WASTEWATER TREATMENT FOR REFINERIESRELIANCE INDUSTRIES LTD. JAMNAGAR, INDIA

Waterleau has acquired and developed technology to meet water treatment demands in the oil & gas industry. For the Reliance Industries Ltd Jamnagar Export Refinery Project (JERP), Waterleau has been responsible for the design, engineering, supply, erection, testing and commissioning of a 4 x 500 m³/hr fully PLC operated Effluent Treatment Plant, designed to contain and treat all EJRP’s process/utility waste water and storm/fire water.

With a capacity of 1,200,000 barrels per day, the Jamnagar refinery is the largest and most efficient oil refinery in the world (Nelson Complexity Index: 14) and the single biggest supplier of fuel to the global market. The design and construction of the wastewater treatment was a challenging project, and implemented with success into the Jamnagar Export Refinery Project.

CASE: RELIANCE, JAMNAGAR

WASTEWATER MANAGEMENT AT RELIANCE JAMNAGAR EXPORT REFINERY PROJECTThe wastewater treatment is carried out in a dedicated state-of-art completely automated & PLC operated effluent treatment plant (ETP) supplied by Ion Exchange Waterleau . The effluent treatment area is designed to contain and treat all internal process/utility waste water and storm/firewater, with the objective of zero discharge from the new refinery complex. The treated water is recycled back to the high total dissolved solids treatment train or guard tanks, as required.

Effluents are segregated into four identical wastewater streams designed for a treatment capacity of 500 m3/h each and maximisation of reuse.

The low total dissolved solids (LTDS) stream, a mixture of process/oily waters which include non-phenolic waste waters, is treated to an effluent quality adequate for reuse for cooling water make up, fire water make up and irrigation water for development and maintenance of the local green belt.

The high total dissolved solids (HTDS) stream is a mixture of process /oily wastewaters that have been in contact with process streams, such as in the crude unit desalters, and have absorbed or dissolved mineral ions such as sodium chloride. This stream also contains (treated neutralised) process solvents such as spent caustics, and phenolic waste water. This water is treated to an effluent quality adequate for re-use as partial make up in a sea water cooling tower.

RELIANCE Jamnagar - India48,000 m³/d - 60,000 kg COD/d

The oily water sewer (OWS) stream is a mixture of process/oil waters which includes oily condensates from various refinery units, sanitary sewage (after primary treatment), drainage from tanks, contaminated storm water etc. The treated OWS effluent is used for horticulture.

Each of the four wastewater streams employs identical equipment for treating effluents.

SLUDGE TREATMENT

The scope of treatment also includes three by-product streams generated during the treatment of refinery wastewater - skimmed or slop oils; oily sludge and biological sludge. Skimmed oil is chemical and heat treated, with recovered oils transferred back to the refinery for reprocessing. Oily sludge is thickened and then transferred back to the delayed coker unit for reprocessing. Biological sludge is thickened, stabilised, dewatered and disposed off to landfill.

Hydraulic load per module

Temperature of wastewater

Max peak oil at inlet

Total oil outlet pre-deoiler

Total oil outlet API separator

pH at DAF outlet

Sulphide at DAF outlet

Total oil at DAF outlet

BOD removal by biotower

F/M (BOD)

BOD removal by extended aeration

COD outlet extended aeration

(only guaranteed with PAC)

SS outlet extended aeration

SS outlet DMF

Turbidity outlet DMF

COD outlet ACF

500 m³/h

< 35°C

10.000 mg/l

< 2.000 mg/l

< 50 mg/l

6.5-7.2

< 10 mg/l

< 15 mg/l

50%

0.08 kg BOD/m³ d

70%

< 100 mg/l

< 30 mg/l

< 5 mg/l

< 8 NTU

< 50 mg/l

WASTEWATER CHARACTERISTICS

LTDS 1 & 2(LOW TOTAL DISSOLVED SOLIDS)

OWS(OILY WATER SEWER)

HTDS(HIGH TOTAL DISSOLVED SOLIDS)

INFLUENT MIXTURE

- Process / oily water

- Non-phenolic wastewaters

EFFLUENT MIXTURE

- Cooling water make-up

- Fire water make-up

- Irrigation

INFLUENT MIXTURE

- Process / oily water, incl. oily concentrates from various refinery units

- Sanitary sewage

- Drainage from tanks

EFFLUENT MIXTURE

Horticulture in GREEN BELT around plant (7,000 acres)

TDS: 160 - 500 TDS: 850 - 1,500

INFLUENT MIXTURE

Process / oily waters in contact with process streams (crude unit de-salters) containing absorbed or dissolved salts

EFFLUENT MIXTURE

Partial make-up water in seawater cooling tower

TDS: 950 - 2,500

Radioweg 18, 3020 Herent (Leuven), Belgiumt. +32 (0) 16 65 06 57 - f. +32 (0) 16 65 06 63info@waterleau.com - www.waterleau.com

The treatment scheme also includes an automatic belt filter press for dewatering biological sludge, two chemical houses; three analyzer houses and twenty samplers skids for automatic sampling and analysis of critical effluent parameters on a continuous basis. Our scope includes supply of specialty polymers and effluent treatment chemicals along with its maintenance by a team of trained and competent process engineers.

The effluent treatment plant is treating 100% effluent generated by the refinery since its commissioning in December 2008 and consistently producing treated effluent (pH 6-8.5, Sulphide < 05.ppm, COD < 50 ppm, Oil & Grease < 5 ppm, Phenol < 0.35 ppm) meeting guarantee parameters for re-use for various applications mentioned earlier.

SKIMMED OILS OILY SLUDGE BIOLOGICAL SLUDGE

TREATMENT

- Chemical treatment

- Heat treatment

- Slop holding tank

- Emulsion breaking tank

REUSERecovered oil transferred to refinery

TREATMENT

- Settling tank (oily sludge)

- Thickener (oil float sludge)

REUSE

Thickened sludge transferred to delayed coker unit

TREATMENT

- Thickening

- Stabilisation

- Dewatering

REUSE

Disposed off to landfill

TREATMENT OF 3 BY-PRODUCT STREAMS