water management at cpclcdn.cseindia.org/userfiles/cpcl-water-management-dr.m.pdfwater...
TRANSCRIPT
Chennai Petroleum Corporation Limited(A Group company of IndianOil)
WATER
MANAGEMENTMANAGEMENT
AT CPCL
Slide 1
February 18-20, 2015
FrameworkCPCL O er ie CPCL- Overview
Water Management : Water Management :
-- Overview
--- History
--- Facilities
-- Present status / Areas of improvement
W f d Slide 2
-- Way forward
CPCL (erstwhile MRL) wasInception
CPCL (erstwhile MRL) wasestablished in 1965 as a JV - PSU with• GOI - 74 %• NIOC, Iran - 13 %• AMOCO, USA - 13 %
AMOCO disinvested in 1985.
GOI disinvested to IOC in March 2001
CPCL is a group company of IOCLwith shareholding as follows:
IOC ……………. 51.89 %NIOC ………….. 15.40 %FII ……………… 14.73 %
Slide 3
Public ………… 4.46 %Others ………… 13.52 %
CPCL Refinery Locations
ManaliManali10.5 MMTPA
Nagapattinam1.0 MMTPA
Slide 444
Process Units – Manali (Fuel & Lube Refinery)
PRIMARY UNITS (MMTPA)
• CDU I 2.8• CDU-II 3.7• CDU-III 4.0
OTHERS (TMTPA)
Wa 30SECONDARY UNITS
(MMTPA) • Wax 30• Propylene 30
H 25
(MMTPA)• FCCU 0.78• OHCU 1.80
• Hexane 25• Lube 235
• VBU 1.15• CCR 0.30• DHDS 1 80
Slide 5
• DHDS 1.80• DHDT 1.80
Manali Refinery as Mother Industry Kothari
POLY BUTYLENEKothari
Petrochemicals(PBFS)
POLYOLPROPYLENE GLYCOL
Manali Petrochemicals
(Propylene)
LINEAR ALKYL BENZENECPCL
(Propylene)
Tamil Nadu Petro-Products
FERTILISERS
(LABFS)
Madras Fertilizers( )
MEK
(Naphtha)
CetexP t h i l
Slide 6
Petrochemicals (MEKFS)
REFINERY PROCESS FLOW DIAGRAM
Water Management-Overview contd.
• Any petroleum refinery requires water under the following headsy p y q g1. Drinking /canteen /sanitary2. Cooling water for cooling /condensingg g g3. Boiler feed water for steam/power generation.4. Service water / fire fighting water/Green belt/gardening
• The quality of each type/category is different• Each category has its own supply & distribution system• Item 1 is met by fresh water presently• Items 2-4 are met by treated wastewater
---Refinery waste water,
Slide 8
--- Sewage and--- Seawater
Water Management-Overview contd.
SOURCES:1. Fresh water : unreliable ,cost prohibitive
2. City sewage : reliable source, but difficult to reuse, processing cost
3. Sea water : reliable source, processing cost, transportation
4. Refinery waste water : Mandatory to reprocess , & reuseThree types: Process waste water (Oil contaminated)Three types: Process waste water (Oil contaminated)
Refinery toilet /canteen waste waterSpill off/ collections in storm water system
Slide 9
Spill off/ collections in storm water system
Water Management –overview contd.
Desalination PlantSewage Reclamation Plants
SRP-1 : 1990 SRP-2 : 2007 2009SRP 1 : 1990 SRP 2 : 2007 20095.8 MGD2.5 MGD 2.5 MGD
Refinery‐ I Refinery II Refinery III 1969 1984 2004 Wastewater Reclamation
Total Capability 13 5 MGD2.8 6.5 10.5 MMTPAWater requirement : 10.00 MGD
Total Capability : 13.5 MGD
Effluent Treatment Plants I, II & III
Zero Discharge Plants4.00 MGD
Slide 10
Zero Discharge Plants ZDP-1 :2002 ZDP-2 :20050.7 MGD 0.8 MGD
Water supply system –overview contd,
Fresh water Reservoir Refinery unitsCooling TowersCooling TowersWork stationsCanteen DM l
ETP feed tanks
Desal plantDM water plantsFire water pondsFire water network
ETPsesa p a
Sewage Reservoir Green Belt
ZDPsSRPsReservoir
Storm water canals & Storm water ponds
Slide 11Out fall Buckingham canal
Water Management -History
• Water consumption at CPCL was 3.5 MGD during 1969 and currently it isin the order of 7 0 MGDin the order of 7.0 MGD.
• Restricted water supply at Chennai• Restricted water supply at Chennai• Rapid industrialization and urbanization• Depletion of water resources• Depletion of water resources• Restricted municipal reservoir capacities
• These necessitated CPCL to go on water conservation and identifyalternate water resources for sustenance of refining operations.
Slide 12
Water Management -HistoryMid 80’ (1984 / 1987) Thi it ti h k d CPCL t fMid 80’s (1984 / 1987)(Acute water shortage was experienced in
This situation has provoked CPCL to go foralternate sources. CPCL’s first SewageReclamation Plant was envisaged in the yearwas experienced in
Chennai City. Industries in Manali were shutdown)
g y1987 and was commissioned in the year 1991.
were shutdown) April-1996 to Sept-1997 Substantial quantity of 53.7 MG of Treated
effluent was used in Cooling Towers.gAug-2001 to Nov-2001 47.5 MG of Chengleput lake water was brought
from a distance of 55 kms by 200-500 tankers /d/day.68.0 MG of Treated sewage / Treated effluent was used in cooling towers.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 11.852014 60.00 11.85
Slide 15
Water Management Initiatives
Facility Year Rs.Cr.
Effluent Treatment Plant-I 1969 1.0
Effluent Treatment Plant-II 1983 5.0
Sewage Reclamation Plant -I 1991 24.5
Ref-I ETP Modernisation 1992 13.5
Ref-II ETP Modernisation 1993 6.7
Zero Discharge Plant -I 2001 4.6
Effluent Treatment Plant-III 2004 23.0Z Di h Pl t II 2005 10 5Zero Discharge Plant-II 2005 10.5RO Reject Recovery Plant 2006 2.0Sewage Reclamation Plant-II 2006 55.0
Slide 15
g5.8 MGD Sea Water Desalination Plant 2009 234.0
FRESH WATER / RAW WATER CONSUMPTION DETAILS
5.006.00
on M
GD
2.003.004.00
onsu
mpt
io
0.001.00
w w
ater
co
Raw
Year
Effluent Treatment Plants (ETPs)F dFeed:• Waste water from Refinery process units
Features of ETPs:• Gravity separation for removal of free oil & oily particulate matter.
F i Chl id f l i & i i i f lfid• Ferric Chloride for coagulation & precipitation of sulfides• Dissolved air floatation to remove emulsified oil, clarification• Biological process (Trickling filter Activated sludge with surface AerationBiological process, (Trickling filter Activated sludge, with surface Aeration,
Diffuser type )• Sand filter and activated carbon filter
Slide 17
ETP- flow sheet
API Oil Flash mixer- Dissolved Air Flotation unit
Ferric & PECaustic
Separator Flotation unit
ClarifierTrickling filterAeration tank
Clarifier PSF & ACF Treated water pond
Slide 18
Sewage Reclamation PlantsF dFeed:• Primary & secondary treated city sewage from CMWSSB.• Primary treatment : Floating mass removal.y g• Secondary treatment : Organic substance removal through
biological process.
Features of SRPs:• Biological process, (Activated sludge, Sequencing Batchg p , ( g , q g
Reactors)with surface Aeration, Diffuser type
• Coagulation flocculation clarification filtration disinfection• Coagulation, flocculation, clarification,filtration,disinfection,
• Ultrafiltration & two-stage RO process
Slide 19
g p
FeCl3 & Secondary
Sewage Reclamation Plant - II (SRP-II)
ClarifierSequencing Pressure Flash Mixer
Anionic Poly dosing
treated sewage
ClarifierSequencing Batch
Reactorsand filter
Flash Mixer Flocculator
475 KL/hr
Ultra-Filtration Break point
chlorinationReverse Osmosis I stage
DegasserI stage .
Chemical dosing Rejects
Reverse RO permeate44 KL/hr
SBS, HCl, Antiscallant
Osmosis II stage
RO permeate tank
396 KL/h 44 KL/h
Rejects
DM Plant feed
396 KL/hrWash Water
44 KL/hr
UF & RO process Ult filt ti M bUltra filtration Membranes
– To remove suspended / colloidal particles and microorganisms to avoid particulate & biological fouling
– Up to 0.01micron size particles will be filtered.– Material: (Poly Ether Sulfone) Membrane– Type : Hollow FiberType : Hollow Fiber
RO Membranes :- To remove dissolved solids to reduce the load on
DM water unit-- 80 % Recovery & 97 5 % salt rejection80 % Recovery & 97.5 % salt rejection– Material : Polyamide Membrane– Type : Spiral wound.
Slide 21
Zero Discharge Plants (ZDPs)
Feed : Treated Refinery waste water
Objectivesj– To maximize reuse of treated Refinery wastewater– To make it suitable for DM water Plant feed
Processing steps in ZDP:Coagulation
Suspended Particle Removal by Pressure Sand Filterp yUltra-FiltrationRO
Slide 22
RO
ZERO DISCHARGE SCHEME
From ETPCoagulant
Equilization
Upflow Filters )
Equilization pond
Coagulation
RO SYSTEM Permeate
UF SKID
Backwash pump
Backwash sump
Water Management Projects
Zero Discharge Plant-2g• Capacity: 1.05 MGD• Project cost : Rs. 10.6 Cr• Commissioning : 2005
Additional Sewage Treatment Project• Capacity: 2 5 MGD• Capacity: 2.5 MGD• Project cost : Rs. 46.68 Cr• Commissioned : Dec ’06
Slide 24
Sewage Reclamation Plant-1 RO skidsSewage Reclamation Plant-1 RO skids
Slide 25
Zero Discharge Plant-2
Slide 26
Desal Plant - Inlet & Outlet Quality
PARAMETERS UNIT SEAWATER
PRODUCTWATERWATER WATER
Fl M3 / H 3284 1100Flow M3 / Hr 3284 1100
pH 8.2 5.0-7.0
TDS ppm 38762 < 350
Turbidity NTU 25-50 < 1
Sodium ppm 12082 < 150
Chlorides ppm 21199 < 220
Slide 27
Chlorides ppm 21199 < 220
Desal RO Plant - Flow Chart
A) PRETREATMENT
Flash mixer
Flocculation tank
Lamella Clarifier
Gravity Sand Filtermixer tank Clarifier Sand Filter
Filter Water Cartridge Filter Cartridge Filter Storage TanksFeed Pumpswith chemical
dosing system
B) RO PLANTB) RO PLANT
High Pressure Feed Pumps
Polyamide Membrane
Energy Recovery Device (Turbo)
C) CHLORINATION SYSTEM
pAssembly Units
( )
Slide 28
Chlorination system for Pretreatment, Post treatment and Seawater intake system.
Sea Water Desalination Plant
To overcome dependency on highcost Metro Water, CPCL hascommissioned a Sea Watercommissioned a Sea WaterDesalination Plant of 5.8 MGDcapacity at Ennore.The plant is based on ReverseThe plant is based on ReverseOsmosis technology.Spiral wound Polyaminemembranes sedmembranes used.Water recovery is 35%Expandable to 10 MGD forpcatering to water requirement offuture projects.Cost of water produced from
Slide 29
pDesalination Plant is Rs.60 / m3.
Aerial View of 2.5 MGD SRP-II
Slide 30
Cost of water produced from Sewage Reclamation Plants – Rs.40 / KL
Desalination PlantIntake well & Pump House
Investment : ` 243.9 Cr. Capacity : 5.8 MGDp y
Desalination Plant dedicated to Nation on 4.7.2009
Intake well & Pump House for Sea Intake well & Pump House for Sea water
Slide 3131 of 48 31
Sea Water Intake SystemSea Water Intake System
• To overcome dependency on high costt t CPCL h i i dmetro water, CPCL has commissioned
Sea Water Desalination Plant of 5.8MGD capacity.
• The plant is based on ReverseOsmosis technology
• Expandable to 10 MGD for catering towater requirement of future projects.
Slide 32
Details of water consumption Figs in MGD
Details 10-11 11-12 12-13 13-14 14-15Fresh water consumption 1.78 0.93 2.56 0.89 0.70Fresh water consumption 1.78 0.93 2.56 0.89 0.70
Desalinated water 0.93 3.37 1.86 2.43 2.30RO permeate- sewage 3.29 2.23 2.05 1.82 2.20Bio treated filtered -Se age
1.05 0.90 1.06 1.10 1.10:
SewageRO Permeate, Refinery waste water
0.65 0.34 0.50 1.07 0.40
Bio treated Filtered Refinery waste water
2.23 2.38 2.24 2.11 2.20
Total water consumption 9.92 10.14 10.26 9.42 8.90Total water consumption 9.92 10.14 10.26 9.42 8.90
Cost of Production Figs in Rs/KL
S.No Details Cost Remarks 1 Fresh water 60 Purchase from
CMWSSB2 Secondary treated sewage 11.853 Desalinated water 76 Average of
past two years 12 13 & 13 144 RO permeate- sewage, Refinery waste water 52
:
12-13 & 13-145 Bio treated filtered -Sewage 26
6 Bio treated Filtered Refinery waste water 15
Power, chemicals, R&M, Employee cost insurance
Refinery waste water treatment & reusePhysical/chemical/biological treatment with /tertiary treatment Treated water from ETPs used for
(i) Full requirement of Fire water system makeup (ii) Full requirement of Service water & Green Belt
Wastewater treatment & reuse
(ii) Full requirement of Service water & Green Belt (iii) Balance /excess quantity as Boiler feed water after processing thro
a. Ultra filtration (UF) to remove submicron particlesb Reverse Osmosis(RO) to remove TDSWastewater treatment & reuseb. Reverse Osmosis(RO) to remove TDSc. Permeate processed thro DM water plant
Fire water network Green beltService water
ETPs Guard Pond
CT Make up
Slide 35
UF/RO/BFW
Refinery waste water treatment & reuseProbable solutionProbable solution
Fire water network Green beltService water
ETPs Guard Pond
Service water
CT Make up Pond CT Make up
UF/RO DMP/BFWMaximize
Maximize RO permeateand blend in FW/ CW systemTo avoid corrosion of pipelines
Slide 36
To avoid corrosion of pipelines
Reclamation of Secondary Treated Sewage Physical/chemical/biological treatment with /tertiary treatment
CT make up
SRPs
UF/RO/DMP/BFW
SRP : Sewage Reclamation PlantCT : Cooling tower:
Slide 37
DMP: De-Mineralisation PlantBFW: Boiler Feed Water
Desalination of Sea-Water Physical/chemical treatment/RO process D li d W d fDesalinated Water used for(i) 60% requirement of Cooling water make up (ii) As Boiler feed water after processing thro DM water plants if required( ) p g p q
CT make up
Desal
CT make upOil Contaminated sea waterFouling & failure RO membranes
DMP/BFW Excess effluent generation due to High
CT : Cooling tower:DMP: De-Mineralisation Plant
g gTDS Desalinated water
Slide 38
BFW: Boiler Feed Water
Performance of Reclamation facilities• Dependence on CMWSSB is not totally eliminated • Dependence on CMWSSB is not totally eliminated • Cost of Reclaimed water almost nearing that of CMWSSB
supply, in case of desal plant, it is higherpp y, p , gAreas that need to be focussed1 Enhance UF/RO membrane useful life1. Enhance UF/RO membrane useful life2. Maximize permeate recovery 3 Reduce lead time for Membrane procurement3. Reduce lead time for Membrane procurementEnabling actions Improve Pre-treatment effectiveness to reduce load on UF & Improve Pre treatment effectiveness to reduce load on UF & RO membranesPre-treatment for RO feed at 2nd /3rd stage
Slide 39
Pre treatment for RO feed at 2 /3 stage Always have stock of UF & RO membranes
Limitations UF membraneUF b tli d t RO bUF membrane costlier compared to RO membraneUF membrane is not an ultimate barrierF d t UF h ld t b i i tFeed to UF should meet some basic requirementUF membrane quality, characteristics very importantM b li ith t f i t d tMembrane suppliers either not aware of or intend to keep users in dark about the limitations of UF
bmembraneStringent guarantee /warranty conditions by OEMsI I di tl d l ith t d ithIn India mostly we deal with traders with poor understanding of Ultrafiltration technology
Slide 4040 of 62
Limitations of UF membraneb d d d• UF membranes are not standardized
• Once a system is finalized, suitable to specific type the same has to continue throughout the life timehas to continue throughout the life time.
• If the UF membrane fails to perform, switch over to othermembrane calls for total system change y g
No standard procedure/test method for t facceptance of
(i) UF/RO membranes,(ii) Micron ‐Cartridge filters (iii)Anti‐scalants/ coagulant aids
Slide 41
Effectiveness of Pre-treatment Activated Sludge Process problemsActivated Sludge Process -problems• Carry over of MLSS from Clarifier of ASP is one of problems
P ttli f MLSS i l ifi t b d• Proper settling of MLSS in clarifier to be ensured
P i i f i t ASP t i fl • Provision of anoxic zone at ASP aerator improves floc. characteristics which settles better at clarifierO d fi i t l ifi b tt l di d it ifi ti i • Oxygen deficiency at clarifier bottom leading de-nitrification is another reason for MLSS carryover.
Slide 42
EFFECTIVENESS OF PRE -TREATMENTBio treatment introd ces man organic imp rities hich are• Bio treatment introduces many organic impurities which are sub‐micron particles, due to carry over of MLSS.
• Organic impurities causing fouling of membranesOrganic impurities causing fouling of membranesEfOM, EPS, Humic acid, proteins polysaccharides etc., Presently not monitored, UF membrane suppliers also not demanding such characteristics
For Removal the above organic impurities the following are theFor Removal the above organic impurities the following are the treatment facilities:• Coagulation /flocculation/sedimentation• Adsorption• Wet air oxidation
E h i i & d i
Slide 43
Every process has its own merits & demerits
Effectiveness of Pre-treatment R l f i i iti Removal of organic impurities Presently coagulation /filtration being usedOptimum dosage by Jar test which is time consumingOptimum dosage by Jar test, which is time consumingFor varying incoming quality it is difficultImprovement in NTU is being monitored in jar testp g jImprovement in NTU does not reflect improvement in organic impurities Organic impurities measurement is the basic requirement in jar test .
No reputed laboratory in city is capable of doing such testIITM & CLRI Chennai have requisite facility and awareness & their
Slide 4444 of 62
IITM & CLRI Chennai have requisite facility and awareness & their services are being utilized
Environment Management : Way forward
Wastewater recycleWastewater recycleMaximizing recycle is possible only by TDS reduction/RO processingprocessingStrengthen pre-treatment so that operation can be sustained with out UF membranewith out UF membraneCost benefit analysis for justifying UF membrane installation.Development of cost effective wet air oxidation process preferably at ambient conditions
Slide 45
p y
PROCESS FLOW CHART
Coagulant & aids dosedDosing of Chlorine
(0 5 TO 1 0 )
Sea Water 5.8 MGD DESALINATION PLANT
Stilling Chamber
(0.5 ppm TO 1.0 ppm)
Flash Mixer Flocculator
Pump House to DesalPlant – 16 Kms.Travel time – 1 Hr.
Sea Water Pump House
Lamella Type clarifier
14 Nos. Gravity Sand Filters
Filter Water Storage Tank
Cartridge Filters
Dosing of Anti -Scalant
Degasser Tank
Filters(4 Nos.)
Sludge bed
110 KV Yard
Dosing of NaOH & Chlorination for pH correction
Feed To Refinery - 17 Kms.Tank
Permeate Tank
RO Banks(2324 Membranes(4x275 m3/hr.)
RO High Pressure Pumps
Slide 4646