Annex I PO1 Process Design Basis Rev 3

I.
PROCESS DESIGN BASIS

PROJECT. DAF Performance and Biological Sludge Separation Page 2 of
Improvements 2022020
Project
C. I. TARRAGONA
INDEX
1. INTRODUCTION ...................................................................................................... 3
2. PROCESS DESIGN BASIS FOR CONCEPTUAL AND BASIC

ENGINEERING PACKAGES ................................................................................... 3
2.1. WASTE WATER TREATMENT PLANT DESCRIPTION 3
2.2. SCOPE 34
3. CAPACITY ............................................................................................................... 56
4. FEEDSTOCKS AND PRODUCT SPECIFICATIONS ......................................... 67

4.1. WASTEWATER CONDITIONS 67
4.2. BIOLOGICAL SLUDGE DATA 78
4.3. PRODUCTS SPECIFICATION 89
5. EFFLUENTS ........................................................................................................... 910
6. DESIGN CRITERIA .............................................................................................. 910
7. BATTERY LIMIT CONDITIONS ........................................................................ 910
8. PLOT PLAN ......................................................................................................... 1011
9. DOCUMENTATION ............................................................................................ 1011
Annex I PO1 Process Design Basis DAF and biological Sludge Separation rev 3PO1 Process Design Basis DAF and biological
Sludge Separation rev 1.docx
1. INTRODUCTION
The purpose of this document is to provide bidders information to realize a Conceptual and
Basic Design to improve DAF performance and biological sludge separation within Waste
Water Treatment Plant of Repsol Petrleo Refinery at Tarragona (Spain). The Plant will be
able to process 300 m3/h of wastewater with a service factor of 365 days per year.
The study must required services contain the following phases:

Conceptual Design
Basic Engineering Package
Technical Services
o Equipment specifications and Equipment Basis for bidders
o Technical and Economical offer Analysis
2. PROCESS DESIGN BASIS FOR CONCEPTUAL AND BASIC ENGINEERING

PACKAGES
2.1. WASTE WATER TREATMENT PLANT DESCRIPTION
The Waste Water Treatment Plant is designed to treat wastewater coming from Refinery,
two Ethylene Plants and Spent Caustic Treatment Plant in Repsol Petrleo Tarragona Site.
The WWTP is composed by the following systems:

VOC Removal Plant (U-457)
API (out of service)
CPI (out of service)
Coagulation/Flocculation
DAF
Chemical Oxidation
Biological Bed
Biological Sludge Separation
For more detailed information see Appendix 1.
2.2. SCOPE
Project Boundaries Con formato: Fuente: Negrita
The project will be limited to the following systems:
a1. DAF
b2. Biological Sludge Separation
Project Phases Con formato: Fuente: Negrita
The project will have the following phases: Con formato: Espacio Despus: 0 pto
1. Screening and Conceptual Study:

The bidder has to compare different alternatives to improve the performance in DAF and
Biological Sludge Separation taking account almost the following issues:
Oil or Sludge separation efficiency
Constructability and Plot constraints
Investment and Operation Cost
VOC emissions Con formato: Prrafo de lista,
Sangra: Izquierda: 1 cm, Primera
Technical References lnea: 0 cm, Con vietas + Nivel: 1 +
Alineacin: 1 cm + Sangra: 1,63 cm
At beginning of the phase, a kick-off meeting in Tarragona will be held in order to clarify
basis and collect all the documentation.
An intermediate meeting will be taken in order to choose best convenient option.
At the end of the phase a meeting in Tarragona will close the study.
Con formato: Espacio Despus: 0 pto
2. Basic Engineering
The scope of Basic Engineering Package is defined in attachment III.
At beginning of the phase, a kick-off meeting in Tarragona will be held in order to clarify
basis and collect all the documentation.
Con formato: Espacio Despus: 0 pto
3. Technical Services during Detail Engineering
The scope of technical Services is defined in attachment IV.
Expected Modifications Con formato: Fuente: Negrita
a1. DAF Improvements Alternatives:

a. New mix air-water application by using pumps technology
b. Improve air control system
b2. Biological Sludge Clarification Alternatives
a. Improve actual current settlement basin located after the biological bed.
b. New Cclarifier system with the current Biological Bed Configurations
c. Improve current settlement basin and install a new Clarifier
Con formato: Justificado, Sangra:
Izquierda: 2,25 cm, Derecha: 1 cm
3. CAPACITY
The average wastewater treated wastewater flowrate is 250 m3/h and the design capacity for
the new Cclarifierd will be 300 m3/h.
In order to improve maintenance of the equipments, new Clarifier has to be defined taking
account that current Clarifier or new Clarifier could be out of service. Therefore, the
following cases have to be considered:
Case A: After current Clarifier
Case B: After current Biological Bed:
The sludge recirculation is 210 m3/h (Current pump flow) and the service factor of
24 h/day.
Other options proposed by bidders will be evaluate. Con formato: Sangra: Izquierda: 1
cm
Expected Biological configuration after project
4. WASTEWATER SPECIFICATIONS
4.1. WASTEWATER PROPERTIES

The average wastewater temperature before DAF is 35 C and a maximum of 43C.
The waste water characteristics after current biological bed are:
Data from January 2015 to May 2016
COMPONENTS AVERAGE MAX

TSS (mg/L) 4300 9000
SVI Collecting Collecting
data data
The waste water characteristics after current Clarifier:
Data fron January 2015 to May 2016
COMPONENTS AVERAGE MAX

TSS (mg/L) 100 700
SVI Collecting Collecting
Data Data
Complete analysis (from 9 samples) after current Clarifier:
COMPONENTS UNIT AVERAGE Max

Amonium (N) mg / L 23,23 33
BOD5 mg / L 152 230
COD non filtrated mg / L 403 660
COD filtrated mg / L 307 473
Inhibitor matters TE/m 3,293 5,5
Kjeldahl Nitrogen (TNK) mg / L 37,1 44
TOC mg / L 145 220
Total Nitrogen mg / L 38,3 54
Amine (ppm) 16,9 29,3
Nitrates (N) mg / L 1,00 1
Nitrites (N) mg / L 0,02 0,04
Benzene g / L 1,91 11
Etilbenzene g / L 1,293 6,5

m,p-Xilene g / L 2,21 8,5
o-Xilene g / L 1,364 6,7
Toluene g / L 1,778 7,8
Total Hydrocarbon mg / L 5,12 5,8
Total sulfur mg / L 1,11 2,9
4.2. BIOLOGICAL SLUDGE DATA
Current characteristics of biological sludge ( two samples) are:
02/12/2015 24/02/2016 01/02/2016

REACTOR REACTOR REACTOR REACTOR
Parameters Unit Recirculation
1 2 1 2
MES mg/L 4950 5420 3153 4070 15600
MESv mg/L 4250 4620 2780 3630 13960
A&G mg/L 2675 2150 1070 1100 4250
A&G
mg/L 156 124 41 27,78 196
filtrated
A&G
mg/g 509 374 326,4 263,5 260
sludge
HC total mg/L 2600 2025 950 830 4000
HC filtrated mg/L 148 100 32 15,76 184
HC sludge mg/g 495 355 291,2 200 245
HC sludge % 49,5 35,5 29,12 20,0 24,5
HC present in biological sludge depends of DAF performance. Bidders can consider HC

content reduction in base of proposed DAF modifications or others proposed
modifications related to this project..
4.3. EFFLUENT SPECIFICATION

The Unit will be modified to comply with the following specifications in the discharge
point:
COMPONENTS COMPOSITION (mg/l)

TSS 25
HC index 2.5
5. EFFLUENTS
Other gaseous effluents (at least CO2, SO2, SO3, NOx, and particles) should be reported.
Other effluents (liquid, used catalysts, etc.) and their disposal or treatment, if any, will be
specified by Bidder.
6. DESIGN CRITERIA
On-stream factor will be 365 d / year

New equipments have to be able to be blocked for maintenance works with the
installation in operation
The new clarifier can be operated in two modes:
a) In series with the actual settlement basin.
The design criteria is: TSS entrance average 100 ppm and maximum of 700 ppm.
b) Can be used after current biological bed
The design criteria is: TSS entrance average 4300 ppm and maximum of 9000 ppm.
Both types of biological configurations have to ensure product specification: 25 ppm TSS.
7. BATTERY LIMIT CONDITIONS
STREAM P T TO / FROM
(kg/cm2g) (C)
Feed:
Wastewater to DAF From Flocculation/coagulation
atm 35
Basin
Wastewater to Biological From Biological Bed
atm* 35
Sludge Separation
Products:
Treated Wastewater atm* 35 To final retention basin
Biological Sludge - - To Biological Bed and Purge
* If a new biological sludge separator is required evaluate the need of pumping
8. PLOT PLAN
The new facility will be located close to the existing Biological Bed.
See Plot Plan.

Cdigo de campo cambiado
ET-B-452-A-42092-H ET-B-452-A-42092-H
0-0.pdf 0-0 rev1.pdf
After awarding the Basic Engineering Package, as soon as possible (no later than two weeks)
a meeting at Tarragona Refinery will be mandatory to check that the proposed area is
adequate to install new equipment.
9. DOCUMENTATION
Wastewater Temperature:
Temperature
wastewater feedstoo
APPENDIX 1
1. Waste Water Streams

The main wastewater streams treated in the WWTP are described below
1.1 Process water and oily water

Process water and oily water gets together in the water trap at units outlet and flows to
WWTP through the same drainage network since U-457 is in operation.
The oily waters contain paraffinic hydrocarbons, crude or fractions and other oils or fats
that require chemical treatment. They come from purges and equipment cleaning, rain from
unit paved areas, from storage tank bunds and tank bottoms purges.
Process waters contain chemical contamination or suspended solids and require physico-
chemical treatments for decontamination. They are originated during crude desalting
process, in steam systems process and in process strippings.
The wastewater treatment plant has the following input lines:

The waste water arrives to WWTP from VOC Removal Plant (U-457) by 10 polyester
reinforced with fiberglass line. There is an automatic valve that regulates the inflow by
controlling the total flow of treatment. Downstream of the automatic line is divided into
three branches. Depending of the de-oiling required, the waste water can flow into the
APIs entrance channel (equipment out of service), to the CPIs entrance channels or to
CPIs outlet channel.
Line from U-456. The waste water from U-456 is pumped to the WWTP and uses the
same channels of the previous line. It is currently out of service because the water de-oiling
is done in U-457.
Line from desorption plant Sludge. The paved area drains from the desorption plant
sludge are collected into a 12 trap that flows to 452 Unit.
Line from slops tanks. The water that are collected in the bund areas of slops tanks and
their purges flows to WWTP by 6 buried line. This line discharge into the same system
than the desorption unit sludge.
1.2 Cooling water purge

This waters has saline contamination from cooling system purges and water regeneration of
demineralization chains. They may contain small concentrations of chemicals from the
cooling water treatment.
This water reaches 452 unit through a 16 " line. The 16 line discharges into a settling
solids channels (called simple separators that remove solids) and afterwards flows to the
final basin (retention basin).
1.3 Stormwater:
The clean rainwater are those that are collected in not contaminated areas, such as streets
and buildings of the industrial site, the racks passing pipes, unit gravel areas and tank
bunds.
The rainwater comes through two channels (south and north) to rainwater basin. The
rainwater basin has three outlets: by overflow into the river, from the bottom exit of the
rainwater basin through the final basin (retention basin), and into head basin storage (U-456
basins) in case of water treatment required.
1.4 Sanitary water:

They come from complex sanitary services. They are pumped into U-452 through a 4" line
which overflows into the biological bed.
1.5 Spent Soda Treatment Plant Effluent (U-463)

This waters contains high organic content (TOC 4000 ppm), and comes from a previous
treatment at a wet oxidation (WAO ) with the pH adjusted to less than 97.
2. Waste Water Treatment Plant Overview

The Waste Water Treatment Plant consists of the following systems:
VOC Abatement Plant (U-457)
Pre-treatment: primary oil separation API's (out of service) and secondary oil
separation CPI's (out of service).
Primary treatment: the coagulation/flocculation basin is divided in two separated
sections, one devoted to flocculation with soda injection (flocculant), and another for
coagulant injection. After the coagulant/flocculant basin there is a D.A.F Clarifier where
floatation of the flocs takes place.
Chemical oxidation: oxygen is injected into two basins where chemical oxidation takes
place.
Secondary treatment: it consists of a biological pre-reactor and a biological reactor,

where in both pure oxygen is injected. Next to biological reactor is located a
Clarification Basin where the sludge is decanted and separated.
Evacuation system through an outfall.
Storage Basin: rainwater basin, final retention basin and security basin.
Sludge Treatment: available storage system and pumping system. The sludge is
pumped to ECOIMSA company, belonging to Tradebe group, and is located next to the
WWTP.
The maximum design capacity of the treatment plant was 300 m3/h.
3 WWTP Systems
3.1 Preatment
Pretreatment of the WWTP consists of a primary de-oiling system (API's) and a secondary
de-oiling (CPIs) currently out of service.
Oil separation takes place in gravimetric tanks of the VOC Abatement Plant (457 unit).
After VOCs removal, the wastewater is sent to the 452 unit via a 10 line. In 452 unit
entrance, there is an automatic valve FV-002 whose mission is to protect the treatment
system. In the case of higher flows to 300 m3/h this valve closes and the water from the U-
457 will overflow into the U-456 basin.
At the entrance of the unit 452, 452-G-17/17-A pump water to the flocculation system.
3.2 Physic-chemical Treatment

The de-oiled water is sent to the coagulation/flocculation basin. The basin is subdivided
into two compartments, called A and B basin:
In the basin A is dossed aluminum polychloride, which acts as a coagulant, and if is
necessary to increase the pH, Soda is dossed too. The basin A has a surface agitator (452-
K-1) that homogenised the water. Water flows through the overflow to Balsa B.
In the B basin flocculent (polyelectrolyte) is incorporated. Afterwards the water is sent
from the bottom to the flotation system.
In DAF unit, the folcs formed during the flocculation reaction are extracted in the surface
and the solids are decanted and send it to Float pits. The water overflows to chemical
oxidation basin.
3.3 Chemical oxidation

The chemical oxidation system aims homogenization and COD reduction. That avoids
possible toxic compounds as sulfides in the biological treatment phase.
The oxidation is carried out in two basins in which is injected continuously oxygen gas,
supplied by pipeline with a pressure of 25 kg/cm2. Each basin has a recirculation line
wastewater consisting of a pumping system, a mixer and gas-liquid ejectors system.
Pumping water to the biological treatment is carried out from the final pit basin II by pumps
452-G-19/19-A.
3.4 Biological Treatment

The biological treatment is aerobic-type with activated sludge. It consists of a Pre-reactor
and a Reactor with pure oxygen injection and a Clarification basin.
The biological Pre-reactor (I) has a volume of 350 m3 and was included in the process as a
measure to improve the original treatment (year of implementation 2000). The biological
pre-reactor-I receives the water coming from chemical oxidation basin and biological
sludge recirculation. It can be injected phosphoric acid as a nutrient and caustic soda for pH
adjustment. Two OXI-DEP equipments are used to inject the necessary oxygen and
maintains the water-sludge mixture in continuous homogenization.
The biological Reactor (II) has a volume of 2016 m3 and it was the only biological
treatment equipment in the original design of the Refinery. In this one is also injected pure
oxygen by three OXY-DEP equipments (452-G-32-A/B/C) that maintain the water-sludge
mixture homogenization and the necessary oxygen need. The waste water can be received
from the biological reactor (I) or chemical oxidation II basin. Orthophosphoric acid and
caustic soda can be dosed too. The biological reactor II overflows to the clarifier by gravity.
The Clarifier has a rectangular shape (41 x 8.7 x 2.1 m). The basin was designed decant the
sludge, which is recirculated to the biological pre-reactor, and the clarified water is drained
to the Retention Basin. The Clarifier has a removal sludge system. It comprises a collection
system surface sludge and sludge superficial removal system and a bottom removal system
by pumping. Clarified water overflows by both sides of the basin and flows to the Retention
Basin by a 14 pipeline.
3.5 Evacuation system and storage basin

3.5.1. Retention basin
The water treated in the WWTP and clean untreated water, reach the retention basin before
discharge to the sea. In the retention basin, all streams are homogenized and solids that may
escape from WWTP are retained. In case of contamination of any input current,
hydrocarbons remain on the surface and it will be close the outfall to the sea.
In the retention the entrance and the exit channel basin are located at the same side. The
basin is divided in two parts to ensure the resident time required. The rainwater, the waste
water treated coming from the clarifier, the cooling water and water coming from the
security basin enter into the entrance channel.
The chemical oxidation basin overflows to the retention basin.
3.5.2 Reserve Basin

The reserve basin is used as a backup storage in case of failure in the emissary and can
retain contamination. This basin also receives water from the groundwater and retention
basin water.
The water safety basin can be sent by pumping (452-G-103-A / B and 452-G-104) to the
retention basin. This water can be also pumped to head basin storage in 456 unit
3.5.3 Rainwater basin

The rainwater basin has three outputs, two bottoms outputs (8 line) - One to send the water
to the head storage basin in unit 456 and another to the retention basin and a superficial
overflow provided with metallic baffle that overflows to the Francol river.
3.5.4 Phreatic Network Pipe

There is an underground pipes network, located under WWTP , which collects groundwater
to avoid high groundwater levels that can damage the partially buried basins. The
underground pipes network flows by gravity to the security basin.
The main equipment design data of the unit wastewater treatment are listed below:
Table 1. Equipment basic data U-452

Equipment Function Capacity
(m3)
Rainwater basin Clean rainwater storage 1596
CPI separator Secondary de-oiling 23 (x 5)
Coagulation basin Coagulant dosage 72
A
Flocculation basin Flocculent dosage 9
B
D.A.F. Floccule elimination 273,6
Oxidation basin Biological entrance COD 1350 (x
reduction 2)
Biological reactor BOD reduction by pur O2 350
I injection
Biological reactor BOD reduction by pur O2 2016
II injection
Clarifier Decanted Sludge and water 738
clarification
Retention basin Water homogenization and solid 9487
retention
Security basin Contaminant retention 14800
Simple separators Cooling water solid elimination 295
Table 2. Pump basic data U-452

Capacity
Equipment Function
(m3/h)
Security basin - water
452-G-103-A/B 100
pump
Security basin - water
452-G-104 300
pump
Water pumped to
452-G-17/17-A 300
flocculation
452-G-102/102- Pumping water from
17
A CPIs to SLOPS system
Chemical oxidation II
452-G-23-A/B 252
recycling pumps
Chemical oxidation II
452-G-23-C 252
recycling pumps I
Pumping water to
452-G-19/19-A 300
biological treatment
Bombas OXI- Homogenisation of
68,4
DEP-S biological pre - reactor I
Sludge recirculation
452-G-8 210
pump clarification basin
Surface sludge pump
452-G-7 15
from clarifier
Biological sludge pump
452-G-9 15
from clarifier
3.6 Sludge Treatment

The sludge produced in the COVs Abatement Plant and in the WWTP are stored and
pumped to the a contractor (Tradebe) Sludge Desorption Plant.
Repsol has three sludge storage tanks, one storage basin, a pumping system, a biological
sludge thickener and a process sludge thickener
During the water treatment process and biological sludge are produced. They have different
origins and treatment:
3.6.1.Process sludge:
Process sludge come from the bottom of the gravimetric tanks (U-457), from pit drains S-5
in U-456, and surface and bottom collectors from D.A.F (U-452).
The process sludge are stored in three tanks, called Float-Pit-B / C / D. The sludge is sent
by pumping (452-G-5/5-A) to process sludge thickener.
Once the sludge is thickened, it is pumped (452-G-3-A / 4 and G-25) to TRADEBE plant.
3.6.2. Biological sludge:

The biological sludge are generated in the biological treatment and sent by pumping (452-
G-9) to biological sludge thickener (452-D-5) before shipment to the Sludge Desorption
Plant.
Thickened biological sludge is sent to the suction pumps 452-G-3/4-A. The water produced
in the thickener overflow to the biological reactor II.
The centrifuged sludge raft is out of service. This can act as a sludge storage raft before
shipment to the plant TRADEBE. The raft can receive sludge from 452-G-3/3-A and 452-
G-4/4-A and can pump sludge to TRADEBE (452-G-25).
As above described, we have two independent lines to pump sludge to TRADEBE:

- Biological sludge line: It can receives sludge from 452-G-3, 452-G-4-A and 452-G-5
pumps.
- Process sludge line: It can receives sludge from 452-G-3-A, 452-G-4 and 452-G-25
pumps.
Table 3. Equipment basic data from sludge treatment plant (U-452)

Equipment Function Capacity
Pumping thickened sludge to
452-G-3/3-A 1,5 m3/h
ECOIMSA
Pumping sludge Float-Pit B to
452-G-4 1,5 m3/h
ECOIMSA
Pumping sludge Float-Pit B/C/D to
452-G-5-5A 15 m3/h
thickner
Pumping thickened sludge from
452-G-25 0,62 m3/h
centrifuged sludge raft to ECOIMSA

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I.

PROCESS DESIGN BASIS

2. PROCESS DESIGN BASIS FOR CONCEPTUAL AND BASIC

4. FEEDSTOCKS AND PRODUCT SPECIFICATIONS ......................................... 67

5. EFFLUENTS ........................................................................................................... 910

6. DESIGN CRITERIA .............................................................................................. 910

7. BATTERY LIMIT CONDITIONS ........................................................................ 910

8. PLOT PLAN ......................................................................................................... 1011

9. DOCUMENTATION ............................................................................................ 1011

The study must required services contain the following phases:

2. PROCESS DESIGN BASIS FOR CONCEPTUAL AND BASIC ENGINEERING

2.1. WASTE WATER TREATMENT PLANT DESCRIPTION

The WWTP is composed by the following systems:

For more detailed information see Appendix 1.

The project will be limited to the following systems:

Project Phases Con formato: Fuente: Negrita

1. Screening and Conceptual Study:

Expected Modifications Con formato: Fuente: Negrita

a1. DAF Improvements Alternatives:

Expected Biological configuration after project

4.1. WASTEWATER PROPERTIES

The waste water characteristics after current biological bed are:

Data from January 2015 to May 2016

COMPONENTS AVERAGE MAX

The waste water characteristics after current Clarifier:

Data fron January 2015 to May 2016

COMPONENTS AVERAGE MAX

Complete analysis (from 9 samples) after current Clarifier:

COMPONENTS UNIT AVERAGE Max

Etilbenzene g / L 1,293 6,5

4.2. BIOLOGICAL SLUDGE DATA

Current characteristics of biological sludge ( two samples) are:

02/12/2015 24/02/2016 01/02/2016

HC present in biological sludge depends of DAF performance. Bidders can consider HC

4.3. EFFLUENT SPECIFICATION

COMPONENTS COMPOSITION (mg/l)

On-stream factor will be 365 d / year

7. BATTERY LIMIT CONDITIONS

See Plot Plan.

1. Waste Water Streams

1.1 Process water and oily water

The wastewater treatment plant has the following input lines:

1.2 Cooling water purge

1.4 Sanitary water:

1.5 Spent Soda Treatment Plant Effluent (U-463)

2. Waste Water Treatment Plant Overview

Secondary treatment: it consists of a biological pre-reactor and a biological reactor,

3.2 Physic-chemical Treatment

3.3 Chemical oxidation

3.4 Biological Treatment

3.5 Evacuation system and storage basin

3.5.2 Reserve Basin

3.5.3 Rainwater basin

3.5.4 Phreatic Network Pipe

Table 1. Equipment basic data U-452

Table 2. Pump basic data U-452

3.6 Sludge Treatment

3.6.2. Biological sludge:

As above described, we have two independent lines to pump sludge to TRADEBE:

Table 3. Equipment basic data from sludge treatment plant (U-452)

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