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The size factor varies from 1.02 for capacities of less
than 24,900 bbl/d to 1.57 for refineries of 150,000
bbl/d or larger. Tables listing the size factors are also
provided in the guidelines. Process factors-listed as a
function of the process configbration-are calculated by
taking into account the various processes, as well as the
relative throughput for each pr0cess.t
Waste-treatment processes
One of the functions of a process engineer is to decide
which treatment process, or combination of processes,
will best perform the necessary job of cleaning up the
wastewater effluent involved, because waste-treatment
facilities contribute significantly to the total cost of a
capital project. Since the cost involves also land and
manpower, future needs must also be considered.
This is often difficult to do, because regulations
change or new regulations come into effect. For this
reason, it is wise many times to institute a development
program, so that as wastewater-quality requirements
become more stringent, treatment processes can be
modified, or new ones added to improve the water
quality. As a refinery expands, a similar program may
be followed to increase wastewater-handling capacity.
An effluent-treatment system involves one or more
stages, depending on the quality of the raw efRuent and
the required pollutant reduction. The various unit processes are categorized in the following manner [3]:
Intermediate
Secondary/tertiary
Sulfidejammonia
stripping
Flotation
Activated sludge
Tilted-plate
separators
Liquid-liquid
Equalization
Primary
extraction
Ponds
Aerated lagoons
Filtration
Filtration for
oil removal
Carbon adsorption
p H control
Chemical oxidation
13
14
INTRODUCTION
The purpose of the primary and intermediate procesSeS is to remove certain pollutants from wastewater
before the water goes to the secondary- and tertiarytreatment processes, because high concentrations of suspended solids or oil may be harmful to the processes.
Contr
Since many waste streams are highly acidic or alkaline-and would therefore be detrimental to biological
processes-it is necessary to control the pH of refinery
wastewaters before they proceed to biological treatment. Sometimes, phosphoric acid or ammonia addition is beneficial for the dual purpose of controlling p H
and supplying the necessary nutrients for downstream
biological processes (see further on, where biological
processes are discussed).
Dissolved-air flotation is normally considered an intermediate or secondary treatment process for further
removal of oil and suspended solids from API-separator
effluents, prior to biological treatment. Ref. 10 reports
how the American Oil refinery at Whiting, Ind., used a
flotation unit-whih included a series of bioflotation
ponds-to treat effluent from secondary treatment.
Apparently, chemical coagulation and air flotation of
the effluent from the aerated lagoon produced a final
effluent that met tertiary-treatment goals.
EPA reports [8] removal efficiencies of 70-85% for
oil, 50-85% for suspended solids, 20-7076 for BOD, and
10-60% for COD, for dissolved-air flotation units.
However, the API Manual [f I] refers to a technical article where better removal efficienciesare reported.
Pilot-plant tests on flocculation-flotation have shown
97% removal OF oil, 75% of solids, and 80%of BOD and
COD. Chemical flocculating agents used to aid flotation are activated silica, and aluminum and ferric salts.
These agents also improved the effectivenessof the flotation unit in removing oil emulsions.
Since the effectiveness of dissolved-air flotation units
varies substantially with the characteristics of the particulate matter, it is imperative that laboratory and pilot tests be run to obtain the necessary design criteria.
Small pilot units can be rented from vendors. Instructions and illustrations for laboratory tests are provided
by the API Manual [If].
In the dissolved-air flotation process, the waste
stream is saturated with air under a pressure of several
atmospheres. This is done by pumping the stream to
40-50 psig, and feeding compressed air a t the pump
suction. The stream is then held in a retention tank for
several minutes so that the air will dissolve. As the
stream exits from the retention tank, it flows through a
pressure-reducing valve-which drops the pressure to
atmospheric-and then into a flotation tank.
When the pressure is released, the air comes out of
solution, forming minute bubbles within the liquid.
These bubbles, which are about 30-120 microns in
diameter, form oii the surfaces of the suspended particles. An aggregate is thus formed, which rapidly rises
to the surface and is skimmed from the flotation tank.
Design details are provided in the API Manual [II]
and in Ref. 12.
Package units are available from various vendors.
Ref. 10 cites the use of surplus boxes in the API separator as flocculation chambers, and indicates that coagulant concentration proved to be important. For instance, a concentration of 30-50 ppm of alum was
sufficient to promote coagulation without deterioration
of effluent quality due to excessive coagulant.
Activated-sludge process
Activated-sludgeproceduresare used extensively for
coagulating and removing nonsettleable colloidal solids, as well as to stabilize organic matter. EPA reports
/8] removal efficienciesof 80-99% for BOD, 50-95% for
COD, 60-85% for suspended solids, 80-99% for oil,
95-99+% for phenol, 33-9976 for ammonia, and
97-100% for sulfides. Thus, a high-quality effluent is
obtainable from a properly designed and operated activated-sludge system.
This particular process is an aerobic biological procedure containing, within a reaction tank, a high concentration of microorganisms, which is maintained by recycling activated sludge. Oxygen is supplied to the
wastewater in the reaction tank either by mechanical
aerators or a diffused-air system. Inasmuch as the microorganisms remove the organic materials by biochemical synthesis and oxidation reactions, the converted organic matter must be removed by sedimentation, prior to final discharge.
The main components of the process are the aeration, or reaction, vessel and the sedimentation tank.
Sludge removed from the sedimentation tank is recycled to the aeration vessel to maintain the required
concentration of microorganisms. Since a portion of the
sludge must be discarded, it is first dewatered and then
used as landfill.
Nutrients-primarily nitrogen and phosphorus-are
required to maintain a healthy growth of microorganisms within the system. These elements are
needed in minimum amounts of 5 Ib nitrogen and 1 It,
phosphorus for every 100 Ib of BOD to be removed
[13]. Generally, refinery wastewater contains enough
ammonia to supply adequate nitrogen, but it may be
deficient in phosphorus. Some of the sources of these elmerits are [ 141:
Water condensate from catalytic cracking units
and normally containing ammonia and other nitrogen
compounds.
Spent phosphoric acid catalyst from polymerization units; the phosphates can be leached from the
catalyst with water.
15
Trickling filters
16
INTRODUCTION
Storm-water
retention
Oily
water
sewer
API
separator
Equalization
basin
Dissolved-air
flotation
Aerated
lagoon
Waste-stabilization ponds
A stabilization pond is simply a large shallow pond
in which bacteria stabilize the wastewater fed to the
pond. Stabilization ponds are classified as aerobic, aerobic-anaerobic, and anaerobic, depending on the type
of biological activity. Since refinery wastes are not normally suited to anaerobic treatment, we will discuss
only aerobic, or oxidation, ponds.
Oxidation ponds are normally about 4 ft deep. Shallow ponds tend to have excessive weed growth, and
deep ponds do not get adequate oxygen transfer to
maintain aerobic conditions. Oxygen-supplied by natural surface aeration and by the photosynthetic action
of the algae present in the pond-is used by bacteria for
the aerobic degradation of organic matter. In turn, algae utilize the nutrients given off by bacteria.
Organic loadings of oxidation ponds reported in the
API Design Manual [f6] range from 20-100 lb
BOD/(acre)(d). Recommended loadings for ponds
handling raw wastes are about 40 lb BOD/(acre)(d).
For ponds downstream of other treatment processes,
loadings as low as 10 lb/(acre)(d) should be used. Retention times range from 1 to 90 days. However, the
API Manual points out that for a pond to be effective,
it should have a retention time of at least 7 days. A p
proximately 30 days is recommended for an organic
loading of 50 Ib BOD/(acre)(d).
EPA reports [8] the following removal efficiencies for
oxidation ponds: 40-35% for BOD, 30-65% for COD,
20-70% for suspended solids, and 50-90% for oil. The
differences in removal efficiencies are due to the wide
variations in loadings and retention times reported
above. Consequently, it is difficult to develop any general design parameters for oxidation ponds. Any parameter must be functionally related to temperature,
solar intensity, wind, organic loading, and the nature
of the waste. Methods for relating these factors are provided in Ref. 17.
The effectiveness of oxidation ponds is also influenced by other factors such as temperature and tur-
- $Ad
filters
Effluent
Fig. 1
Aerated lagoons
Aerated lagoons operate generally by the same basi
principles as do oxidation ponds. Mechanical-aeratio
equipment, associated with aerated lagoons, results in
higher concentration of bacteria than is present
dation ponds. Consequently, land requirements
for aerated lagoons than for oxidation ponds
equal loadings. Retention time is usually 3-10 d.
moval efficiencies are 75-95% for BOD, 60435%
COD, 40-65% for suspended solids, 70-9076 for
90-99% for phenol, and 95-10076 for sulfides [SI.
Aeration of the lagoon keeps most of the solids in
pension. One method of decreasing th
ids in the effluent is to have a sedimentatio
the lagoon, where the water is calm enou
residence time is adequate to allow sedimentatio
the solids. Otherwise, it may be necessary to include
settling tank.
Since, like the oxidation pond, an aerated lag
sensitive to temperature, in colder climates the
formance is hampered during the winter months.
sources [f9]recommend that solids be
lagoon during the winter to improve pe
to operate the lagoon essentially the same as
17
Stormwater
retention
Oily
water
sewer
separator
basin
flotation
filters
system
Effluent
1
Fig. 2
Filtration
Filtration is used only when it is necessary to obtain
a very high-quality effluent or recycle stream. The effluent from activated-sludge systems contains organic
matter in suspended or colloidal form that can be filtered; typically, the effluent ranges in content between
5 and 50 mg/l, which can be even further reduced to
around 3 to 20 mg/l in a granular-media filter.
The results of filtering an activated-sludge effluent
through a dual-media filter containing anthracite and
sand are reported in Ref. 20. The solids in the effluent
from a pilot-activated sludge unit are said to have a bimodal particle-size distribution. T h e smaller particles
were in the 1-5-micron range, while the larger ones
were in the 50-180-micron range. This makes the dualor tri-media filters superior to the single-medium sand
filter, where the larger particles tend to plug the filter,
running times are shortened, and smaller particles are
allowed to pass. With a dual-media filter, much more
efficient solids removal and longer filter runs are experienced.
Typical dual-media filters are: anthracite and sand;
activated-carbon and sand; resin beds and sand; and
resin beds and anthracite. Filtration rates are in the
2-10-gpm/ft2 range, with 5-6 gpm/ft2 being typical. It
is recommended that a pilot study be done for a particular system, because filter performance is very dependent on the particular characteristics of the specific
liquid feed.
Carbon adsorption
There has been a tremendous amount of development in recent years in the use of activated carbon for
the removal of dissolved organic material from wastewater. Carbon adsorption is normally used for final
Chemical oxidation
The primary application of chemical oxidation is for
the reduction of phenols and cyanides in waste streams,
b y oxidants such as chlorine or ozone. Thcse processes,
18
INTRODUCTION
References
I . Fcdcral Rrgisfn, Vol. 3p: No. 91, May 9.1914.
2. Fcdnol Regirfer, Vol. 44,No. 90,May 20, 1975.
3. Carnes, B.A., Ford, D.L., and Brady, S . , Treatment of Refinery Wastc-
waters for Reuse, National Conferma on Complete WateReux, Washington, D.C., Apr. 1973.
4. Wastewater Engineering: Collection, Treatment, Disposal. pp. 638-644,
Mctcalf and Eddy, Inc., Ncw York.
5. Weisbcr , E., and Stockton, L).L., WateReusc in a Petrolcum Refinery,
Nationaf Conference on Complete WatcRcux. Apr. 1973.
6. Anncsen, R., and Could, G., Sour-Water Procruing Turru Pmblcm Into
Payout, C h n Eng., Mar. 22,1971, pp. 67-69.
7. API Manual on Disposal of Refinery Waste, Volume of Liquid Wastes,
Chap. 15, American Petroleum Institute ( M I ) , Washington, D.C.
8. Development Document for Proposed Effluent Limitations Guidelines
and Ncw Source Performance Standards for Pctrolcum Refining, Dcc.
1973, p. 1 IO, Environmental Protection Agency, Washington, D.C.
9 . API Manual on Disposal of Refinery Waste, Volume of Liquid Waste,
Chap. 5 and 6, API, Washington, D.C.
IO. Franzcn, A,, Skogan, V., and Grutsch,J.. Chon. Eng. Prop., Vol. 68, No. 8,
Aug. 1972, pp. 65-72.
1 1 . API Manual on Disposal of Refinery Waste, Volume of Liquid Waste,
Chap. 9. API, Washington, D.C.
12. Wastewater Engineering: Collection, Treatment, Disposal, pp. 299-301,
Metcalf and Eddy, Inc., New York.
13. Dahlstrom, D., Lash, L., and Boyd, J., Biological and Chemical Treatment of Industrial Wastes, Chon. Eng. Bok..Voi. 66, No. 1 I , Nov. 1970,
pp. 41-48.
14. API Manual on Disposal of Refinery Wastes, Volume of Liquid Waste,
Chap. 13,pp. 13-14,API, Washington,D.C.
15. Ibid.,Chap. 13,pp. 13-41.
16. Ibid.,Chap. 13, pp. 13-54.
17. Wastovatcr Engineering: Collection, Treatment, Disposal, pp. 556-564,
Metcalf and Eddy, Inc., Ncw York.
18. Ibid., pp. 533-542.
19. Ibid., p. 543.
20. Ibid., pp. 644-650.
21. Hutchins. R.A., Chan Eng. Rogr., Vol. 69, No. I I . Nov. 1973, p. 48.
22. API Manual on Disposal of Rcfincry Wastes, Volume of Liquid Waste,
Chap. 10, pp. 1039, API, Washington, D.C.
23. Lovcn, A. W., C h n Eng. Roogr.,Vol. 69. No. I I , Nov. 1973, pp. 56-62.
24. Porter, J.W., Blake, J.H., and M i l l F , R.T., Zem Discharge of Wastewater fmm Petrolcum Rcfincries, ational Conferenoc on Complete WateRcuse, Washington,D.C.,Apr. 1973.
The author
Kenneth E. Bush is Manager, PrEngineering, for T h e Frantz Co., Suite
400, Bank of Woodlake Bldg.. 2600 South
Casncr, Houston, TX 77063. His
ruponsibilitia include moeu daign of
pctrolcum refincries anichcmical plants,
as wcll as wastcwatcr-treatment and
cncrgy-cfficiencystudies. A rcgisted
professional engineer in TCXM.
he is also
chairman of the State AtTain
Subcommittee of the Critical I u u n
Committee of the AlChE South Tcxar
Saction. He holds B.S. and M.S. degma in
chemical en imring. thc former from
Tcxas A&bfUnivcnity, thc l a t t a frum
the University of Houston.
Edited by
Vincent Cavaseno
and the Staff of Chemical Engineering