Refinery Wastewater Process Modeling with GPS-X™content.4cmarketplace.com/presentations/JoyceFabiyi.pdf · Refinery Wastewater Issues • Refineries are also facing tightening metals

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


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


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


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


Refinery Wastewater SystemsDe-Salters

Sour Water/Scrubbers

DistillationBlowdown

Stormwater

Cooling TowerBlowdown

Tank Drains


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?


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


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


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


How Is It Used?Create Model

Calibrate to Known

Performance

Simulate Different

Scenarios

Simulate “Base Case”

Compare and Evaluate0

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Simulated Measured


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)


Physical/Chemical Processes?• Handles biological treatment and solids separation

• As well as other processes

• Oil and grease separators

• pH management

• PAC

• Chemical addition


Case Studies


GPS-X™ - Features


GPS-X™ - FeaturesIntuitive modeling ……. …and simulation views

Quick panel views for all objects Sankey Graphs


GPS-X™ - Features


GPS-X™ - FeaturesSelect Control Variables

Sensitivity analysis

Clarifier behavior

Treatment thresholds


GPS-X™ - Largest Number of Unit Objects


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)


Case Study 1: Develop a calibrated model of a petroleum refinery WWTP to support plant analysis, decision making and process optimization

Plant layout



New API unit developed

Plant layout

GPS-X™ has the largest process object library of any process modeling software



GPS-X™ provides accurate representation of a facility’s process layout


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.


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


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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Existing One Train Out of Service


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


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


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


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™


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


SimuWorks™ Overview

• Advanced operator training and education• Plant optimization and cost saving strategies• Project and risk analysis• Key decision making support tool


Simulator Interface

Clickable Diagram

Simulation control

Flyover panel

Output graphs /

input panel


Step 1:Click on Unit Process

Step 2:Adjust Parameters

Step 3:Press Start

Step 4: See Results


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)


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


Technical Support


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

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Refinery Wastewater Process Modeling with GPS-X™content.4cmarketplace.com/presentations/JoyceFabiyi.pdf · Refinery Wastewater Issues • Refineries are also facing tightening metals