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A. Veawab
5. OIL REFINING
5.1 Overview
Objective:
Separate and in some cases alter hydrocarbons in crude oil to produce commercial products
Overall process:
CRUDE OIL
DESALTING
FRACTIONATION
Atmospheric distillation
Vacuum distillation
CONVERSION PROCESS
Catalytic cracking
Coking
Hydrocracking
Visbreaking
Alkylation
Polymerization
FINISHING PROCESS
Amine treating
Hydrotreating
Solvent deasphalting
Solvent dewaxing
Etc.
Remove salts
Alter hydrocarbons
Upgrade gasoline
Convert vacuum residuals (gas oil, coke,
distillate) to gasoline, petrochemical feedstock
Convert gas oil, cracked oil, residuals to lighter
hydrocarbon
Reduce viscosity of atmospheric distillation
residual to distillate and tar
Unite olefins and isoparaffins
Unite two or more olefins
COMMERCIAL PRODUCTS
Fuel gas, Liquefied petroleum gas (LPG), Gasoline, Jet fuels, Kerosene, Fuel oils, Diesel fuel
oils, Residual fuel oils, Lubricants, Greases/ waxes
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Process
water
Desalted crude
Unrefined
crude
Emulsifier
Heater
GRAVITY
SETTLER
Effluent water
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005)
Waste
Effluent water
containing inorganic salts + other chemicals such as ammonia, caustic, acid,
chlorides, sulfide, suspended solids)
sent to wastewater treatment facility
H2S
released when the fluid (water + oil containing sulfur) is heated.
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5.2.2 Fractionation
Objective
To separate hydrocarbons into fractions of different ranges of boiling point => use distillation
Process
1) Atmospheric distillation
Operation:
Desalting crude oil is passed through a furnace (400oC) where hydrocarbons are boiled, thus
generating a great volume of hot hydrocarbon vapors.
Hot hydrocarbon vapors + crude oil residue enters the bottom of atmospheric fractionator
(flash zone)
Vapors of hydrocarbons with the lowest boiling point range (C1 C4) flow up to the top of
the fractionator and are sent to a gas separator to separate out gasoline (a mixture of butane
and propane). The lighter gases are then sent to downstream process to produce methane,
ethane, etc.)
Vapors of hydrocarbons with lower boiling point ranges condense to liquids at different
heights (temperatures) of fractionator => liquid products are drawn from the side of the
fractionators.
Each side stream of liquid products is mostly contaminated with lighter hydrocarbons. To
remove the lighter hydrocarbons, the liquid product is sent to a stripper (at bottom) where hot
steam (stripping agent) is injected. The lighter hydrocarbons are stripped out, flow upward
with the steam, leave the stripper top and are sent back to the upper portion of the
fractionator (where the lighter hydrocarbons are condensed). The steam leaves the
fractionators to the gas separator where water is separated out and sent to wastewater
treatment facility.
Gas
Gas (butane and lighter)
+
GAS
SEPARATOR
Gasoline
Kerosene
Light gas oil
Heavy gas oil
DESALTER
Crude oil
Furnace
Residuum
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005)
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2) Vacuum distillation
Objective
To separate crude oil residue (heavy hydrocarbons) from the atmospheric fractionators =>
produce lubricating oil and gas oil
Why not raising temperature in the atmospheric fractionator to separate these higher boiling
point (less volatile) hydrocarbons?
At temperatures > temperatures in atmospheric fractionators, the crude oil residue tends to
thermally decompose or crack.
How the vacuum fractionator can separate the crude oil residue without thermal decomposition?
Boiling point decreases with reducing pressure. => pressure can be reduced to 50-100 mmHg
=> lubricating oil is separated at 250-350oC. => gas oil is separated at 150oC.
To vacuum
system
VACUUM
TOWER
Lubricating oils
Residuum
Furnace
Vacuum residuum
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005)
ENPE 490
A. Veawab
5.2.3 Visbreaking
Objective
To convert residual oil (from atmospheric & vacuum distillation process) to light hydrocarbons
(gas oil, LPG and gasoline)
Concept
Use heat to crack large to smaller hydrocarbon molecules => reduce viscosity of residual oil
Operation
Residual oil is heated in a furnace and sent to a soaker where sufficient time is provided for
thermal cracking of residual oil.
Vapors of cracked oil products (gas oil, LPG and gasoline) are quenched by a heat exchanger
to stop thermal cracking and then introduced to a fractionator for product separation.
Steam strippers are used to purify the cracked oil products by separating lighter hydrocarbons
and recycling them back to the fractionators
In the soaker, a steam injection process may be used to remove organics deposits.
Gas + gasoline
Quench
Gas oil
FRACTIONATOR
Cracked or
visbroken residue
SOAKER
Feed
Furnace
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005)
Waste
Fugitive emissions
Wastewater produced from steam strippers (ammonia, chloride, phenol, mercaptans..)
Air emissions (combustion gases from the furnace and boiler that produces steam for steam
stripping => particulates, CO2, SOx, NOx, VOcs. Etc.)
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5.2.4 Coking
Objective To convert residual oil (from atmospheric & vacuum distillation process) to light
hydrocarbons (gas oil, LPG and gasoline)
Concept
Use heat to crack large to smaller hydrocarbon molecules
Operation
Residual oil is heated in a furnace and begins to crack. => produce vapors of gas oil and
gasoline and other light hydrocarbons
Cracking continues at a coke drum where vapors of cracked products are separated and sent
to a fractionators for product separation. Side steam strippers are used to purified the
products.
Solid coke and uncracked liquids are left in the coke drum.
*** Once one coke drum is filled up with solid coke + liquids, this drum will be out of service for
cleaning and another drum will be in use.
Cleaning the coke drum:
Purges steam through the drum => Produce more vapors of cracked products (reduce content
of petroleum coke (solid) => condense these vapors and send to a phase separator to separate
vapor, oil, and sour water (containing sulfur compounds).
Coke (solid) is removed from the coke drum by using high pressure water.
FRACTIONATOR
COKE DRUM
COKE DRUM
Gas + gasoline
Gas oil
Feed
Furnace
Heavy distillate
Recycle
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005)
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Waste
Fugitive emissions through leak and vents
Air emissions
combustion gases from the furnace and boiler that produces steam for steam stripping
=> particulates, CO2, SOx, NOx, VOcs. Etc.
Particulates from decoking (using high pressure water)
Wastewater produced from:
steam strippers
Cleaning the coke drum => decoking, steam purging
(contains hydrogen sulfide, ammonia, suspended solids, chloride, phenol, mercaptans, etc.)
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Gas to recovery
Waste heat
boiler
Water
Gasoline
Fractionator
Reactor
Stripping
steam
Regenerator
Fresh feed
Slurry
settler
Air
Wash oil
Recycle
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005)
Waste
Air emissions (significant => main source that contributes to air emissions)
Combustion gas from the heater that uses to preheat feed oil
Off gas from the catalyst regenerator (containing entrained catalyst powder => PMs +
CO)
SOx and NOx from catalytic cracker (reactor riser)
Wastewater from
Catalytic cracker (water contains hydrogen sulfide and ammonia)
Steam stripper (water contains oil, suspended solid, phenol, cyanide, hydrogen
sulfide, ammonia, and spent catalysts
Spent catalysts => landfill, land treatment, separation of metal
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5.2.6 Hydrocracking
Objective
To convert kerosene, atmospheric gas oil, vacuum gas oil to naphtha, diesel and jet fuel
Concept
Crack high molecular weight aromatic hydrocarbons => use heat + catalyst + HYDROGEN
GAS => lower boiling point ranges of products
***Aromatic hydrocarbons resist FCC.
***FCC is used for cracking paraffin (single bond C-C).
***hydrogen gas is available from catalytic reforming operation within refinery.
Fresh gas
Quench
gas
Product
Recycle gas
compressor
1st
stage
2nd
stage
HP
separator
LP
separator
Recycle
Feed
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005)
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Operation
Feed oil is preheated, mixed with hydrogen gas, and introduced to 1st fixed bed
hydrocracking reactor packed with catalyst.
At 1st reactor, hydrocracking takes place. => produce a mixture of cracked H-C vapors
+hydrogen gas
The hydrocracking products from 1st reactor leave the reactor, are cooled down by a series of
heat exchanger, and sent to HP- and LP-separator to separate hydrogen gas from the 1st
reactor products.
The separated hydrogen gas is passed through a recycle gas compressor and sent to hydrogen
gas storage for reuse. The hydrocracking products are sent to a fractionator (stripper) to
separate products and recycle the heavier products (at the bottom) to a 2nd hydrocracking
reactor.
At the 2nd reactor, further hydrocracking takes place. The cracked products are sent to mix
with cracked products from 1st reactor.
Waste
Air emissions
combustion gas from a furnace
fugitive emissions through leak and vents
Sour wastewater at the top of fractionators
Propylene (toxic) => light end product => found in both air emissions & wastewater
Spent catalyst => toxic metals (nickel, cobalt and molybdenum)
5.2.7 Hydrotreating
Objective
to remove sulfur and nitrogen from gasoline, jet fuel, kerosene, diesel fuel, and fuel oil
*** sulfur is converted toH2S (hydrogen sulfide). H2S is removed in amine treating process.
e.g.
CH3-S-C4H9 +H2 => CH4 + C4H10 + H2S
CH3-S-S-CH3 + H2 => 2CH4 + H2S
When remove sulfur, the process is called hydrodesulfurization.
***nitrogen is converted to NH3 (ammonia).
***aromatic H-C is converted to saturated H-C.
Concept
Undergo hydrogenation in the presence of catalyst and hydrogen gas => boiling ranges of
products do not change much.
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Operation
Feed (liquid) is mixed with hydrogen (gas) and preheated in a furnace.
In the furnace, the mixture of feed and H2 is totally vaporized and heated to a required
temperature.
The vapor mixture is sent to a fixed bed reactor packed with catalyst. => reactions between
feed and H2 take place. =>hot reaction products are formed and leave the reactor to a cooler
=> reaction products are a mixture of liquid + gas (mostly H2 + H2S)
After cooler, the reaction products are sent to a phase separator. H2 is separated and recycled
for use. If H2S exists => use amine treating. Liquid products are sent to a fractionator where
the products are separated (at the bottom) and others (e.g. CH4, C2H4, H2S..) are separated
(at the top).
Hydrogen
make-up
Hydrogen recycle
Fuel gas
Unstabilized
light distillate
Feed
Desulfurized product
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005)
Waste
Air emissions
combustion gas from a furnace
H2S in off-gas stream of fractionator. => sent to amine treating and sulfur recovery
units
fugitive emissions through leak and vents (BTEX & other volatiles)
Sour wastewater (containing ammonia and H2S) at the top of fractionators for product
separation
Propylene (toxic) => light end product => found in both air emissions & wastewater
Spent catalyst => toxic metals
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n-heptane toluene + H2
Operation
***Feed (naphtha) must be pretreated in a hydrotreater to remove sulfur and nitrogen
compounds before catalyst reforming. => because sulfur and nitrogen compounds deactivate
most catalyst metals (e.g. platinum)
Feed is preheated and then sent to a reactor where reforming takes place in the presence of
heat + catalyst (packed in the reactor).
As reforming continues in the reactor, temperature is reduced (due to endothermic reaction)
=> yield of reforming decreases => thus, feed is partially reformed => the product from 1st
reactor must be re-heated before it is introduced to the next reactor (in figure, 3 reactor are
used.)
The product stream from the final reactor is passed through a separator to separate hydrogen
gas (produced during reforming) and liquid product.
The liquid product is fed to a fractionators to separate light hydrocarbon from the reformate
(gasoline).
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Reactor
Reactor
Reactor
Feedstock
Furnace
Furnace
Furnace
Light hydrocarbon
Hydrogen recycle
Separator
Reformate
Fractionator
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005)
Waste
Fugitive emissions of volatile compounds
Toluene, xylene and benzene (toxic aromatics produced during reforming) => highly
volatile
Air emissions from process heaters and furnaces => combustion gases (particulates, SOx,
NOx, CO and volatile hydrocarbons)
Spent catalysts
5.2.9 Isomerization
Objective
To increase octane number of gasoline (pentane C5/hexane C6) and to produce feedstock
(isobutane-C4) for alkalation process
Concept
Similar to catalytic reforming => but only convert normal paraffins to their isomers (i.e. C4 C6
from the catalytic reformer)
For example: n-butane isobutane
-C-C-C-C-
-C-C-CC
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To fuel gas
Iso-C4 product
DEBUTANIZER
Butane feed
Organic
chloride
makeup
Feed heater
STABILIZER
DEISOBUTANIZER
C5+ reject
Makeup gas
Isomerized butane recycle
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005)
Waste
Fugitive emissions from leak and vents
Combustion gases from furnace
Sour water (HCl (catalyst dissolved in water + water) and caustic wastewater (used to
neutralize chloride catalyst)
Calcium chloride neutralization sludge => disposed off-site
5.2.10 Alkalation
Objective To produce high-octane gasoline
Concept
Olefins (propylene and butylene) from FCC or hydrocracking + isobutane + acid catalyst
(sulfuric acid or hydrofluoric acid) high octane paraffinic hydrocarbons (alkylate) which
is a premium blending stock for gasoline
Reaction takes place at 0-30oC
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Operation
Olefins is mixed with isobutene and fed to a reactor where alkalation takes place in the
presence of an acid catalyst. => products leaving the reactor are alkylate + isobutene (+
propane) + acid catalyst
The product mixture is sent to an acid settler to separate out the acid catalyst (bottom layer of
the settler) from the hydrocarbon product. The acid catalyst is then recycled back to the
reactor for reuse.
The hydrocarbon product (top layer of the settler) is washed with caustic to remove the
residual of acid catalyst, and then distilled to separate the alkylate from isobutane.
Recycle isobutane
Feedstock
REACTOR
ACID SETTLER
Alkylate
CAUSTIC
SCRUBBER
Recycle acid
Fresh acid
DEISOBUTANIZER
Reject acid
Alkalation unit using sulfuric acid catalyst (Redrawn from J. G. Speight Environmental Analysis and
Technology for the Refining Industry, John Wiley & Sons, Inc. (2005))
Waste
Fugitive emissions of volatile compounds in the feed and the process vents
strong odor from sulfonated organic compounds and organic acid (catalyst) even at
low concentration For hydrofluoric acid alkylation unit:
o acidic H-C gas (hydrogen fluoride) is sent to a separate closed-relief
system where the acid is neutralized.
o Basins are covered, and the acid catalyst is water-washed or passed
through an activated carbon bed to remove odor.
Air emissions => combustion gases from process boiler to produce steam for distillation/
steam stripper
Wastewater from water washing, steam stripper => contaminated with oil and other
impurities
Neutralization sludge from the caustic scrubber (removal of acid catalyst from product) =>
consists of calcium fluoride and unreacted lime => to landfill or to steel manufacturing plants
and hydrofluoric acid manufacturer
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5.2.11 Deasphalting
Objective
To remove asphaltenes and resins from vacuum fractionation (distiallation) residue => used for
producing lubrication oil
Concept
Liquid-liquid extraction => Use propane (liquid) to extract oil from vacuum fractionation residue
feedstock at 38-60oC
***Volume of propane used for oil extraction = 4-8 times the volume of feedstock
Operation
At deasphalting tower: => Oil is extracted from the feedstock by liquid propane.
Feedstock (oil + asphaltenes + resins) is fed to the top of a deasphalting tower and flows
downward
Liquid propane is fed to the bottom of the deaphalting towere and flows upward.
As the feedstock is in contact with the liquid propane, oil from the feedstock transfers to the
liquid propane.
Liquid propane + oil leaves the top of the deasphalting tower while the feedstock
(asphaltenes + resins) is contaminated with liquid propane and leaves the bottom of the
deasphalting tower.
At solvent vaporizers:
The mixture of propane + oil from the top of the deasphalting tower is heated to vaporize or
recover propane from oil. => The remaining oil (deasphalted oil) is sent to the deasphalted
oil stripper.
The recovered propane is sent back to a propane work drum and recycled for use.
At deasphalted oil stripper:
The deasphalted oil is distilled with steam to strip out the remaining propane for further
purification. => remove propane and recycle propane for reuse => produce deasphalted oil
At asphalt flash drum & stripper:
The mixture of asphaltenes + resins from the bottom of the deasphalting tower is sent to aa
furnace for preheating and a flash drum & stripper to remove propane and recycle propane
for reuse.
Waste
Wastewater
o Propane-contaminated water from propane recovery
o Steam stripping wastewater (containing oil + propane)
Air emissions
o Fugitive emissions of propane and combustion gases
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Compressor
Solvent
condenser
Jet
condenser
Solvent
vaporizer
Propane
work drum
Feed
Water
Solar water
Deasphalting
tower
Asphalt
flash drum
Deasphalted
oil stripper
Superheated steam
Asphalt
stripper
Deasphalted oil
Superheated steam
Asphalt
furnace
Asphalt
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005))
5.2.11 Dewaxing
Objective
To remove wax from vacuum fractionation residue => improve flow property and produce
lubrication oil
Concept
Use a solvent to dilute oil portion => reduce temperature to crystallize wax => then use filter to
separate wax from oil
Solvent = mixture of methyl ethyl ketone (MEK) + toluene => most used***
Waste
Wastewater
o solvent-contaminated water from solvent recovery
o Steam stripping wastewater (containing oil + solvent)
Air emissions
o Fugitive emissions of solvent and combustion gases
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Operation
Feedstock (oil + wax) is mixed with a solvent, and then passed through a heat-exchanger and
a chiller to reduce its temperature and crystallizes wax.
The mixture of oil + solvent + wax crystal is sent to a rotary filter to separate wax. During
filtration, additional solvent may be added in order to maintain sufficient liquid for easy
handling.
Wax crystal (+ solvent) is heated in a heater and an evaporator to strip out and recover the
solvent. The recovered solvent is recycled for reuse.
Oil (+ solvent) is heated in a heater and an evaporator to recover solvent for reuse and
produce dewaxed oil.
Solvent
Wash
solvent
Slack wax
evaporator
Rotary
filter
Chiller
Heater
Dewaxed oil
evaporator
Heater
Dewaxed
oil
Feed
Slack wax
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005))
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Service type
Valves
Gas
Light liquid
Gas
Light liquid
Gas
Light liquid
Gas
Light liquid
Pump seals
Others
Fittings
TOTAL (kg/hr)
Number of
components
installed at the
marketing
terminal
28
593
0
25
20
85
224
4,025
Average
emission factor
(kg/hr/source)
1.3E-05
4.3E-05
6.5E-05
5.4E-04
1.2E-04
1.3E-04
4.2E-05
8.0E-06
5,000
Subtotal (kg/hr)
0.0004
0.0255
0.0000
0.0135
0.0024
0.0111
0.0094
0.0322
0.0944
Same as method 1
Count total number of components in each group (component type/service type)
with screening values <10,000 ppmV and 10,000 ppmV
Same as method 1
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Source: California Implementation Guidelines for Estimating Mass Emissions of Fugitive Hydrocarbon Leaks at
Petroleum Facilities prepared by the California Air Pollution Control Officers Association Engineering Managers
Committee and the California Air Resources Board Staff (February 1999).
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EXAMPLE: Estimate fugitive emissions of hydrocarbons from three large heaters at a refinery
using the screening value range method.
Component/
service type
Valves (gas)
Pressure relief
valves (gas)
Connector (gas)
Open-ended line
(gas)
TOTAL (kg/hr)
Screening value
range (ppmv)
<10,000
10,000
<10,000
Number of
components
screened
164
7
3
Screening value
range factor
(kg/hr/source)
6.0E-04
2.626E-01
4.47E-02
Subtotals (kg/hr)
0.098
1.838
0.134
10,000
<10,000
10,000
<10,000
0
703
11
10
1.691
6.0E-05
3.75E-02
1.5E-03
0.000
0.042
0.413
0.015
10,000
1.195E-02
0.024
900
96
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Source of leaks
Seal
Stem or gland area of valve body (caused by failure of valve
packing or O-ring
Gasket, bolts on flanges
Outlet of sampling valve
Seal
Seal/ operate too close to the set point
Point of line open to the atmosphere
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INCINERATOR
STACK TO
ATMOSPHERE
Claus process
= partial combustion of H2S to S => catalytic conversion of unburned H2S to S
Operation
At furnace:
H2S-rich gas is partially burned with one-third the stoichiometric quantity of air.
o Some H2S is converted to SO2 (Reaction 1)/ the rest of H2S remains unburned.
o Some SO2 further reacts with H2S and produces elemental sulfur (liquid) (Reaction 2).
2H2S + 3O2 2H2O + 2SO2
2H2S + SO2 2H2O + 3S
(Reaction 1)
(Reaction 2)
At catalytic converters:
Hot gas from the furnace (containing unburned H2S + SO2) is passed over a series of catalyst
beds (alumina) to react SO2 with unburned H2S =>produce elemental sulfur liquid (Reaction 2)
Catalytic section
Tail gas
H2S
Furnace
Air
Liquid sulfur
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005))
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Hydrogen
To Disposal
Reactor
Lean Amine
Absorber
Cooler
Claus Unit
Tail Gas
Loaded Amine
Redrawn from James H. Gary, Glenn E. Handwerk and Mark J. Kaiser Petroleum Refining: Technology and
Economics 5th edition, CRC Press Taylor & Francis Group (2007).
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5.3.2.3 Control of carbon monoxide (CO), volatile organic compounds (VOCs) and catalyst
dusts from catalyst regeneration
Source: Regenerator of catalyst in FCC unit (hot air is passed through regenerator to remove
coke deposited on the spent catalyst => produce CO + VOCs + catalyst particulates
Concept:
Burn CO + VOCs in waste heat boiler => convert to CO2 + H2O
Remove catalyst particulates from gas stream using electrostatic precipitator (ESP) or cyclone
separator
Gas to recovery
Waste heat
boiler
Water
Gasoline
Fractionator
Reactor
Stripping
steam
Regenerator
Fresh feed
Air
Slurry
settler
Wash oil
Recycle
Redrawn from J. G. Speight Environmental Analysis and Technology for the Refining Industry, John Wiley &
Sons, Inc. (2005)
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Secondary treatment
Remove soluble organics
Use biological treatment => microorganism consumes dissolved organics
Use activated sludge, trickling filter or rotating biological contactor
Activated sludge
Secondary
settling tank
From primary
treatment
Effluent
Aeration tank
Sludge
Return sludge
Aeration tank:
Air (oxygen) is supplied => Microorganisms consume organics in wastewater as food.
Microorganisms grow => flocculate to form mass of microbes (activated sludge)
Secondary settling tank (clarifier):
settle out activated sludge return most sludge to aeration tank waste the rest of sludge
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Trickling filter
From primary
treatment
Secondary
settling tank
Effluent
Trickling filter
Sludge
Trickling filter:
Wastewater passes through bed microorganisms consume organics microbial growth
on the packing (sludge)
Packing = stone or plastic media => provide contact between microorganisms and organics.
Secondary settling tank (clarifier):
Settle out activated sludge return some effluent to trickling filter waste sludge
Rotating biological rotator (RBC)
Rotating disks
Secondary
settling tank
From primary
treatment
Effluent
Wastewater
holding tank
Sludge
RBC = a series of closely spaced discs (3-3.5 m in diameter) mounted on a horizontal shaft
One-half of disc surface area is immersed in wastewater.
Rotating disks
Disks bring microorganisms into contact with wastewater => as disks rotate, wastewater is
aerated/ microorganisms consume organics => microorganisms grow on the disks
Secondary settling tank (clarifier):
Settle out sludge waste sludge
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NITRIFICATION/ DENITRIFICATION
Objective:
To control nitrogen and ammonia level in the treated wastewater (to meet regulatory limit)
Reasons for nitrogen and ammonia control:
To reduce or prevent algae growth in receiving water
To prevent depletion of dissolved O2 in water
**ammonia is toxic to fish and consumes oxygen in receiving water as it converts to NO3-.
Methods for nitrogen control:
Avoid discharge of spent amines
Proper removal of NH3 in sour water stripping process
Treat wastewater by nitrification/denitrification process
Sources of wastewater feed (containing low organic contents)
Stripped sour water from sour water stripper
Treated wastewater from secondary biological wastewater treatment processes (activated
sludge, trickling filter etc.)
Process:
1) Nitrification: (aeration tank)
Nitrification bacteria + NH4+ + 2O2 NO3- + H2O + 2H+
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108
pollution
ENPE 490
A. Veawab
Example: A sludge with a 6% solids concentration occupies a total volume of 300 m3. What is
the water content of the sludge?
a) What is the mass of the sludge solids?
b) If the sludge is further concentrated (or dewatered) to a volume of 200 m3, what will the
solids concentration be? What will the water content be?
Example: A volume of 500,000 gal of sludge contains 100,000 lb of dry solids.
a) What is the solids content of the sludge expressed in percent?
b) If the sludge is concentrated to 4 percent solids, what will its volume be?
Example: A flow of 4ML/d with raw TSS = 240 mg/L and raw BOD = 220 mg/L enters a
trickling filter sewage treatment plant. Removal efficiency in the primary settling tank is 50% for
TSS and 30% for BOD.
a) Compute the mass of primary sludge solids generated per day.
b) Compute the mass of secondary sludge solids generated per day.
c) If the primary and secondary sludges are combined and the mixture has a solids
concentration of 4%, what is the total volume of sludge generated per day?
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Sludge treatment
Refinery sludge => aesthetically displeasing + harmful + too much water ( => cannot be
directly disposed => need treatment prior to disposal
Reasons for sludge treatment:
Volume reduction
Stabilization of organics
1) Sludge thickening
Objective: To increase concentration of sludge => reduce volume of sludge to be treated
Methods:
1.1 Dissolved-air flotation
Suitable for activated sludge
Operation:
Air is injected into sludge under pressure. => air dissolves in sludge.
Sludge is fed into an open tank (at atm. pressure) => lots of air bubbles come out of
sludge => float sludge particles to the surface => form layer of sludge
Skim off the layer of sludge that floats
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ENPE 490
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2) Sludge stabilization
Objective: To reduce odor and pathogenic organisms
Methods:
1.1 Lime stabilization
Add lime (Ca(OH)2 or CaO) to the sludge to raise pH to about 11 or above => help
reduce odor and kill pathogens
Simple BUT gives temporary solution => with time, pH drops
1.2 Aerobic digestion
Extension of activated sludge system
Sludge is treated in a dedicated aeration tank for a long time (about 30 days)
Population of microorganism will decline with time (die) when nutrient becomes limited.
Produce aerobically digested sludge
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ENPE 490
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3) Sludge dewatering
Objective : To remove water content from the sludge
Methods:
3.1 Sand bed
Most cost effective means of dewatering (given the availability of the land)
Consists of tile drain in gravel covered by sand (0.25 m thick)
Operation:
Pour sludge onto the bed => water & solids are separated => solids are entrained on the
bed surface while water seeps into the bed layers through the tile drain
Evaporation takes place to convert liquid sludge to solid. (about 3 months drying time)
Remove the dried sludge to disposal
In some areas => sand beds are enclosed under greenhouses to promote evaporation and
present rain.
Problem encountered => sand does not drain well => clogging of sand due to sludge
Wet sludge
Dry sludge
Sand
Gravel
Drain
Drain
Redrawn from P. Aarene Vesilind, Susan M. Morgan and Lauren G. Heine Introduction to Environmental Engineering, 3 rd edition SI, Cengage
Learning (2010).
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Polymer
Drainage
Dewatering
Cake
Wash
Redrawn from P. Aarene Vesilind, Susan M. Morgan and Lauren G. Heine Introduction to Environmental Engineering, 3rd edition SI, Cengage
Learning (2010).
3.3 Centrifuge
http://www.hutch-hayes.com/prod-decantercentrifuges.html
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Operation:
Pump sludge into a rotating centrifuge at high speed. (polymer may be used to
improve dewatering behavior of sludge.)
Solids are pushed to the wall of centrifuge by centrifugal force => scarped out by
a screw conveyor (cake) => To disposal
Liquid supernatant (centrate) is discharged from centrifuge to the wastewater
treatment.
Calculation
Use mass balance
Assume: steady-state operation, no liquid or solids are produced or consumed in centrifuge
Example:
A wastewater sludge centrifuge operates with a feed of 40L/min and a feed solids concentration
of 1.2%. The cake solids concentration is 22% solids and the centrate solids concentration is 500
mg/L. What is the recovery of solids?
4) Disposal of sludge
Incineration (convert organics to CO2 + H2O + ash (go to landfill))
Land spreading/ farming
Secure landfill for hazardous wastes
Sale as fertilizer
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ENPE 490
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115