Refinery Wastewater Process Modeling with...
Transcript of Refinery Wastewater Process Modeling with...
3/8/16 Page 1Industrial Wastewater Process Modeling with GPS-X™
Refinery Wastewater Process Modeling with GPS-X™
Malcolm Fabiyi, PhDHydromantis USA
John Joyce, PhD PESAGE EnvironmentalFebruary 2016
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Outline• Issues in refinery wastewater• Typical Refinery Wastewater systems• Overview of Hydromantis• Modeling tools and their application• GPS-X™ • Industrial WWTP case studies• SimuWorks• Conclusion
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Refinery Wastewater Issues• Varying crude stocks and where those crude’s come from
present differing wastewater issues to refineries --- very much more so now than in the past…..
• Refineries are also now evaluating:• End of life API’s, DAF’s
• Evaluating higher rate DGF’s and DNF’s
• And evaluating how capital cost can be deferred by optimizing existing wastewater process units
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Refinery Wastewater Issues• Refineries are also facing tightening metals discharge limits
• Mercury• Selenium• Arsenic
• Many membrane bio-reactors being designed & installed
• Troublesome Inorganics --- cyanides, salts• Toxicity/bioassay compliance
• Need for surge capacity
• Reducing treatment costs
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Refinery Wastewater SystemsDe-Salters
Sour Water/Scrubbers
DistillationBlowdown
Stormwater
Cooling TowerBlowdown
Tank Drains
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Refinery Wastewater Issues• If you are responsible for managing the wastewater system at a
refinery or chemical plant……• Even the more simplistic….
• What is my optimal MLSS
• What is my optimal aeration rate
• What is my optimal RAS/WAS rate
• Or the more complex….(before you have to engage a wastewater consultant)• What happens if a biological contactor, MBR, or new DGF is installed in
this location or that location?
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Refinery Wastewater Issues• There are two fantastic modeling tools that refinery and
chemical plant wastewater managers and engineers should avail themselves of:
Dynamic Wastewater Treatment Modeling• Process design• Energy models• GHG models
• Controller models• Real-time• Optimization
Operator Training and Plant Analysis System• Customized
interface• GPS-X™ platform
• Operational support• Planning• Training
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Traditional Design Models• Based on simplified mass balance models
• Assume steady-state• Constant influent loading and operating conditions
• No change in solids storage in clarifiers or aeration basins
• Equations solved to predict tank sizes, sludge production, and performance given SRT, MLSS, etc.
• Design parameters from simple models serve as inputs to more comprehensive dynamic models
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Why Use Modeling?• Cheaper than building/modifying the real system
• Easier than carrying out testing on existing systems
• Risk-free - see the consequences beforeimplementation
• Get results quickly
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How Is It Used?Create Model
Calibrate to Known
Performance
Simulate Different
Scenarios
Simulate “Base Case”
Compare and Evaluate0
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Features of Industrial Activated Sludge• Can have high soluble COD fraction
• High temperatures
• Highly variable influent characterization
• Nutrient deficiency common
• Varying sludge settleability
• Dynamic
• Can have multiple influent streams of interest (VOCs, Oil & Grease, Hydrocarbons, Phenols, Colloidal materials, Sulfur, Amines, Metals)
• Can have high strength fractions (e.g., Spent caustic)
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Physical/Chemical Processes?• Handles biological treatment and solids separation
• As well as other processes
• Oil and grease separators
• pH management
• PAC
• Chemical addition
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Case Studies
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GPS-X™ - Features
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GPS-X™ - FeaturesIntuitive modeling ……. …and simulation views
Quick panel views for all objects Sankey Graphs
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GPS-X™ - Features
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GPS-X™ - FeaturesSelect Control Variables
Sensitivity analysis
Clarifier behavior
Treatment thresholds
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GPS-X™ - Largest Number of Unit Objects
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GPS-X™ Supports a Broad Range of Custom Projects• Selenium removal• API/CPI separators• Oil & grease removal• 1,4 Dioxane removal in WWTP• Process water simulator• Capacity evaluation• Biotransformation of estrogenic
hormones*• Water reservoir simulation• Coupled CFD & process
dynamics• Calibration of PAC + IFAS
treatment process• Customized process simulators
*Natural estrogenic hormones 17βestradiol (E2) and estrone (E1), and the synthetic estrogen 17α-ethinylestradiol (EE2)
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Case Study 1: Develop a calibrated model of a petroleum refinery WWTP to support plant analysis, decision making and process optimization
Plant layout
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Case Study 1: Develop a calibrated model of a petroleum refinery WWTP to support plant analysis, decision making and process optimization
New API unit developed
Plant layout
GPS-X™ has the largest process object library of any process modeling software
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Case Study 1: Develop a calibrated model of a petroleum refinery WWTP to support plant analysis, decision making and process optimization
GPS-X™ provides accurate representation of a facility’s process layout
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Step-Feed Activated Sludge
EqualizationGrit Basins
Neutralization
Diversion
Influent
Belt-filter Presses
Clarifiers
Chemical Manufacturing Facility, WWTP
Treats waste from plant that manufactures chemicals, plastics, and synthetic fibers
Case Study 2: Development of model for assessing impacts of loading changes, operational changes, toxic spills, etc.
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Step-Feed Activated Sludge
EqualizationGrit Basins
Neutralization
Diversion
Influent
Belt-filter Presses
Clarifiers
•Q = 27 MGD•Organic acids & alcohols (COD = 1700 mg/L)•Solids (TSS = 140 mg/L)•Ammonia, nitrates, phosphates
•4 trains with 3 aeration basins each•Step feed strategy varies•Mixed liquor sampled from each basin
•Some denitrification
Chemical Manufacturing Facility, WWTPCase Study 2
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Case Study 2: Model Setup - GPS-X™ Layout• Activated Sludge
• Elevated temperatures (26 to 36 degrees C)• ASM3 default kinetic values allowed better
calibration than values of Koch et al. (2000) • Decreased:
• Maximum autotrophic growth rate to match ammonia in basins
• Added simultaneous nitrification/denitrification to ASM3 to handle observed denitrification in aeration basins
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Case Study 3: Pharma Facility• Plant treats pharmaceutical wastewater
using MBBRs (with fungal and bacterial reactors), PAC, and DAFs
• Developed, calibrated, & verified plant model
• Model capable of predicting behavior of fungal biomass
• Model used to assess impact of number of aeration trains in service, influent loading, temperature, airflow, & nutrient addition
Hydromantis, Inc.www.hydromantis.com
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Case Study 4Developed customized GPS-X™ tool that is used to:
• Provide predictive analyses for plant operation, e.g. spill control assistance
• Help GE meet the effluent criteria
• Help optimize plant operation
• Provide a customized operator training platform
• Savings to operators of > $36,000 USD per year
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Case Study 5• WWTP treats waste from 3 chemical production facilities
• Studies conducted using GPS-X™:• Capacity evaluation
• Sensitivity of plant performance to nitrogen loading to the plant
• Bottleneck evaluation
• Determined aeration power requirements
• Dynamic analysis of plant
• Safety margin for plant capacity
• Development of management plan for facility
• Used industrial pollutant library (IP) to track specific chemicals
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Case Study 6• Developed model of WWTP at chemical plant
• Activated sludge treatment system
• GPS-X™ model used to:• Investigate aeration control options• Investigate opportunity for MLSS control• Investigate impact of loading changes to the plant• Determine best approach to handle high-flow events
• GPS-X™ used to model other DOW plants
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Applications of Modeling in Industrial WWT Applications Application areas Modeling focus Software tool
Aeration demand • O2 for supplementation• O2 for organic treatment
GPS-X™
VOC & Odor emissions – reporting and analysis
• Emissions reduction• Contaminant fate• Odor stripping
Toxchem™
Process optimization, planning,training & knowledge mgt.
• Plant optimization• Production throughput constraint evaluation
GPS-X™ & SimuWorks™
Contaminant degradationmechanism – Metals & organics
• Product, by-product, metabolites• Speciation, transport and fate
GPS-X™ & Toxchem™
Bulking control • O2 demand vs organic loading GPS-X™
Aeration efficiency • Oxygen transfer efficiency• Fouling estimation
GPS-X™
Spent caustic treatment • Incremental O2, VOC stripping implications, Capacity validation, pH effects
GPS-X™ & Toxchem™
Overall process design & optimization
• Process tank sizing & configuration• Capital cost, operating cost• Alkalinity, pH
CapdetWorks™ & GPS-X™
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Next Generation Uses of Models
Engineers are trained in refinery processes
….Sometimes do a rotation in the WWTP
“It took me about 5 months to understand the activated sludge
process” – Engineer at Major Refinery
Facility
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SimuWorks™ Overview
• Advanced operator training and education• Plant optimization and cost saving strategies• Project and risk analysis• Key decision making support tool
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Simulator Interface
Clickable Diagram
Simulation control
Flyover panel
Output graphs /
input panel
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Step 1:Click on Unit Process
Step 2:Adjust Parameters
Step 3:Press Start
Step 4: See Results
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Example #1: Troubleshooting Nitrification• Initial Case: poor performance – not nitrifying, poor COD
removal• Influent quality:
• COD = 750 mg/L• TKN = 100 mg/L
• Ammonia = 80 mg/L
• Soluble P = 12 mg/L• pH = 7.0
• Temperature = 28C (82F)
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Conclusions• Activated sludge models can be applied to industrial
WWTPs
• Modeling is powerful, cost-effective tool for design, process analysis, trouble-shooting, optimization, planning, and training
• Modeling is becoming a required process skill
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Technical Support
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Material Copyright © 1992-2016 Hydromantis Environmental Software Solutions, Inc.
All rights reserved
Wastewater modeling and design solutions
Dr. Malcolm Fabiyi, PhD
Dr. John M. Joyce, PhD PE