CASE STUDYJAMNAGAR REFINERY

KARTIKEYA VERMA11CH30009

India Refineries: Installed Capacity and Crude Oil Processing (MMTPA / MMT)

There are 22 refineries currently operating all over India

All India Total Installed Capacity is 215.1 Million Metric Ton Per Annum

Crude Oil Processing (MMTPA)0

10

20

30

40

50

60

70

54.2

23.827.5

11.515.1

60

20

IOCL HPCL BPCL CPCL ONGC RIL EOL

JAMNAGAR REFINERY IN BRIEF

It’s a Private sector Crude oil refinery owned by Reliance industries Limited

The refinery was commissioned on 14 July 1999 with an installed capacity of 668,000 barrels per day (106,200 m3/d). It is currently the largest refinery in the world

The existing refinery complex at Jamnagar has more than 50 process units, which together process the basic feedstock, crude oil, to obtain various finished products deploying the following major refining processes

Crude oil distillation (Atmospheric as well as vacuum distillation)

Catalytic cracking (Fluidised Catalytic Cracker)

Catalytic reforming (Platforming)

Delayed Coking

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BLOCK FLOW DIAGRAM OF CRUDE OIL DISTILLATION IN A REFINERY

HAZARDOUS WASTE FROM REFINERY

VOC EMISSIONS

• 0.5 to 6 kg/ton of crude

COOLING SYSTEMS

• 3.5-5 m3 of wastewater generated per ton of crude

OTHERS EMISSIONS

• BTX (Benzene, Toluene and Xylene) 0.75 to 6 g/ton of crude

• Sulfur oxides 0.2-0.6 kg/ton of crude

• Nitrogen oxides 0.006-0.5 kg/ton of crude

SOLID WASTE AND SLUDGE

• 3 to 5 kg per ton of crude (80 % should be considered as hazardous waste because of the heavy metals and toxic organic presence)

POLLUTED WASTEWATER

• BOD 150-250 mg/l

• COD 300-600 mg/l

• Phenol 20-200 mg/l

• Oil 100-300 mg/l (desalter water)

• Oil 5000 mg/l in tank bottom

• Benzene 1-100 mg/l

• Heavy metals 0.1-100 mg/l

ENVIRONMENTAL STANDARDS FOR PETROLEUM OIL REFINERIES EFFLUENTS

S. No. Parameter Limiting value for concentration (mg/l except for pH)

Limiting value for quantum(kg/1000 ton of crude processed, except for pH)

1 pH 6.0 – 8.5 -2 Oil & Grease 5 23 BOD3 days, 270C 15 64 COD 125 505 SS 20 86 Phenols 0.35 0.147 Sulphide 0.5 0.28 CN 0.2 0.089 Ammonia as N 15 610 P 3 1.211 Cr (VI) 0.1 0.0412 Total Cr 2 0.813 Pb 0.1 0.0414 Hg 0.01 0.00415 Ni 1 0.416 Cu 1 0.417 Benzene 0.1 0.0418 Benzo(a)pyrene 0.2 0.08

SOURCES OF EMISSIONS

• SO2 emitted from fuel fired to meet energy requirement

• SO2 emitted from FCC unit• SO2 emitted from SRU (sulphur recovery unit)

Sources of SO2

• Fuel Type• Fuel nitrogen or hydrogen content• Operational condition like temperature, residence time, O2 concentration

Sources of NOx

• Fugitive emission from valves, flanges, pump• Storage tank• Loading unloading system

Sources of VOCs

• Process heater and boiler units(burning oil)• FCC units and catalyst regenerators

Sources of PM

EMISSIONS CONTROL TECHNIQUES

• Flue gas desulphurisation• Two three stage SRU• De-sulphurisation catalyst additive in FCC

SO2

• Low NOx burner[reducing maximum temperature, O2 concentration]• Fuel Dinitrification• Diluent ejection

NOx

• Standard Mechanical seal or equivalent control for pumps and compressors• Standard for periodic inspection and maintenance

VOCs

• Tertiary cyclone• Electrostatic Precipitator• Wet flue gas scrubbers

PM

WASTE WATER MANAGEMENT AT RELIANCE JAMNAGAR REFINERY

The waste water treatment is carried out in a dedicated state of the art completely automated Effluent treatment plant

Effluent stream Guard tank and Equalization tank

API separators installed with continuous oil

skimming and sludge removal facility

Solid and emulsified oil removal by

dissolved air flotation units (DAF)

Stage 1 biological treatment- bio- towers with pH

correction at outlet

Stage 2 a plug flow nitrification/de-nitrification with

aeration tank

Clarification(with INDION polymer

dosing to aid settlement)

Dual media Filtration Activated Carbon adsorption

Disinfection –with chlorine and chlorine

dioxide

Treated waste water storage

Chemical dosing facility(common)

Sludge and oil handling (common)

WASTE WATER MANAGEMENT AT RELIANCE JAMNAGAR REFINERY

LTDS 1 & 2(Low Total Dissolved

Solids)

INFLUENT MIXTUREProcess / Oily water

Non-Phenolic wastewatersTDS : 160 - 500

AFTER TREATMENTCooling water make-up

Fire water make –upIrrigation

OWS(Oily water sewer)

INFLUENT MIXTUREProcess / Oily water, from

various refinery unitsSanitary Sewage

Drainage from tanksTDS : 850 – 1,500

AFTER TREATMENT Horticulture in Green BeltAround plant (7,000 acres)

Effluents are segregated into four

identical waste stream design for

treatment capacity of 500 m3/h

HTDS(High total dissolved

solids)

INFLUENT MIXTUREProcess / Oily water, in

contact with process streams (Crude units de-salters)

TDS : 950 – 2,500

AFTER TREATMENTPartial make up water

Seawater cooling tower

WASTE WATER CHARACTERISTICS DURING VARIOUS STAGES

Hydraulic load per module 500 m³/h

Temperature of wastewater < 35°C

Max peak oil at inlet 10.000 mg/l

Total oil outlet API separator < 50 mg/l

pH at DAF outlet 6.5-7.2

Sulphide at DAF outlet < 10 mg/l

Total oil at DAF outlet < 15 mg/l

BOD removal by biotower 50%

BOD removal by extended aeration 70%

COD outlet extended aeration < 100 mg/l

SS outlet extended aeration < 30 mg/l

SS outlet DMF < 5 mg/l

Turbidity outlet DMF < 8 NTU

COD outlet ACF < 50 mg/l

TREATMENT OF 3 BY-PRODUCT STREAMS FROM ETP

SKIMMED OILS

TREATMENTS- Chemical treatment- Heat Treatment- Slope Holding tank- Emulsion breaking tank

REUSERecovered oil transferred to

refinery

OILY SLUDGE

TREATMENTS- Settling tank (oily sludge)- Thickener (Oil float sludge)

REUSEThickened sludge transferred to

delayed Coker unit

BIOLOGICAL SLUDGE

TREATMENTS- Thickening- Stabilization- Dewatering

REUSEDisposed of to landfill

Treated Effluent Quality Dated (Oct’13 to Mar’14)

Sr. no Parameters Permissible limit(mg/l) Actual value(mg/l)

1. Chemical Oxygen Demand 125 38-50

2. Biochemical Oxygen Demand 15 <5-7

3. Oil and grease 5.0 0.8-1.2

REFRENCES

1. Technical EIA guideline Manual for petroleum Refining Industry by IL&FS Ecosmart Limited Hyderabad.

2. Environmental Clearance report Jamnagar oct2012-mar2013

3. Emission standard and regulatory report by Dr. S.K. Taygi, Senior scientist, CPCB, Delhi

4. Wastewater treatment for refineries RIL Jamnagar, India , report by WATERLEAU.

5. Website : www.cpcb.nic.in, www.wikipedia.org

THE END

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