Sohar Refinery Environmental Improvement Projects (EIP)

Environmental Improvement Plan
Sohar Refinery
Feb 2014
Page 1 of 18
Waste Water Treatment Plant Improvements
• Background
The treatment of the waste water of the Refinery was
malfunctioning for a long period. Almost no purification
occurred and the water effluent quality was far away
from the standards. The water also emitted vapours
that caused strong odour.
Page 2 of 18
WWTP – 2013 Projects
• Biological improvement (bio augmentation) by addition of special enzymes
by KAM Biotechnology.
• Further cleaning and repairs of basins/equipment.
• Replacing sand and gravel in Sand Filters.
• Building of additional and more robust spent caustic treatment unit from in
order to have a 100% back-up system.
• Replacing of gravel and activated carbon in Activated Carbon Filters.
• Optimization of the primary units (API and DAF) by different chemicals
from different suppliers to select the best chemicals (on-going).
Page 3 of 18
WWTP – 2013 Projects
• More tight control of waste water production and draining from the refinery
plants. Continuous operation surveillance and monitoring of the WWTP.
• Ensure the implementation of preventive maintenance and repairs of all
equipment in the refinery that have direct influence to WWT operation.
• Preparation to implement Zero Discharge Policy: Plan is to send SR
treated effluent water from WWTP into Majis centralized treatment facility.
Page 4 of 18
WWTP – 2013 Results
• All parameters are within standard except ammonia.
• Significant odour emissions reduction.
Parameters/p
pm
COD
2011
>1,50
0
Standards/p
2013
Feb
2014
413
110
157
200
Nov
Nov
2012
pm
Oil & grease
31
12.5
8
6.5
15
TSS
83
31.7
8
36
30
Phenols
56
<0.1
<0.1
<0.1
0.002
Ammonia
128
57.2
96
29
1
Water
quality into
WWTP
Water
quality
from
WWTP
Page 5 of 18
Odour Nuisance Reduction
• Background
For mitigating odours from SR, the primary area for
odour source has been the refinery Waste Water
Treatment Plant. However Hydrocarbon emissions in
other parts of the Refinery could also contribute to
odour. Orpic is taking various actions for controlling
odour emissions, generated from the refinery complex
starting with WWTP. Orpic continues to identify the
possible other sources of odour within the SR.
Page 6 of 18
Odour Nuisance Reduction
• Installation of temporary spent caustic treatment unit.
• Installation of deodorizing additive in basins of WWTP that emit gases in
December 2011.
• Use of E-noses for odour detection in September 2012.
• A project was launched to cover the WWTP basins, collect the gases and
treat the gases to remove odour components. The project was divided into
3 phases. Phase-I is the coverage of the basins and has been completed
in October 2012.
• Phase-II Odour control project of installing a ventilation system for some
of the covered basins (API and DAF), completed and started up in August
2013.
• An odour mapping study to identify all possible sources of odour within the
SR was completed in July 2103. Sources other than the WWTP were
identified, mainly vents of certain tanks and Oily Water sumps. Actions are
being launched to equip all these sources with a system to collect the
vapours.
• Installation of HC and H2S detectors at the impound basin November
2013.
Page 7 of 18
Odour Nuisance Reduction
• Phase-III Odour control project of installing scrubber and/or thermal
oxidation (RTO) system by end of 2014. The EPC contract tender was
floated and several offers were received. Currently in process to evaluate
the offers and to select the EPC contractor. This last step will completely
avoid any odour coming from the WWTP.
• As part of the odour reduction program, Orpic assigned a number of its
engineers to work in shift along with the process Operators.
• Other initiative Orpic took to reduce odours is by launching the “Coin Your
Ideas” campaign.
Page 8 of 18
Odour Nuisance Reduction
Results
• Odour emissions and hydrocarbon releases from the Refinery have
decreased significantly, e-Nose readings show less frequent peaks of
emissions and also the intensity has decreased.
25
22
23
20
13
15
10
10
5
0
0
Jan
8
4
2
1
0
1
Feb
Mar
Apr
May
Jun
Jul
Aug Sep
Oct
Nov
Phone Calls Statistics (Complaints)
Date
Phone call
Validation
5/1/2014
One
Not Valid
10/1/2014
One
Valid
15/1/2014
One
Not Valid
29/1/2014
One
Not Valid
1/2/2014
One
Not Valid
15/2/2014
One
Not Valid
Orpic hotline number:
80077337
Page 9 of 18
Sohar Refinery Flaring
Projects:
• A project was completed to connect the fuel gas system of the Refinery with
Aromatics Plant.
• Continue to enhance chillers reliability and using both STG’s to produce
power.
• A study has started to recover the remaining low pressure gas that still is
flared and that cannot be recovered by the means mentioned above.
Results
• Routine flaring rate has been reduced by more than 60% from average of
12.5 tons/hr to 4.5 tons/hr.
Sohar Refinery Flaring Long Term Trend
Average
多項式 (Average)
14.0
12.0
TPH
10.0
8.0
6.0
4.0
2.0
0.0
2010
2011
2012
2013 YTD
Page 10 of 18
SOx Emissions Reduction
Background
• As part of the original Refinery construction,
a Wet Gas Scrubber (WGS) was installed in
Sohar Refinery to reduce Sulfur Dioxide (SO2)
gas emissions from the RFCC unit.
• Due
to the changes in RFCC feed quality (higher sulphur
content) from the original design assumptions, Sohar Refinery
experienced higher Sulfur Dioxide emissions than design. Also
poor dispersion of the plume exiting from the WGS stack was an
issue.
Page 11 of 18
SOx Emissions Reduction
• Original Equipment Manufacturer (OEM) Alstom was contracted for
debottlenecking the existing WGS. An EPC was awarded to Alstom to
implement the modifications and to retrofit. GTB awarded the contract (19
M$) in September 2012.
• In October 2012, the packing material level in WGS increased to 100% as a
first short term step. Higher scrubbing efficiency and lower emissions was
observed.
Inlet SO2
Outlet SO2
Efficiency
Outlet SO2
After packing
volume increased
from 70% to 100%
(mg/Nm3)
(mg/Nm3)
(%)
(ppmv)
7,919
1,500
81
526
• On 20 February 2013, mobilization of manpower and lifting equipment started
onsite, to implement planned WGS modifications.
• On 11 March 2013, Fire incident occurred in the WGS Unit, resulting in major
damage to the entire equipment. On 20 March 2013, recovery plan started to
re-build the damaged Wet Gas Scrubber, re-instate the sea water system and
other utilities on a fast track.
Page 12 of 18
SOx Emissions Reduction
• For a period of 2 months, the agreement was obtained from MECA/SEU to
operate the refinery without the WGS but meeting a SOx limit which was
similar to the emissions that Orpic had in first half of 2012. Orpic has taken
measures (use of imported low sulphur feedstock and use of DeSox catalyst)
and was able to stay below the agreed limit.
• On 24 May 2013, the main parts of the Wet Gas Scrubber (Absorber Shell &
Cone) were delivered to site, manufactured by local vendor.
• On 20 June 2013, Completion of mechanical works with a three seawater
booster pumps arrangement.
• On 3 July 2013, Wet Gas Scrubber put in
cold circulation with two seawater booster
pumps. All systems were checked in detail.
• On 27 July 2013, Wet Gas Scrubber put in
operation with hot flue gases.
Page 13 of 18
900.0
800.0
700.0
600.0
500.0
mg/Nm3 400.0
300.0
200.0
100.0
0.0
01 August 2013
05 August 2013
09 August 2013
13 August 2013
17 August 2013
21 August 2013
25 August 2013
29 August 2013
02 September…
06 September…
10 September…
14 September…
18 September…
22 September…
26 September…
30 September…
04 October 2013
08 October 2013
12 October 2013
16 October 2013
20 October 2013
24 October 2013
28 October 2013
01 November…
05 November…
09 November…
13 November…
17 November…
21 November…
25 November…
29 November…
03 December…
07 December…
11 December…
15 December…
19 December…
23 December…
27 December…
31 December…
04 January 2014
08 January 2014
12 January 2014
16 January 2014
20 January 2014
24 January 2014
28 January 2014
01 February 2014
05 February 2014
09 February 2014
13 February 2014
SOx Emissions Reduction
• October 2013, the remaining external components (heater system of the flue
gases coming from the WGS, fourth standby seawater booster pump) are
installed.
Results
After WGS
Revamp
Inlet SO2
(mg/Nm3)
Outlet SO2
(mg/Nm3)
Efficiency
(%)
Outlet SO2
(ppmv)
7,919
780
90
273
SO2 of WGS
857.1
SO2
Design SO2
Page 14 of 18
SOx Emissions Reduction
• A further reduction is expected after the implementation of the Sohar Refinery
Improvement Project (SRIP). As a results of the new Refinery units that will
be installed as part of the SRIP, the Sulfur in the RFCC feed will be lowered
to 1.8 wt% which resulted in less SOx precursors. Also the amount of flue
gases to be scrubbed will decrease. The impact on the WGS performance is
that the 350 mg/Nm3 will be met after start-up of New Units mid-2016.
After SRIP
Inlet SO2
(mg/Nm3)
Outlet SO2
(mg/Nm3)
Efficiency (%)
Outlet SO2
(ppmv)
5,016
350
93
122.8
Page 15 of 18
Leak Detection and Repair (LDAR)
Projects 2013:
• An LDAR survey was conducted to all refinery units using best practices
LDAR and Infrared camera scan.
Result
Page 16 of 18
Waste Management
• Export more than 19,000 tons of RFCC spent catalyst from Al Bhatinah
facility and on-site.
• Construct on-site hazardous/non-hazardous waste storage facility.
• Continue to find more outlets for different type of waste.
Accumulative tons
25,000
20,000
tons
15,000
10,000
5,000
0
Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr- May- Jun- Jul- Aug- Sep- Oct- Nov- Dec- Jan- Feb12
12
12
12
13
13
13
13
13
13
13
13
13
13
13
13
14
14
Accumulative tons 480 970 1,430 2,010 3,190 4,210 5,430 6,750 9,570 10,31 10,61 11,33 13,27 15,43 17,57 18,83 19,14 19,52
Page 17 of 18
Waste Management
RFCC spent catalyst stored on-site
January 2013, total of 8,600 tons.
No RFCC spent catalyst stored onsite Feb 2013.
Page 18 of 18