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Chennai Petroleum Corporation Limited

(A Group company of IndianOil)

WATER
MANAGEMENT
AT CPCL

February 18-20, 2015


Slide 1
Framework
CPCL-
CPCL Overview
O er ie
Water Management :
-- Overview
--- History
--- Facilities
-- Present status / Areas of improvement
-- Way
W forward
f d
Slide 2
Inception
CPCL (erstwhile MRL) was
established 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 IOCL


with shareholding as follows:
IOC . 51.89 %
NIOC .. 15.40 %
FII 14.73 %
Public 4.46 %
Others 13.52 %
Slide 3
CPCL Refinery Locations

Manali
10.5 MMTPA

Nagapattinam
1.0 MMTPA

4
4 Slide 4
Process Units Manali (Fuel & Lube Refinery)

PRIMARY UNITS (MMTPA)

CDU I 2.8
CDU-II 3.7
CDU-III 4.0
SECONDARY UNITS OTHERS (TMTPA)
(MMTPA)
Wa
Wax 30
FCCU 0.78
OHCU 1.80 Propylene 30
VBU 1.15 H
Hexane 25
CCR 0.30 Lube 235
DHDS 1 80
1.80
DHDT 1.80
Slide 5
Manali Refinery as Mother Industry
Kothari
POLY BUTYLENE
Petrochemicals
(PBFS)
Manali POLYOL
Petrochemicals PROPYLENE GLYCOL
(Propylene)
Tamil Nadu LINEAR ALKYL
CPCL Petro-Products BENZENE
(LABFS)

Madras Fertilizers FERTILISERS


(
(Naphtha)
)

Cetex
MEK
P t h i l
Petrochemicals
(MEKFS)
Slide 6
REFINERYPROCESSFLOW
DIAGRAM
Water Management-Overview contd.
Anyy p
petroleum refineryy requires
q water under the following
g heads
1. Drinking /canteen /sanitary
2. Cooling
g water for cooling
g /condensing
g
3. 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,
--- Sewage and
--- Seawater Slide 8
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 , & reuse


Three types: Process waste water (Oil contaminated)
Refinery toilet /canteen waste water
Spill off/ collections in storm water system

Slide 9
Water Management overview contd.

SewageReclamationPlants DesalinationPlant
SRP 1 : 1990
SRP-1 SRP-22 : 2007
SRP 2009
2.5MGD2.5MGD 5.8MGD

Refinery IRefineryIIRefineryIII
WastewaterReclamation
1969 1984 2004
2.8 6.5 10.5MMTPA Total Capability 13 5 MGD
TotalCapability:13.5MGD
Waterrequirement:10.00MGD

EffluentTreatmentPlantsI,II&III
4.00 MGD Zero Discharge Plants
ZeroDischargePlants
ZDP-1 :2002 ZDP-2 :2005
0.7MGD0.8MGD Slide 10
Water supply system overview contd,

Fresh water Reservoir


Refinery units
Cooling Towers
ETP feed tanks
Work stations
Desal
esa pplant
a Canteen
DM water plants
l
Fire water ponds ETPs
Sewage
Fire water network
Reservoir SRPs Green Belt
ZDPs

Storm water canals & Storm water ponds

Out fall Buckingham canal Slide 11


Water Management -History

Water consumption at CPCL was 3.5 MGD during 1969 and currently it is
in the order of 7.0
7 0 MGD.
MGD

Restricted water supply at Chennai


Rapid industrialization and urbanization
Depletion of water resources
Restricted municipal reservoir capacities

These necessitated CPCL to go on water conservation and identify


alternate water resources for sustenance of refining operations.

Slide 12
Water Management -History
Mid 80s
80 (1984 / 1987) This situation
Thi it ti has
h provoked
k d CPCL to t go for
f
(Acute water shortage alternate sources. CPCLs first Sewage
was experienced in Reclamation Plant was envisaged
g in the yyear
Chennai City. 1987 and was commissioned in the year 1991.
Industries in Manali
were shutdown)
April-1996 to Sept-1997 Substantial quantity of 53.7 MG of Treated
effluent was used in Cooling
g Towers.
Aug-2001 to Nov-2001 47.5 MG of Chengleput lake water was brought
from a distance of 55 kms by 200-500 tankers
/day.
/d
68.0 MG of Treated sewage / Treated effluent
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 11.85

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 23.0
Z
Zero Discharge
Di h Pl
Plant-II
t II 2005 10 5
10.5
RO Reject Recovery Plant 2006 2.0
g Reclamation Plant-II
Sewage 2006 55.0
5.8 MGD Sea Water Desalination Plant 2009 234.0
Slide 15
FRESH WATER / RAW WATER CONSUMPTION
DETAILS
on MGD

6.00
5.00
onsumptio

4.00
3.00
2.00
w water co

1.00
0.00
Raw

Year
Effluent Treatment Plants (ETPs)
Feed:
F d
Waste water from Refinery process units

Features of ETPs:
Gravity separation for removal of free oil & oily particulate matter.
Ferric
F i Chloride
Chl id forf coagulation
l i & precipitation
i i i off sulfides
lfid
Dissolved air floatation to remove emulsified oil, clarification
Biological process,
process (Trickling filter Activated sludge,
sludge with surface Aeration,
Aeration
Diffuser type )
Sand filter and activated carbon filter

Slide 17
ETP- flow sheet
Caustic Ferric & PE
API Oil Flash mixer- Dissolved Air
Separator Flotation unit

Aeration tank
Trickling filter Clarifier

Clarifier PSF & ACF Treated water pond

Slide 18
Sewage Reclamation Plants
Feed:
F d
Primary & secondary treated city sewage from CMWSSB.
Primaryy treatment : Floating
g mass removal.
Secondary treatment : Organic substance removal through
biological process.

Features of SRPs:
Biological
g process,, ((Activated sludge,
p g , Sequencing
q g Batch
Reactors)with surface Aeration, Diffuser type

Coagulation,
Coagulation flocculation,
flocculation clarification,filtration,disinfection,
clarification filtration disinfection

Ultrafiltration & two-stage


g RO p
process

Slide 19
Sewage Reclamation Plant - II (SRP-II)
Secondary FeCl3 &
treated Anionic Poly
sewage
dosing
Sequencing Clarifier Flash Mixer Pressure
Batch Flocculator sand filter
475 KL/hr Reactor

Degasser Reverse Ultra-


Filtration Break point
Osmosis
chlorination
I stage .

44 KL/hr Rejects
Reverse Chemical dosing
RO permeate
tank Osmosis Rejects SBS, HCl,
II stage Antiscallant
396 KL/hr
KL/h 44 KL/hr
KL/h
DM Plant Wash Water
feed
UF & RO process
Ult filtration
Ultra filt ti Membranes
M b
To remove suspended / colloidal particles and micro
organisms to avoid particulate & biological fouling
Up to 0.01micron size particles will be filtered.
Material: (Poly Ether Sulfone) Membrane
Type : Hollow Fiber

RO Membranes :
- To remove dissolved solids to reduce the load on
DM water unit
-- 80 % Recovery & 97.5
97 5 % salt rejection
Material : Polyamide Membrane
Type : Spiral wound.

Slide 21
Zero Discharge Plants (ZDPs)

Feed : Treated Refinery waste water


Objectives
j
To maximize reuse of treated Refinery wastewater
To make it suitable for DM water Plant feed

Processing steps in ZDP:


Coagulation
p
Suspended Particle Removal byy Pressure Sand Filter
Ultra-Filtration
RO

Slide 22
ZERO DISCHARGE SCHEME

From ETP
Coagulant

Equilization
pond
Coagulation
Upflow Filters )

UFSKID
RO SYSTEM Permeate

Backwash
pump
Backwash
sump
Water Management Projects

Zero Discharge
g Plant-2
Capacity: 1.05 MGD
Project cost : Rs. 10.6 Cr
Commissioning : 2005

Additional Sewage Treatment


Project
Capacity: 2.5
2 5 MGD
Project cost : Rs. 46.68 Cr
Commissioned : Dec 06

Slide 24
Sewage Reclamation Plant-1 RO skids

Slide 25
Zero Discharge Plant-2

Slide 26
Desal Plant - Inlet & Outlet Quality

PARAMETERS UNIT SEA PRODUCT


WATER WATER

Fl
Flow M3 / Hr
H 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
Desal RO Plant - Flow Chart

A) PRETREATMENT

Flash Flocculation Lamella Gravity


mixer tank Clarifier Sand Filter

Cartridge Filter Cartridge Filter Filter Water


with chemical Feed Pumps Storage Tanks
dosing system

B) RO PLANT

High Pressure Polyamide Energy Recovery


Feed Pumps
p Membrane Device ((Turbo))
Assembly Units

C) CHLORINATION SYSTEM
Chlorination system for Pretreatment, Post treatment and
Seawater intake system.
Slide 28
Sea Water Desalination Plant

To overcome dependency on high


cost Metro Water, CPCL has
commissioned a Sea Water
Desalination Plant of 5.8 MGD
capacity at Ennore.
The plant is based on Reverse
Osmosis technology.
Spiral wound Polyamine
membranes used.
sed
Water recovery is 35%
Expandable
p to 10 MGD for
catering to water requirement of
future projects.
Cost of water p produced from
Desalination Plant is Rs.60 / m3.
Slide 29
Aerial View of 2.5 MGD SRP-II

Cost of water produced from Sewage Reclamation Plants Rs.40 / KL


Slide 30
Desalination Plant
Intake well & Pump House

Investment : ` 243.9 Cr.


Capacity
p y : 5.8 MGD

Desalination Plant dedicated to Nation on 4.7.2009

Intake well & Pump House for Sea


water

31 of 48
Slide 3131
Sea Water Intake System
To overcome dependency on high cost
metro
t water,
t CPCL has
h commissioned
i i d
Sea Water Desalination Plant of 5.8
MGD capacity.

The plant is based on Reverse


Osmosis technology

Expandable to 10 MGD for catering to


water requirement of future projects.

Slide 32
Details of water consumption
Figs in MGD
Details 10-11 11-12 12-13 13-14 14-15
Fresh water consumption 1.78 0.93 2.56 0.89 0.70

Desalinated water 0.93 3.37 1.86 2.43 2.30


RO permeate- sewage 3.29 2.23 2.05 1.82 2.20
:

Bio treated filtered - 1.05 0.90 1.06 1.10 1.10


Se age
Sewage
RO Permeate, Refinery 0.65 0.34 0.50 1.07 0.40
waste water
Bio treated Filtered 2.23 2.38 2.24 2.11 2.20
Refinery waste water
Total 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
CMWSSB
2 Secondary treated sewage 11.85
3 Desalinated
: water 76 Average of
past two years
4 RO permeate- sewage, Refinery waste water 52
12 13 & 13-14
12-13 13 14
5 Bio treated filtered -Sewage 26

6 Bio treated Filtered Refinery waste water 15

Power, chemicals, R&M, Employee cost insurance


Refinery waste water treatment & reuse
Physical/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
(iii) Balance /excess quantity as Boiler feed water after processing thro
a. Ultra filtration (UF) to remove submicron particles
Wastewater
b Reverse Osmosis(RO)
b. treatment
to remove TDS & reuse
c. Permeate processed thro DM water plant

Green belt
Fire water network
Service water
CT Make up
ETPs Guard
Pond
UF/RO/BFW
Slide 35
Refinery waste water treatment & reuse
Probable solution
Green belt
Fire water network
Service water

Guard
ETPs
Pond CT Make up

Maximize
UF/RO DMP/BFW

Maximize RO permeate
and blend in FW/ CW system
To avoid corrosion of pipelines

Slide 36
Reclamation of Secondary Treated Sewage
Physical/chemical/biological treatment with /tertiary treatment

CT make up

SRPs

UF/RO/DMP/BFW

SRP : Sewage Reclamation Plant


CT : Cooling tower:
DMP: De-Mineralisation Plant
BFW: Boiler Feed Water
Slide 37
Desalination of Sea-Water
Physical/chemical treatment/RO process
D li
Desalinated d Water
W usedd for
f
(i) 60% requirement of Cooling water make up
((ii)) As Boiler feed water after pprocessingg thro DM water pplants if required
q

CT make up
Oil Contaminated sea water
Desal Fouling & failure RO membranes

DMP/BFW Excess effluent ggeneration due to High


g
TDS Desalinated water
CT : Cooling tower:
DMP: De-Mineralisation Plant
BFW: Boiler Feed Water
Slide 38
Performance of Reclamation facilities
Dependence on CMWSSB is not totally eliminated
Cost of Reclaimed water almost nearing that of CMWSSB
supply,
pp y, in case of desal p
plant,, it is higher
g
Areas that need to be focussed
11. Enhance UF/RO membrane useful life
2. Maximize permeate recovery
3 Reduce lead time for Membrane procurement
3.
Enabling actions
Improve Pre
Pre-treatment
treatment effectiveness to reduce load on UF &
RO membranes
Pre-treatment
Pre treatment for RO feed at 2nd /3rd stage
Always have stock of UF & RO membranes
Slide 39
Limitations UF membrane
9 UFmembranecostliercomparedtoROmembrane
UF b tli d t RO b
9 UFmembraneisnotanultimatebarrier
9 F d t UF h ld
FeedtoUFshouldmeetsomebasicrequirement
t b i i t
9 UFmembranequality,characteristicsveryimportant
9 M b
Membranesupplierseithernotawareoforintendto
li ith t f i t dt
keepusersindarkaboutthelimitationsofUF
membrane
b
9 Stringentguarantee/warrantyconditionsbyOEMs
9 InIndiamostlywedealwithtraderswithpoor
I I di tl d l ith t d ith
understandingofUltrafiltrationtechnology

40 of 62 Slide 40
Limitations of UF membrane
UFmembranesarenotstandardized
b d d d
Onceasystemisfinalized,suitabletospecifictypethesame
has to continue throughout the life time
hastocontinuethroughoutthelifetime.
IftheUFmembranefailstoperform,switchovertoother
membranecallsfortotalsystemchange
y g
Nostandardprocedure/testmethodfor
acceptanceof
t f
(i)UF/ROmembranes,
(ii)MicronCartridgefilters
(iii)Antiscalants/coagulantaids

Slide 41
Effectiveness of Pre-treatment
Activated Sludge Process -problems
problems
Carry over of MLSS from Clarifier of ASP is one of problems
Proper
P settling
ttli off MLSS in
i clarifier
l ifi tot be
b ensuredd

P
Provision
i i off anoxici zone att ASP aerator
t improves
i fl
floc.
characteristics which settles better at clarifier
Oxygen
O ddeficiency
fi i att clarifier
l ifi bbottom
tt lleading
di dde-nitrification
it ifi ti iis
another reason for MLSS carryover.

Slide 42
EFFECTIVENESS OF PRE -TREATMENT
Bio
Biotreatmentintroducesmanyorganicimpuritieswhichare
treatment introd ces man organic imp rities hich are
submicronparticles,duetocarryoverofMLSS.
Organicimpuritiescausingfoulingofmembranes
Organic impurities causing fouling of membranes
EfOM,EPS,Humicacid,proteinspolysaccharidesetc.,
Presentlynotmonitored,UFmembranesuppliersalso
notdemandingsuchcharacteristics
ForRemovaltheaboveorganicimpuritiesthefollowingarethe
For Removal the above organic impurities the following are the
treatmentfacilities:
Coagulation/flocculation/sedimentation
Adsorption
Wetairoxidation
Everyprocesshasitsownmerits&demerits
E h i i &d i
Slide 43
Effectiveness of Pre-treatment
Removal
R l off organic
i impurities
i iti
Presently coagulation /filtration being used
Optimum dosage by Jar test,
test which is time consuming
For varying incoming quality it is difficult
Improvement
p in NTU is being g monitored in jjar test
Improvement 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 test


IITM & CLRI Chennai have requisite facility and awareness & their
services are being utilized
44 of 62 Slide 44
Environment Management : Way forward

Wastewater recycle
9Maximizing recycle is possible only by TDS reduction/RO
processing
9Strengthen pre-treatment so that operation can be sustained
with out UF membrane
9Cost benefit analysis for justifying UF membrane
installation.
9Development of cost effective wet air oxidation process
ppreferablyy at ambient conditions

Slide 45
PROCESS FLOW CHART

Sea Water 5.8 MGD DESALINATION PLANT


Coagulant &
Dosing of Chlorine
aids dosed
0 ppm))
(0 5 ppm TO 11.0
(0.5
Pump House to Desal
Plant 16 Kms.
Travel time 1 Hr.

Stilling Chamber Flash Mixer Flocculator


Sea Water Pump House

Lamella Type 14 Nos. Gravity Filter Water


clarifier Sand Filters Storage Tank

Cartridge
Filters
(4 Nos.)
Sludge bed Dosing of Anti -
Scalant

110 KV Yard
Degasser
Tank
Feed To Refinery - 17 Kms.

RO High RO Banks Permeate Dosing of NaOH


Pressure Pumps (2324 Membranes Tank & Chlorination for
(4x275 m3/hr.) pH correction

46 Slide 46