrease in sulphur dioxide emissions. However, in order to remain competitive we were
forced to increase the refinery’s productivity, thus reversing on some of the reductions in SO2
emissions. This has been identified as a future objective.
Substantial reductions in SO2 emissions have been achieved in our power plant through the operation
of two natural gas-fired turbines and their attendant waste heat boilers. By increasing the conversion
capacity in 2004 by expanding the Coker a further reduction of heavy fuel oil (which causes SO2
emissions) was possible. In 2009 the firing of residual fuel in the CDU2 ended. Hence the firing of
residual fuel is now restricted to CDU1 and two power station boilers.
Carbon dioxide (CO2)

Carbon dioxide emissions, which are the primary cause of global warming, are unavoidable when
fossil fuels are used. Most of the CO2 we generate comes from our power plant furnaces and
processing installations. We also generate CO2 through hydrogen production, which involves catalytic
cracking of fuel gas/propane/butane and water needed, for hydrogenation. It should be borne in mind
that production of sulphur-free gasoline and diesel fuels, which is done for environmental reasons, has
increased the need for hydrogen.
The systematic monitoring of energy consumption and measures to reduce consumption allow for the
creation and assessment of possible avenues for optimization, as well as the formulation of concrete
objectives, particularly in regard to future projects.
BP Lingen has taken part in Emission Trading since the beginning of 2005. In accordance with the
Emissions Trading System the participants will be authorized CO2 Emission Right for a limited time
period. The surplus Emission Rights will be traded on the open market.
Nitrogen dioxide emissions

It has been scientifically established that the simultaneous presence of hydrocarbons, nitrogen dioxide
and sunlight in the atmosphere promotes ozone formation.

Threshold ozone levels are increasingly being observed both in urban areas with high levels of vehicle
traffic during the summer months as well as in rural areas with more moderate conditions.
Our energy and maintenance programs allow these factors and we have replaced numerous older
furnaces with modern low NOX units.
Volatile hydrocarbons
In order to recover volatile hydrocarbons (VOC) during the storage and handling of gasoline, we have
installed a hydrocarbon collection system in our refinery that is continuously expanded to meet
process requirements for new products. Volatile hydrocarbons generated during filling and handling
pass through our hydrocarbon collection system to the vapor recovery plant where the hydrocarbons
are recovered and are then sent to other units for further processing. In 2009 the vapor recovery plant
was supplemented with two furnaces to burn the surplus of vapors.
The activity mainly responsible for hydrocarbon emission (e.g. filling gasoline tanker trucks) has been
converted to a bottom loading system which completely eliminates atmospheric hydrocarbon
emissions.
We have also retrofitted our installations and pipeline flanges with high quality sealing materials with a
view to preventing even minor, gradual emissions as well. Hence extensive remediation actions were
taken over the last years to obtain best available technology in terms of emission limitations in the tank
farm.
Smoke, noise and unpleasant odours

When plants are commissioned or shut down, the combustion of excess gases can give rise to
transient flaring. The resulting noise, bright light and unpleasant odours are disturbing. We are firmly
committed to keeping this type of pollution to a minimum so that we can avoid disturbing those who
live near our production facilities.
We have taken organizational and technical steps to avoid noise and unpleasant odours and it is our
policy to immediately eliminate the sources of such problems, insofar as they are identifiable.
Wastewater treatment
All wastewater generated by the refinery is processed in a biological wastewater treatment plant that is
monitored by environmental agencies. Processing and discharge of the treated wastewater are
continually monitored and comply with required limits.
Key parameters such as nitrogen content, pH value, volume, chemical oxygen demand and
temperature are continuously monitored, thus enabling us to ascertain that the treatment plant is
operating efficiently.
In-company measures we have taken for the treatment of sour water (water with sulphur components)
have increased the effectiveness of our wastewater treatment plant and have reduced the level of
unpleasant odours generated by the refinery.
The predominantly biological sludge from the plant is burned in our emissions-controlled waste
incineration plant. Annual statistical highlights pertaining to the operation of the wastewater treatment
plant are published in the public notices section of a regional newspaper, the Lingener Tagespost.
Waste
Regulations regarding the separated collection, storage, recycling and removal of waste are an
integral part of waste management procedures at our refinery. Rather than recycling or disposal we
make every effort to avoid generating waste. Waste is processed in collaboration with recognized

professional waste removal companies, and we comply with all applicable regulations so as to ensure
proper waste processing. In 2009 large amounts of old sewage sludge were disposed.
Unit 1995 2000 2005 2008 2009

Waste:
• External recycling t 100 690 120 85 460
• External waste removal t 1,470 470 3,000 480 3575
• Incinerated waste t 7,000 7,300 7,800 7,000 6,800
Wastewater:
• Rainwater 1000m³ 110 140 120 110 110
• Groundwater 1000m³ 610 520 740 540 410
• Wastewater discharged 1000m³ 2,100 1,740 2,060 2,100 2,000
into the river Ems
• Biological sludge m³ 5,750 6,300 6,600 6,500 6,500
Fig 10: Waste and wastewater production
Soil
A rigorous in-company reporting system supplements legal regulations pertaining to procedures for
dealing with soil contamination resulting from the spillage of oil and hydrocarbon based substances.
Site cleanliness is rated according to the number of untoward events and the subsequent cleanup
efforts. The causes of all such events are thoroughly investigated with a view to learning from
experience and devising preventive strategies for use by others as well. We have also established a
comprehensive groundwater protection system that is monitored using a series of wells on the refinery
site.
Natural resources
It is now widely accepted that the use of fossil fuels as a natural resource has a significant
environmental impact (global warming) and that the world’s supply of fossil fuels is limited.
As an energy supplier for the transport industry and heating market, we are committed to using natural
resources in a responsible manner and to devising additional energy saving measures through our
ongoing energy monitoring program.
In 2009 200 kt of bio-strain fuel components were blended into fuels.
Corporate citizenship
Our commitment to dealing responsibly with and protecting the environment and safeguarding the
health and safety of all human beings is firmly embedded in BP’s corporate charter. Maintaining good
relationships with the communities in which we operate and building a relationship of trust and
cooperation with these communities as well as governmental organizations are our top priorities.
We also actively support the development of facilities that promote the well being of our employees
and people who live in close proximity to our production facilities.
The frequent visits we receive at our refinery from various groups bear testimony to the open and
honest dialogue that we conduct with all interest groups.

Turnaround 2006
In 2006 the refinery went through the biggest Turnaround of its history. Information regarding the
effects on the environment was collated and evaluated. This knowledge will be used in the next
Turnaround in 2011.
Objectives for the coming year

Our goal for the next year is to continue pursuing our current activities with a view to doing everything
possible to ensure that no harm befalls any person or the environment.
Fig. 11: Tank farm
1. Air
When replacing and maintaining our installations, we use materials and machines that help to avoid
noise and odour pollution.
We intend to conduct additional studies and projects with the aim to optimize and reduce energy
consumption, which will in turn reduce emissions.
2. Water
We persevere to increase the efficiency of our water treatment processes to fall well below the limit
values.
Fig. 12:
Unloading a ship in
the harbour with air
curtain oil boom

3. Soil
The groundwater monitoring will continue as well as the control program to avoid soil contaminations.
4. Training
Training programs aimed at increasing employee refinery workers’ awareness of workplace safety and
environmental issues will continue. Each of our employees is required to know and comply with all
applicable rules and regulations.
Third party contractors are likewise obligated to comply with these rules and have incorporated them
into their own construction site regulations. We also check this in the course of conducting the kinds of
audits for these companies that we conduct for our own activities.
5. Legal regulations
The refinery of course complies with all applicable legal regulations and we plan to expand the scope
of our own regulations with the objective to developing a self-monitoring process.

BP-Lingen - Erdöl-Raffinerie Emsland Environmental Statement 2010

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BP-Lingen - Erdöl-Raffinerie Emsland

Umweltbericht EnvironmentReport 2010.doc page 1 of 14 Issued: March 03rd, 2010

Environmental policy and management

No accidents, no harm to human beings, no environmental damage.

Health, safety, security, environment and quality (HSSEQ) tracking

Fig. 1: OMS Performance Improvement Cycle

Umweltbericht EnvironmentReport 2010.doc page 2 of 14 Issued: March 03rd, 2010

Avoid all accidents and injuries;

Umweltbericht EnvironmentReport 2010.doc page 3 of 14 Issued: March 03rd, 2010

Fig. 2: Production facilities in Germany

Crude oil feed

Umweltbericht EnvironmentReport 2010.doc page 4 of 14 Issued: March 03rd, 2010

Fig. 3: Crude oil feed to refinery

Products of Erdöl-Raffinerie Emsland (BP-Lingen):

LPG (propane, butane)

Umweltbericht EnvironmentReport 2010.doc page 5 of 14 Issued: March 03rd, 2010

Refinery power plant

Total SO 2 em issions for the refinery

The refinery’s environmental impact

Environmental impact factors

Misc. Products Leakages

Umweltbericht EnvironmentReport 2010.doc page 6 of 14 Issued: March 03rd, 2010

Fig. 6: Environmental impact factors

Compliance with legal regulations

Records of all refinery related legal requirements

Continuous monitoring enables us to ascertain

Fig. 7: The refinery and its environs

Umweltbericht EnvironmentReport 2010.doc page 7 of 14 Issued: March 03rd, 2010

Key environmental factors

Key environmental factors

SO2; volatile hydrocarbons (VOC),

Hydrocarbons (oil), ammonia,

Fig. 8: Environmental factors

Umweltbericht EnvironmentReport 2010.doc page 8 of 14 Issued: March 03rd, 2010

Substance Unit 1995 2000 2005 2008 2009

SO2 kt 4.3 3.5 2.0 2.2 1.5

Sulphur dioxide emissions

Carbon dioxide (CO2)

Nitrogen dioxide emissions

Umweltbericht EnvironmentReport 2010.doc page 9 of 14 Issued: March 03rd, 2010

Smoke, noise and unpleasant odours

Umweltbericht EnvironmentReport 2010.doc page 10 of 14 Issued: March 03rd, 2010

Unit 1995 2000 2005 2008 2009

Fig 10: Waste and wastewater production

In 2009 200 kt of bio-strain fuel components were blended into fuels.

Umweltbericht EnvironmentReport 2010.doc page 11 of 14 Issued: March 03rd, 2010

Objectives for the coming year

Fig. 11: Tank farm

Umweltbericht EnvironmentReport 2010.doc page 12 of 14 Issued: March 03rd, 2010

Umweltbericht EnvironmentReport 2010.doc page 13 of 14 Issued: March 03rd, 2010

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