11. oil refinery sector - gcpc-envisgcpcenvis.nic.in/experts/oil refinery sector.pdf · oil...

Gujarat Cleaner Production Centre

CLEANER PRODUCTION

OIL REFINERY SECTOR

Gujarat Cleaner Production Centre - ENVIS Centre

CLEANER PRODUCTION OPPURTUNITIES

IN

OIL REFINERY SECTOR

OPPURTUNITIES


OIL REFINERY

An oil refinery or petroleum refinery

processed and refined into more useful products such as

naphtha, gasoline, diesel fuel,

gas. Oil refineries are typically large, sprawling

extensive piping running throughout, carrying streams of

processing units.

Common process units found in a refinery:

• Desalter unit washes out salt from the crude oil before it enters the atmospheric

distillation unit.

• Atmospheric distillation unit distills crude oil into fractions.

• Vacuum distillation unit further distills residual bottoms after atmospheric distillation.

• Naphtha hydrotreater unit uses

distillation. Must hydrotreat the naphtha before sending to a Catalytic Reformer unit.

• Catalytic reformer unit is used to conver

higher octane reformate (reformer product). The reformate has higher content of

aromatics and cyclic hydrocarbons). An important byproduct of a r

released during the catalyst reaction. The hydrogen is used either in the hydrotreater or

the hydrocracker.

• Distillate hydrotreater unit desulfurizes distillates (such as diesel) after atmospheric

distillation.

• Fluid catalytic cracker (FCC) unit upgrades heavier fractions into lighter, more valuable

products.

• Hydrocracker unit uses hydrogen to upgrade heavier fractions into lighter, more

valuable products.

• Visbreaking unit upgrades heavy residual oils by thermally cracking them into li

more valuable reduced viscosity products.

• Merox unit treats LPG, kerosene or jet fuel by oxidizing

• Alternative processes for removing mercaptans are known, e.g.

process and caustic washing.

• Coking units (delayed coking

oils into gasoline and diesel fuel, leaving petroleum coke as a residual product.


OIL REFINERY

petroleum refinery is an industrial process plant where

processed and refined into more useful products such as

asphalt base, heating oil, kerosene and liquefied petroleum

Oil refineries are typically large, sprawling industrial complexes with

running throughout, carrying streams of fluids between large

Common process units found in a refinery:

washes out salt from the crude oil before it enters the atmospheric

Atmospheric distillation unit distills crude oil into fractions.

unit further distills residual bottoms after atmospheric distillation.

unit uses hydrogen to desulfurize naphtha from atmospheric


unit is used to convert the naphtha-boiling range molecules into

(reformer product). The reformate has higher content of

aromatics and cyclic hydrocarbons). An important byproduct of a reformer is hydrogen


Distillate hydrotreater unit desulfurizes distillates (such as diesel) after atmospheric

(FCC) unit upgrades heavier fractions into lighter, more valuable

unit uses hydrogen to upgrade heavier fractions into lighter, more

unit upgrades heavy residual oils by thermally cracking them into li

more valuable reduced viscosity products.

unit treats LPG, kerosene or jet fuel by oxidizing mercaptans to organic

Alternative processes for removing mercaptans are known, e.g. doctor sweeten

and caustic washing.

delayed coking, fluid coker, and flexicoker) process very hea


2 | P a g e

where crude oil is

processed and refined into more useful products such as petroleum

liquefied petroleum

complexes with

between large chemical

washes out salt from the crude oil before it enters the atmospheric

unit further distills residual bottoms after atmospheric distillation.

to desulfurize naphtha from atmospheric


boiling range molecules into

(reformer product). The reformate has higher content of

eformer is hydrogen


Distillate hydrotreater unit desulfurizes distillates (such as diesel) after atmospheric

(FCC) unit upgrades heavier fractions into lighter, more valuable

unit uses hydrogen to upgrade heavier fractions into lighter, more

unit upgrades heavy residual oils by thermally cracking them into lighter,

to organic disulfides.

doctor sweetening

, fluid coker, and flexicoker) process very heavy residual



• Alkylation unit produces high

• Dimerization unit converts olefins

example, butenes can be dimerized into isooctene which may subsequently be

hydrogenated to formisooctane

• Isomerization unit converts linear molecules to higher

blending into gasoline or feed to alkylation units.

• Steam reforming unit produces hydrogen for the hydrotreater or hydrocracker.

• Liquefied gas storage vessels store propane and similar gaseous fuels at pressure

sufficient to maintain them in liquid form. These are usua

"bullets" (i.e., horizontal vessels with rounded ends).

• Storage tanks store crude oil and finished products, usually cylindrical, with some sort of

vapor emission control and surrounded by an earthen

• Amine gas treater, Claus unit

sulfide from hydro desulfurization

• Utility units such as

plants generates steam, and instrument air systems include pneumatically

operated control valves and an

• Wastewater collection and treating systems consist of

flotation (DAF) units and further treatment units such as an

to make water suitable for reuse or for disposal.

• Solvent refining units use solvent such as

aromatics from lubricating oil stock or diesel stock.

• Solvent dewaxing units remove the heavy waxy constituent’s

distillation products.


unit produces high-octane component for gasoline blending.

olefins into higher-octane gasoline blending components. For

can be dimerized into isooctene which may subsequently be

isooctane. There are also other uses for dimerization

unit converts linear molecules to higher-octane branched molecules for

blending into gasoline or feed to alkylation units.

unit produces hydrogen for the hydrotreater or hydrocracker.

Liquefied gas storage vessels store propane and similar gaseous fuels at pressure

sufficient to maintain them in liquid form. These are usually spherical vessels or

"bullets" (i.e., horizontal vessels with rounded ends).

Storage tanks store crude oil and finished products, usually cylindrical, with some sort of

vapor emission control and surrounded by an earthen berm to contain spills.

Claus unit, and tail gas treatment convert

hydro desulfurization into elemental sulfur.

Utility units such as cooling towers circulate cooling water,

, and instrument air systems include pneumatically

and an electrical substation.

collection and treating systems consist of API separators

and further treatment units such as an activated sludge

to make water suitable for reuse or for disposal.

Solvent refining units use solvent such as cresol or furfural to remove unwanted, mainly

aromatics from lubricating oil stock or diesel stock.

Solvent dewaxing units remove the heavy waxy constituent’s petrolatum

3 | P a g e

octane gasoline blending components. For

can be dimerized into isooctene which may subsequently be

. There are also other uses for dimerization.

octane branched molecules for

unit produces hydrogen for the hydrotreater or hydrocracker.

Liquefied gas storage vessels store propane and similar gaseous fuels at pressure

lly spherical vessels or

Storage tanks store crude oil and finished products, usually cylindrical, with some sort of

to contain spills.

reatment convert hydrogen

circulate cooling water, boiler

, and instrument air systems include pneumatically

API separators, dissolved air

activated sludge biotreater

to remove unwanted, mainly

petrolatum from vacuum



4 | P a g e


Environmental Issues:

Potential environmental issues associated with petroleum refining include the

following:

• Air emissions

• Wastewater

• Wastes

Air Emissions

Exhaust Gases

Exhaust gas and flue gas emissions (carbon dioxide (CO2), nitrogen oxides

(NOX) and carbon monoxide (CO)) in the petroleum refining sector result

from the combustion of gas and fuel oil or diesel in turbines, boilers,

compressors and other engines for power and heat generation. Flue gas is

also generated in waste heat boilers associated with some process units

during continuous catalyst regeneration or fluid petroleum coke combustion.

Flue gas is emitted from the stack t

Unit, from the catalyst regenerator in the Fluid Catalytic Cracking Unit

(FCCU) and the Residue Catalytic Cracking Unit (RCCU), and in the sulfur

plant, possibly containing small amounts of sulfur oxides. Low

should be used to reduce nitrogen oxide emissions.

Venting and Flaring

Venting and flaring are important operational and safety measures used in

petroleum refining facilities to ensure that vapors gases are safely disposed

of. Petroleum hydrocarbons are emitted from emergency process vents and

safety valves discharges. These

be flared. Excess gas should not be vented, but instead sent to an efficient

flare gas system for disposal. Emergency venting may be acceptable under

specific conditions where flaring of the gas stream is not pos


Environmental Issues:





ompressors and other engines for power and heat generation. Flue gas is



Flue gas is emitted from the stack to the atmosphere in the Bitumen Blowing



plant, possibly containing small amounts of sulfur oxides. Low-

should be used to reduce nitrogen oxide emissions.




safety valves discharges. These are collected into the blow-down network to



specific conditions where flaring of the gas stream is not pos

5 | P a g e





ompressors and other engines for power and heat generation. Flue gas is



o the atmosphere in the Bitumen Blowing



-NOX burners




down network to



specific conditions where flaring of the gas stream is not possible, on the


basis of an accurate risk analysis and integrity of the system needs to be

protected. Justification for not using a gas flaring system should be fully

documented before an emergency gas venting facility is considered. Before

flaring is adopted, feasible alternatives for the use of the gas should be

evaluated and integrated into production design to the maximum extent

possible. Flaring volumes for new facilities should be estimated during the

initial commissioning period so that fixed volume fl

developed. The volumes of gas flared for all flaring events should be

recorded and reported. Continuous improvement of flaring through

implementation of best practices and new technologies should be

demonstrated.

The following pollution prevention and control measures should be

considered for gas flaring:

• Implementation of source gas reduction measures to the maximum

extent possible;

• Use of efficient flare tips, and optimization of the size and number

of burning nozzles;

• Maximizing flare combustion efficiency by controlling and optimizing

flare fuel / air / steam flow rates to ensure the correct ratio of

assist stream to flare stream;

• Minimizing flaring from purges and pilots, without compromising

safety, through measures includi

reduction devices, flare gas recovery units, inert purge gas, soft

seat valve technology where appropriate, and installation of

conservation pilots;

• Minimizing risk of pilot blow

and providing wind guards;

• Use of a reliable pilot ignition system;





d, feasible alternatives for the use of the gas should be



initial commissioning period so that fixed volume flaring targets can be




pollution prevention and control measures should be

considered for gas flaring:

Implementation of source gas reduction measures to the maximum

Use of efficient flare tips, and optimization of the size and number

of burning nozzles;

ing flare combustion efficiency by controlling and optimizing


assist stream to flare stream;

Minimizing flaring from purges and pilots, without compromising

safety, through measures including installation of purge gas



conservation pilots;

Minimizing risk of pilot blow-out by ensuring sufficient exit velocity

viding wind guards;

Use of a reliable pilot ignition system;

6 | P a g e




d, feasible alternatives for the use of the gas should be



aring targets can be




pollution prevention and control measures should be

Implementation of source gas reduction measures to the maximum

Use of efficient flare tips, and optimization of the size and number

ing flare combustion efficiency by controlling and optimizing


Minimizing flaring from purges and pilots, without compromising

ng installation of purge gas



out by ensuring sufficient exit velocity


• Installation of high integrity instrument pressure protection

systems, where appropriate, to reduce over pressure events and

avoid or reduce flaring situations;

• Installation of knock

where appropriate;

• Minimizing liquid carry

with a suitable liquid separation system;

• Minimizing flame lift off and / or flame lick;

• Operating flare to control odor and visible smok

visible black smoke);

• Locating flare at a safe distance from local communities and the

workforce including workforce accommodation units;

• Implementation of burner maintenance and replacement programs

to ensure continuous maximum flare effic

• Metering flare gas.

To minimize flaring events as a result of equipment breakdowns and plant

upsets, plant reliability should be high (>95 percent), and provision should

be made for equipment sparing and plant turn down protocols.

Fugitive Emissions

Fugitive emissions in petroleum refining facilities are associated with vents,

leaking tubing, valves, connections, flanges, packings, open

floating roof storage tanks and pump seals, gas conveyance systems,

compressor seals, pressure relief

and loading and unloading operations of hydrocarbons. Depending on the

refinery process scheme, fugitive emissions may include:

• Hydrogen;

• Methane;


Installation of high integrity instrument pressure protection


avoid or reduce flaring situations;

Installation of knock-out drums to prevent condensate emissions,

where appropriate;

Minimizing liquid carry-over and entrainment in the gas flare stream

with a suitable liquid separation system;

Minimizing flame lift off and / or flame lick;

Operating flare to control odor and visible smoke emissions (no

visible black smoke);

Locating flare at a safe distance from local communities and the

workforce including workforce accommodation units;

Implementation of burner maintenance and replacement programs

to ensure continuous maximum flare efficiency;

Metering flare gas.



be made for equipment sparing and plant turn down protocols.


leaking tubing, valves, connections, flanges, packings, open


compressor seals, pressure relief valves, tanks or open pits / containments,


refinery process scheme, fugitive emissions may include:

7 | P a g e

Installation of high integrity instrument pressure protection


prevent condensate emissions,

over and entrainment in the gas flare stream

e emissions (no

Locating flare at a safe distance from local communities and the

Implementation of burner maintenance and replacement programs




leaking tubing, valves, connections, flanges, packings, open-ended lines,


valves, tanks or open pits / containments,



• Volatile organic compounds (VOCs), (e.g. ethane, ethylene,

propylene, butanes, butylenes, pentanes, pentenes, C6

benzene, toluene, xylenes, phenol, and C9 aromatics);

• Polycyclic aromatic hydrocarbons (PAHs) and other semi volatile

organic compounds;

• Inorganic gases, including hydrofluoric aci

alkylation, hydrogen sulfide, ammonia, carbon dioxide, carbon

monoxide, sulfur dioxide and sulfur trioxide from sulfuric acid

regeneration in the sulfuric acid alkylation process, NOX, methyl tert

butyl ether (MTBE), ethyl tertiary

ether (TAME), methanol, and ethanol.

The main sources of concern include VOC emissions from cone roof storage

tanks during loading and due to out

hydrocarbons through the floating roof seal

fugitive emissions from flanges and/or valves and machinery seals; VOC

emissions from blending tanks, valves, pumps and mixing operations; and

VOC emissions from oily sewage and wastewater treatment systems.

Nitrogen from bitumen storage tanks may also be emitted, possibly

containing hydrocarbons and sulfur compounds in the form of aerosols.

Other potential fugitive emission sources include the Vapor Recovery Unit

vents and gas emission from caustic oxidation.

Recommendations to prevent and control fugitive emissions include

the following:

• Based on review of Process and Instrumentation Diagrams (P&IDs),

identify streams and equipment (e.g. from pipes, valves, seals, tanks

and other infrastructure components) likely to lead t

emissions and prioritize their monitoring with vapor detection

equipment followed by maintenance or replacement of components as

needed;


Volatile organic compounds (VOCs), (e.g. ethane, ethylene,

propylene, butanes, butylenes, pentanes, pentenes, C6

benzene, toluene, xylenes, phenol, and C9 aromatics);

Polycyclic aromatic hydrocarbons (PAHs) and other semi volatile

organic compounds;

Inorganic gases, including hydrofluoric acid from hydrogen fluoride



regeneration in the sulfuric acid alkylation process, NOX, methyl tert

butyl ether (MTBE), ethyl tertiary butyl ether (ETBE), t

ether (TAME), methanol, and ethanol.


tanks during loading and due to out-breathing; fugitive emissions of

hydrocarbons through the floating roof seals of floating roof storage tanks;




bitumen storage tanks may also be emitted, possibly



vents and gas emission from caustic oxidation.

ns to prevent and control fugitive emissions include

Based on review of Process and Instrumentation Diagrams (P&IDs),


and other infrastructure components) likely to lead to fugitive VOC



8 | P a g e

Volatile organic compounds (VOCs), (e.g. ethane, ethylene, propane,

propylene, butanes, butylenes, pentanes, pentenes, C6-C9 alkylate,

Polycyclic aromatic hydrocarbons (PAHs) and other semi volatile

d from hydrogen fluoride



regeneration in the sulfuric acid alkylation process, NOX, methyl tert-

butyl ether (ETBE), t-amylmethyl


breathing; fugitive emissions of

s of floating roof storage tanks;




bitumen storage tanks may also be emitted, possibly



ns to prevent and control fugitive emissions include

Based on review of Process and Instrumentation Diagrams (P&IDs),


o fugitive VOC




• The selection of appropriate valves, flanges, fittings, seals, and

packings should be based on their cap

fugitive emissions;

• Hydrocarbon vapors should be either contained or routed back to the

process system, where the pressure level allows;

• Use of vent gas scrubbers should be considered to remove oil and

other oxidation products

bitumen production);

• Incineration of gas should be conducted at high temperature

(approximately 800 °C) to ensure complete destruction of minor

components (e.g. H2S, aldehydes, organic acids and phenolic

components) and minimize emissions and odor impacts;

• Emissions from hydrofluoric acid (HF) alkylation plant vents should

collected and neutralized for HF removal in a scrubber before being

sent to flare;

• Naphtha, gasoline, methanol / ethanol, and MTBE / ETBE /

loading / unloading stations should be provided with vapor recovery

units.

Sulfur Oxides

Sulfur oxides (SOx) and hydrogen sulfide may be emitted from boilers,

heaters, and other process equipment, based on the sulfur content of the

processed crude oil. Sulfur dioxide and sulfur trioxide may be emitted from

sulfuric acid regeneration in the sulfuric acid alkylation process. Sulfur

dioxide in refinery waste gases may have pre

levels of 1500 -7500 milligrams per cubic meter (mg/m


The selection of appropriate valves, flanges, fittings, seals, and

packings should be based on their capacity to reduce gas leaks and

Hydrocarbon vapors should be either contained or routed back to the

process system, where the pressure level allows;

Use of vent gas scrubbers should be considered to remove oil and

other oxidation products from overhead vapors in specific units (e.g.

bitumen production);

Incineration of gas should be conducted at high temperature



nents) and minimize emissions and odor impacts;

Emissions from hydrofluoric acid (HF) alkylation plant vents should


Naphtha, gasoline, methanol / ethanol, and MTBE / ETBE /




l. Sulfur dioxide and sulfur trioxide may be emitted from


dioxide in refinery waste gases may have pre-abatement concentration

7500 milligrams per cubic meter (mg/m3)2.

9 | P a g e

The selection of appropriate valves, flanges, fittings, seals, and

acity to reduce gas leaks and

Hydrocarbon vapors should be either contained or routed back to the

Use of vent gas scrubbers should be considered to remove oil and

from overhead vapors in specific units (e.g.

Incineration of gas should be conducted at high temperature



Emissions from hydrofluoric acid (HF) alkylation plant vents should


Naphtha, gasoline, methanol / ethanol, and MTBE / ETBE / TAME




l. Sulfur dioxide and sulfur trioxide may be emitted from


abatement concentration


Recommended pollution prevention and minimization measures

include the following:

• Minimize SOX emissions through desulfurization of fuels, to the extent

feasible, or by directing the use of high

with SOX emission controls;

• Recover sulfur from tail gases using high efficiency sulfur recovery

units (e.g. Claus units)

• Install mist precipitators (e.g. electrostatic precipitators or brink

demisters ) to remove sulfuric acid mist;

• Install scrubbers with caustic soda sol

alkylation unit absorption towers.

Particulate Matter

Particulate emissions from refinery units are associated with flue gas from

furnaces; catalyst fines emitted from fluidized catalytic the handling of coke;

and fines and ash generated during incineration of sludges. Particulates may

contain metals (e.g. vanadium, nickels). Measures to control particulate may

also contribute to control of metal emissions from petroleum refining.

Recommended pollution prevention and mini

include the following:

1. Install cyclones, electrostatic precipitators, bag filters, and/or wet

scrubbers to reduce emissions of particulates from point sources. A

combination of these techniques may achieve >99 percent abatement of

particulate matter;

2. Implement particulate emission reduction techniques during coke

handling, including:

• Store coke in bulk under enclosed shelters

• Keep coke constantly wet



Minimize SOX emissions through desulfurization of fuels, to the extent

feasible, or by directing the use of high-sulfur fuels to units equipped

controls;

Recover sulfur from tail gases using high efficiency sulfur recovery

units (e.g. Claus units)3

Install mist precipitators (e.g. electrostatic precipitators or brink

demisters ) to remove sulfuric acid mist;

Install scrubbers with caustic soda solution to treat flue gases from the

alkylation unit absorption towers.



and ash generated during incineration of sludges. Particulates may




Install cyclones, electrostatic precipitators, bag filters, and/or wet



Implement particulate emission reduction techniques during coke

Store coke in bulk under enclosed shelters

Keep coke constantly wet

10 | P a g e


Minimize SOX emissions through desulfurization of fuels, to the extent

sulfur fuels to units equipped

Recover sulfur from tail gases using high efficiency sulfur recovery

Install mist precipitators (e.g. electrostatic precipitators or brink

ution to treat flue gases from the



and ash generated during incineration of sludges. Particulates may



mization measures

Install cyclones, electrostatic precipitators, bag filters, and/or wet



Implement particulate emission reduction techniques during coke


• Cut coke in a crusher and convey it to an intermediate storage silo

(hydrobins)

• Spray the coke with a fine layer of oil, to stick the dust fines to the

coke

• Use covered and conveyor belts with extraction systems to maintain

negative pressure

• Use aspiration systems to extract and collect coke dust

• Pneumatically convey the fines collected from th

fitted with exit air filters, and recycle the collected fines to storage.

Greenhouse Gases (GHGs)

Carbon dioxide (CO2) may be produced in significant amounts during

petroleum refining from combustion processes (e.g. electric power

production), flares, and hydrogen plants. Carbon dioxide and other gases

(e.g. nitrogen oxides and carbon cracking regeneration units and other

catalyst based processes; monoxide) may be discharged to atmosphere

during in-situ catalyst regeneration of noble

maximize energy efficiency and design facilities (e.g. opportunities for

efficiency improvements in utilities, fired heaters, process optimization, heat

exchangers, motor and motor applications) to minimize energy use. The

overall objective should be to reduce air emissions and evaluate cost

effective options for reducing emissions that are technically feasible.

Wastewater

Industrial Process Wastewater

The largest volume effluents in petroleum refining include “sour” process

water and non-oily/non-sour but highly alkaline process water. Sour water is

generated from desalting, topping, vacuum distillation, pretreating, light and

middle distillate hydrodes


Cut coke in a crusher and convey it to an intermediate storage silo

coke with a fine layer of oil, to stick the dust fines to the

Use covered and conveyor belts with extraction systems to maintain

Use aspiration systems to extract and collect coke dust

Pneumatically convey the fines collected from the cyclones into a silo


Greenhouse Gases (GHGs)



roduction), flares, and hydrogen plants. Carbon dioxide and other gases



situ catalyst regeneration of noble metals. Operators should aim to




overall objective should be to reduce air emissions and evaluate cost


Industrial Process Wastewater


sour but highly alkaline process water. Sour water is


middle distillate hydrodesulphurization, hydrocracking, catalytic cracking,

11 | P a g e

Cut coke in a crusher and convey it to an intermediate storage silo

coke with a fine layer of oil, to stick the dust fines to the

Use covered and conveyor belts with extraction systems to maintain

e cyclones into a silo




roduction), flares, and hydrogen plants. Carbon dioxide and other gases



metals. Operators should aim to




overall objective should be to reduce air emissions and evaluate cost-



sour but highly alkaline process water. Sour water is


ulphurization, hydrocracking, catalytic cracking,


coking, Visbreaking / thermal cracking. Sour water may be contaminated

with hydrocarbons, hydrogen sulfide, ammonia, organic sulfur compounds,

organic acids, and phenol. Process water is treated in the sour

unit (SWS) to remove hydrocarbons, hydrogen sulfide, ammonia and other

compounds, before recycling for internal process uses, or final treatment and

disposal through an onsite wastewater treatment unit. Non

but highly alkaline process water has the potential to cause Waste Water

Treatment Plant upsets. Boiler blowdown and demineralization plant reject

streams in particular, if incorrectly neutralized, have the potential to extract

phenolics from the oil phase into the water p

emulsions in the WWTP

Wastes

Hazardous Wastes: Spent Catalysts

Spent catalysts result from several process units in petroleum refining

including the pretreating and catalytic reformer; light and middle distillate

hydrodesulphurization; the hydrocracker; fluid catalytic cracking (FCCU);

residue catalytic cracking (RCCU); MTBE/ETBE and TAME production;

butanes isomerization; the dienes hydrogenation and butylenes

hydroisomerization unit; sulfuric acid regeneration; selective catalytic

hydrodesulphurization; and the sulfur and hydrogen plants. Spent catalysts

may contain molybdenum, nickel, cobalt, platinum, palladium, vanadium

iron, copper and silica and/or alumina, as carriers.

Recommended management strategies for catalysts include th

following:

• Use long life catalysts and regeneration to extend the catalyst life

cycle;

• Use appropriate on

submerging pyrophoric spent catalysts in water during temporary




organic acids, and phenol. Process water is treated in the sour water stripper



disposal through an onsite wastewater treatment unit. Non-oily / non

ne process water has the potential to cause Waste Water



phenolics from the oil phase into the water phase, as well as cause

Hazardous Wastes: Spent Catalysts



on; the hydrocracker; fluid catalytic cracking (FCCU);






iron, copper and silica and/or alumina, as carriers.

Recommended management strategies for catalysts include th

Use long life catalysts and regeneration to extend the catalyst life

Use appropriate on-site storage and handling methods, (e.g.,


12 | P a g e



water stripper



oily / non-sour

ne process water has the potential to cause Waste Water



hase, as well as cause



on; the hydrocracker; fluid catalytic cracking (FCCU);






Recommended management strategies for catalysts include the

Use long life catalysts and regeneration to extend the catalyst life

site storage and handling methods, (e.g.,



storage and transport until they can reach

treatment to avoid uncontrolled exothermic reactions);

• Return spent catalysts to the manufacturer for regeneration or

recovery, or transport to other off

handling, heavy or precious metals recovery / recycl

disposal

Other Hazardous Wastes

In addition to spent catalysts, industry hazardous waste may include

solvents, filters, mineral spirits, used sweetening, spent amines for CO2,

hydrogen sulfide (H2S) and carbonyl sulfide (COS) removal, activated

carbon filters and oily sludge from oil / water separators, tank bottoms, and

spent or used operational and maintenance fluids (e.g. oils and test liquids).

Other hazardous wastes, including contaminated sludges, sludge from jet

water pump circuit purificat

alumina from hydrofluoric (HF) alkylation, may be generated from crude oil

storage tanks, desalting and topping, coking, propane, propylene, butanes

streams dryers, and butanes isomerization .

Recommended industry

hazardous waste include the following:

• Send oily sludges from crude oil storage tanks and the desalter to

the delayed coking drum, where applicable, to recover the

hydrocarbons;

• Ensure excessive cracking is not condu

to prevent production of an unstable fuel oil, resulting in increased

sludge and sediment formation during storage;

• Maximize recovery of oil from oily wastewaters and sludges.

Minimize losses of oil to the effluent system. Oil


storage and transport until they can reach the final point of


Return spent catalysts to the manufacturer for regeneration or

recovery, or transport to other off-site management companies for

handling, heavy or precious metals recovery / recycl

Other Hazardous Wastes




arbon filters and oily sludge from oil / water separators, tank bottoms, and



water pump circuit purification, exhausted molecular sieves, and exhausted



streams dryers, and butanes isomerization .

stry-specific management strategies for

hazardous waste include the following:

Send oily sludges from crude oil storage tanks and the desalter to


Ensure excessive cracking is not conducted in the Visbreaking unit


sludge and sediment formation during storage;

Maximize recovery of oil from oily wastewaters and sludges.

Minimize losses of oil to the effluent system. Oil can be recovered

13 | P a g e

the final point of


Return spent catalysts to the manufacturer for regeneration or

site management companies for

handling, heavy or precious metals recovery / recycling, and




arbon filters and oily sludge from oil / water separators, tank bottoms, and



ion, exhausted molecular sieves, and exhausted



specific management strategies for

Send oily sludges from crude oil storage tanks and the desalter to


cted in the Visbreaking unit


Maximize recovery of oil from oily wastewaters and sludges.

can be recovered


from slops using separation techniques (e.g. gravity separators and

centrifuges);

• Sludge treatment may include land application (bioremediation), or

solvent extraction followed by combustion of the residue and / or

use in asphalt, where fe

require stabilization prior to disposal to reduce the leachability of

toxic metals.

Non-hazardous Wastes

Hydrofluoric acid alkylation produces neutralization sludges which may

contain calcium fluoride, calcium

fluoride, magnesium hydroxide and magnesium carbonate. After drying and

compression, they may be marketed for steel mills use or landfilled.



Sludge treatment may include land application (bioremediation), or


use in asphalt, where feasible. In some cases, the residue may



contain calcium fluoride, calcium hydroxide, calcium carbonate, magnesium



14 | P a g e


Sludge treatment may include land application (bioremediation), or


asible. In some cases, the residue may



hydroxide, calcium carbonate, magnesium



11. oil refinery sector - gcpc-envisgcpcenvis.nic.in/experts/oil refinery sector.pdf · oil...

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