PROJECT REPORT ONWASTE WATER TREATMENT With an example of Waste Water Treatment Plant of Bharat Petroleum Refinery

SUBMITTED IN PARTIAL FULFILLMENT FOR THE COURCE OF MASTER OF SCIENCE (Ecology and Environment) CONDUCTED BY SIKKIM MANIPAL UNIVERSITY OF HEALTH, MEDICAL AND TECHNOLOGICAL SCIENCES.

SUBMITTED BYSANTOSH B. RANE

Roll No.- 2003510718

INDEX

CHAPTER NO I II III INTRODUCTION

TOPIC

PAGE NO. 4 6 7

PROBLEM ON HAND ORGANISATION PROFILE

IV

CHEMISTRY OF SEWAGE PURIFICATION

23

V VI VII VIII IX

INTRODUCTION TO WASTE WATER TREATMENT PLANT PROCESS DESCRIPTION PROCESS CONTROL ROUTINE OPERATIONS CONSUMPTION OF CHEMICALS & UTILITIES

29 37 45 52 59

SUMMARY

63

LIST OF FIGURES AND TABLES FIGURE/TABLE DESCRIPTION PAGE NO. NO. 4.1 Strategy for wastewater management at manufacturing 17 complex. 4.2 Process applicable to industrial wastewater treatment 19 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 7.1 8.1 8.2 8.3 9.1 9.2 9.3 9.4 9.5 9.6 9.7 Design basis Oil characteristics Treated effluent quality Utilities Service water Climatic data COD design basis Technical specifications for chemicals Abbreviations Nutrients additions Process flows Process temperatures Process pressures Basic chemical consumption Powder activated carbon Polyelectrolyte Dosing rates Nutrients consumption DAP consumption Utility consumption 31 27 32 32 33 33 34 35 39 46 48 50 56 59 59 60 60 61 61 62

CHAPTER - I INTRODUCTION Ever since man progressed from hunting to an agriculture , with corresponding development of stable communities ,the phenomenon of water pollution has been his constant companion . As agricultural methods improved , a smaller percentage of population produced all the food needed ; larger communities and diverse secondary industries developed and diverse secondary industries developed and grew into present modern society. Concurrent with this growth was the increase in waste material and the problem of its disposal. When the waste from a community was relatively small the easiest method of disposal was the throw it away, usually into the nearest receptacle. Since man cannot exist without water, community development and city growth centered in areas where the water supplies were adequate and continuous. Initially, this meant development in river valleys, and thus the nearest receptacle for wastes was the river or stream nearest to inhabitation. As civilization progressed and trade became more important, cities were developed on trade routes and along navigable water ways. The result being that, at present, narrow coastal strips contain the major proportion of population and industry. This development, of course, immediately opened another disposal area. What better disposal system could be found than estuaries, bays and the vast wide ocean. The major fallacy is that disposal to the ocean is a misnomer, in that oceanic conditions are not met in the inshore waters. What is seen, however, is a coastal water system that is completely unique to each coastal section, with characteristics that depend in part on the given topography and wind conditions. It is in this particular area that the question of pollution takes on a new meaning. In a body of water polluted when it directly affects man, or should it be classified as polluted when the ecological structure is first upset? The hydrosphere is a dynamic system in physiochemical and biligical equilibria, and there is no doubt that normally active water way hs a large capacity to assimilate wastes. However, in many areas this capacity has now reached its limit or even been exceeded, so that many water ways have become increasingly contaminated. Some expales of water systems, where the effects of pollution have become apparent, are the Abriatic, Baltic, Mediterranean seas, the Ganga, Yamuna, Gomatie, Godavari and Thames rivers, the Great lakes in America and Canada, the Dal Lake in India. However, any dynamic system has a remarkable capacity for regeneration and with intelligent planning even the most seriously polluted water-ways be brought back into a normal state. An example of river regeneration on a large scale is the on going attempt to clean the Ganges. A common ground for pollutants is their mode of entry into the water system. Broadly speaking, water-ways are subject to entry of pollutants by

1. 2. 3. 4.

Direct discharge into the river-water system. Run off and/or seepage with subsequent transport Reactions and transport across the sir-water interface. Reactions and transport across the water-sediment interface.

Under all condtions, entry of the pollutant is either in dissolved or particulate form, or may be converted to these forms by chemical reactions. Wastewater is used water. It includes substances such as human waste, food scraps, oils, soaps and chemicals. In homes, this includes water from sinks, showers, bathtubs, toilets, washing machines and dishwashers. Businesses and industries also contribute their share of used water that must be cleaned. Wastewater also includes storm runoff. Although some people assume that the rain that runs down the street during a storm is fairly clean, it isn't. Harmful substances that wash off roads, parking lots, and rooftops can harm our rivers and lakes. It's a matter of caring for our environment and for our own health. There are a lot of good reasons why keeping our water clean are an important priority: Fisheries: Clean water is critical to plants and animals that live in water. This is important to the fishing industry, sport fishing enthusiasts, and future generations. Wildlife Habitats: Our rivers and ocean waters teem with life that depends on shoreline, beaches and marshes. They are critical habitats for hundreds of species of fish and other aquatic life. Migratory water birds use the areas for resting and feeding. Recreation and Quality of Life: Water is a great playground for us all. The scenic and recreational values of our waters are reasons many people choose to live where they do. Visitors are drawn to water activities such as swimming, fishing, boating and picnicking. Health Concerns: If it is not properly cleaned, water can carry disease. Since we live, work and play so close to water, harmful bacteria have to be removed to make water safe.

The project which I have selected tells about Industrial Waste Water treatment Plant of Bharat Petroleum Corporation Limited. As from past seven years I have been working with the process department of this corporation. And domestic sewage purification CHAPTER II PROBLEM ON HAND The state of rivers,lakes in a country is an expression their environments and magnitude of human activities. In India allthe 14 major rivers and their tributaries have become increasingly polluted. Nearly 70% of the water is polluted with community wastes from human settlements. For centuries rives and lakes have been vegetating itself of the community wastes a biodegradably organic matter and there would not be any pollution even today. However 30% of Industrial effluents make the 70% biodegradable matter to nonbiodegradable and hence all rivers are highly polluted. The majority of mills and factories utilize large volumes of water for the process and other works, thus resulting in pollution of water ot an extend dependent on the particular industry and the nature of the process. The large water requirements of many industries and the utilization of water for power generation, and cooling purposes, as a solvent were, indeed some of the chief reason for the establishment of so many factories on the banks of rivers, lakes and the cause of so many of pollution problems. Water is one of the nature resources that has been consistently overused by our Industries, The Industries consume it, waste it and pollute it without orrying about consequences. The industrial demand for water has increased steadily in absolute terms, as well as in proportion to agricultural and domestic consumption. The overall demand for water by industries was 6 bkl in 1970, 150 bkl in 1990, and 180 bkl in 2000 AD and is expected to be 270 bkl by 2025 AD. The water discharged by industries is 100 times more polluted than discharges of community waste of human settlements,. Such discharged water contain effluents, acids and metal ion which, if not removed at source, create more problems to sewage disposal. The staking of Indian industrys thrust could arise: because of the following reasons : i) A lack of awareness about conservation of water; ii) Water priced at an unreasonable low value; iii) The industrial units not being charged for cleaning up the polluted water they discharge. Industries may be charged at a uniform rate for every unit of pollution that they add to the water or differentially according to the various kinds of pollution they cause to the entire environment. Some permutation of the two paths should bring out an even stricter regime. Alternatively there should be a proper water management policy econcerning water for industries. The industry that is polluting water or environment should entirely be respondible for it and should pay the price. This is the so-called Polluter Pay Principle. Unless this is enforced, industry may bring pressure from time-to-time to get the kind of

interpretation that serves it own ends. If industrialist are made to pay half the price, they will show increased expenditure and obtain a 100% grant from the government and as a result, it will never be possible to enforce the law. So industries must bear the entire burden of pollution. CHAPTER III

ORGANISATION PROFILE
Oil has always been associated with power, prosperity and dominance. The early history of oil-giants and their arrival in India too, is a fascinating sequence of realignments of power, through mergers and agreements for dominance of market. The story begins with formation of the standard oil trust in the 1860s and its subsequent merger with rival royal Dutch/ shell and Rothschilds to form Asiatic Petroleum (India), which joined hands with the Burma oil company to form the Burma-shell oil storage and Distribution Co (India) Ltd. With nationalization in 1978, the company comes to be known as Bharat Petroleum Corporation Limited (BPCL). The Company started with the marketing of Kerosene then came canned petrol followed by service stations. In 1932 when civil aviation arrived in India the company had to honor fuelling J.R.D. Tatas historic solo flight from Karachi to Bombay. The company refinery in Bombay was commissioned in 1955.As a true pioneer would, it introduced LPG as a cooking fuel to Indian kitchen and all along it went beyond selling petroleum to educate the customer. Bharat Petroleum, now is Indias second largest oil company in terms of market share and has a turn over exceeding Rs330Billion.Today the company produces adverse range of producers from petrochemical and solvents to air craft fuel and specialty lubricant and market them through 4510 petrol station, 967 kerosene dealers and 1389 LPG distributors, beside supplying fuel directly to hundreds of industries and several international and domestic airlines. With complete deregulation of the oil sector envisaged by 2002, competition from international majors and Indian private companies would be fierce. Bharat Petroleum is determined to succeed in this competitive environment. The company is gearing up to serve its more then Thirty Million customers better and to become the most preferred suppliers to them. The company embarked upon a strategic change in 1996 and the implementation of the change plan is now underway. The organization structure has been revamped and six strategic Business units have been created. The new structure is based on business processes, is flexible, more responsive to external changes has few layers and above all ensures a much higher customer focus.

To support growth, several projects are planned through joint ventures, which include new refineries, petroleum pipelines, import and distribution of Liquefied Natural Gas (LNG) and distribution of Piped Natural Gas.

ENVIRONMENT MANAGEMENT IN BPCL REFINERY

During the process of modernization and diversification of the refinery in the last four decades notable progress has also been made. In the area of population control, Environment protection is core part of the vision of BPCL, safety and environmental performance is integral part of efficient business. Hence it is the responsibility of each and every individual associated with the corporation to observe and practice environmental standards.

ENVIRONMENTAL MANAGEMENT SYSTEM: BPCL refinery has a well- developed comprehensive environment management system (EMS) including environmental policy and objectives implementing it will result in effective management of resources and reduction in wastes leading to cost reduction, improvement in pubic image and increased international competitiveness while improving the environmental performance.

MANAGEMENT INFRASTRUCTURE FOR ENVIRONMENTAL CONTROL: The environment section carries out various pollution control activities, develops new ideas as part of prevention of pollution at source itself, with the implementation of schemes to upgrade environmental standards uses basic approach recycling treatment for removal of pollutants and use of cleaner fuels. The environmental section also lies with the state and central government authorities on various environmental matters. Two-Tier environmental committee has been setup in refinery including Top and middle management to periodically review the environmental management programmes and performance for further improvement.

ENVIRONMENTAL QUALITY MONITORING LABORATORY MONITORING INSTRUMENTS & OTHER FACILITIES:

The environmental control laboratory Operates round the clock and is manned by technically qualified and experienced chemists /analyst. Apart from carrying out routine monitoring in the in-house laboratory periodic checks on various parameters on effluents and emissions are carried out with the help of external laboratories. In addition continuous monitoring system for ambient air and stack emission are also installed. As a part of liquid effluent monitoring, various effluent parameters are checked in the laboratory. Oil and grease total suspended solids, PH, Sulfides, phenol, BOD, and COD are tested periodically with the help of following equipment. 1. Auto BOD analyzer (For BOD analysis of water sample) 2. Multi parameter water analyzer (For analysis of parameters like COD, Ammonical nitrogen, sulfides, chlorides, Phenols, etc ;) 3. Auto oil contents analyzer (For measurement of oil contents in water)

AMBIENT AIR & STACK MONITORING STATION: Three numbers of continuous Ambient Monitoring station are located at different location chosen based on the predominant wind direction, position of the neighboring population sites and with respect to source of emission in the refinery and decided in coordination with Maharashtra Population Control Board (MPCB) These station measure pollutants such as sulphur dioxide, oxides of nitrogen, Carbon monoxide, repairable suspended particle matter, Hydrogen sulphides, methanic and nonmethanic hydrocarbon as well as meteorological parameter such as wind speed, wind direction, ambient temperature and relative humidity. In addition to the above ambient air quality is measured by standard equipments including high volumes samples as per prescribed BIS methods through an outside agency periodically. Source emissions are monitored at continuous stack monitoring station (SMS). In addition to this a portable instrument for monitoring sulphur dioxide and oxides of nitrogen levels from furnace stacks .Also stack monitoring for source emissions is carried out independently through outside part periodically. As a part of management information system a centralized data acquisition system for AMS/ SMS is installed recently.

AMBIENT AIR QUALITY MANAGEMENT: In the refinery, major sources of air pollution are furnaces/ boilers for SO 2, NOX and catalytic cracker Regenerator for CO, SPM and to some extent storage tanks for

hydrocarbons. The various pollution abatement measures taken at refinery are as low as follows: Use of low sulphur fuel Adaptation of an integrated approach to energy conservation through operational changes In addition sulphur recovery unit tall flare stack and furnace stack have been provided. The refinery is the first in the country to put up facilities for the production of Methyl Tertiary Butyl Ether (MTBE) which is used for production of unleaded gasoline and thereby reducing vehicular emission. Also there is intensive tree plantation in and around the refinery to improve the ambient air quality. A considerable reduction in emission levels has been achieved due to the above measures. To facilitate proper monitoring and control of gaseous pollutants continuous ambient air / stack monitoring station have been provided.

MONITORING TECHNIQUES: The Continuous ambient air and stack monitoring station use sophisticated state of the art technology like pulse fluorescence, chemilumini scene, Beta ray attenuation. Gas filters coRelation and infrared measurement etc, to monitor parameters like SO 2, NOX. Respirable suspended particulate matter, Carbon Monoxide, and H2S.

NOISE POLLUTION: Noise monitoring is regularly carried out at various locations in the refinery area. Personal protective equipments such as ear plugs / ear muffs are provided wherever required. Low Noise Burners have been installed in DHDS unit, New High Efficiency Boiler, High vacuum unit Heater and FCCU charge Heater. LIQUID EFFLUENT MANAGEMENT: The main sources of water pollution are process plant / product tanks for oil and grease and sour water for phenol and sulphides. LIQUID EFFLUENT TREATMENT FACILITIES: It consists of three stage of oil recovery system. Normally the oil contaminated process water from the process plant enters the main drainage system only after it has been oil free by means of plant oil catchers. The oil carry over can occur only in emergency cases, such as leaking coolers etc. In order to prevent this three emergency oil catcher are provided in series. It minimizes the loss of oil due to evaporation and also eliminates the risk of emulsification of oil due to turbulence.

Liquid effluent from Refinery meets the Statutory Stipulation laid down by Maharashtra Pollution Control Board (MPCB), Central Pollution Control Board (CPCB) and Minimal National Standard (MINAS). In order to meet the more stringent MINAS, a modern waste water treatment plant is installed. WASTE WATER TREATMENT PLANT: It consists of the following: Segregation of process waste water from the Cooling Water system including collection and pumping system from the various plants to the waste water Treatment plant. Reduction in quantity of effluent generation and provision of surface condensers (Replacing barometric condensers) in vacuum distillation unit. Plant process based on combining physical, chemical & biological treatments to effectively control the quality of effluent discharge. It is based on Powdered Activated Carbon Treatment (PACT) and Wet Air Generation (WAR) for the first time in India. Other measures taken for control of liquid effluent quality and quantity include provision of mechanical seals instead of gloat packing in pumps, replacement of plant oil catcher by modern corrugated plate interceptors, installation of air fin coolers, sea cooling water circulation system for refinery and installation of sour water striper. A Tertiary plant is installed to convert effluent into raw water.

ENVIRONMENTAL INITIATIVES: I. Diesel Hydro sulpherisation Unit (DHDS): It reduces the sulphur content in total diesel produced from 1% Wt (max) to less than 0.25% Wt. II. New Sulphur Recovery unit (SRU): Two sulphur recovery unit trains are installed to recover sulphur with 99% efficiency. III. Recalculating Cooling Water System: Refinery uses sea water as cooling medium in process units. To reduce the quality and temperature of the effluent from the refinery in addition to improving its quality, the refinery has provided a Recalculating sea cooling water system. IV. Methyl Tertiary Butyl Ether (MTBE): It is the first such unit in India for manufacture of Oxygenates. MTBE is blended in Motor Spirit as an octane booster to replace Tetra-Ethyl Lead (TEL) thereby reducing lead oxide emission from vehicles.

V.Mumbai Manmad Pipeline (MMPL): It is 252 km long and 18 inch diameter pipe line from Mumbai to Manmad to transport MS/SK/HSD reducing road movement and thereby minimizing the chances to road accident and vehicular emission. VI. Carbon MonoOxideBoiler: Carbon mono oxide from catalytic cracking unit is utilized for generation of steam thereby reducing CO emission and conserving energy.

OTHER ENVIRONMENTAL INITIATIVES: Installation of new and talk main flare stack and taller stack for furnace / boiler in process unit for better dispersion of fuse gases. Installation of Oxygen and CO analyzers in furnace stack for monitoring of oxygen thereby controlling oxygen for increasing furnace efficiency and control of combustion in furnace. Conversion of fixed roof tanks to Floating roof tanks on lighter hydrocarbon service to reduce hydrocarbon loss thereby reducing fugitive emissions. Use of clean fuel such as Bombay High Association was (BHAG) in captive power plant. Modern Amine Treatment Unit (ATU) to ensure that the fuel gas internally generated in the refinery process is fully stripped of sulphur Enhanced DM Plant performance by providing new resin mixed bed for generation purpose thereby reducing effluent generation. Installation of semi automatic decantation valve for draining of water from hydro carbon tanks, thereby reducing effluent generation. Continuous hydrocarbon Analyses for monitoring of fugitive emission.

MEASURES FOR HANDLING SOLID WASTE:-

The only hazardous waste generated in the refinery is hydrogen oily sludge form crude tank bottom. Hydrocarbon sludge is minimized by operation of rotary jet mixes in crude oil tanks. Oily Sludge is further minimized by circulating hot gas oil. The recovered hydrocarbons are recycled for processing as slop oil in crude tank. The residual sludge is sold to Ministry of Petroleum and Natural gas (MOP & NG) Approved parties for manufactured Bioremediation treatment of oily earth material is being carried out in refinery using Bio culture.

ENVIRONMENT MONTH CELEBRATION:Every year the month of February is celebrated as Environment month in refinery where in special lectures on environment are arranged, banners displayed essay /suggestion competition / quiz on environment are held. Also 5th June, the world Environment Day is celebrated in refinery every year. Every month contractors, supervisors are trained on environmental conservation and Environment management system by skill staff specialized vertical programmes for management latest environment as well as non-management staff for water management Latest environment developments etc are conducted by training center. Ecology and aesthetic around refinery is maintained by planting more than 15000 trees around refinery staff colony and sports club. Recognition of effort of refinery towards environment protection is seen from the various awards won by Refinery in the field on environment. Refinery is also certified IS0 14001.

MANAGEMENT STRTEGIES FOR POLLUTION PREVENTION AND WASTE MINIMISATION:

The goal of any pretreatment programme is to manage the waste stream in a manner that ensures regulatory requirements are consistently and co- effectively met. The critical factor for successful development and implementation of a management strategy is the continuous commitment of every one involved within the company, beginning with top management, to support the objectives of the agreed strategy. Management must recognize the benefits of pollution prevention and waste minimization and integrate these practices into the corporate or plant philosophy. In plant survey In developing a wastewater management strategy, it is first necessary to have detailed information on the wastewater generated within the facility. In plant surveys generate data on sources, chemical compositions, quantities, variations, distribution and discharge frequencies and duration of all industrial process waste streams. These data are used to

establish a baseline description of the wastewater produced at the facility and develop or model possible management strategies. Additionally the baseline data provides a starting point for considering the effect of future production growth, water conservation efforts or changing regulatory requirements. The most important aspect of conducting an in plant survey is making it as complete as possible. This requires a full understanding of all production activities with in the facility and detailed, accurate drawings of the plant showing the locations of the various processing units, their waste distribution, and wastewater production and collection systems. The waste stream from each unit process is studied, measured and analyze to determine the frequency, quantity and flow rate of the discharge and nature and concentration of the pollutants present. If possible flow measurements and sample collections should be performed using permanent monitoring stations. If these are not available, temporary data collection points should be used. The frequency, extent and type of monitoring and sampling needed depend on the nature and variability of each waste stream. To ensure that the characterization of each waste stream is complete and representative, it is often appropriate to prepare an advance sampling and monitoring plan to guide the study. Once all individuals waste streams have been fully characterized, they can be stored and grouped according to the types and/or concentrations of pollutants present or the applicability of environmental protection categorical pretreatment standards. During the survey, raw material use and production records should be obtained. Correlations between production or material use and waste generation can then be developed for future decisionmaking. Identifying Categorical Waste Streams: Any waste streams covered by categorical pretreatment standards should further be identified as subject to either production based standards .the allowable concentrations of specific pollutants are directly related to the production rate of the process generating waste system. The combined waste formula is used to determine compliance of categorically regulated waste streams that are diluted by non categorically regulated waste streams before pretreatment U.S.EPAs guidance manual (1985) describes in greater details the use of both production based pretreatment standards and the combined waste stream formula. Identifying Wastewater generating Operations: In performing in plant survey; It is important to include not only waste streams directly attributable to the various unit processes, but also waste streams generated from cross media pollution control efforts, including waste streams from wet air scrubbers blow down, sludge dewatering, or miscellaneous sources such as product change washouts, site cleanup efforts, yard drainage, non contact cooling water, or secondary containment spillage Although the volume of these auxiliary waste streams may be relatively small their effect on the treatability of the total industrial wastewater generated by the facility Significant.

In light of increasing restrictions and costs associated with off-site disposal of spent concentrated plating or solvent baths, many facilities are considering on site treatment of these Basis, they must be considered an incorporated into the in-plant survey and management plan because of their potential to overload any treatment system that is designed to treat only regular or continuous flow process wastewater. In conducting an in-plant survey, it may also be beneficial to categorize waste streams according to pollutant types to determine if some contain only conventional pollutants such as biochemical oxygen demand (BOD) and suspended solids. In many instances, waste streams containing only conventional pollutants may require no further pretreatment and be discharged without treatment to a wastewater treatment plant (WWTP) classifying waste streams according to pollutants types also may expose any incompatibility between waste streams and subsequent need to segregate the waste streams until the incompatibility is removed. For example, plating shops may generate both acidic and cyanide-containing waste streams that would be dangerous to combine before cyanide treatment is completed. Preparing mass balances: The information obtained from in plant surveys of various waste water generating operations is used to prepare mass balance of the flow waste loads within the facility. Mass balances serve as cross check to confirm that all flows and pollutants loads have been accounted for in the survey and that no major waste streams or pollutant generating operations have been missed. Properly prepared mass balance provides data that can be used in preparing a treatment strategy and determining flow equalization requirements. They also serve as indicators of potential areas where waste minimization or pollution prevention practices should be considered or implemented. The individual mass balances once prepared, can be consolidated into an overall mass balance for the entire facility. It possible, the results of the combined should be verified by measuring the flow of the total effluent from the facility over a representive period of time while simultaneously analyzing it for pollutants of concern.

Manufacturing Complex

In plant Survey Flow rate, Volume Chemical Composition

Regulatory Requirements Clean water act Clean air act Resource conservation and recover act Local ordinances

In plant control Waste minimization Integrated (air, water & solid environment control) Recycle / Reuse Process modification Water conservation Recycling Regulatory compliance Monitoring National pollutant system permit Pretreatment permit

Pretreatment alternatives Pretreatment of discharge to WWTP Treatment for direct

Cost Capital, operating & maintenance WWTP treatment surcharge Offsite treatment

Discharge WWTP Receiving stream

Figure 4.1 Strategy for waste water management at manufacturing complex

In- plant control: Once the mass balance for the facility is completed and the sources and loadings of the various waste streams have been determined, it is appropriate to consider options for the control and reduction of pollutants to reduce the concentrations and volumes of the waste streams that needs pretreatment. It efforts to eliminate, recycle or reclaim waste water through changes in production activities are unsuccessful; steps should be taken to reduce the quantity of waste water that requires treatment. These steps include implementing good housekeeping practices, using spill- control measures such as spill-containment enclosure and drip trays around tanks, eliminating any wet floor and using rinses that are either static or do not have any over spray. Proper house keeping should be practiced at all the times, because it can be one of the most cost effective measures for reducing pollutant loading and maintaining compliances with regulatory requirements. The management strategy for the control and treatment of a facilitys wastes need to be incorporated at the beginning of the plan and linked with all other components of the planning and implementation process. Benefits of a well- implemented plan include lower costs, improved product quality, increased production, improved public relations, reduced liability and successful regulatory compliance. Water conservation and recycling: Efforts to conserve recycle should be incorporated into the waste minimization programme or initiated as a separate activity with its own specific goals. The benefits of reducing the volume of waste water discharge through recycling, reuse and other conservation methods may include lower capital costs for the conservation of smaller pretreatment system and lower operating costs for the system because of possible reduction in the variability of the waste streams being treated. Water conservation alternatives include, but are not limited to the reuse of cooling water as product makeup or cleanup water, collecting storm water for non critical water uses, flowrestricting or water- saving devices and the recycling of water in closed loop systems. Once all internal applications for waste reuse, recycling and conservation are maximized and implemented the possibility remains that treated wastewater, if suitable can be used by outside contractors for irrigation, dust control or other tasks that normally would be fresh water. If the treated effluent is discharged to a WWTP, consideration should be given to the presence of any potential pollutants that may interfere with the WWTPs ability to reclaim its treated wastewater or use it for wetlands reclamation projects. Pretreatment: Pretreatment of industrial waste water before discharge to a WWTP may be necessary for several reasons. Some industries are subjected to federal or local pretreatment standards

because they discharge organic and inorganic pollutants that can damage conveyance system, cause inhibitory effects or pass through the WWTP treatment processes or interferes with selected sludge disposal alternatives. Other industries may voluntarily choose pretreatment to reduce or avoid WWTP surcharges on pollutants such as BOD and suspended solids. In rare instances, the waste water solids or residuals resulting from the pretreatment process may be valuable in their own right such as when they contain significant amounts of precious metals. Pretreatment system can be installed to assist with the reclamation if these materials. Before selection of the pre-treatment option industries must consider several factors that will affect the decision making process. WWTPs treatment process characteristics may require more restrictive industrial discharge limits in some cases. The selection of pretreatment options must guarantee that the constructed pretreatment facility as well as discharge will comply with all regulatory requirements. Additionally long term considerations should be addressed in the selection process, including provisions for additional treatment in the future to meet changing regulatory requirements or for the addition of modular system to account for long term flow variations. In some instances, field scale pilot testing, trial uses of modified production processes or research and development must be conducted before implementation of a pretreatment programme.

Table 4.2 Processes applicable to industrial wastewater treatment Pollutant

Biological oxygen demand ( bio degradable organics)

Processes
Aerobic biological: activated sludge, aerated lagoons, trickling filters, rotating biological contractors, oxidation ditches, stabilization basins, packed bed reactor Anaerobic biological: anaerobic lagoons. Anaerobic filters, anaerobic contact, fluidized bed reactors Sedimentation, floatation, screening, filtration, coagulation/flocculation/sedimentation of forth floatation Carbon adsorption, chemical oxidation, ammonia stripping, nitrification and denitification, ion exchange, breakpoint chlorination Precipitation, biological uptake, ion exchange Membrane filtration, evaporation and electro dialysis, chemical precipitation, ion exchange Membrane filtration, evaporation and electro dialysis, chemical precipitation, ion exchange Ion exchange, reverse osmosis, electro dialysis coagulation/flocculation/floatation, ultra filtration, aeration, chemical oxidation adsorption, biological treatment

Total suspended solids Refractory organics (COD, TOC) nitrogen Phosphorous Heavy metals Dissolved organic solids Oil and grease Volatile compounds

Physical separation: Physical separation process typically includes flow equalization, screening, sedimentation, floatation, aeration and adsorption, Screening is used to remove coarse soils and prevent damage to or clogging of downstream equipment. Manually cleaned screens work well but cleaning them requires labor and many overflows from clogging. Flow equalization dampens flow variation and thus achieves a fairly constant flow rate to the sever system. It also dampens the concentration and mass flow of wastewater constituents, yielding a more uniform loading to WWTP. Flow equalization helps to reduce the size of pretreatment facilities. Sedimentation is the removal of suspended solids by gravity separation in a quiescent basin. The proper design of bottom slope and scraper blades and the appropriate number of arms will reduce this problem. Surface scam may cause odors that can be controlled by frequent removal. Dissolved air floatation (DAF) is used to remove suspended solids by causing them to rise to the surface. DAF, systems are reliable chemical addition is often used to enhance the performance. These systems require little land area but air compressor noise to be controlled and sludge must be treated and receive proper disposal. Filtration is solid liquid separation process in which the liquid passes through a porous medium to remove fine suspended solids. Filtration is reliable and requires little use of land. However backwash water will need to be treated, resulting in the production of solids, which require disposal. Aeration may be used to strip volatile compound from industrial waste water. Diffused aeration or mechanical aeration typically used. Proper design must be ensure that off gases do not cause air pollution problems. Adsorption is the accumulation of a substance at the surface of solid material called adsorbent. Carbon system generally consists of vessels in which granular carbon is placed, forming a filter bed through which wastewater passes. Adsorption system requires little land. Under anaerobic conditions, biological activity in carbon beds may generate hydrogen sulphides, which has an unpleasant odor. Powdered carbon may be used instead of granular carbon, but typically it is fed to waste water using chemical feed equipment rather than being contained in a bed or column. Chemical pretreatment: Chemical pretreatment process typically includes pH neutralization, chemical precipitation, oxidation- reduction and ion exchange. Neutralization involves the addition of acids or bases to waste water for adjusting pH to an allowable range, typically Ph 5 to 9. Acidic wastewater is neutralized with lime (CaOH2), caustic soda (NaOH) or soda ash (Na2CO3) etc. Alkaline wastewaters are typically neutralized with sulfuric acid, hydrochloric acid or carbon dioxide.

Neutralization is simple and reliable but typically requires automatic feed equipment, pH monitors/controllers and multiple mixing tanks. To reduce chemical uses and costs, mixing of alkaline and acidic wastewater should also be considered. Chemical precipitation is another chemical treatment method often used to treat industrial wastewater. Chemical coagulation and flocculation are used to precipitate dissolved wastewater contaminants and from floc particles, which settles readily in sedimentation basins. Chemical precipitation can easily remove heavy metals phosphorus from industrial wastewater. Oxidation reduction is used occasionally to remove pollutants from industrial wastes. Oxidation-reduction systems have high mechanical reliability. Off gases must meet air pollution requirements, however oxidation reduction system may not be economically attractive in some cases. In ion exchange process ions held by electrostatic forces to charged functional group on a solid surface are exchanged for ions of similar charge in the wastewater. Ion exchange may be used for removal of heavy metals, ammonia and radioactive pollutants. The process is reliable and relatively easy to operate if automatic controls are used.

Biological pretreatment: Biological pretreatment of industrial wastewaters may be used to reduce BOD/suspended solids loads to WWTPs, degrade potentially toxic compounds or reduce nutrient levels. Biological systems include activated sludge, lagoons, trickling filters, rotating biological contractors and anaerobic processes. Where wastewater are compatible however economies of the scale often indicates that WWTP treatment of biodegradable wastewater better serves the community than does installation of several biological pretreatment systems. Cross media pollutants: In selecting pretreatment options cross media pollutant generation must be considered. Many pretreatment facilities generate sludge that requires handling, treatment and disposal. The treatment and disposal of sludge especially if it exhibits hazardous waste characteristics can be expensive and cumbersome considering the multitude of sludge and hazardous waste regulations at the local, state and national levels. Some pretreatment processes may result in air emissions, such as off gases from air stripping of certain industrial wastewaters that must comply with applicable air pollution standards. Processes such as ion exchange, ultra filtration and reverse osmosis result in rejected steams requiring disposal. Safety considerations: Selection of pretreatment options also involves safety considerations. Under certain conditions electrical and mechanical equipments if incorrectly installed, inadequately maintained or improperly used can caused electrical shock or other bodily injury. Waste water gases and pathogenic microorganisms can also create health hazards. Chemicals such

as chlorine sulphides or ammonia that are either present in the waste water or added during treatment can create noxious vapors or otherwise causes acute or chronic injuries to plant personal or the public if control measures are in adequate.

Offsite Pretreatment: In formulating management strategies for the pretreatment of the wastewater alternatives for offsite pretreatment should also be considered. Offsite pretreatment generally means removing all or a part of the wastewater generated by a facility and pre treating it at another location so that it is suitable for disposal an offsite pretreatment facility may or may not be a resource conservation and recovery act (RCRA) hazardous waste treatment facility depending on whether the waste accepted meet the RCRA definition of hazardous and whether the facility is RCRA permitted. Typically, the offsite facility is nearby and designed to treat specific types of waste water from several firms in the area such as plating shops or printed circuits facilities at a lower cost then comparable treatment by the individual facilities generating waste streams. However offsite treatment facilities are typically only conveniently or economically available in certain metropolitan areas and may be subjected to strict regulatory requirement that can result in the imposition of conditions and constrains on the wastewater generating facilities.

Process Monitoring: The goal of any industrial wastewater pretreatment management strategy is to achieve cost effective regulatory compliance by implementing waste minimization, wastewater recycling, and water conservation and wastewater treatment by the most appropriate treatment processes. To determine whether this goal is being achieved, the strategy must include a monitoring component that provides information on the effectiveness of the strategy and allows for necessary corrections. The primary purpose of monitoring is to ensure and verify that compliance with regulatory requirements such as discharge permits conditions or categorical discharge standards are consistently met. Besides providing economic benefits a good monitoring programme is useful in assessing the effect of process or raw material changes or waste minimization efforts, detecting potential upsets with the system that could cause discharge violations or sludge discharges and estimating loading surcharges that may be imposed by the WWTP receiving the discharge. The monitoring of the incoming wastewater also allows for improved process control, particularly in processes involving chemical addition or in the activated sludge process. Industrial facilities are increasingly using statistical process control techniques to ensure compliance. An effective monitoring system is integral to the pretreatment system design and should be planned at the conceptual stage. Inclusion of properly designed monitoring points and

equipment as part of the total system design can significantly reduce future monitoring costs and provide for improved pretreatment system operation. Finally, in the event of the spills, sludge discharge or chronic violations a WWTP may initiate a demand-monitoring monitoring programme against a facility in response to the problem. Once the problem has been resolved and continuous compliance is achieved the demand-monitoring programme is usually rescinded and normal monitoring schedule is resumed. Cost analysis: In developing a management strategy for the control of industrial waste water from a facility it is important to develop a comprehensive cost analysis for the different options under consideration. Although cost figures strongly depend on local conditions and regulatory requirements, certain elements should be incorporated into the facilitys management strategy before selecting a pretreatment option. These include determining the capital cost of the pretreatment system, the operating cost (including costs of chemical, energy, labor, compliance and residual disposal) and maintenance costs to keep the system operating in a manner that allows for continues compliance. Cost information database for pretreatment of industrial waste are limited. This is because of the almost infinite variety of pretreatment waste streams to be treated. This variation makes it difficult to develop a large database of treatment cost. There is however sources of information on the more common waste stream that can or a rough comparison of treatment options. In additions sources of information usually exits as case limited in the number of technological compared. Industrial association and trade groups such as the American Petroleum Institute or the Chemical Manufactures Association are also a good source of information on specific waste streams because they may track and record these data for their members. It is important to use current and accurate cost and performance data because the technological and treatment costs constantly change.

CHAPTER IV CHEMISTRY OF SEWAGE PURIFICATION: Waste effluents from human communities are of two types : i) domestic sewage is largely composed of metabolic wastes, as well as animal and vegeatable wastes from the kitchen, which are almost totally biodegradable, and (ii) Industrial wastes may be non bidegradable but most of them are over poisonous to the organisms which degrade domestic waste and as a consequence, must be treated separately. Sewage from modern large towns and cities must be adequately treated before discharge. SEWAGE TREATMENT: In addition, sewage contained suspended mineral matter, bacteria, viruses and dissolved salts. Sewage treatment can suitably be classified into three distinct types. The three stages of sewage treatment is i) Primary treatment : removes larger suspended particles from sewage and produces a liquid which contains only colloidal and dissolved matter. ii) Secondary treatment : removes the bulk of the organic matter present in the fluid, using biochemical oxidation processes, and provides an effluent which can be discharged into the sea and rivers, making an effluent which can be discharged into the sea river, making use of natural biochemical processes to complete the purification. iii) Tertiary treatment processes use the effluent from secondary treatment as feed and produce water which is of drinking water standard. Most sewage plants only go as far as seconday treatment, but in recent years the demand for tertiary treatment has stepped up as the need for complete recycling of water has increased. Primary and Secondary Treatment of Sewage : The crude sewage from the sewers is first stored for about one week before treatment. Normal sterilization treatment with chlorine, ozone or similar substances is extremely effective in killing off bacteria but has little effect on the much smaller viruses. By allowing bacteria to multiply, the viruses are killed off. Bacteria can then be separated, by filtration system and sterilization without any diificulty. The crude sewage next passes through a rough screen that separates off large humps, disintegrates them and resuspends them in the main sewage flow. Grit and oil removal tanks follow, where floating insoluble materials are taken off, as are heavy stones and grit particles which sink to the bottom. Invariably such tanks are circular in shape and are equipped with top and bottom scraping devices to eliminate sludge and scum. The bottom scraper is connected to a rotating spider network suspended either at the centre of the tank or form a radical bridge above the water surface. In former case, drive is from the centre of tank and in the latter case at the periphery. In the radial bridge assembly there is considerable flexibility in force. The sludge is drawn of at the bottom of the steeply sloping tank by means of telescopic values by which extraction flow rate can be adjusted and also prevent value of lockage fully automatic diaphragm extraction values are also widely used. The sludge from these primary settling tanks can then be passed on to a

sludge digester if sewage methane is required for combustion purposes. Alernatively the sludge can be passed on directly to driers and incinerators. The liquid from the primary settling tank passes on to a biological purification plant. The typical bacterial purification beds, usually have a diameter of 40 m or more and head loss in the flow of water usually exceeds 250-300 mm of water. Sprinkled joints which cause little friction and are not sensitive to variations in inlet pressure are used. These beds need very large quantities of filtering material, yet the purification, efficiency of a single bed seldom exceeds 80%. To achieve better purification, either several bacterial beds in series or recirculation flow are necessary. The tanks are either rectangular or circular in shape. Depths of water varying approximately between 3.5 m and 7 m are employed and air is supplied by rotary blowers. This air is distributed by mean of nonclog diffusers fitted with flaps or through porous media. The amount of air which passes through is automatically adjusted on the basis of the concentration of impurities in the effluent. This is done by means of a redox potential regulator or a dissolved oxygen probe. In general, the treatment time varies between 1.5 and 3 hours which is roughly half the time usually required in the more traditional types of bacterial beds. Excess sludge is removed by means of telescope or automatic valve and water is returned to the primary settling tank. Water, which is drawn from the biological purification plant is commonly considered clean enough to be pumped into the rivers. If further purification is needed-as for example, when the water is to be recycled directly into the towns water system-clarifiction, using such materials as activated into the towns water system-clarification, using such materials as activated carbon, followed by sterilization with chlorine, ozone or ultraviolet radiation is necessary. Digesting of Sludge : During methane fermentation, sludge loses between 40% and 60% of its volatile matter and its volume is, reduced by about 60%. In order to increase the capacity of a certain sludge digester one of the following technique is commonly employed : 1. The mixture of sludge and effluent is heated, using steam or hot water, in order to increase the rate of fermentation and 2. The sludge is thoroughly recirculated inside the digester in order to eliminate void space which also improve its homogeneity. In many cases, multistage digestion systems are used to improve efficiency. In general, when planning digestion plants for the sewage out flow of a city, it is reasonable to allow a digester volume of about 30 litre per head of population seved. Thus a total digester plant volume of around 30 million litre is desirable for a city of 1 million inhabitants. The methane produced during the digestion of sewage sludge is burned primarily for steam production to heat the sludge fed into the digester. In very large plants, sewage methane can also be used for operation of gas engines. These operate on the total energy principle to produce electricity for work purpose and any excess heat is used for sludge heating. However it is generally uneconomical to install gas engines unless the sewage plant serves

at least 300,000 inhabitants, for smaller plants the inverstment costs tends to be far too high. Much of the digested sludge produced is then dried on special drying beds. Modern practice tends to frown on the use of these for several reasons. Drying beds occupy a learge ground area and offensive smells are created which lower the amenity value of the surrounding district. The sludge, even when dry, is difficult to handle and has an unpleasant appearance. New sewage works therefore prefer a system of thickening followed by filtration. Ater emerging from a thickener, the sludge is passed into one or more vacuum filters where most of the water is drawn off. The filtered sludge has a dry matter content of more than 30% and is often palletized and stored to be used either directly as an agricultural fertilizer, or mixing with house hold refuse prior to composting. In general, the digested mixture of primary and secondary sludge is filtered directly. However, in the case of a multistage plant, and where biological treatment is carried out later, filtration may be used at the beginning of the process. Filtration and Removal of Colloidal Matter : The water which emerges from the second filter contain colloidal particles, insect larval, algal, as well as dangerous amoeboid organisms, all of which cannot be eliminated by standard sterilization procedures even. Filtration is carried out by passing the water through porous material. In most cases filtration mediums serve only to remove particles larger than the pores of the medium but also as matrix for endearing microorganism which secrete enzymes. These enzymes coagulate much of the colloidal material present in the water and facilitate their removal. Often surface active filter mediums are sued. These serve to retain colloidal material in the adsorbed state on the filter medium itself. The main filter mediums for water are snd and kieselguhr. The advantage of these materials, compared with more static filter mediums like cloth or porous porcelains is that granular filter mediums are much easier to wash. Kieselgur is employed for smaller filters, like those used in the cleaning of swimming pools. For large scale industrial practice, sand and gravel beds are preferred between 600 mm and 1500 mm thick. Once the filtration medium is fully loaded, it is agitated by a mixture of compressed air and water but the pure sand is reclaimed by sedimentation. Both slow and fast filtration are employed in the purification of water obtained from sewage effluents. Slow filtration is three stage process. The first consists of coarse filters which remove large particles. These operate at a rate of about 1 m/hr. The second consist of prefilters which remove every thing by colloidal particles. The water passes through these at a rate of 500 mm/hr. Finally there are proper filters, through which water passes at the rate of only 200 mm/hr. The purpose of these is to coagulate colloidal particles susceptible to bacterial action and to remove them, and to act as surface active agents for

adsorption of other colloids. An essential feature of this form of filtration is the formation of bacterial membrane, which can take several days after the medium has been washed. Fast filtration takes place at a rate of up to 20 m/hr. This is incapable of removing colloid particles which have to be coagulated prior to passage of the water into the filer plant. The filter medium used for fast industrial water filtration consists of 98% SiO2, with effective size being between 0.3 mm and 1 mm diameter for standard filters, and 2 mm diameter for prefilters. Many different types of filter plants are in the market, each having its own operational characteristics. Sewage treated by primary and secondary methods has, in the past, been discharged directly into rivers without further treatment and in th vast majority of cases even noe. Organic wastes sparated in this way most of which is biodegradable to yield methane gas and the solids may be used as organic fertilizer. The biochemistry of this decomposition will be discussed in detail in Section 3.13 Teritiary Methods of Water Treatment These are summarized as follows : 1. 2. 3. 4. 5. 6. 7. 8. Acrivated carbon in the form of either granules or powder Micro straining. Sepecial selective coagulants, High density aeration process; Removal of Phosphate by Precipitation; Removal of nitrogen compounds; Electro-chemical methods, and Sterilisation of effluents.

1. Activated carbon: one of the most efficient agents for removal of dissolved and suspended impurities is actived carbon that can be activated by heating to 930c, when adsorbed material is driven off from its surfaces. Carbon surfaces are ,in general ,more active with respect to aromatic than aliphatic compounds and reveal a greater adsorption for branched chain types. Amines, carbonyl group, double bonds ,sulphonic groups and nitro groups all tend to make the compounds concerned adsorb more rapidly. 2. Microstraning: This is a form of simple filtration which uses very finely woven stainless steel wire fabrics drawn to diameters that are barely visible. Such micro straining techniques can be used for the classification of potable water and even for filtering finished drinking water because of their efficiency in removing both inorganic particles such as fine dust, metallic scales, etc. and living organisms such as algae, diatoms, amoebae, and some of the larger bacteria. The use of two-stage micro straining has been found effective in reducing suspended solids at a cost lower than that of competing tertiary purification system. 3. Coagulant:Coagulation is the process of co-operation of tiny particles of matter with larger pieces of solid matter so that they sink to the bottom much more rapidly. A

typical precipitant is aluminium sulphate, which reacts with dissolved calcium bicarbonate as follows : Al2 (SO4)3 + Ca (HCO3)2 Al (OH)3 floc + 3 CaSO4 The aluminium hydroxide flocculent engulfs colloidal suspended particles and carries Them down.The most widely used flocculents are aluminium sulphate, ferric sulphate, ferrous sulphate and sodium aluminate. A mix of potassium permanganate and ferrous suphate reacts as follows : FeSO4 + KMnO4 + 2H2O Fe(OH)3 + MnO2 + KHSO4

High intensity Aeration Process : These cosist of forced aeration of activated and constitute extremely effective methods of accelerating the reaction process because (1) sufficient circulation of sewage and activated sludge is known to achieve constant and intimate intermixing and (2) the supply of excess oxygen supports the biological process which are involved. Removal of Phosphate by Precipitation : Sewage contains between 1.5 g to 3.7 g of phosphorus per person per day of which hardly any is removed by standard sewage works practice. The addition of 200 ppm of Al2(SO4)3 gives a 95-99% removal of suspended and dissolved phosphates, while dosing with 300 ppm of Al2(SO4)3 removes well over 99% of phosphates. The reaction which takes place is the following : Al(OH)3 + PO34 + 3H + 4NaOH NaAlO2 + Na3PO4 + 5H2O Calcium chloride is then added to get calcium phosphate 2Na3PO4 + 3CaCl2 Ca3(PO4)2 + 6NaCl The calcium phosphate is then filtered off. Removal of nitrogen Compounds : Treated sewage often contains appreciable percentages of bound nitrogen. Nitrates can be removed by the following two methods : i) ii) Coagulation with iron compounds and lime followed by filtration. This method is about 90% effective. The use of ion exchange resins. Amberlite IR410 resin is used quite widely, but one needs to sue 30-55 parts by weights of resin for each part of nitrate present in water. Nuclear sulphonic acid cation exchange resins such as Nalcite HCR are somewhat more economical, requiring only 16-22 parts by weight of resin for each part of nitrate. The limit of removal for both resins is about 1 ppm of nitrate in water. Amberlite IR-120 has somewhat smiliar characteristics.

Electro Chemical Methods : A more recent method of sewage treatment uses electrolysis. Sewage and seawar are mixed in the ration of 3:1. The mixture is fed into a series of electrolytic cells with a graphite anode beneath and a cast iron grill cathode above. The hydraulic supply is in paralled but the electricity supply is in series. The result of passing an electric current is to produce chlorine gas at the anode and sodium hydroxide and hydrogen gas at the chathode. This forms sludge flocculates which are recirculated and finally separated out by settling. The chlorine concerntration is kept at about 100 ppm in order to prevent the sewage from purifying. The final product has a free chlorine concentration of about 5% which is enough to kill off coliform bacteria. The technique produces a reduction of about 60% in BODF. Sterilisation of Effluent The main methods of sterilizing water are the follwer i) Chlorine and its Derivative ii) Ozone doising and iii) Ultra violet irradiation. i) ii) iii) Chlorine and its Derivatives : For the sterilization of water either chlorine gas or one of the two salts, sodium hypochlorite or calcium hypochlorite, used. Chlorine in small concentrations effiectively kills most bacterial. Ozone dosing : There are several commercial ozonisers in the market designed to operate at about 12,000 V obtained by means of a standard transformer. Ultra violet irradiation : The maximum bacterial action is when the wavelength of the rays is in the vicinity of 260 mm. Ultra violet light is produced by a mercury vapour lamp. This method is commercially viable when relatively small quantities of water are to be treated.

CHAPTER V

INTRODUCTION TO WASTE WATER TREATMENT PLANT

The information contained in this document is intended to provide a guide line for operation and maintenance of the waste water treatment plant at Bharat Petroleum Corporation Limited Mumbai. It is of utmost importance that each operator read and understands the details furnished herewith by close reference to P&I drawings and equipment manufacturers. Frequent reference to all the drawings and manuals will be required until the operating personnel are thoroughly familiar with the information contained therein: 1. Treatment System:-The refinery processes both Bombay High and Middle East crude to produce various petroleum products. The major units considered for this effluent treatment plant comprise of Crude Distillation Unit (CDU), Catalytic Cracker Unit (CCU), Fluid Catalytic Cracking (FCC), Kero Merox Units, Aromatic plant, Bituminous Blowing Unit (BBU) and future projects viz. Xylene and N-paraffin units. The present facility is designed for treatment of 240 cu.m per hour of combined stream containing pollutants like oil sulphides, phenolics, BOD and suspended solids. Treatment of this waste water presents difficulty for conventional biological waste treatment. Choice of Powdered Activated Carbon Treatment (PACT) was made as it provides a highly effective process to meet the stringent Minimal National Standards (MINAS).In the PACT waste water treatment system powdered activated carbon is used in conjunction with conventional biological treatment. The addition of activated carbon enhances the removal of absorbable organics and compounds difficult to biodegrade. It also provides other benefits like operational flexibility to handle shock loads and improved sludge settling. Wet Air Regeneration (WAR) of spent carbon is used in conjunction with the PACT process to eliminate the secondary biological sludge and to regenerate the carbon for reuse. The combined waste water is equalized and then subjected to free and emulsified oil separation before going to powdered activated carbon treatment. The treated effluent meeting MINAS is sent to guard pond from the PACT system. The excess solids containing biomass and spent carbon are wasted from the PACT system and sent to Wet Air Regeneration (WAR) System. The oily/chemical sludge generated in the plant is dewatered by a centrifuge before disposal.

2. Design Basis:
TABLE 5.1

Influent characteristics

Strea m A

Strea m B 30 1776 636 1650 139 21770 2815 12425 10-12 45 1.01

Stream combined A+B 240 400 120 257 57 7535 2815 12425 6-10 45 1.01

Design flow, M3/hr BOD5 mg/lit Sulphides " Phenolics " Suspended mg/lit Oil mg/lit Chlorides mg/lit

210 204 47 58

solids 46 5502 2815

Total dissolved solids 12425 mg/lit pH Value Temp (max.) deg C Sp. Gravity 6-8 45 1.01

Note: Plant is designed for treatment of stream "C" i.e. combined stream "A" and "B" BOD value does not include the BOD exerted by phenolics. High dissolved solids are due to cooling water entering the process waste-stream by way of pump gland cooling water, floor and equipment washings in the main refinery process plants. Hence, the nature of these dissolved solids is that of sea water. Stream "A" is oil containing process waste water and stream "B" consists of segregated concentrated streams comprising of sour condensates from FCC, CCU units and spent caustic from Kero Merox unit.

3. Oil Characteristics:
TABLE 5.2

Specific gravity of 0.97 oil Pour point hydrocarbons of 48 deg. (max.) C

4. Treated Effluent Quality:

TABLE 5.3

Parameter

Concentration Quantum Limit Limit (max.) mg/lit (max.) kg of pollutant 1000T of processed crude

Oil grease Phenols Sulphides

and 10 1 0.5
0

7 0.7 0.35 10.5

BOD3 @ 27 15 C

COD Suspended solids pH value

250 20 5.5 to 9.0

11.0

5. Utilities:
TABLE 5.4

Steam a. MP Steam Pressure kg/cm2a Temp deg C b. LP Steam Pressure kg/cm2a Temp deg C

Min.

Norma Max. l

Mech. Design

17 300

17 340

20 360 370

3.5 Sat.

4.0 Sat.

4.5 180

10 200

6. Service Water:
TABLE 5.5

Supply pressure at grade kg/cm.sq.a 4.5 Return pressure at grade kg/cm.sq.a Supply temp. deg C for exchanger 35 design

Max. return temp at any exchanger 45 deg C outlet Quality: pH Turbidity NTU Alkalinity, ppm as CaCO3 ppm Hardness as CaCO3 ppm Calcium Total Sodium as CaCO3 ppm Bicarbonate as CaCO3, ppm Chloride as Cl ppm Sulphates as SO4, ppm Silica as SiO2,ppm Total dissolved solids, ppm Suspended solids, ppm Iron as Fe, ppm Organic matter 7-8.3 20 50 23 47 127 174 6 10 20 80 18 0.1 Nil

7. Climatic Data:
TABLE 5.6

Design dry bulb temp deg C Design wet bulb temp deg C Max./minimum temp deg C Barometric pr. milli bar Normal Maximum Minimum

42 28 42/15 1005 1015 999

Max. relative humidity @ 32 deg C 100 %

Max. recorded rainfall in 24 hrs 685 mm

8. Other Requirements: a. Plant is designed for an on stream factor of 365 days of continuous operation per year. b. Required turn-down ratio of 40% of design capacity for flow and pollution load. c. A storage capacity of 350 M3 for receiving stream B and equalization tank (2 nos) of 12 hours capacity for stream C. d. Guard for treated effluent of 12 hrs holding capacity. e. Sulphides indicated in the effluents characteristics are as Na2S, NaHS and RSH reported as S f. In the indicated pH range H2S as dissolved gas is negligible. g. Phenolics are biodegradable in nature provided proper environment for phenol degradation is created in biological treatment process.

9. COD design basis :

TABLE 5.7

BOD Less Sulphides Background BOD Equivalent COD of background Equivalent COD of S Equivalent COD of Phenolics

400 mg/lit 240 mg/Lit. 160 mg/Lit. = 160 x 2 = 120 x 2 = 257 x 2.38 Total 320 mg/lit 240 mg/lit 612 mg/lit 1172 mg/lit

BOD of waste for aeration = 400 + Phenolics BOD = 400 + (257 x 2.38 x 0.66) = 808 mg/lit All of the oxygen required to convert sulphides to sulphates is added to aeration requirement. In addition, one half of the sulphides are assumed to be oxidized in WAR from 5 to S04--. This provides additional safety in oxygen requirement in the aeration basin as well as WAR system. Ratio of free oil to emulsified oil is 9:1 (min) (Maximum emulsified oil content will be 10% w/w of the total oil content in the influent.)

10. Technical Specification for Chemicals:

TABLE 5.8

1. Powder Activated Carbon: Base material Particle size Surface area Moisture as packed Ash content Tamped density pH of water extract virgin MRE Regenerated MRE 2. Hydrochloric Acid: Standard Grade Concentration 3. Polyelectrolyte Type Solubility Design concentration Application 4. DAP: Standard Application IS 6448 - 1980 (first revision) To use as a nutrient source for Nitrogen & Phosphorous in biodegradation of waste water. IS 1781 - 1975 (First revision) To use as a nutrient source for Liquid cationic Polyelectrolyte Easily soluble proportions 0.5 to 1% in water in all IS 265-1976 Technical 35% HCl Coal, lignite, bark char, coconut shell 70% max passing 325# 90% min passing 200# 500 M2/g (min) 2.0% (max) 15% (max permissible 35%) 480-640 kg/M3(min) Neutral > 70% > 100%

5. Urea. Standard Application

Nitrogen in waste water. 6. Nitric Acid: Standard Grade Specific gravity

biodegradation

of

IS 264-1976 (Second revision) Technical 42 Deg Baume.

To enhance settling of fine activated carbon/biomass particles. To enhance dewatering of sludge which contains oil activated carbon & inorganic ash? There is no biosludge. To enhance the agglomeration of oil particles in flotation unit for separation from water.

ABBREVIATIONS
TABLE 5.9 COD - Chemical Oxygen Demand BOD - Biochemical Oxygen Demand DO - Dissolved Oxygen F/M - Food to Micro-Organism Ratio HDT- Hydraulic Detention Time MLSS - Mixed Liquor Suspended Solids MLVSS- Mixed Liquor Volatile Suspended Solids PAC- Powdered Activated Carbon Q- Rate of Flow R - Recycle Pumping Rate RCS - Return Carbon Sludge Concentration SRT - Solids Residence Time Va - Volume of Aeration Basin DAP - Di Amonium Phosphate RSH - Mercaptans Na2S - Sodium Sulfide NaHS - Sodium Bi-sulfide PACT - Powdered Activated Carbon Treatment WAR - Wet Air Regeneration MRE - Molasses R.E. TSS -Total Suspended Solids PO4 - Phosphate NH3-N - Ammonical Nitrogen TKN -Total Kjeldahl Nitrogen P -Phosphorous WCS -Waste Rate

W - Waste Flow M3/hr

WWTP- Waste Water Treatment Plant

CHAPTER - VI

PROCESS DESCRIPTION
Process effluent from BPCL refinery enters into the waste water treatment system in two streams A & B with a flow rate of 210 M 3/hr and 30 M3/hr respectively. Major pollutants present are oil, BOD5, phenols and sulphides. The waste water treatment system consists of following stages: 1. Pre-treatment 2. Powdered Activated Carbon Treatment (PACT) 3. Wet Air Regeneration (WAR) 1. Pre-treatment:-This section involves equalization of various streams and oil separation system. i) Equalization: Stream A contains process waste water streams and stream B is comprising of segregated concentrated streams of sour condensates from FCC, CCU units and spent caustic from Kero-Merox unit. The composition of streams A and B differ significantly, stream B being much stronger than A. The various sub streams of B are first taken to a storage tank, called stream B tank (99 T 02 A,B).Composite stream B is then pumped (99 P 01 A,B) and mixed with stream A in an equalization tank (99 T 01 A,B). The equalized streams are well mixed using an agitator (99 A12 A, B). The equalized waste water stream C is then pumped to free and emulsified oil removal section, with the help of forward flow pumps (99 P 02 B, C) and Centrifugal pump (99 P 02 A).

ii) Oil Separation:-The combined stream C coming out from equalization tanks is rich in oil content which is present both as free and emulsified oil. The oil removal is accomplished in two stages. Free Oil Removal: Corrugated plate interceptor (99 CPI 01) is used to remove free oil content of combined stream. The oily water flows over packs of tilted parallel corrugated plates. The flow is evenly distributed over the plates and a laminar flow exists in each channel. Because of the difference in specific gravities of oil and water, the oil droplets rise and attach to the underside of the upper plate. The oil film which is constantly being formed on the underside of each plate creeps slowly upwards along the plates. At the top of each plate the oil film is disengaged from waste water. The separated oil collects as a layer on the top of the liquid surface in the CPI tank. The oil layer is allowed to collect until it overflows an adjustable weir into an oil collection box from where it is sent to slop oil sump (99 SU 01) and then pumped out intermittently by means of slop oil pump (99 P12 A, B).Suspended solids present in the influent stream, settle below the plate pack from where they are pumped (99 P10 A, B) intermittently to sludge tank (99 T 08). Emulsified Oil Removal: Effluent from corrugated plate interceptor contains very finely dispersed oil droplets. These droplets are electrically charged and cannot be separated by CPI as the gravity forces are overruled by electrical charges of particles. Following steps are involved to separate emulsified oil:Neutralisation: After the free oil separation the waste water stream is neutralized to pH 6 to 7 in neutralization tank (99 T 13). The neutralization is carried out by adding HCL from acid dosing tank (99 T 12 A, B) through acid dosing pumps (99 P13 A, B). Acid is taken to the dosing tank from HCL storage tank (99 T-03) by means of transfer pump (99 P 23 A, B). Air Flotation: In the Induced air flotation (IAF) tank, (99 IAF 01) the neutralized waste water stream is mixed with air bubbles. The air bubbles attach themselves to the oil globules thereby reducing the density of the same. The oil globules then float rapidly to the free liquid surface in the flotation basin together with the entrained air bubble, to form a froth layer which is removed on continuous basis. The flotation tank is divided into compartments. From the last clean water compartment, a centrifugal pump (99 P03 A,B,C) recalculates the clean water through an overhead header to a down comer having a nozzle and eductor system which ensures even dispersion of finely divided air

bubbles throughout the liquid. Both oil and oil wet suspended solids will float as they are attached to the minute air bubbles. Oil and suspended solids accumulate on the surface of the liquid, where they are continuously removed from flotation compartment by means of constantly rotating skimmer blades into a trough. This flotation sludge is pumped (99 P11 A, B) to the inlet of CPI. The bottom of the IAF tank is connected to CPI sludge pump for removal of settled solids . 2. Powdered Activated Carbon Treatment (PACT):-The PACT Wastewater Treatment System is a biological treatment and physical adsorption process combined into a single unit process. Powdered activated carbon is added to the conventional activated sludge process to adsorb non biodegradable compounds and provide improved removal of biodegradable materials. Following equalization, free oil removal, neutralization and emulsified oil removal the influent waste water stream flows by gravity into the aeration basin (99 AB 01).In the aeration basin, carbonaceous BOD is removed via biological assimilation and non degradable, absorbable material is adsorbed on the powdered carbon. Three aeration blowers (99 B 01 A, B, C) provide required air for the aeration. Coarse bubble diffusers are used to disperse the air in the aeration basin. Mixed liquor from the aeration tank passes to a chamber where a polymer solution is added to aid in solids capture and settling. The flocculated mixed liquor then passes to the clarifier (99 CL 01) where the solids settle. A rake mechanism (99 A 10) moves the settled solids to the centre draw-off point where recycle pumps (99 P 08 A, B, C) return the solids to the aeration basin on a continuous basis Solids are controlled in the aeration basin by periodic wasting of mixed liquor to a sludge thickener (99 ST 01) by means of Waste pump (99 P 07 A, B). The relatively dilute slurry (mixed liquor) is allowed to settle in the sludge thickener tank and the supernatant is returned to the aeration basin by gravity. These thickened solids are then periodically withdrawn and transported by slurry pump (99 P09 A, B) to slurry tank (99 T 10) for regeneration. The treated water overflows the clarifier and is led directly to guard pond (99 GP 01) by gravity. Virgin carbon can be added directly to the aeration basin to replace carbon removed from the system. Virgin carbon is added daily by manually initiating the addition sequence. This is described in detail in Section 5.2Treated waste water overflows from the guard pond into effluent sump (99 SU 02) from where it is pumped out by means of effluent pump (99 P06 A, B, and C).

a) Flow to the Aeration System:

Influent: Waste water from IAF unit (99 IAF 01) flows to the Aeration basin (99 AB 01) by gravity. Make-up Carbon: Make-up carbon addition can be introduced daily into the aeration basin (99 AB 01). Carbon slurry is prepared in PAC tank (99 T 06) and transported by dosing pumps (99 P 16 A, B). Nutrients: A nutrient solution prepared in nutrient tanks (99 T 05 A, B) supplies required phosphorous and nitrogen to the aeration basin by metering pumps (99 P 15 A, B). The nutrient pump flow is controlled manually. The nutrient tanks are equipped with agitators (99 A 02 A, B). The tank is manually filled by admitting service water via valve no. 751.1 and 751.2 and adding the required amount of nutrients. Thickener Overflow: Supernatant from sludge thickener (99 ST 01) flows by gravity to aeration basin (99 AB 01). Treated Effluent: Provision for recycle of treated effluent pumped by effluent pumps (99 P 06 A, B, C) back to aeration basin (99 AB 01) is made. Scrubber Water: Treated effluent which is used as a scrubbing liquid for vent gases through scrubber-1, (99 C 0l), Scrubber-2 (99-C-02) and Atmospheric Separator, (99 AS 01) of Wet Air Regeneration Unit, blows by gravity back to aeration basin (99 AB 01).

b) Aeration System: In the aeration basin the waste water will aerate in the presence of powdered activated carbon, biomass and non-volatile material (ASH) to remove BOD.The micro organisms in the aeration basin remove the organic compounds that are measured by the BOD/COD analysis by consuming it as food. This is called metabolism. Metabolism consists of two separate on-going processes; respiration and synthesis. The desired micro-organisms are aerobic. That is they require free oxygen dissolved in the mixed liquor for respiration. In the respiration process the micro organisms consume organic compounds and oxygen dissolved in the wastewater and convert (oxidize) them to carbon dioxide and water. The micro-organisms also reproduce, using a portion of the food, for synthesis of new cell growth. The required oxygen is made available to the Micro-organisms by bubbling air into the water (Mixed liquor) in the aeration basin. Some of the oxygen is dissolved in the water and in this dissolved form becomes available to the micro-organisms. The available oxygen is measured as D.O. (dissolved oxygen) and should be held in the range of 2-4 ppm to maintain adequate biological

activity and promote the predomination of the proper species of aerobic Micro-organisms. Low D.O. levels (less than 1.0 ppm) promote the reproduction of filamentous, poorly settling micro-organisms. D.O levels greater than 4.0 ppm are not required because the biomass oxygen requirements are well satisfied at 2.0-4.0 ppm oxygen. D. O. levels above 4.0 at design BOD loading could also result in a poor settling floc (high effluent S.S.) caused by the increased air rates mixing the aeration tank too vigorously. D.O. level in the aeration basin is continuously monitored by D.O. analyzer. Oxygen requirements for biological uptake are provided by two of three aeration blower (99 B 01 A, B, C). The blower will provide compressed air through coarse bubble diffusers located throughout the aeration basin. Each blower is sized for 50% of total plant requirements. It is in the aeration tank that the substrate in the waste water is consumed as food by the biomass or adsorbed on the carbon. The substrate represents food, and air is added to supply oxygen needed for respiration. The micro-organisms will multiply (increase in population) as long as there is flow of substrate to the aeration basin, oxygen and the appropriate environmental conditions such as temperature, pH etc. exist. The solids residence time (SRT) is determined by the mass of solids removed from the aeration basin/clarifier system each day. The SRT must be controlled at some desirable value. If 10 days is the target SRT so the biological solids retain good settling characteristics then every day one tenth of the solids from the aeration tank (assuming negligible solids in the clarifier sludge blanket) must be removed from the system to the sludge thickener. This is done by the waste pumps (99 P 07 A, B). The biomass fraction will be replaced by new cell growth and the carbon fraction will be replaced by adding virgin carbon. The wasted solids are collected and thickened in thickener (99 ST 01) prior to being sent for regeneration.

c) Flow to Clarifier (99 CL 01): The mixed liquor from the aeration basin flows to a chamber where a polymer solution is added to enhance solids capture and settling in the clarifier. The mixed liquor then flows to the clarifier where the solids settle. The clarifier collects the mixed liquor solids and thickens it to sludge with a consistency of typically 35% wt. This material is returned to the aeration tank to maintain the solids inventory in the process via two of three recycles pumps (99 P 08 A, B, C). Supernatant overflows the clarifier weir and is conveyed to guard pond (99 GP 01 A, B).A rake mechanism in the clarifier moves the thickened sludge (biomass, carbon and ash) to the center bottom draw off nozzle. The clarifier rake drive has two high torque switches. The first JAH-1 will activate an alarm, if tripped, indicating high torque. The

second (JAHH-1) torque switch will, if tripped, stop the drive motor and activate another alarm. The sludge blanket in the clarifier shall be maintained at a minimum. Since PACT sludge settles and compacts very well, a minimum sludge blanket will reduce recycle pumping problems. d) Recycle Sludge Flow: From the clarifier the sludge is normally recycled back to the aeration tank or can be wasted to the thickener (99 ST 01). The direction of the recycle, pump discharge, (recycle or waste) is determined by the position of valves No. 415/1 and 465/1. Recycle flow rate is measured by on-line magnetic flow meter (FE-05). e) Polyelectrolyte Addition: Polyelectrolyte is fed to the flocculation chamber by two metering pumps (99 P 17 A, B). The pump flow is controlled manually. The Polyelectrolyte tank (99 T 07 A, B) is equipped with a low speed mixer. The tank is manually filled by admitting water via valve no. 761.1/1 or 761.2/1 and adding the required amount of dry polymer or neat polymer (as received) solution from a drum (manually). The water is shut off and the agitator is started. After a minimum of 30 minutes the agitator may be stopped. f) Make-up Carbon Addition: The addition of make-up powdered activated carbon (PAC) is done intermittently once per day, for example, to replace PAC losses. Make-up carbon slurry from the PAC tank is directed to the aeration tank. g) Scum Removal: Floating solid in the clarifier (99 CL 01) are collected in scum sump (99 SU 05) and transferred intermittently by timer operated scum pumps (99 P 05 A, B) to slurry tank (99 T 10) of Wet Air Regeneration System.

2. Wet Air Regeneration (WAR) System: Solids comprised of powdered activated carbon and associated adsorbed material and biological solids are wasted from the PACT system as necessary to control that process. This spent carbon slurry is sent for regeneration to the WAR Unit. Spent carbon is supplied to the WAR Unit by either of two centrifugal feed pumps, (99 P 22 A, B). The slurry is pumped under positive pressure (approx. 50 to 70 psig) to the inlet of a diaphragm type high pressure pump (99 P 21 A, B). The positive pressure is an operational requirement for the high pressure pump. Its operation is fully described in Section 5.3.The high pressure pump discharges the spent carbon slurry at normal system pressure (maximum of 1100 psig) to the inlet of a inner pipe of double pipe heat exchanger (99 E 01). Flow from the high pressure pump is adjustable within the design hydraulic

operating range of the WAR Unit (10 to 24 gpm) to meet operational requirements. Air required for Wet Air Regeneration, compressed to normal system pressure (max. 1100 psig) by two of three process air compressors (99 K 01 A,B and C) is introduced into the system at two locations. These are immediately downstream of the high pressure pump (with the slurry flow) and secondly, directly to the inlet of the reactor. The spent carbon slurry/compressed air mixture flows through the inner pipe of the process heat exchanger (99 E 01) where heat is recovered. Heat from the hot reactor products flowing through its outer pipe is transferred to the spent carbon/air mixture within the tubes. Use of this heat exchanger recovers energy that otherwise would be wasted. This enhances the economics of the WAR Unit by lowering the overall energy input requirement. The preheated slurry and air flow from the tube outlet of the process heat exchanger to the tube inlet of the start-up heat exchanger (99 E 02). This second heat exchanger supplies additional heat to the slurry/air mixture. Thermic fluid from a heater (99 E 03) is circulated through its outer pipe by means of thermic fluid pump (99 P 24 A, B). Heat from the fluid is transferred to the incoming (inner side) flow of preheated slurry and air. The flow of thermic fluid through the shell is regulated by appropriate instrumentation to maintain the desired reactor temperature. The preheated slurry/air mixture flows from the startup heat exchanger tube into the reactor (99 R 01). The mixture enters the reactor bottom, flows upward through four expanded metal baffles and exits the top. The baffles ensure good mixing as the flow passes from bottom to top. During the period of time it takes for this to occur (retention time), chemical reactions (oxidation) take place. These reactions regenerate the powdered activated carbon by destroying the adsorbed biological and other solids. As they occur, the heat is liberated. This heat, which can be observed in the difference between reactor inlet and outlet temperatures, must be controlled by proper selection of process variables. These must be selected to maximize adsorbed material destruction with minimal loss of carbon. The reactor outlet temperature is controlled by regulation of its inlet temperature. Retention time in the reactor is nominally one hour based upon 20 gpm hydraulic flow rate. To ensure proper regeneration of the powdered activated carbon, a minimum of 3 percent excess oxygen must be present in the process off gases. This holds true regardless of all other parameters. The resultant mixture of oxidized process products (regenerated carbon, water, soluble material and gases) exits the reactor and then

flows to the Inlet of outer pipe of the process heat exchanger. The reactors outgoing hot oxidized products flow through the process heat exchangers shell in the direction opposite to the flow of incoming spent carbon slurry and air. This counter-current flow in the heat exchanger maximizes the transfer of heat from shell to tube products. Under specific operating conditions, the amount of heat generated in the reactor will be sufficient to sustain WAR Unit operation without use of supplemental heat from the start-up heat exchanger. When the reactor inlet and hence reactor outlet temperatures will be controlled by exchange of heat in the process heat exchanger or by adjustment of spent carbon slurry flow, this is called auto thermal operation. In auto thermal operation, preheated spent carbon and air will merely flow through the tubes of the start up heat exchanger. The reactor inlet temperature will be controlled strictly by heat exchanged within the process heat exchanger. Control of heat transfer is accomplished by adjusting one or more of the following: Carbon slurry flow rate. Carbon slurry solids concentration. Air bypass around the process heat exchanger. Slight variation in Reactor pressure increase 10-20 psig as heat transfer rate declines with sealing.

Air flow with the spent carbon slurry through the heat exchanger tubes enhances heat transfer. That is, within limits, increased air flow increases heat transfer and decreased air flow decreases heat transfer. Ideally the full output of the compressors should flow through the tubes of the heat exchangers with the spent carbon slurry to achieve maximum heat recovery. In specific instances, during auto thermal operation, bypassing some compressed air around the heat exchanger tubes may be required to maintain the correct reactor temperature or improve temperature control. System instrumentation accommodates this control strategy. The reactor products flow from the process heat exchanger shell to the pressure control valves (PCV's) located on PCV pots (99 V 02 A,B). As the mixture passes through a PCV (only one is in service at a time), it is depressurized and discharged to Atmospheric separator (99 AS 01) which allows the vapours to separate from the solids and liquids. The vapours from the separator pass through scrubbers (99 C 01 and 99 C 02) prior to discharge by vent blower (99 B 03 A, B). The solids (regenerated PAC) and liquids are sent from the Atmospheric separator to Aeration Basin (99 AB 01). In the PACT system, as in all biological treatment processes, there is an accumulation of solids.

These solids include bio-solids, inert material or ash, and activated carbon. When these solids are processed by wet air oxidation, the biosolids are destroyed and the carbon is regenerated. Some ash is dissolved in the wet oxidation process and some ash settles in the bottom of the reactor vessel. The ash accumulated in the reactor is removed by periodic blow downs. The ash removed from the reactor is depressurized into a blow down pot (99 V 03) where it is mixed with water to reduce its temperature. The resultant ash slurry is piped to a sludge tank (99 T 08) where it is stored for eventual dewatering. Since regeneration of spent carbon inevitably results in the loss of some carbon, a virgin carbon make up system is also provided to replace this loss. Need for make up carbon addition is indicated by laboratory analysis of the powdered activated carbon/biomass ratio, which should be about 3:2. If this ratio falls below 3:2 virgin carbon addition is indicated. SLUDGE DISPOSAL: The sludge is generated from three sources in the treatment plant: i) From oil separation system. ii) From Blow down system in WAR Unit. iii) From equalization tank. The settled solids in the form of oily sludge are removed intermittently from the bottom of Corrugated Plate Interceptor (99 CPI 01) and transferred to sludge tank (99 T 08) with the help of CPI sludge pump (99 P l0 A, B). Any solids settled at the bottom of Induced Air Floatation Unit (99 IAF 01) are also directed to the suction of the same pump. The blow down solids containing activated carbon and inorganic ash, are transported along with service water from blow down tank (99 V 03) by pressure differential to sludge tank (99 T 08). A provision is also made to transfer the solids settled in the equalization tank (99 T 01 A, B) occasionally to sludge tank (99 T 08). Forward flow pumps (99 P 02 A, B, C) are used for this purpose. A homogenized mixture of all solid from the sludge tank is fed to the centrifuge (99 W 01 A, B) by centrifuge pumps (99 P 18 A, B). The centrifuge is designed for eight hours operation per day. The centrate from the centrifuge is collected in centrated tank (99 T 09) and transferred to equalization tank (99 T 01 A, B) with the help of centrate pumps (99 P04 A, B). The dewatered sludge in the form of a cake is

discharged from the centrifuge bottom. This can be collected in trolleys for further disposal. To enhance the solids capture in the centrifuge a polyelectrolyte dosing system is provided. It consists of Polyelectrolyte tanks (99 T 04 A, B) and the dosing pumps (99 P 14 A, B). The Polyelectrolyte at required concentration is dosed at the inlet of the centrifuge.

CHAPTER - VII

PROCESS CONTROL

1. PACT SYSTEM. A control scheme whether for activated sludge or PACT should maintain a balance between sorption and stabilization Such schemes will also be based on sludge wasting (and addition of virgin carbon in the required amounts)

While PAC affects sorption and stabilization, its major contribution is to the sorptive capacity of the system, PAC concentration or dosage levels will thus be primarily determined by the pollutant removals required, which may be measured by effluent characteristics. Control of the PACT system thus involves two different but related elements. Addition of virgin PAC and wasting of excess Mixed Liquor Suspended Solids (MLSS).

Once the appropriate "initial charge" of PAC has been added to the system, only make up carbon need be added. Make up is necessary to compensate for effluent PAC losses and the amount of spent PAC lost in the Wet Air Regeneration unit. Wasting of sludge from the system biological Sludge Age which will permit growth of desirable flora. In this respect-control by solid, wastingPACT is exactly the same as activated sludge as one would expect based on the inherently biological nature of PACT. Sludge Age is defined as the age, in days, which results when the system total solids mass is divided by the daily rate at which solids are removed from the system. This parameter is thus seen to be the same as Solids Residence Time (SRT) or Mean Cell Residence Time (MCRT) often seen in wastewater treatment reference literature. In addition to the control of the system as just discussed, the following operational parameters should be monitored closely: i) Dissolved oxygen (D.O) - It is recommended that D.O levels be kept between 2-4 mg/l in the aeration basin, and should not be allowed to drop, to less than 1.0 mg/l for any reason. Severely detrimental to the PACT system, such low levels may result in poor effluent quality which may persist beyond restoration of proper D.O. levels. D.O. levels greater than 4 mg/l do nothing to enhance treatment and consume more power than necessary for treatment. At design, BOD loading (or greater) to the aeration tank, D.O. levels above 4 mg/l can shear the biological floc and lead to poor settling in the clarifier (high effluent S.S). ii) Return or recycle sludge (RCS) Pumping rate, R- It is recommended that the sludge which settles to the bottom of the final clarifier be returned to the aeration tank as quickly as possible .This is done to prevent too much sludge from accumulating in clarifier, which would then become anaerobic or septic as well as increasingly difficult to scrape and pump. Too great a sludge blanket can also lead to excessive loss of solids in the clarifier overflow. Polyelectrolyte dosage- It will be necessary to determine an approximate range of polyelectrolyte dosage based on bench-scale testing (which should be done on site). The polymer is added to increase capture of fine solids which would otherwise be lost in the
iii)

effluent, and to improve sludge settleability overall. Normally 0.25-3.0 mg/l of cationic polymer is required to produce an acceptable effluent suspended solids concentration. iv) Nutrient addition- It may be necessary to add so-called macro nutrients to the aeration tank to assure growth of desirable organisms. Nitrogen in the form of ammonium ion and phosphorous in the form of phosphate ion are good (usable) sources of these elements. They are typically abundant in municipal waste waters, but frequently must be added to industrial wastewaters otherwise undesirable organisms such as filaments may proliferate. Nutrient nitrogen and phosphorous requirements are given in proportion to BOD in the ratio of 100 parts BOD, 5 parts nitrogen and 1 part phosphorous. Operation and control of the PACT system have been discussed in terms of the following parameters: Wasting (proper SRT) Carbon addition (Carbon Dose) D.O. control (2-4 mg/l D.O) Return or recycle sludge pumping rate (no sludge blanket). Polyelectrolyte dosage Maintaining proper nutrient (Nitrogen & phosphorous) levels

Any problems which arise during operation of a PACT Wastewater Treatment System will be found to have its cause in one or more of these six parameters. Sample Calculations: a) Biomass Level: The influent stream contains pollutants (suspended colloidal and dissolved solids) which the PACT system must remove to meet required plant effluent limitations. The portion of the waste Measured as BOD will have to be stabilized (converted to CO2, water and cell structure Material) biologically. The question arises: How much biomass is needed to stabilize a given amount of BOD loading? A commonly used parameter which relates influent loadings and the biomass which results from those loadings is the F/M ratio. F = food or BOD loading, M = microorganism mass/M may be applied to PACT much in the same way it is used in activated sludge systems: The normal Activated sludge F/M is in the range of 0.2-0.5. To calculate a target MLVSS the F/M ratio chosen should be within this range. Example: i) Lets assume that the BOD loading to the plant is projected at 808 mg/l.

ii) The average plant flow is Projected at 240 cu.m/hr iii) The volume of the aeration tank is 4315 cu.m Convert BOD loading in mg/l to kg/day. F = 808 mg/l x 240 cum/hr x 24hr/day x 0. 001 = 4654 kg/day. For an F/M of 0.35 (mid way between 0.2 and 0.5).

iv) To avoid problems associated with relatively higher values of F/M (analogous to low SRT) such as turbid effluent containing significant solids and BOD due to the dispersed bacterial growth which characterizes operation at high F/M (short SRT), it is recommended that M-kgs of MLVSS in system be increased. This may be accomplished by decreasing wasting rates (raising SRT). To illustrate the point here -biomass level-however, assume we choose a biomass which will make F/M = 0.24 (M=.19392 kg). This allows BOD excursions up to about 9696 kgs/day without exceeding F/M = 0.50 but we assume that the average BOD remains at about 46547 kgs/day. This is saying that at an F/M of 0.24 we can double the short term loading on the Plant without causing bleed through of BOD or change the biology to an extent that would hamper treatment assuming ,ample oxygen, nutrient, hydraulic capacity and a readily degradable waste are provided 2). Carbon (PAC) Level: The solids carried in the aeration tank are not just MLVSS .Associated with the living portion of the biological floc are many inert, inorganic materials like grit and a portion of each living organism is also inorganic. We commonly differentiate these fractions in the laboratory by burning or ashing samples in a muffle furnace at 550 deg to 660 deg C. In the PACT system about 5-35% of the virgin PAC added as initial charge or make up PAC is ash .When a sample of MLSS is analyzed for its various component PAC biomass and ash-there is no distinction made regarding where the ash in the sample came from .Therefore, the following applies equally whether there is PAC in the system or not. We choose, for example, to operate the system with a mixed liquor volatile carbon concentration at say 4.39 g/l because experience has shown Acceptable treatment results with this carbon level. Given an aeration tank volume of 4315 cu.m then: Vol. Carbon = 43.15 cu., m x 4.39 g/l = 18943 kg Virgin carbon as delivered may be approximately 15% ash, 85% PAC. To get 18943 kgs of volatile carbon will require: Virgin carbon = 18943 / 22,286 kg

3). Wasting: Again this is the means by which the process is controlled. PAC levels in the PACT system are determined by pilot scale work or experience. Based on this information, PAC addition to the system is essentially an independent variable, which can be maintained at as high or low a level as required (or desired). Biomass level, on the other hand, is not an independent variable because the amount of biomass which can be developed in any system depends upon the amount of food available to that biomass. Therefore, the concept of control of PACT by wasting reflects the fact that what is really being controlled is the biomass. We can add as much PAC as we want, but we will only get as much biomass as the influent loading will support. Experience has shown that the biomass, which results from a wasting level based on a 5-20 day SRT, performs its functions well and we are able to avoid development of nuisance biogrowths. As dictated by actual operation, the SRT may be changed to optimize the treatment. The calculation of daily waste is quite simple, no matter what SRT is chosen. W kgs/day = M (MLSS) kgs/SRT days. The MLSS concentration is measured at 12.5g/l for example Then: M (MLSS) kg = 12.5g/l MLSS x 4315 = 53938 Choose SRT = 10 days (design value), then W = M/SRT-Effluent S.S., if effluent SS concentration is low, we can neglect this term M/SRT = 53938 kgs / 10days = 5394 kgs/day, is amount can be wasted as return sludge, whose concentration has been measured at 30 g/l (Also calculated as one twentieth of the aeration tank volume if the solids blanket in the clarifier is negligible) W (Cu.M/day) = 5394kgs/day / MLSS g/l W (Cu.M/day) = 5394 kgs/day / 30 g/l = 180 cum/day. W = 180 Cu.M/day. Let the waste flow rate = 25 cum/hr (assumed for this example). Then the total time in hours to waste for the day .Then the total time in hours to waste for the day is to be calculated. Wasting should be done throughout the day at equal intervals. Lets say that wasting will be done every 2 hours or 12 times per day. Wasting duration for each will be derived. Set the waste mode timer to waste 36 minutes every 2 hours

4). Carbon Addition Rate:

Carbon addition = Carbon Wasted (given negligible effluent losses). The amount of volatile PAC wasted is based on the amount of volatile PAC in the MLSS. From B.1: The mixed liquor contains 18943 kg of volatile carbon. Since we are wasting one twentieth (l/SRT) of the total mass of MLSC every day, we will remove: 1/SRT x MLVC = 1/20 x 18943 kgs. = 947 kgs of volatile carbon/day. To get an equivalent, amount of virgin PAC:

5). Polymer Addition: A cationic polyelectrolyte (polymer) of high molecular weight, applied at the correct dosage, can significantly reduce the amount of suspended solids the clarifier effluent. Dosage requirements can be roughly determined by the bench jar test. Your polymer supplier will usually be glad to demonstrate his/her product and suggest dosage rates a wide range of brands and types of polymer should be tested initially keeping in mind the economics involved. One suppliers "cheap" polymer may work just as well as another suppliers "expensive" brand or even exceed the high priced polymers performance. Polymer dosage is usually expressed in terms of parts per million For Example: Lets say that the polymer chosen demonstrates good particulate capture at 1.5 ppm as demonstrated by the jar test. Assume a plant flow of 240 cu.m/hr plus a recycle rate of 80% or 200 cu. m/d for a total flow to the clarifier of 440 cu. m/hr. Convert this clarifier influent flow, in cu.m/d to kgs of polymer required. 440 cu.m/h x 24 x 1.5 mg/l x 0.001 = .15.9 kg/d. 6). Nutrient Addition: The following example shows how to determine whether there is a nutrient deficiency in the PACT system influent, and how to calculate the quantity of additional nutrients required to correct the deficiency. Once the nutrient chemical feed rate (in kg/day) is determined, the chemical feed equipment must be set to feed the calculated amount of nutrient based on 24 hour period. (In continuous flow PACT systems the nutrients should be fed, (Preferably in proportion to flow). In batch PACT systems the nutrients should be added during the waste water feed step of the process cycle).

Example: Calculate the required amount of additional nutrient to correct a nutrient deficiency. Given: (for this example only)
TABLE 7.1

PACT influent BOD PACT influent TKN PACT influent P

= = =

808 mg/l 15 mg/l 5 mg/l 5760 cum/d 100/5 100/1 9.5 kg/d = =. 20 100g

PACT average daily influent = flow Suggested BOD/N Suggested BOD/P weight weight ratio = ratio =

TKN returned from WAR unit =

Calculate nutrient needed to achieve the suggested BOD/N/P ratios Nutrient Needed = PACT influent BOD, mg/l x Q cu.m/d x 0.001/ suggested ratio, BOD/nutrient N needed, kg/d = 808 x 5760 x 0.001/100 = 232 kg/d. Calculate the nutrient addition. If the answer is zero or a negative number, no nutrient need be added. Nutrient Addition = 808 x 5760 x 0.001/100 = 46.5 kg/d Calculate weight of commercial chemical to be added per day. For N: 100% Urea, kg/day =

Nutrient addition using estimated BOD and nitrogen values. As stated previously, a desirable BOD: N: P weight ratio based on influent BOD is 100:5:1. For practical purposes an estimate of organic loading to the PACT system can be used especially if nutrient addition rates have to be adjusted on a daily basis. Therefore, analysis such as chemical oxygen demand (COD) is necessary to provide quick analytical result COD analyses can be run within several hours and an estimated BOD value can be calculated once a BOD:COD ratio has been established. To establish, a BOD/COD ratio, parallel COD and BOD analyses of the PACT influent should be conducted over a period of 90 days or longer .Once the BOD: COD ratio is known; a BOD can be estimated based on a measured COD. Estimated BOD, mg/l = (COD, mg/l) (Ratio BOD/COD) As an estimate for nitrogen content in the PACT influent, ammonianitrogen (NH3-N) can be used since it is easier to run in the lab than the Total Kjeldahl Nitrogen (TKN) analysis .However, a correlation between

NH3-N and TKN must be developed also. Again, this ratio of TKN/NH3-N should be established over a period of 90 days or longer using parallel TKN and NH3-N analyses of the PACT influent. Estimated N, mg/l = (NH3-N, mg/l) (Ratio TKN/NH3-N)

Example: Estimate the BOD loading based on a COD analysis For this example lets say that over a 3 month period of time, the influent BOD/COD ratio is consistently 0.5 .In other words, the organic loading to the PACT system can be expressed as BOD = (COD) (0.5) Given COD = 1150 mg/l Estimated BOD, mg/l (COD, mg/l) ratio BOD/COD. Estimated BOD, mg/l = (1150) (0.5) = 575 mg/l Use the estimated BOD in the nutrient calculation in place of actual BOD. Example: Estimate N available in the PACT influent based in the TKN/NH3-N ratio. For this example, lets say that over a 3 month period of time the TKN/NH 3-N ratio is consistently l0.0

Given: NH3-N = 1.5 mg/l Estimated N, mg/l = (1.5) x (10) = 15 mg/l Use the estimated N in the nutrient calculation in place of the actual TKN. Note: TKN measures organic nitrogen plus ammonia-nitrogen in the sample. This analysis, better quantities total nitrogen available to the biomass.

CHAPTER - VIII

ROUTINE OPERATIONS

A. Routine Operation of PACT System: Maintain the following process control parameters during normal operation of the plant. Influent flow range: 100 to 240 M3/hr Clarifier recycle rate: Maintain zero (minimal) clarifier sludge blanket in clarifier. (Initially set at 80% of influent. Monitor sludge blankets twice per 8 hour shift. Adjust recycle pump flows accordingly).
TABLE 8.1

Mixed liquor D.O. : Mixed Liquor pH : Nutrient addition :

2-4 ppm (2ppm minimum) 6.5-7.5 Maintain clarifier effluent Nitrogen (NH3-N) and phosphorus (P) in the range of 1-3 ppm.

Polymer rate

feed :

Maintain minimal "suspended solids" in effluent. SRT: 7-13 days (10 days SRT recommended to start with. SRT may be increased slowly if nuisance biogrowths do not cause effluent quality to deteriorate).

The operator should perform the following recommended duties in developing an operators routine for the plant.

Collect samples and perform analysis as recommended to monitor plant operation and meet MINAS requirement (Laboratory Staff). Perform maintenance as recommended by equipment manufacturers. (See Equipment Operation and Maintenance Manual). Check air flow distribution, to ensure proper D.O. and mixing. Check and record return sludge flow. Check final clarifier to ensure no (minimal) sludge blanket. Adjust return as required. Fill out log sheets as required. Check that required chemical additives are available in storage tanks. Check and record all feed rates. Ensure delivery at feed point. Recalibrate system. As required. Check flow of waste sludge to ensure that proper waste rates are achieved. Remove concentrated sludge from sludge thickener (99-ST-01) as required. Feed carbon daily to Aeration basin (99-AB-01) from the carbon feed system Set the scum tank timer to pump only as much scum as accumulates in the scums tank. Excessive amounts of scum are likely due to another cause such as inadequate wasting or excessive overflow from the sludge thickener tank back into the aeration basin. Correct these problems before attempting further corrections to scum system. Clean out polymer tank weekly. Check flow of seal water to recycle pumps twice per shift

Note: It is strongly recommended that a preventive maintenance programme which follows guidelines set down in the Equipment Operation and Maintenance Manual, for all plant equipment, be developed and implemented. Such a preventive maintenance program should contain a schedule for cleaning, lubrication, inspections, adjustments, calibrations and maintaining protective coatings for plant equipment. With proper maintenance the equipment can be expected to last its full anticipated service life. B. Routine operations of war system: i). Spent Carbon Slurry and Process Air Flow Rates: Regeneration of spent carbon slurry by the WAR Unit is a process which forces the biological solids and other contaminating materials associated with the activated carbon particles to react with oxygen. This oxidation results in the conversion of these materials into other compounds, leaving the activated carbon particles available for re-use. The oxygen required by the system is supplied in the air delivered by the process air compressor (air contains 21% oxygen). The amount of air required to regenerate the carbon (oxidize the contaminants) in a gallon of spent carbon slurry will vary depending on the chemical oxygen demand (COD) of the slurry. The most practical method for

determining whether enough oxygen is being supplied is to sample the gases leaving the WAR Unit and analyze this sample to determine its oxygen content. A continuous sampling/analyzing system is installed for this purpose. It is recommended that this residual oxygen content be maintained in the range of 3-5%, with approximately 3% as an indication of optimum conditions. A value lower than 2% is taken to indicate "oxygen starvation" which may result in insufficiently regenerated carbon. A value higher than 5% indicates inefficient operation because a greater rate of carbon slurry flow could be processed at the existing rate of air flow, and because the excess air has a cooling effect within the system. If the oxygen content of the offgas exceeds about 7%, this cooling effect can be great enough to make auto thermal operation of the unit impossible. In light of these principles, it is recommended that the standard operating practice whenever possible should be to operate two process air compressors at their full capacity and then adjust the spent carbon slurry flow rate to whatever value yields 3-5% residual oxygen reading. This will in general result in the maximum production of regenerated carbon per Rupee of operating cost. The Wet Air Regeneration Unit is nominally designed to process spent carbon slurry at 20 gpm. The high pressure pump is capable of pumping 25 gpm. A sample of regenerated carbon shall be taken periodically, and analyzed for soluble COD. This value should be less than 170 mg per gram of feed biomass solids. Higher values may indicate improper operation or instrumentation out of calibration. It is anticipated that temperatures in the range of 237 deg to 249 deg C will be required to properly regenerate the spent carbon slurry. Should the need arise to operate at higher temperatures, consideration to pressure and process piping velocities must be given. Figure5.1 details minimum reactor pressures required for specific reactor inlet and outlet temperatures. These MUST be used during operation to insure maximum heat exchanger tube and shell velocities are not exceeded. Failure to comply will cause increased wear to process piping with eventual erosion failures probable. ii). Process Temperatures: Spin type thermocouples and RTD are mounted on the process piping at numerous locations throughout the WAR Unit. The signals produced by these thermocouples & RTD are sent to the Panel Indicators where the corresponding temperature values may be observed. The following table

lists the locations monitored by the thermocouples and RTDs and the temperature range normally observed at each location while operating with a reactor outlet temperature of 243 deg C.
TABLE - 8.2

Description Location

of

Monitored Temperature Deg C Within 14 ambient deg

Range C of

Process air compressor discharge (one RTD on common Discharge line compressors). for all three

Air temperature.

Spent carbon/air to process heat exchanger Spent carbon/air to hot oil heat exchanger Reactor inlet Reactor middle Reactor outlet Regenerated carbon and vapours from process heat exchanger . Hot oil heat exchanger oil supply Hot oil heat exchanger oil return

13-32

176-188

193-227 232-243 237-254 93-149

249-260 240-252

Thermometers are also provided for indication of temperatures at various other locations in the Unit. The following table lists their locations and the temperature range normally observed at each location While these temperature ranges reflect anticipated values for the WAR unit as newly installed, the operator must be aware that observed temperatures will in time begin to fall outside the given ranges. This

reflects changing conditions in the unit-primarily the accumulation of scale deposits on the internal surfaces of the heat exchangers. Accurate logging and proper interpretation of this data will help to determine when solvent washing is necessary to restore efficient operation. The temperature control system is designed to maintain the reactor outlet temperature which is critical for the regeneration of the carbon. The proper reactor pressure must be maintained at the selected reactor temperature indicated by the graph. During startup and under low COD conditions; the anticipated operating procedure is to control the reactor outlet temperature by controlling the flow of hot oil through the hot oil heat exchanger. The temperature controller position the hot oil control valve for more or less energy input in the process. The hot oil control valve directs more or through the hot oil heat exchanger when more heat is need and bypasses more oil past this heat exchanger when less needed. As mentioned previously in this chapter, when certain operating conditions are obtained, the Wet Air Regeneration Unit will operate without further heat addition from the hot oil system. At this point, the chemical reactions taking place inside the reactor generate sufficient heat to keep the process operating without outside heat input. This is called auto thermal or self sustaining operation. The reactor outlet temperature must still be controlled during this mode of operation. When operating auto thermally, the temperature controller must be in the "AIR" mode of control. In the AIR mode, the output signal of the controller is no longer directed to the hot oil control valve; it is directed to a control valve which admits process air into the flow of slurry and air entering the reactor. This means that under auto thermal operation, the total flow of air into the process is divided, part mixed with spent carbon slurry and passing through the heat exchanger tubes, and the remainder injected into the preheated slurry and air mixture emerging from the heat exchanger tubes just before entering the reactor. Air passing through the tubes of the heat exchangers causes turbulence within the tubes. This turbulence promotes good heat transfer since new material is continually exposed to the walls of the pipe. Reducing the air flow through the heat exchangers will reduce the turbulence, thereby reducing the efficiency of the heat exchangers. When the bypassed air enters the preheated stream a temperature drop is observed as the bypassed air preheats and becomes saturated with water vapours at the elevated temperature.

iii). Process Pressures:

A number of field-located pressure gauges are provided to indicate pressures at various points throughout the WAR Unit. Pressure measurements at certain other points are transmitted to the Instrument control panel. Pressures that will typically be observed at various points with the WAR Unit in normal operation at 900 psig reactor pressure are summarized by the following table (asterisks following instrument numbers refer to explanatory notes following table:
TABLE 8.3

Description of Monitored Press. Range PSIG Location High pressure pump inlet High pressure discharge 40-60

pump 900-1000

Spent carbon/air to process 900-1000 heat exchanger Process air Discharge Process air Discharge Process air Discharge compressor compressor compressor A 900-1000 B 900-1000 C 900-1000

Hot oil heat exchanger tube 900-950 inlet Reactor inlet *Reactor outlet 850-900 850-900

Process heat exchanger shell 800-860 outlet Vapours to scrubber Solvent pump discharge Hot oil suction circulating 0-9 25-55 pump 0-5

Hot oil circulating discharge Instrument air header Service water header NOTE.

pump 0-40 80-100 60-80

This pressure is shown both on a field pressure gauge and transmitted to the Instrument control panel. As in the case of the temperature readings discussed in the preceding section, it should be noted that some of process pressures indicated by these gauges are interrelated. In the discussion of the pressure control valves, the pressure in the reactor is the critical pressure in the WAR process, and is indirectly controlled by the PCVs. From this, it can be easily seen that not only the reactor pressure, but all process line pressures upstream of the PCVs to the outlets of the high pressure pump and process air compressors, are ultimately controlled by the PCVs. It is recommended that initial pressure readings be taken and recorded, with calibrated instrumentation to log system operating pressures of the original "clean" system prior to startup on waste. Solvent wash schedules will be determined through observation of the rate of pressure drop increases through the system, and through observation of temperature profiles in the heat exchangers. For example, when the heat exchangers and process piping are clean, a certain resistance to flow of materials will be exerted by the heat exchangers and process piping. This resistance will result in a drop in pressure from the outlets of the high pressure pumps and process air compressors through the system to the PCVs. Recorded pressure readings will show what this pressure drop is with clean heat exchangers and piping. As operating hours accumulate and scale is deposited, the resistance to flow will increase, resulting in a larger pressure drop through the system. (Pressure readings will show an upward trend at the pumps and compressors, but will remain the same at the reactor as reactor pressure is maintained by controller set point, and will show a downward trend at the PCVs). Observation of an increasing trend in system pressure drop in combination with observation of process temperatures as described in the preceding section will with experience yields a reliable means of judging when solvent cleaning is required. For this reason, accurate

reading and recording and regular comparison of process pressure are very important and must be an established operating routine.

C. Routine duties during operations: Every half hour, the operator should make a general walk through inspection of the installation, checking: All temperature, pressure, and flow indicators to determine if they are indicating their normal operating range. If not, make the necessary adjustments required. For unusual sounds and/or vibrations from operating equipment. Packing leakage at valves and pumps. Every hour, the operator should make a general inspection as described in 1.0 plus: Record all the hourly readings called for on the operation log sheet Take all hourly samples required for evaluation by plant management, or samples as required by the regulatory authorities. Proper protective attire must.

Once per shift, the operator should: Drain condensate from all instrument air pressure regulators and the oxygen analyzer drip leg. Check oil levels in the operating equipment with special attention to the process air compressor. Record totals for all materials (oils, chemicals parts, etc.) used in the Unit on that shift. Vent both pressure vessels of the high pressure pump to remove any air accumulations. If necessary, this frequency should be increased. Once a day, the daily log sheets must be finalized including totals of water and power usage for the day. This is very important, as it will permit comparison of the Units performance from day to day, which makes anticipation of system maintenance requirements possible. For example, daily pressure and temperature readings can be compared to determine when solvent cleaning is necessary. At least once per day the process oxygen analyzer should be checked for proper calibration. The procedure outlined in the start-up chapter of this manual should be followed. As dictated by WAR Unit Operational requirements, ash MUST be removed from the reactor by following the "reactor blow down procedure". The frequency and duration of the blow down MUST be adapted to meet the existing needs. It will

largely depend upon the ash content of the spent carbon slurry and the volume being routinely processed. NOTE: In addition to the routine duties detailed in this chapter and elsewhere in this manual, the operator must understand and perform all other operation and maintenance duties required for each piece of equipment as detailed in the manufacturers manuals provided for those pieces of equipment.

CHAPTER - IX

CONSUMPTION OF CHEMICALS AND UTILITIES

Maximum consumption of chemicals is given below:

TABLE 9.1

Powder Carbon Polyelectrolyte Nutrients

Activated :

176 kgs/day 264kgs/day 48kgs/day 166kgs/day.

Hydrochloric Acid (35%) : : :

Basis of Chemical Consumption: i) Powdered Activated carbon:

TABLE 9.2

Volatile carbon dosing : Make up carbon Dosing concentration Characteristics Carbon Base Material of : : :

340 mg/lit 158.6 kg/day 5-10%

Coal, lignite, bark Char, coconut shell.

Particle size

90% min. passing 200 mesh 70% max passing 325 mesh

Surface area Ash content Moisture as packed

: : :

Minimum 500 sq.m/gm 15% maximum 2% maximum > 70% > 100%

Virgin carbon molasses : r.e. Regenerated molasses r..e. carbon :

ii) Hydrochloric acid (35%): This is required for neutralization of influent after CPI before going to air flotation unit. Acid requirement is based on max. PH of 10 to be brought down to 6-7.

iii) Polyelectrolyte: Following requirements are considered:

TABLE 9.3

Unit

Flow M3/hr

Dosing Rate Mg/lit 3.5 1.5 1%

Consumpti on kg/day 20.16 15.90 8.20

Air floatation 240 Unit PACT Clarifier Centrifuge solids 440 820kg/ d

44.26

Dosing rates are based on active ingredients:

TABLE 9.4

Characteristics: Type Solubility Flash point Dosing concentration : : : : Liquid cationic polyelectrolyte Easily soluble in water in all proportions. Above 90 deg C 0.5 to 1%

iv) Nutrients:
TABLE 95

BOD5 load BOD5:N:P Required P Required N

: : : :

189kg/hr 100:5:1 1.89kg/hr 9.45kg/hr

Assuming a minimum TKN of 15 mg/lit and P of 5 mg/lit is available in refinery waste water, available N=3.6 kg/hr and P=1.2 kg/hr. TKN returned from WAR Unit=3.94 kg/hr. Additional N required=5.85 kg/hr. Additional P required=0.69 kg/hr. Following chemicals will be required.

TABLE 9.6

DAP Urea Dosing concentration

= = =

2.93 kg/hr 4.0kg/hr 166.0 kg/day 10%

Total consumption =

v) Nitric Acid: Concentrated Nitric acid (42 deg Be) is required for occasional cleaning of WAR Unit. This is diluted to 5% concentration for cleaning purpose. Consumption of Nitric acid (42 deg Be) = 90 lit/wash.

vi) Utilities: Maximum consumptions of utilities are as follows:

TABLE 9.7

Power Steam L.P Service Water For compressor Cooling make up For dosing systems Instrument air

: :

13856 KWH/day 1.0 tpd

: : :

0.3 M3/hr 24.0 M3/day 45 Nm3/hr

Note: The figures do not cover the following: Water: For pump, seal, flushing, floor wash cleaning and any other general purpose. Power: For spare feeders and equipments, plant and street lighting, single phase utilities/welding, non process loads like solvent and sludge handling systems. Office workshop, laboratory and start-up consumption and other miscellaneous loads. (WAR system power consumption is averaged on annual basis). Instrument Air: For any requirement other than the continuous requirement of instrumentation loops.

Basis of utilities Calculations: Power: Based on BHP, V belt losses and motor efficiency. Steam: LP steam is required in oil sump and CPI to take care of any occasional congealing of oil/hydrocarbons. Service Water: Actual requirement of cooling water for compressor is 19 M3/hr. By provision of a recycle cooling tower, only make up water of 0.8 M 3/hr is considered on continuous basis.

Note: The figures indicated are subject to measurement tolerance of 5%.

CHAPTER - X

SUMMARY
We has learned that the activities of modern industrial economies, driven by consumer demands and burgeoning populations, can alter delicate natural balances. We can no longer

pretend that nothing will happen as the planet is subjected to billions of tons of pollutants. It is not that Earth itself is necessarily fragile. It may be, rather, that our own tenure turns out to be less secure and less inevitable as a consequence of the planets response to unnatural conditions created by human actions. We learned wastewater treatment use because it is so interconnected with the other uses of water. Much of the water used by homes, industries, and businesses must be treated before it is released back to the environment. The major aim of wastewater treatment is to remove as much of the suspended solids as possible before the remaining water, called effluent, is discharged back to the environment. As solid material decays, it uses up oxygen, which is needed by the plants and animals living in the water. "Primary treatment" removes about 60 percent of suspended solids from wastewater. This treatment also involves aerating (stirring up) the wastewater, to put oxygen back in. Secondary treatment removes more than 90 percent of suspended solids. The industry that is polluting water or environment should entirely be respondible for it and should pay the price. BPCL refinery has a well- developed comprehensive environment management system (EMS) including environmental policy and objectives implementing it will result in effective management of resources and reduction in wastes leading to cost reduction, improvement in pubic image and increased international competitiveness while improving the environmental performance. . Plant process based on combining physical, chemical & biological treatments to effectively control the quality of effluent discharge. It is based on Powdered Activated Carbon Treatment (PACT) and Wet Air Generation (WAR). As a part of liquid effluent monitoring, various effluent parameters are checked in the laboratory. Oil and grease total suspended solids, PH, Sulfides, phenol, BOD, and COD are tested periodically with the help equipment. And It is maintained as per standards.Can be recycled /desposed.

ACKNOWLEDGEMENT

I record my sincere thanks and gratitude to the management of BHARAT PETROLEUM REFINERY, MAHUL MUMBAI and my colleagues in the refinery to help me in completing the project. I am highly obliged to all the officers and process personals from MINAS plant and all the personals related to Energy and Environment dept. for valuable suggestion and guidance while preparing this project work. Sincere thanks to faculty member and all my colleagues for their constant support and guidance.

-SANTOSH B. RANE BPCL REFINERY MAHUL, MUMBAI