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Waste minimisation and loss prevention for improving effluent water quality
and rendering more water suitable for reuse are discussed
M
ore refiners are finding reason to ration- Greater public awareness of environmental
alise their water consumption. However, issues Often, public sentiment urges the reduc-
so many issues impact the amount and tion of water consumption and effluent.
quality of water required that most are unaware The availability of fresh water and the licence
of their own performance and of the opportuni- to discharge effluent directly both affect sustain-
ties to improve. A 360-degree approach to able operation and are, therefore, worth much
improving water management in oil refineries more than the annual cost of water import or
has therefore been implemented, ranging from disposal.
benchmarking issues to typical inefficiencies
encountered in water usage and incorporating Benefits
best practice improvements. This approach has Better water management may enable expansion
been successfully applied to several refineries. or higher throughput by freeing up fresh water. It
can also improve effluent quality due to reduced
Changing conditions contamination, better waste water segregation
Compared to other industries, oil refiners have and longer residence time in treatment units. It is
had relatively few concerns about water usage. also likely to reduce operating costs associated
However, the situation is changing. Factors with water purchase, pumping, treatment (chemi-
contributing to a growing need for better water cals, resin, air compression) and heating (steam
management are: use, boiler blow-down).
Processing dirtier crudes With specific gravities Possible additional benefits include less fouling
closer to water, (slop) oil is harder to separate from and corrosion in process equipment, better
(waste) water and desalting is more difficult. Sour desalting of crude oil, colder cooling water
crudes cause more waste water contamination (better vacuums, higher LPG recovery) and an
Clean fuels production More desulphurisation improved public image.
can overload sour water strippers and sulphur
recovery units, thus impacting waste water quali- Challenges
ties. Often, deeper conversion requires site With the proprietary WaterPinch methodology
expansion and increased water consumption and software, KBC Energy Services carried out
Stricter emissions regulations There are more water minimisation projects in many branches of
gas flows to scrub and more waste water contam- industry, including oil refining, which presents
inants to remove particular challenges due to:
Climatic changes Increased rainfall can reduce Distribution of water consumption Typically,
residence time in waste water treatment (WWT) cooling towers and steam generation account for
and even overflows, whereas reduced rainfall can 8085% of water consumption. Most other users
mean less dilution of final effluent are relatively small and widespread
Less rainfall, falling ground water levels and Complex water chemistry Refining processes
higher municipal and/or agricultural consumption release a great variety of contaminants, each of
These factors can also reduce fresh water which can determine the reusability of water for
availability certain applications and cause problems with
Benchmarking
WWTP Waste
Quantitative benchmarking of a
water
Storm water
Tank water/
refinerys water consumption implies
flares the calculation of objective water
Discharge
efficiency and compares this to a
database of results from other refin-
Figure 1 Water-related utility systems in oil refining eries, such as the KBC Best
Technology (BT) analysis for energy
usage. Ideally, as in the case of BT
analysis, it should also provide an
BFW objective refinery-specific best prac-
tice target in terms of tonnes of
Service
water
Reformer Amine
plant
Desuperheating water imported per barrel of crude
& waste-heat
boilers processed. To do this, the calcula-
FCC (+HDS)
coking/ SRU tions need to account for differences
Washing, CDU/VDU/
pump seals, visbreaking HDS in:
etc.
Cooling water systems Once-
through cooling water, as opposed
SWS
to make-up for a circulating system,
is normally not counted in the water
Steam SWS consumption per tonne of crude oil
and should therefore lead to a lower
Indirect
heating
Live
steam
target
Excess
SSW Refinery configuration Clean fuels
Desalters
Cond. Spent production requires more contami-
rtm. Process caustics
condensate nant removal. Coking processes are
Waste
dirty and cause swings in waste
water water production, while downstream
(chemical) processes add their own
complications
Figure 2 Generic water consumption in oil refining processes Quality of imported water (for
example, saline or potable) The proc-
effluent discharge. Contaminant interactions ess of preparing water for use in boilers and
pose threats of VOC emissions, scale formation, processes gives reject flows that depend in size
corrosion, bio-fouling, sludge build-up and more, on the quality of imported water.
making the application of quantitative tools very Water usage is further affected by:
difficult Crude types processed (sweet or sour, light or
Poor metering Usually caused by relative heavy) This determines how much contamination
Developing a base case Other blue fonts are trustworthy flow estimates
Red fonts indicate guessed values
To find a refinerys specific Black fonts indicate calculated values
water consumption (tonnes of Blow-down flow was estimated using a reasonable blow-down percentage
Water in the feed is thought to be negligible
water imported per barrel of Drinking water was estimated from person equivalents
crude processed), one must be
clear about which battery limit Figure 3 A sample process unit water balance
water flows should be counted.
Water or steam going to associated petrochemi- for data collection; often a single summer month,
cal processes, or to third parties, should be during which all the major water-consuming
disregarded. processes are running normally.
A site-wide water balance is not strictly Due to insufficient flow metering, achieving a
required, since we are only talking about (fresh) balance may require many types of information,
water imports. However, to verify key measure- such as stoichiometry, valve openings and
ments and help with sifting out the non-refinery pipe diameters, concentrations or temperatures
water flows, it is a great tool. For finding before and after mixing, design values pro-rated
improvements at a later stage, it is to current production and more. KBC recom-
indispensable. mends documenting each data source and
Producing a useful water balance is challeng- its reliability.
ing in this branch of industry. Water, although Figure 3 shows a well-documented water
used in many ways (Figures 1 and 2), has histori- balance around a process unit. Separate process
cally been of little concern. The upkeep of water balances like this should be combined into a site-
systems and reliable metering are generally wide balance and resulting flows cross-checked
found wanting. The strategy presented here is to against main meters on water import, demin
actively involve all relevant staff and start from production, steam generation and waste water
both ends simultaneously the utility systems flow.
and the processes. Eventually, both will have to
meet and be reconciled. Improvement opportunities
A good base-case time period must be chosen A holistic approach to water reduction requires