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WATER
MANAGEMENT
AT CPCL
Manali
10.5 MMTPA
Nagapattinam
1.0 MMTPA
4
4 Slide 4
Process Units Manali (Fuel & Lube Refinery)
CDU I 2.8
CDU-II 3.7
CDU-III 4.0
SECONDARY UNITS OTHERS (TMTPA)
(MMTPA)
Wa
Wax 30
FCCU 0.78
OHCU 1.80 Propylene 30
VBU 1.15 H
Hexane 25
CCR 0.30 Lube 235
DHDS 1 80
1.80
DHDT 1.80
Slide 5
Manali Refinery as Mother Industry
Kothari
POLY BUTYLENE
Petrochemicals
(PBFS)
Manali POLYOL
Petrochemicals PROPYLENE GLYCOL
(Propylene)
Tamil Nadu LINEAR ALKYL
CPCL Petro-Products BENZENE
(LABFS)
Cetex
MEK
P t h i l
Petrochemicals
(MEKFS)
Slide 6
REFINERYPROCESSFLOW
DIAGRAM
Water Management-Overview contd.
Anyy p
petroleum refineryy requires
q water under the following
g heads
1. Drinking /canteen /sanitary
2. Cooling
g water for cooling
g /condensing
g
3. Boiler feed water for steam/power generation.
4. Service water / fire fighting water/Green belt/gardening
SOURCES:
1. Fresh water : unreliable ,cost prohibitive
Slide 9
Water Management overview contd.
SewageReclamationPlants DesalinationPlant
SRP 1 : 1990
SRP-1 SRP-22 : 2007
SRP 2009
2.5MGD2.5MGD 5.8MGD
Refinery IRefineryIIRefineryIII
WastewaterReclamation
1969 1984 2004
2.8 6.5 10.5MMTPA Total Capability 13 5 MGD
TotalCapability:13.5MGD
Waterrequirement:10.00MGD
EffluentTreatmentPlantsI,II&III
4.00 MGD Zero Discharge Plants
ZeroDischargePlants
ZDP-1 :2002 ZDP-2 :2005
0.7MGD0.8MGD Slide 10
Water supply system overview contd,
Water consumption at CPCL was 3.5 MGD during 1969 and currently it is
in the order of 7.0
7 0 MGD.
MGD
Slide 12
Water Management -History
Mid 80s
80 (1984 / 1987) This situation
Thi it ti has
h provoked
k d CPCL to t go for
f
(Acute water shortage alternate sources. CPCLs first Sewage
was experienced in Reclamation Plant was envisaged
g in the yyear
Chennai City. 1987 and was commissioned in the year 1991.
Industries in Manali
were shutdown)
April-1996 to Sept-1997 Substantial quantity of 53.7 MG of Treated
effluent was used in Cooling
g Towers.
Aug-2001 to Nov-2001 47.5 MG of Chengleput lake water was brought
from a distance of 55 kms by 200-500 tankers
/day.
/d
68.0 MG of Treated sewage / Treated effluent
was used in cooling towers.
2003-2004 Arranged Tankers from Poonamalle borewells.
Slide14
Water Management -History
Year Cost of Fresh Water (Rs / m3) Cost of Sewage (Rs / m3)
1991-92 8.40 0.90
1994-95 25.00 3.00
1998-99 40.00 5.40
2010 60.00 10.20
2014 60.00 11.85
Slide 15
Water Management Initiatives
6.00
5.00
onsumptio
4.00
3.00
2.00
w water co
1.00
0.00
Raw
Year
Effluent Treatment Plants (ETPs)
Feed:
F d
Waste water from Refinery process units
Features of ETPs:
Gravity separation for removal of free oil & oily particulate matter.
Ferric
F i Chloride
Chl id forf coagulation
l i & precipitation
i i i off sulfides
lfid
Dissolved air floatation to remove emulsified oil, clarification
Biological process,
process (Trickling filter Activated sludge,
sludge with surface Aeration,
Aeration
Diffuser type )
Sand filter and activated carbon filter
Slide 17
ETP- flow sheet
Caustic Ferric & PE
API Oil Flash mixer- Dissolved Air
Separator Flotation unit
Aeration tank
Trickling filter Clarifier
Slide 18
Sewage Reclamation Plants
Feed:
F d
Primary & secondary treated city sewage from CMWSSB.
Primaryy treatment : Floating
g mass removal.
Secondary treatment : Organic substance removal through
biological process.
Features of SRPs:
Biological
g process,, ((Activated sludge,
p g , Sequencing
q g Batch
Reactors)with surface Aeration, Diffuser type
Coagulation,
Coagulation flocculation,
flocculation clarification,filtration,disinfection,
clarification filtration disinfection
Slide 19
Sewage Reclamation Plant - II (SRP-II)
Secondary FeCl3 &
treated Anionic Poly
sewage
dosing
Sequencing Clarifier Flash Mixer Pressure
Batch Flocculator sand filter
475 KL/hr Reactor
44 KL/hr Rejects
Reverse Chemical dosing
RO permeate
tank Osmosis Rejects SBS, HCl,
II stage Antiscallant
396 KL/hr
KL/h 44 KL/hr
KL/h
DM Plant Wash Water
feed
UF & RO process
Ult filtration
Ultra filt ti Membranes
M b
To remove suspended / colloidal particles and micro
organisms to avoid particulate & biological fouling
Up to 0.01micron size particles will be filtered.
Material: (Poly Ether Sulfone) Membrane
Type : Hollow Fiber
RO Membranes :
- To remove dissolved solids to reduce the load on
DM water unit
-- 80 % Recovery & 97.5
97 5 % salt rejection
Material : Polyamide Membrane
Type : Spiral wound.
Slide 21
Zero Discharge Plants (ZDPs)
Slide 22
ZERO DISCHARGE SCHEME
From ETP
Coagulant
Equilization
pond
Coagulation
Upflow Filters )
UFSKID
RO SYSTEM Permeate
Backwash
pump
Backwash
sump
Water Management Projects
Zero Discharge
g Plant-2
Capacity: 1.05 MGD
Project cost : Rs. 10.6 Cr
Commissioning : 2005
Slide 24
Sewage Reclamation Plant-1 RO skids
Slide 25
Zero Discharge Plant-2
Slide 26
Desal Plant - Inlet & Outlet Quality
Fl
Flow M3 / Hr
H 3284 1100
pH 8.2 5.0-7.0
Slide 27
Desal RO Plant - Flow Chart
A) PRETREATMENT
B) RO PLANT
C) CHLORINATION SYSTEM
Chlorination system for Pretreatment, Post treatment and
Seawater intake system.
Slide 28
Sea Water Desalination Plant
31 of 48
Slide 3131
Sea Water Intake System
To overcome dependency on high cost
metro
t water,
t CPCL has
h commissioned
i i d
Sea Water Desalination Plant of 5.8
MGD capacity.
Slide 32
Details of water consumption
Figs in MGD
Details 10-11 11-12 12-13 13-14 14-15
Fresh water consumption 1.78 0.93 2.56 0.89 0.70
Green belt
Fire water network
Service water
CT Make up
ETPs Guard
Pond
UF/RO/BFW
Slide 35
Refinery waste water treatment & reuse
Probable solution
Green belt
Fire water network
Service water
Guard
ETPs
Pond CT Make up
Maximize
UF/RO DMP/BFW
Maximize RO permeate
and blend in FW/ CW system
To avoid corrosion of pipelines
Slide 36
Reclamation of Secondary Treated Sewage
Physical/chemical/biological treatment with /tertiary treatment
CT make up
SRPs
UF/RO/DMP/BFW
CT make up
Oil Contaminated sea water
Desal Fouling & failure RO membranes
40 of 62 Slide 40
Limitations of UF membrane
UFmembranesarenotstandardized
b d d d
Onceasystemisfinalized,suitabletospecifictypethesame
has to continue throughout the life time
hastocontinuethroughoutthelifetime.
IftheUFmembranefailstoperform,switchovertoother
membranecallsfortotalsystemchange
y g
Nostandardprocedure/testmethodfor
acceptanceof
t f
(i)UF/ROmembranes,
(ii)MicronCartridgefilters
(iii)Antiscalants/coagulantaids
Slide 41
Effectiveness of Pre-treatment
Activated Sludge Process -problems
problems
Carry over of MLSS from Clarifier of ASP is one of problems
Proper
P settling
ttli off MLSS in
i clarifier
l ifi tot be
b ensuredd
P
Provision
i i off anoxici zone att ASP aerator
t improves
i fl
floc.
characteristics which settles better at clarifier
Oxygen
O ddeficiency
fi i att clarifier
l ifi bbottom
tt lleading
di dde-nitrification
it ifi ti iis
another reason for MLSS carryover.
Slide 42
EFFECTIVENESS OF PRE -TREATMENT
Bio
Biotreatmentintroducesmanyorganicimpuritieswhichare
treatment introd ces man organic imp rities hich are
submicronparticles,duetocarryoverofMLSS.
Organicimpuritiescausingfoulingofmembranes
Organic impurities causing fouling of membranes
EfOM,EPS,Humicacid,proteinspolysaccharidesetc.,
Presentlynotmonitored,UFmembranesuppliersalso
notdemandingsuchcharacteristics
ForRemovaltheaboveorganicimpuritiesthefollowingarethe
For Removal the above organic impurities the following are the
treatmentfacilities:
Coagulation/flocculation/sedimentation
Adsorption
Wetairoxidation
Everyprocesshasitsownmerits&demerits
E h i i &d i
Slide 43
Effectiveness of Pre-treatment
Removal
R l off organic
i impurities
i iti
Presently coagulation /filtration being used
Optimum dosage by Jar test,
test which is time consuming
For varying incoming quality it is difficult
Improvement
p in NTU is being g monitored in jjar test
Improvement in NTU does not reflect improvement in organic
impurities
Organic impurities measurement is the basic requirement in jar
test .
Wastewater recycle
9Maximizing recycle is possible only by TDS reduction/RO
processing
9Strengthen pre-treatment so that operation can be sustained
with out UF membrane
9Cost benefit analysis for justifying UF membrane
installation.
9Development of cost effective wet air oxidation process
ppreferablyy at ambient conditions
Slide 45
PROCESS FLOW CHART
Cartridge
Filters
(4 Nos.)
Sludge bed Dosing of Anti -
Scalant
110 KV Yard
Degasser
Tank
Feed To Refinery - 17 Kms.
46 Slide 46