Wastewater Treatment Training

Essential Expertise for Water, Energy and Air SM

Introduction to
Refinery/Petrochemical
Wastewater Treatment
presented by:
Dr Cailing Deng
Industrial Technical Consultant

SM
Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 Purpose, Process, Payoff

• Purpose
 The purpose of this course is to help you to understand Refinery
wastewater treatment and raw water treatment.
• Process
During this program, you will learn:
 Primary Wastewater Treatment
 Secondary Biological Wastewater Treatment
 Sludge Dewatering
 Opportunity Crude processing and impact on WWTP
 Raw Water Treatment
• Payoff
As a results of participating the Wastewater/Raw water treatment course, you
will:
 Gain more knowledge in Wastewater/Raw water treatment.
 Operate and Control your Wastewater/Raw water treatment plant better.
 Make your plant compliant with government regulation.

SM
Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 Purpose of Wastewater Treatment

• Remove suspended and dissolved pollutants

• Protect the aquatic environment
• Protect drinking and industrial water supply
• Recovery of raw materials (oil, product)
• Water quality control for recycling

SM
Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 Water Pollution
• Total Suspended Solids (TSS)
 Causes turbidity; visually dirty water, sludge
• Oil and Grease (O&G)
 Float layers not desired in the environment
 Surface “sheen”
• Dissolved organics
 Deplete oxygen from natural waters as Biological and Chemical Oxygen
Demand (BOD and COD)
• Ammonia
 Oxygen depletion
• Phosphate nutrients
 Can cause algal blooms
• Specific contaminants: Metals, BTEX, Phenols, etc.

SM
Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 Why should you care about Wastewater?

• Environmental is critically important… and becoming

more important
 Heavy fines
 Bad press
 Sustainability
• Legislation is tightening
• Wastewater characteristics are changing

Therefore understanding and improving the Effluent Treatment

Plant is critical to compliance with government regulation

SM
Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 Typical Wastewater Treatment Objectives

• Remove suspended and dissolved pollutants to meet

permit effluent limits
 Total Suspended Solids (TSS)
 Oil and Grease (O&G)
 Remove Organics (BOD / COD)
 Specific contaminants: Ammonia (NH3N), Metals, etc.
• Potentially clean water enough to recycle

All equipment and processes in wastewater plant are

aimed at achieving these objectives

SM
Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 Refinery Wastewater Sources & Characters

Wastewater
Sources

Crude tank

Slop oil tank

Sour water
stripper

Ammonia unit

Sulfur recover

Cooling water Stormwater

blowdown

Storm water

High High High High With heavy

Characters High Solid
organic acid ammonium
Oil/Grease COD metals

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Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 Sour Water Stripper

Stormwa
ter

Sources Contaminants
• Atmospheric / Vacuum Units • NH3, H2S, Cl, phenols, Neutralizers
• Hydrotreaters • NH3, H2S, Cl, phenols
• FCCUs / Hydrocrackers • NH3, H2S, CN, phenols, carbonates, water based
amine quats
• Coker / Visbreaker • NH3, H2S, Cl, CN, phenols,carbonates, quated amines

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Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 Amine Unit/Sulphur Recovery

Source
• Amine Units
• Sulfur Recovery

Contaminants
• NH3, Amines, CN
Stormwa
ter
• H2S, lower pH (H2SO4)

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Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 Crude Tanks

Source
• Crude tank &
Stormwat
tank farm
er
drainage

Contaminants
• Hydrocarbons, metals, • Water clarifiers [WCs],
• Oilfield chemicals (emulsion breakers [EBs], • Corrosion & scale inhibitors,
• Dispersants, hydrate inhibitors

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Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 Slop Oil Recovery

Source
• Water Treatment
• Desalters

Contaminants
pH, EBs, Rag Layers,
Solids, Emulsions,
Stormwa
ter Hydrocarbons, Skimming
sludge

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Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 Storm Water Tanks

Stormwat
er

Source Contaminants
• Rain water runoff • Hydrocarbons, dirt, solids
• Equipment washing • Surfactants, hydrocarbons, solids
• Fuels • Spent caustic

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Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 Cooling Water Blow-down

Stormwate
r

Source Contaminants
• Cooling Tower • Hydrocarbons, organic , polymers, orthophosphates,

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Essential Expertise for Water,
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Essential Expertise for Water, Energy and Air
 Big Impact: Crude Unit Desalting

Stormwat
er

• Largest Source of Contaminants to WWTP

• Important to understand link between Crude Unit and WWTP

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Essential Expertise for Water,
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Essential Expertise for Water, Energy and Air
 Crude Unit Impacts on WWTP
WWTP Influent
WWTP Main Impact Area and Bottlenecks
Challenge

High Solids Loading Primary Treatment, Dewatering, Incineration

High Oil and Grease Primary Treatment, Secondary Treatment, Sludge

Loading Dewatering

High COD Secondary Treatment and Clarification

Metals: Hg, Se, Ca Environmental Permit Compliance

Organic Acids Secondary Treatment

Secondary Treatment, Environmental Permit

Amines, Ammonia
Compliance
 Typical Wastewater Treatment Process Diagram
Refinery and Olefin plant
Preliminary treatment Primary treatment Secondary treatment Tertiary
treatment
Aeration basin/
EQ tank API Flotation/Clarifier 2nd clarifier Media filter
A/O system

RAS

WAS

Sludge Sludge
tank tank
Centrifuge Belt press
Sludge handling

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Essential Expertise for Water,
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Essential Expertise for Water, Energy and Air
 Wastewater Contaminant Distribution in the WWTP

High
High Organic
High COD High
High Acids
Solids Ammonium
Oil/Grease
Aeration basin/
EQ tank API Flotation/Clarifier 2nd clarifier Media filter
A/O system

RAS

High Oil High Effluent

Solids High Heavy
/Grease WAS
Solids Metals

Sludge Sludge
tank tank
Centrifuge Belt press

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Essential Expertise for Water,
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Essential Expertise for Water, Energy and Air
 A Refinery Wastewater Treatment Process

Water recycle

Wastewater
Primary Anoxic Tank 1st stage 1st stage
EQ Tank Clarifier
Clarifier aeration tank

RAS
WAS

Emergenc Primary WAS RAS

y Tank sludge

2nd stage
Sludge 2nd stage
Centrifuge Clarifier
tank aeration tank

Tertiary sludge Tertiary

Discharge
Clarifier

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Essential Expertise for Water,
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Essential Expertise for Water, Energy and Air
A Petrochemical (Olefin) Wastewater Treatment Process

Aeration
Wastewater Basin -A
2nd
EQ Tank DAF Clarifier Retention
Basin Discharge
Aeration
Basin - B

RAS
Emergency
Tank
DAF sludge WAS

Sludge Sludge
Belt tank
Send to Deposit
Press

Filtrate
Send to Aeration basin

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Essential Expertise for Water,
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Essential Expertise for Water, Energy and Air
A Petrochemical (PTA) Wastewater Treatment Process

Waste
water
EQ Tank Anaerobic Aeration 2nd Tertiary
bioreactor Basins Clarifier Clarifier
Discharge
RAS

WAS

Belt press Sludge

Thickeners

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Essential Expertise for Water,
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Essential Expertise for Water, Energy and Air
 A Typical Wastewater Treatment Process

Preliminary Primary Secondary Tertiary

treatment treatment treatment treatment

Gross Primary Sludge Secondary

solids sludge Dewatering sludge

• Gross solids removal

• Gross oil removal
• Flow equalisation
• Chemical equalisation

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Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 A Typical Wastewater Treatment Process

Primary effluent quality:

TSS < 50 – 200 mg/L
O/G < 30 – 100 mg/L
Metals: Meet discharge limit

Preliminary Primary Secondary Tertiary

treatment treatment treatment treatment

Gross Primary Sludge Secondary

solids sludge Dewatering sludge

• Oil removal
• pH adjustment
• Metals removal
• Suspended solids removal
• Colloidal solids removal

SM
Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 A Typical Wastewater Treatment Process

Secondary effluent quality:

COD < 100 mg/L
Meet country
BOD5 <50 mg/L
discharge
TSS < 50 - 100 mg/L regulations
O&G < 10 mg/L

Preliminary Primary Secondary Tertiary

treatment treatment treatment treatment

Gross Primary Sludge Secondary

solids sludge Dewatering sludge

• Soluble biodegradable organics removal

• Colloidal solids removal
• Nutrient removal, e.g. Nitrogen removal

SM
Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 A Typical Wastewater Treatment Process

Meet
government
regulations!

Preliminary Primary Secondary Tertiary

treatment treatment treatment treatment

Gross Primary Sludge Secondary

solids sludge Dewatering sludge

• Polish suspended solid/oil removal

• Polish COD removal

SM
Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 A Typical Wastewater Treatment Process

Preliminary Primary Secondary Tertiary

treatment treatment treatment treatment

Gross Primary Sludge Secondary

solids sludge Dewatering sludge

• Sludge disposal volume.

• Sludge disposal cost

• Sludge thickening or stablization

• Dewater the sludge to reduce sludge
disposal volume

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Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 QUESTIONS?
……
……

SM
Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air
 THANK YOU!

SM
Essential Expertise for Water,
SM Energy and Air
Essential Expertise for Water, Energy and Air