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TÜV SÜD South Asia Pvt. Ltd
WATER AUDIT AT HALDIA REFINERY
INDIAN OIL CORPORATION LIMITED, REFINERIES DIVISION, HALDIA REFINERY
Project: Detailed report of water audit at Haldia Refinery Document : Final Report Submission Dates: April 2015 Version Number: 4 Revision Number: 4
WATER AUDIT AT HALDIA REFINERY
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Contents 1. ACKNOWLEDGEMENT .................................................................................................. 4
2. ABBREVIATION............................................................................................................... 5
3. EXECUTIVE SUMMARY ................................................................................................ 6
4. CHAPTER 1: INTRODUCTION ....................................................................................... 8
1.1. Background ...................................................................................................................... 8
1.2. Objective .......................................................................................................................... 8
1.3. Limitation ......................................................................................................................... 9
5. CHAPTER 2: INVENTORY OF WATER USE ................................................................ 9
2.1. Water Footprint .................................................................................................................. 11
2.2. Fresh water withdrawn ....................................................................................................... 12
2.3. Water Consumption ........................................................................................................... 16
2.4. Effluent generation and reuse ............................................................................................ 18
2.5. Plant Water Balance Diagram ............................................................................................ 22
6. CHAPTER 3: Water utilization ........................................................................................ 25
3.1. Cooling Tower................................................................................................................ 25
3.2. RO Unit .......................................................................................................................... 29
3.3. Process ............................................................................................................................ 31
3.3.1. Fuel oil block .......................................................................................................... 31
3.3.2. Lube oil block ......................................................................................................... 36
3.3.3. DHDS ...................................................................................................................... 40
3.4. DM Plant ........................................................................................................................ 44
7. CHAPTER 4: WATER CONSUMPTION REDUCTION OPPORTUNITIES ............... 47
4.1. Water conservation across process units ............................................................................ 47
4.2. Cooling Tower ................................................................................................................... 49
4.3. DM Plant ............................................................................................................................ 50
4.4 Monitoring ......................................................................................................................... 50
8. CHAPTER 5: CONCLUSION ......................................................................................... 51
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Table 1: Synopsis of water loss from cooling tower ....................................................................... 6
Table 2: Water withdrawal from tube well ................................................................................... 12
Table 3: Water withdrawn/ sourced from PHE ............................................................................. 13
Table 4: Water sourced through HFC tube well ........................................................................... 14
Table 5: Total raw water withdrawn ............................................................................................. 15
Table 6: Segregation of water consumption ................................................................................. 17
Table 7: Raw and total water consumed ....................................................................................... 18
Table 8: ETP capacities ................................................................................................................ 20
Table 9: Effluent Treatment .......................................................................................................... 20
Table 10: Cooling Tower specification......................................................................................... 25
Table 11: Estimation of water saving through increased COC in PCT cooling tower ................. 26
Table 12: Estimation of water saving through increased COC in TPS cooling tower ................. 27
Table 13: Estimation of water saving through increased COC in DHDS cooling tower ............. 27
Table 14: Estimation of water saving through increased COC in OHCU cooling tower ............. 28
Table 15: Estimation of water saving through increased COC in GT cooling tower ................... 28
Table 16:Water use as bearing water in CDU-2 ........................................................................... 33
Table 17: Water use for bearing cooling in CDU-I ..................................................................... 34
Table 18: Water use for bearing cooling in CRU/KHDS ........................................................... 34
Table 19: Estimation of bearing cooling water used in FOB ........................................................ 35
Table 20: Total financial saving ................................................................................................... 35
Table 21: Water use for bearing cooling in loss across unit 39 (MCW) ..................................... 37
Table 22: Water use for bearing cooling in loss across unit 84 (CIDW) .................................... 37
Table 23: Water use for bearing cooling in loss across unit 32 ( PDA) ..................................... 38
Table 24: Water use for bearing cooling in loss across unit 31 ( VDU-1) ................................. 38
Table 25: Water use for bearing cooling in loss across unit 37 (VBU) ...................................... 38
Table 26: Water use for bearing cooling in loss across unit 33 ( FEU) ..................................... 38
Table 27: Water use for bearing cooling in loss across unit 35 ( HFU) .................................... 38
Table 28: Total water used for bearing cooling in LOB ............................................................... 39
Table 29: Water use for bearing cooling in Unit 24,25 (old HGU and DHDS) .............................. 40
Table 30: Water use for bearing cooling in VDU-II unit ............................................................ 41
Table 31: Water use for bearing cooling in MSQ units ............................................................... 41
Table 32: Water use for bearing water cooling in FCCU ......................................................... 42
Table 33: Water use for bearing cooling in ARU and SWS unit ................................................ 42
Table 34: Water use for bearing cooling in OHCU Block........................................................... 43
Table 35: Total water used for bearing cooling across all the units ............................................. 44
Table 36: Estimation of financial loss .......................................................................................... 44
Table 37: DM Water generation & Condensate recovery from different units ............................ 45
Table 38: DM water supply to units and processes ...................................................................... 45
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Figure 1: Schematic diagram of water inventory areas ............................................................... 10
Figure 2: Specific water consumption .......................................................................................... 11
Figure 3: Specific water consumption and water re-use Figure 4: Specific water consumption 2014-15 .......................................................................... 111
Figure 5: Average water withdrawn from tube well on monthly basis......................................... 12
Figure 6: Average water withdrawn from tube-well on hourly basis ......................................... 122
Figure 7: Average water sourced from PHE on monthly basis .................................................. 133
Figure 8: Average water sourced from PHE on hourly basis .................................................... 133
Figure 9: Total water sourced from HFC tube well on monthly basis ...................................... 144
Figure 10 : Average water sourced from HFC tube well on monthly basis ............................... 144
Figure 11: Total raw water withdrawn per month ( cumulative for three source) .................... 155
Figure 12: Average hourly water withdrawn from three sources .............................................. 155
Figure 13:Source wise water withdrawn .................................................................................... 166
Figure 15: Water supply network across FOB unit .................................................................... 321
Figure 16: pump draining water to drain in FOB
Figure 17: Water is being supplied to Pump No SS-121 under maintenance 35 Figure 18: Steam condensate routed to drain .............................................................................. 38
Figure 19: Condensate drain across unit no 39 ........................................................................... 39
Figure 20: Bearing cooling water drained to surface drain in Unit-82 ..................................... 410
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ACKNOWLEDGEMENT This study has been conducted by TUV SUD under guidance of Shri P. S. Goswami. TUV SUD wishes to thank the following individuals that contributed technical expertise and guidance in providing direction and support in conducting the water audit. Shri S. Chaudhuri Shri R Paul Shri R Tirkey Shri K C Nayek Shri Prabir Mandal Shri Susanta Mandal Shri Mukul Sarkar Shri Biju Antony We trust that the findings of this study will help the management in improving the performance with optimum water consumption in M/s. Indian Oil Corporation Ltd., Haldia Refinery
TÜV SÜD South Asia Pvt. Ltd
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ABBREVIATION Acronym DescriptionIOCL Indian Oil Corporation LimitedFCCU Fluidised Catalytic Cracking UnitVBU Visbreaking UnitDHDS Diesel HydrodesulphurizationVDU Vacuum Distillation UnitCDU Crude Distillation UnitHSD High Speed DieselFO Fuel OilGT Gas TurbineLPG Liquefied Petroleum gasK-HDS Kero- Hydrodesulfurization UnitPDA Propane Deasphalting UnitFOB Fuel Oil BlockOHCU Once Through Hydrocracker UnitCRU Catalytic Reforming UnitSRU Sulphur Recovery UnitARU Amine Recovery UnitSWS Salt Water StripperSDU Solvent Dewaxing UnitLOB Lube Oil BlockPCT Process Cooling TowerTPS Thermal Power StationDM plant Demineralization Plant (Water treatment)
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EXECUTIVE SUMMARY Water is critical, directly or indirectly, in the entire process of evolution, growth and survival of all living beings and it plays a vital role in the industrial development. Water has come to be
its supply can threaten the life, livelihood as well as the functioning of the economy. Conserving water resources in this strategic
maintaining economic growth but also for the human development objectives that aim at alleviation of poverty, unemployment and meeting the Millennium Development Goals (MDGs). IOCL has always been in the forefront of promoting inclusive and sustainable development and reducing water footprint is one of its endeavors towards contributing to environmental cause. This is due to increased reuse of waste water and nearly zeroing discharge. Developing an inventory or water balance is a first step of water audit. The unit has substantially slashed its water usage with current specific water consumption in tune of 0.85 m3/MT in compared to 1.75 m3/MT in 2009-10. The specific water consumption is very much in tune with the national practice of water usage of 1 m3/MT. Some of the critical areas were identified that were resulting to water loss and improvement could further lower the specific water consumption and few are outlined as follows.
1. Measurement is the first step towards resource conservation. It is thus recommended that the monitoring devices which are non functional should be repaired or replaced .
2. Cooling tower is the major water consuming area in the plant. Almost 47% of the water consumed is towards makeup of cooling tower. It was found that the COC is maintained at a level between 1.5 to 2.5, drift eliminator and mist eliminator condition has been damaged in many locations resulting to increased water loss through evaporation. It is highly recommended that the COC be improved in the range of 5 to7 depending upon the economics of scale. An synoptic estimation of possible water saving by increasing the COC is outlined as follows:
Table 1: Synopsis of water loss from cooling tower Sl. No
Name of the Cooling Tower
Current COC
Annual water saving (m3/annum) Improving COC to 5 Improving COC to 7
1 PCT 2.1 565899 637449 2 TPS 2.51 210488 217006 3 DHDS 2.51 564269 678332 5 OHCU 588023 621264 6 GT 13771 174111 Total (million m3) 1.94 2.32
3. Bearing and jacket cooling water being drained. The water as observed has the slightest
or little contamination. However when drained this water is subjected to hydrocarbon contamination and is thereafter being treated in ETP enhancing the cost of treatment and also the stress on treatment plant.
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Sl. No Name of Unit Water quanity (m3/hr)
1 CDU-2 49.41 2 Unit 21, 22 and 23 8.86 3 Unit 39 ( MCW ) 1.01 4 Unit 84 ( CIDW) 5.63 5 Unit 32 ( PDA) 16.61 6 Unit 31 ( VDU-1) 8.01 7 Unit 37 ( VBU) 0.56 8 Unit 33 ( FEU ) 0.04 9 Unit 35 ( HFU) 3.94 10 Old HGU and DHDS (Unit
24 and 25) 8.32
11 VDU-II unit 21.52 12 FCCU 19.03 13 ARU & SWS 0.07
Total water quantity (m3/hr) 143.1
It is recommended that water that is being drained out after bearing cooling or jacket cooling of the utility be collected in existing or newly constructed pit near the unit. The water from this pit is to be directed to a storage tank (within the unit or across the blocks depending upon the availability of space within the units) . The water stored in this storage tank can be pumped again to bearing cooling water piped network of the particular units or to cooling water return line. This can result in substantial water saving.
4. All the water collected from different units with different level of contamination is being drained to a common effluent plant or treatment. This practice actually increases the level of contamination of the less contaminated water.
5. Reducing leaks and over flows: Leakages from overground and underground fire water lines need to be attended.
6. Dedicated periodic operation and maintenance followed by review and monitoring. 7. In DM Plant area leaky valves, taps, coupling/flanges must be fixed immediately. Water
flowing through pH and conductivity sensors may be routed to the raw water tank. A series of other recommended measures are discussed in the subsequent chapters.
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CHAPTER 1: INTRODUCTION 1.1. Background Freshwater is essential to all forms of life and fundamental for human health, for sustainable socio-economic development, and for food security. Even though our planet consists mainly of water but the availability of fresh water is limited. Out of the enormous supply of about 1.36 billion cubic kilometers of water bodies 97% is too salty for human consumption. Of the remaining 3%, most is frozen in polar ice caps or glaciers, or lies hidden away in deep groundwater aquifers which are inaccessible for humans. This leaves human race with a meager 1 % to be shared among not only amongst more than 7 billion people but also with other freshwater and terrestrial organisms. According to a recent estimate by the International Food Policy Research Institute (IFPRI) and Veolia, around 36% of the world's population is already living in water-scarce regions. Looking forward to 2050, around 52% of the world's population, producing 45% of its GDP, is expected to be living in such regions. The water fresh water resources are currently under stress from direct impacts of rapid global changes: population growth, improved living standard, migration, urbanization, climate change, land-use changes and economic development. Once a water abundant country, with per capita water availability of around 4,100 m3 /capita/year (1960) has now turned 'water stressed' with per capita water availability poised at a meagre 1580 m3 /capita/year (2009). Businesses and investors across the world are fast awakening to the reality of water scarcity and its potential to jeopardize economic growth. There is also a growing realization amongst the industrial facilities to conserve water and minimize the use of freshwater through water harvesting, wastewater treatment and reuse. Water audit is the first step and systematic approach towards water conservation as it identifies the key areas of water wastage and recommends measures towards water conservation. 1.2. Objective As a part of the corporate environmental management program and also to upgrade the ongoing water conservation initiatives, the management of Indian Oil Corporation Ltd, initiated a comprehensive water audit program at Haldia Refinery. The objective of water audit is to identify potential and derive opportunities towards reduction of volume and cost of raw water used in the refinery. Subsequently, IOCL, Haldia has appointed M/s TUV SUD South Asia Pvt. Ltd. To undertake the afore mentioned tasks. The objective of water audit is to assess the following.
To establish water balance, To identify losses both physical and non-physical, To identify and priorities areas which need immediate attention in terms of reduction of
water wastage. To raise awareness on monitoring water consumption
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To identify water conservation opportunities To find out simple low cost or no cost measures to conserve water
1.3. Limitation 1. Due to heavy scaling in the supply water network measurement was not possible using
ultrasonic flow meter in most of cases after repetitive endeavor. Secondary/PLC data is being used for analysis wherever data is available.
2. Due to heavy scaling, colour coating undertaking onsite measurement at unit level pertaining to the input and output water flow water balance was not possible.
CHAPTER 2: INVENTORY OF WATER USE The objective of developing a water inventory is to establish a balance between the water withdrawn and water consumed across the process boundary. Water consumption is a subset of total water withdrawn and is the more appropriate measure for resource utilization as this represents water that is removed from the ecosystem and thus made unavailable for future use. Consumption apart from process requirement happens when water evaporates or is contaminated to the point of being unusable. Wastewater discharges of fresh water to aquifers also represent losses of water from an ecosystem because the freshwater is no longer available for use. IOCL, Haldia and its refining process comprises of complex systems of multiple operations where water is being used. The process in a petroleum refinery requires water, however, not each process needs raw or treated water, and water can be cascaded or reused in many places. A large portion of the water used in a petroleum refinery is continually recycled. There are losses to the atmosphere, including steam losses and cooling tower evaporation and drift losses. A smaller amount of water at some point of time also leaves with the products. Understanding water balance for a refinery is a key step towards optimizing water usage, recycle and reuse as well as optimizing performance of water and wastewater treatment systems.
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Typical schematic water flow in and out of the refinery unit is presented as follows:
Figure 1: Schematic diagram of water inventory areas
Rain/Storm Water Steam Loss Cooling Tower Evaporation and Drfit
HFC
PHE Water in Product
Water in Crude
Recycle
Ground Water Waste Water
Refinery ProcessUnits
Loss oling ater
und WWaste Water
Recycle RR
de
WP
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2.1. Water Footprint Statistical assessment of water inventory represented a reduction in specific water consumption across last five years. The specific water consumption has further lowered across the 1st half of2014-2015.
Figure 2: Specific water consumption
Figure 3: Specific water consumption and water re-use
The decrease in specific water consumption can also be attributed to increased water re-use. The quantum of average water re-use has increased from 257m3/hr in 2008-09 to 697 m3/hr across2014-15 (half yearly).
Figure 4: Specific water consumption 2014-15
0.968 0.917 0.851 0.844 0.697 0.702
0
0.5
1
1.5
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14
(m3/
tonn
e)
Specific Water Consumption
Specific Water Cosnumption (m3/tonne)
1.45 1.75 1.37
1.04 1.13 0.95 0.85
0
0.5
1
1.5
2
2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 (Sp-14)
Spec
ific
wat
er
cons
umpt
ion
(m3/
MT)
Specific Water Consumption (m3/tonne)
1.45 1.75
1.37
1.04 1.13 0.95 0.85
26% 27%
45%
62% 49%
75%
93%
0%
20%
40%
60%
80%
100%
0
0.5
1
1.5
2
2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 (Sp-14)
m3/
tonn
e
Water reuse and Specific Water water consumption
Specific Water Cosnumption (m3/tonne)
Percentage of water re-used to fresh water consumption
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2.2. Fresh water withdrawn Water intake in the plant utility is from three major heads
1. From PHE (public health engineering department) supply 2. From HFC tube well and 3. Pumped from in plant tube well
Tube Well Sixteen numbers of tube-wells are located within the plant boundary and used to draw underground water based on requirement. The cumulative water drawn across 1st six month of 2014-15 is presented in the table below. Table 2: Water withdrawal from tube well Amount of Water in m3
April 2014 May 2014 June 2014
July 2014
Aug 2014 Sep 2014 Average
Cumulative 119651 96101 80856 88714 104276 109892 99915 Hourly 166 133 108 119 140 152 136 Figure 5: Average water withdrawn from tube well on monthly basis
Figure 6: Average water withdrawn from tube-well on hourly basis
119651
96101 80856
88714 104276 109892
99915
0
20000
40000
60000
80000
100000
120000
140000
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-04 Average
wat
er w
ithd
raw
in
m3/
mon
th
Average water withdrawn from tubewell
166
133 108
119 140
152 136
0
50
100
150
200
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-04 Average
Wat
er w
ithd
raw
n in
m
3/hr
Water withdrawn from tubewell
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Measurement and Verification The water withdrawn through tube well is monitored using ultrasonic flow meter. The flow rate data measured is cross verified with the PLC data recorded in house using online flow meter depicting a close resemblance with the data recorded by online flow meter.
From PHE Raw water is procured from public health engineering department/JUSCO is the major source of raw water obtained by the refinery. The water intake across for last six months as follows: Table 3: Water withdrawn/ sourced from PHE Amount of Water in m3
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-04 Average
Cumulative 525674 473296 441980 384850 265740 273854 394232 Hourly 730 657 594 517 357 380 539 Figure 7: Average water sourced from PHE on monthly basis
Figure 8: Average water sourced from PHE on hourly basis
525674
473296 441980
384850
265740 273854
394232
0
100000
200000
300000
400000
500000
600000
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-04 Average
Wat
er w
ithd
raw
n m
3/m
onth
Water sourced PHE
730 657
594 517
357 380
539
0
200
400
600
800
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-04 Average
wat
er s
ourc
ed in
m3/
hr Water sourced from PHE on hourly basis in m3
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HFC tube well Raw water is also sourced from the HFC tube well depending upon demand. The water sourced through HFC tube well is as follows: Table 4: Water sourced through HFC tube well Amount of Water in m3
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-04 Average
Cumulative 64623 61957 62013 71614 66983 50524 62952 Hourly 90 86 83 96 90 70 86 Figure 9: Total water sourced from HFC tube well on monthly basis
Figure 10 : Average water sourced from HFC tube well on monthly basis
64623 61957 62013
71614 66983
50524
62952
0
10000
20000
30000
40000
50000
60000
70000
80000
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-04 Average
Wat
er w
ithd
raw
n in
m3/
mon
th
Water Withdrawn from HFC tube well
90 86 83
96 90
70
86
0
20
40
60
80
100
120
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-04 Average
Wat
er w
ithd
raw
n m
3/hr
Water withdrawn from HFC tubewell
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Total raw water withdrawn Total water withdrawn from three sources is cumulated and presented below. The total raw water withdrawn is as follows: Table 5: Total raw water withdrawn Amount of Water in m3
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14 Average
Cumulative 709948 631354 584849 545178 436999 434270 557100 Hourly 986 877 786 733 587 603 762
Figure 11: Total raw water withdrawn per month (cumulative for three source)
Figure 12: Average hourly water withdrawn from three sources
709948
631354 584849
545178
436999 434270
557100
0
100000
200000
300000
400000
500000
600000
700000
800000
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-04 Average
wat
er w
ithd
raw
n m
3/m
onth
Total water withdrawn m3/month
986 877
786 733
587 603
762
0
200
400
600
800
1000
1200
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-04 Average
Wat
er w
ithd
raw
n m
3/ho
ur Average water withdrawn m3 /hour
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Analysis and synthesis Data information presented in the section above resembles that maximum water is sourced from PHE followed by in-house tube well and HFC tube well. Based on the average hourly water withdrawn the share of different source from which raw water is being withdrawn presented as follows:
Figure 13:Source wise water withdrawn
2.3. Water Consumption Water use across the refinery can be categorized both under consumptive and non-consumptive usage pattern. Consumptive use refers to water that is drained/discharged to the atmosphere or that is incorporated in the products/process. Evaporation and windage losses in a cooling tower and the discharge of process steam into the atmosphere are few cases of consumptive use across the refinery. The discharge of once-through cooling water, cooling-tower blow down, and discharge to waste of the condensate from a steam trap and effluents are non-consumptive uses. The sum of consumptive uses and effluents equals the water requirement.
Tube well 18%
PHE/JUSCO 71%
HFC well 11%
Source wise water withdrawn
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Figure 14: Water consumption
As per the technical information provided by the plant the typical consumption of water in the refinery is around 36,000 m3/day. Utility units like cooling tower, DM plant consumes the major share of water followed by drinking/ domestic water, service water, fire fighting water make up and process units. The water consumptions and its share in the total consumption are presented below.
Table 6: Segregation of water consumption Unit Water Consumption (m3/day)
Cooling tower make up 16800
DM water production 10800
Drinking / domestic 1920
Service water 1200
Fire fighting water make 3840
Process unit 1440
The graphical clearly evident that utilities like cooling tower and DM plant are the major water consumers. Both of these utilities consume 77% of the total in-house water requirement of the refinery. The process unit to that extent only shares 4% of the total water being consumed. Raw water Consumption Raw water consumption can broadly be categorized under the following heads:
1. Cooling tower makeup 2. Service Water 3. DMF make up 4. Fire tank make up 5. Drinking water
Cooling tower make up
47%
DM plant 30%
Drinking / domestic 5%
Service water 3%
Fire fighting water make up
11%
Process unit 4%
WATER CONSUMPTION
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6. DM plant input7. TPS RO raw water consumption8. PHE makeup to DMP
Raw water consumed across the last two quarter is tabulated below and compared with the total water consumed: Table 7: Raw and total water consumed Amount of Water in m3
Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14 Average
Total raw water intake Cumulative 709948 631354 584849 545178 436999 434270 557100Hourly 986 877 786 733 587 603 762
Water Reuse Hourly 691 668 621 699 772 778 704
Analysis Out of 762 m3 of raw water intake the amount of water reused is 704 m3 (> 92%) on an average.
2.4. Effluent generation and reuse Refinery consumes large volume of water with a significant amount being consumed for cooling. Refineries generate a significant amount of wastewater with and without hydrocarbon contamination. The process waste water originates from the process like fractionation, cracking, reforming, polymerization and alkalizations. Wastewater also include water rejected from boiler feed-water pre-treatment processes (or generated during regenerations), cooling tower blow-down, or that leaves the refinery. The major pollutant in the waste water includes oils and chemicals (acids, alkalies, sulphides and phenolics). Contaminated wastewater is typically sent to ETP unit that is located at the facility. Cooling tower blow down water and wastewater from raw water treating receives treatment at the wastewater treatment plant (WWTP) before discharge. Water that has not been in direct contact with hydrocarbons for example, water used for bearing cooling, condensate drain which has only minimal contamination can be a source for reuse and is discussed in the water conservation section.
Process Waste Water Water that is generated in the process units is represented by the following categories:
De-salter effluent;Sour water;Tank bottom draws; andSpent caustic.
De-salter effluent Inorganic salts are present in crude oil as an emulsified solution of salt (predominantly sodium chloride). The source of the aqueous phase is the naturally occurring brine that is associated with
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the oil field from where the crude is extracted. The amount of water received at the refinery with the crude varies widely but an approximate range would be 0.1 2.0% volume. The salts contained in the aqueous phase are variable and range from 10 to 250 pounds per thousand barrels (p.t.b.) of crude. The salts are present mostly in the form of chlorides of sodium, magnesium and calcium. Typically, the first operation in a refinery crude unit is desalting, which is used to wash out the salt present in the crude. The most important reasons for removing the salts from the crude are to: Prevent plugging and fouling of process equipment by salt deposition; and Reduce corrosion caused by the formation of HCl from the chloride salts during the
processing of the crude. Sour Water Steam is used in many processes in refineries as a stripping medium in distillation and as a diluent to reduce the hydrocarbon partial pressure in catalytic cracking and other applications. The steam is condensed as an aqueous phase and is removed as sour water. Since this steam condenses in the presence of hydrocarbons, which contain hydrogen sulphide (H2S) and ammonia (NH3), these compounds are absorbed into the water at levels that typically require treatment. The typical treatment for sour water is to send it to a stripper for removal of H2S and NH3. Steam is used to inject heat into the strippers. High performance strippers are able to achieve < 1 ppm H2S and < 30 ppm NH3 in the stripped sour water. With these levels, the stripped sour water is an ideal candidate for recycle/reuse in the refinery.
Tank Bottom Draw: The incoming crude to refineries normally contains water and sediments (mud) that are picked up when the oil is extracted from the wells this is referred to as bottom sediment and water (BS&W). When the crude is stored in large tanks, the BS&W settles to the bottom and must be periodically removed to prevent a buildup of this material which would otherwise result in a loss of storage capacity. Water draws are normally sent to either the wastewater treatment or to a separate tank where the solids are separated from the oil and water.
Effluent Collection The liquid waste water generated from different units/area in the refinery is segregated into three basics streams. 1. Oily sewer: This system comprising of underground piping network collects the oily water
and delivers it to effluent treatment plant. 2. Storm water sewer: Open channel network 3. Domestic sewerage Effluent Treatment The waste water obtained from across the plant facility is treated in two number of effluent Treatment Plants. The effluent treatment plant broadly comprises of 1. Effluent Tank 2. API (for old ETP) and TPI (new ETP)
WATER AUDIT AT HALDIA REFINERY
REPORT VERSION: 4, April 2015
Page
20
Table 8: ETP capacities ETP Designed Capacities Old ETP Peak flow of 840m3/hr for 4 hrs and 540m3/hr for 24 hrs Enhanced Capacity with new ETP 790m3/hr in dry weather and 1100 m3/hr in wet weather 3. Equalisation Tank 4. Bio Tower and Bio tower feed swamp 5. Aeration Tank 6. Clarifier Working Principle The old ETP works on the method of chemical coagulation, flocculation and sedimentation along with oxidation of both organic and inorganic by chlorine. The physical and chemical treatment is followed by biological treatment under aerobic conditions.
Capacity Utilization Table 9: Effluent Treatment (Based on September 2014 data during audit) Effluent Treatment Plant Throughput (m3/hr) Reuse (m3/hr) % Reuse OLD ETP 434 255 58.80 New ETP 529 454 85.85 Total 963 709 73.7
WATER AUDIT AT HALDIA REFINERY
REPORT VERSION: 4, April 2015
Page
21
Water Inventory The plant water inventory is presented as follows1:
18%
3%
13%
26%
7%
5%
6%
7%
1%
5%
4%
1%
3%PHE/HFC/TW water losses
Drinking water
RO-3 Permeate
PHE/HFC/TW water for service water
PHE/HFC/TW water to HRSCC
Cooling tower makeup GTCT
PHE/HFC/TW -fire water
DM Plant input
Cooling tower makeup TPSCT
Cooling tower makeup PCT
Cooling tower makeup DHDSCT
Cooling tower makeup OHCUCT
Input for TPS RORefinery
PHE/JUSCO
HFC
Tubewell
ETP-Old
ETP-New
Page22
2.5.
Pla
nt W
ater
Bal
ance
Dia
gram
112
Loss
22
53
Loss
25CT
1511
0CT
3953
189
Reje
ct25
LOSS
132
27
225
12
RO1.
12.
11.
1.1
306
2.1.
116
52.
1.1
530
695
642
2.2
1.2
2.2.
153
1.2.
147
92.
2.2
225
1.2.
253
2.2.
316
41.
2.3
110
2.2.
49
642
2.3
Tota
l 45
1.26
9915
2.4
Loss
243
2.5
Tota
l 69
4
RO to
CT
RO to
DM
RO to
MBF
RO
for
Inta
ke to
RO
ETP
old
ETP
new
Tota
l Int
ake
Cons
umpt
ion
HRS
CC I/
L in
m3/
hr71
8
RO-1
+RO
3
RO fe
ed ta
nk in
m3/
hr
Clar
ifie
r O/L
in m
3/hr
9164
MBF
tank
m3/
hr
Back
was
h RO
fe
ed ta
nk
45
14Ef
flue
nt G
ener
atio
n in
m3/
hr98
9
336
Fire
Wat
er in
m3/
hr11
4
PDA
Scr
b in
m3/
hr31
Loss
from
ove
r flo
w a
nd d
rain
in
m3/
hr
RO ETP
Tota
l Los
s CT
434
ETP
Old
TW
P in
m3/
hrET
P ne
w i
n m
3/hr
530
RO to
CT
RO U
NIT
Evap
orat
ion
Loss
1.
1.2
Tota
l Los
s CT
Mak
e U
p Ra
w W
ater
Cool
ing
Tow
er
Blow
Dow
n
RO -3
pro
cess
tank
in
m3/
hr
RO fl
ashi
ng in
m
3/hr
RO -2
pro
cess
in
m3/
hr
104
Rive
r /op
en d
rain
in
m3/
hr89
Tota
l Los
s
RO -1
pro
cess
in m
3/hr
541
RO -1
per
mat
e ta
nk in
m
3/hr
462
306
75
Serv
ice/
Dri
nkin
g in
m3/
hr
DM
F fe
ed ta
nk in
m3/
hr
BELC
O in
m3/
hr
25 40 95
Bear
ing
Cool
ing
wat
er i
n m
3/hr
208
ETP
in m
3/hr
200
PDA
in m
3/hr
TTP
in m
3/hr
CT B
W in
m3/
hr
35 0
Des
alte
r in
m3/
hr
5Ta
nks
in m
3/hr
R E F I N E R Y P R O C E S S
Fire
wat
er in
m3/
hr
Raw
wat
er to
fire
tank
in
m3/
hr0
TPS
RO ra
w w
ater
co
nsum
ptio
n in
m3/
hr36
PHE
mak
eup
to D
MP
in m
3/hr
0141
Ser
vice
wat
er+
HRS
CC+D
MFm
ake
up+
Fire
ta
nk(A
)in
m3/
hr
DM
pla
nt in
put(
Raw
wat
er) i
n m
3/hr
252
Tota
l Fre
sh
Wat
er/R
aw W
ater
in
take
from
PH
E/JU
SCO
, HFC
w
ell a
nd T
ube
wel
l A
vera
ge W
ater
inta
ke in
m3 /h
r (A
vera
ge :
Apr
il 20
14- S
ep 2
014)
762
Cool
ing
Tow
er (P
CT, D
HD
S,
TPS,
OH
CU. G
T) in
m3/
hr47
9
79D
rink
ing
Wat
er i
n m
3/hr
WA
TER
AU
DIT
AT
HA
LDIA
REF
INER
Y
RE
POR
T V
ER
SIO
N: 4
,Apr
il 20
15
Page23
The
wat
er b
alan
ce o
f the
pla
nt is
pre
pare
d ba
sed
on th
e da
ta in
form
atio
n ov
er th
e to
tal a
mou
nt o
f wat
er in
put (
raw
and
trea
ted
wat
er)
efflu
ent g
ener
ated
and
trea
ted.
The
wat
er in
take
and
con
sum
ptio
n fr
om v
ario
us so
urce
for t
he m
onth
of A
pril
and
Sept
embe
r 201
4 an
d th
e ef
fluen
t bal
ance
for t
he m
onth
of S
ep 2
014w
as u
sed
to d
evel
op th
e w
ater
bal
ance
of t
he p
lant
. The
wat
er in
take
and
con
sum
ed a
re
outli
ned
belo
w:
Para
met
er
Apr
il-14
May
-14
June
-14
July
-14
Aug
ust-1
4Se
ptem
ber-1
4A
vera
ge
M3 /h
rR
aw w
ater
Gen
erat
ion:
H D
A (P
HE/
JUSC
O)
730
657
594
517
357
380
539
HFC
90
8683
9690
7086
Tube
wel
ls16
613
310
911
914
015
313
7T
otal
Raw
Wat
er R
ecei
pt:
986
877
786
733
587
603
762
Perm
eate
in ta
nk4
1-1
.31
0.1
-0.0
51
Rec
ycle
d E
TP
wat
er S
tatu
s:R
O-1
per
mea
te fr
om E
TP to
CT'
s0
21
2791
110
39R
O-1
per
mea
te t
o D
MP
RW
T16
521
626
624
622
722
722
5R
O-3
INPU
T 10
410
386
107
104
9410
0R
O-0
1 pe
rmea
te fo
r RO
flus
hing
911
98
99
9T
OT
AL
RO
-1 W
AT
ER
OU
TPU
T27
833
236
338
843
244
037
2
RO
wat
er C
onsu
mpt
ion:
DM
pla
nt in
put(t
hrou
gh E
TP R
O)
165
214
264
246
227
227
224
TPS
RO
per
mea
te57
358
20
117
Coo
ling
tow
er m
ake
up (t
hrou
gh T
TP R
O)
02
127
9111
039
ETP
RO
3 IN
PUT
TO M
B-0
6/07
//DM
RA
W T
AN
K95
9281
104
9990
94T
otal
RO
wat
er c
onsu
mpt
ion
317
343
354
380
418
428
373
Coo
ling
tow
er m
ake
up( D
HD
SCT)
380
382
367
372
319
300
353
Coo
ling
tow
er m
ake
up( O
HC
UC
T)67
6862
6268
7166
Ro-
02 to
OH
CU
CT/
DH
DS
CT
1413
1319
1414
15
WA
TER
AU
DIT
AT
HA
LDIA
REF
INER
Y
RE
POR
T V
ER
SIO
N: 4
, Apr
il 20
15
Page24
Para
met
er
Apr
il-14
M
ay-1
4 Ju
ne-1
4 Ju
ly-1
4 A
ugus
t-14
Sept
embe
r-14
Ave
rage
M
3 /hr
Coo
ling
Tow
er m
ake
up (P
CT)
70
21
7
6 6
15
21
Coo
ling
Tow
er M
ake
up( T
PS C
T)
40
35
25
33
34
40
34
Serv
ice
wat
er+
HR
SCC
+DM
Fmak
e up
+ Fi
re ta
nk(A
) 16
5 13
6 20
7 16
2 84
90
14
1 D
rinki
ng w
ater
81
80
77
79
79
78
79
D
M p
lant
inpu
t(Raw
wat
er)
83
47
23
10
1 0
27
Raw
wat
er to
Fire
Tan
k 0
0 0
0 0
0 0
TPS
RO
raw
wat
er c
onsu
mpt
ion
119
74
16
7 0
1 36
PH
E m
akeu
p to
DM
P 0
0 0
0 0
0 0
Tot
al R
aw w
ater
con
sum
ptio
n 10
04
842
785
732
590
594
758
TO
TA
L C
ON
SUM
PTIO
N
1264
11
51
1130
11
09
1008
10
22
1114
T
PS R
O p
lant
per
mea
te
57
35
8 4
0 0.
6 17
R
w fl
ow
119
75
17
7 0
1.1
36
Rec
over
y 48
%
47%
47
%
52%
0%
54
%
48%
T
TP
RO
PL
AN
T O
UT
PUT
DE
TA
ILS:
HR
SSC
I/L
flow
=ET
P+R
aw W
ater
57
8 62
9 58
3 60
5 67
7 71
8 63
2 U
F flo
w
463
499
479
487
543
585
510
RO
-1+R
O-2
per
mea
te
287
335
366
400
437
445
378
RO
-3 IN
PUT
from
ETP
to D
M p
lant
/Raw
tank
95
92
81
10
4 99
90
94
R
O-1
per
mea
te to
DM
P 16
5 21
4 26
4 24
6 22
7 22
7 22
4 R
ecov
ery
62%
67
%
76%
82
%
80%
76
%
74%
Page
25
CHAPTER 3: Water utilization 3.1. Cooling Tower Cooling tower is most important utility in the refinery that functions as an inexpensive and dependable means of removing low grade heat from water. The purpose of cooling system is to remove undesirable heat so that optimum temperature and pressure is maintained. Hot water from heat exchanger and process is sent to the cooling tower which after heat exchange ( in multi cell cooling tower) is sent back again to the heat exchangers or other units. Cooling water circulates in a closed circuit. The mechanical draft cooling tower uses large fans to force or suck air through circulated water. The water falls downward over fill surface which helps to increase the contact time and thereby maximizes heat transfer between two. In addition, formation of droplets increases the contact surface of the falling water, which in turn helps in releasing the heat contained in water. The water lost in the process of cooling due to evaporation is replenished through makeup water. The IOCL has the following cooling tower with the following specification.
Table 10: Cooling Tower specification Cooling Tower Recirculation Rate (m3/hr) System Hold Up Max. Blow Down Rate
Specification Operational (m3) PCT 18000 14500 4000 110 M3/Hr
DHDS 21000 17500 4000 350 - 400 M3/Hr TPS 5400 5000 1100 60 - 80 M3/Hr
OHCU 8500 8500 1700 75 M3/Hr GT 1000 1000 254 7 M3/Hr
The major water losses in a cooling tower are 1. Blow-down: Blow-down is facilitated to controls the buildup of dissolved solids by replacing
the more highly concentrated system water with an equal volume of fresh, less concentrated make up water. Blow down is a function of cycle of concentration (COC). COC is the ratio of the solids level of circulating water to that of makeup water. Solids level in makeup water gets concentrated in circulating water due to evaporation. Since only the water can evaporate and dissolved solid remains in the liquid phase, the evaporation process causes an increase in the concentration of dissolved solids in the re-circulating cooling water.
2. Evaporation: Loss of water by conversion into vapour form through cooling tower during cooling process
3. Drift loss: A small portion of cooling water lost through cooling tower apart from blow-down.
Estimation of theoretical water requirement Evaporation rate: Re-circulating rate × Delta T/ 560 Blow down + Windage: Evaporation rate / (COC-1)
WATER AUDIT AT HALDIA REFINERY
REPORT VERSION: 4, April 2015
Page
26
Make up water rate: Evaporation +Blow down +Windage +Leakage Un-accounted loss: Actual makeup water - Theoretical make up water Estimation of water saving through increased COC 1. Process Cooling Tower Process cooling tower is a cross flow induced draft cooling tower comprising of 9 cells. The cooling tower comprises of PVC splash fills and wooden tower frame material. The cooling tower is designed for recirculation rate of 18000m3/hr with designed delta T of 100C and system hold up capacity of 4000 m3. However the cooling tower is currently operating at recirculation rate of 14500 m3/hr , 4 0C delta T and COC of 2.1. Approx. 180-200 m3/hr of raw water is required to make-up the losses due to evaporation, drift and system leakage in PCT.
Table 11: Estimation of water saving through increased COC in PCT cooling tower System Parameters Actual Unit Proposed
COC -5 Proposed COC -7
Recirculation Rate : 14500 m3/hr 14500 14500 Average COC : 2.1 5 7 Delta T Across CT : (conservative as against 10 0C designed)
4 Deg. C
4 4
Evaporation from CT : 98 m3/hr 98 98 Blow Down Loss 89 m3/hr 25 16 Total makeup 187 m3/hr 123 114 Reduction in make up m3/hr 65 73 Annual water saving m3 565899 637449
2. TPS Cooling tower TPS is a counter flow induced draft cooling tower comprising of 3 cells. The cooling tower comprises of PVC filming fills and wooden tower frame material. The cooling tower is designed for recirculation rate of 5400m3/hr with designed delta T of 120C and system hold up capacity of 1100 m3. However the cooling tower is currently operating at recirculation rate of 5000 m3/hr , 1 0C delta T and COC of 1.34.
WATER AUDIT AT HALDIA REFINERY
REPORT VERSION: 4, April 2015
Page
27
Approx. 35-40 m3/hr of raw water is required to make-up the losses due to evaporation, drift and system leakage in TPS.
Table 12: Estimation of water saving through increased COC in TPS cooling tower System Parameters Actual Unit Proposed
COC -5 Proposed COC -7
Recirculation Rate : 5000 m3/hr 5000 5000 Average COC : 1.34 5 7 Delta T Across CT : 1 °C 1 1 Evaporation from CT : 9 m3/hr 9 9
Blow Down 26 m3/hr 2 1 Drift loss 35 m3/hr 11 10 Total loss 5000 m3/hr 24 25 Reduction in make up m3/hr 210488 Annual water saving m3 5000 3. DHDS Cooling Tower
DHDS is a counter flow induced draft cooling tower comprising of 7 cells. The cooling tower comprises of PVC packed fills and RCC tower frame material. The cooling tower is designed for recirculation rate of 21000m3/hr with designed delta T of 120C. However the cooling tower is currently operating at recirculation rate of 17500 m3/hr , 5 0C delta T and COC of 2.51. Approx. 275-300 m3/hr of raw water is required to make-up the losses due to evaporation, drift and system leakage in DHDS CT.
Table 13: Estimation of water saving through increased COC in DHDS cooling tower System Parameters Actual Unit Proposed
COC -5 Proposed COC -7
Recirculation Rate : 17500 m3/hr 17500 17500 Average COC : 2.51 5 7 Delta T Across CT : 5 °C 5 5 Evaporation from CT : 156 m3/hr 156 156 Blow Down 103 m3/hr 39 26 Total loss 260 m3/hr 195 182 Reduction in make up m3/hr 64 77 Annual water saving m3 564269 678332
CASE PRESENTATION: CII Excellence in Water Management 2008 UNIT: Reliance Industries Limited, Dahej Manufacturing Division. The unit has increased its cooling tower cycle of concentration from 5 to 7.5. The unit achieved an annual saving of 130km3 of raw water resulting in monetary saving of 10.5 lakhs.
WATER AUDIT AT HALDIA REFINERY
REPORT VERSION: 4, April 2015
Page
28
4. OHCU Cooling Tower DHDS is a counter flow induced draft cooling tower. The cooling tower is designed for recirculation rate of 8500m3/hr with designed delta T of 50C. However the cooling tower is currently operating at recirculation rate of 8500 m3/hr, 3 0C delta T and COC of 1.58. Approx. 110-120 m3/hr of raw water is required to make-up the losses due to evaporation, drift and system leakage in OHCU CT.
Table 14: Estimation of water saving through increased COC in OHCU cooling tower System Parameters Actual Unit Proposed
COC -5 Proposed COC -7
Recirculation Rate : 8500 m3/hr 8500 8500 Average COC : 1.58 5 7 Delta T Across CT : 3 °C 3 3 Evaporation from CT : 46 m3/hr 46 46 Blow Down 79 m3/hr 11 8 Total loss 124 m3/hr 57 53 Reduction in make up m3/hr 67 71 Annual water saving m3 588023 621264 5. GT Cooling Tower
GT is a counter flow induced draft cooling tower. The cooling tower is designed for recirculation rate of 1000 m3/hr with designed delta T of 120C. However the cooling tower is currently operating at recirculation rate of 1000 m3/hr, 110C delta T and COC of 4.03. Approx. 20-30 m3/hr of raw water is required to make-up the losses due to evaporation, drift and system leakage in GT CT.
Table 15: Estimation of water saving through increased COC in GT cooling tower System Parameters Actual Unit Proposed
COC -5 Proposed COC -7
Recirculation Rate : 1000 m3/hr 1000 1000 Average COC : 4.03 5 7 Delta T Across CT : 11 °C 11 3 Evaporation from CT : 20 m3/hr 20 5 Blow Down 6 m3/hr 5 1 Total loss 26 m3/hr 25 6 Reduction in make up m3/hr 2 20 Annual water saving m3 13771 174111
WATER AUDIT AT HALDIA REFINERY
REPORT VERSION: 4, April 2015
Page
29
3.2. RO Unit The reclamation unit incorporates high rate clarification, filtration, ultrafiltration (UF) and reverse osmosis (RO) phases.
ETP Unit HRSC
DMF Feed Tank
DMF
Basket Stainer
Ultra Filter
RO Feed Tank
RO 1 MCF
RO 1 Process
RO 1 Permate
Tank
RO 2 Process Reject
Reject
River/ETP
Output
OHCU CT Makeup
CT raw water makeup
RO 3 Process/
Tank
Reject
DM Plant (Cation)
PHE Water
WATER AUDIT AT HALDIA REFINERY
REPORT VERSION: 4, April 2015
Page
30
The RO permeate obtained is used as boiler make-up water. The water balance of the RO section is presented below:
Following practices are recommended for membrane exchange A.) Low permeability necessitating a higher CEB frequency, higher energy consumption and lower plant availability. The permeability value has a basic tendency to fluctuate, which is due mainly to variable secondary effluent quality from upstream ETPs. Therefore, the maximum achievable permeability (average of the three highest daily values in the subsequent operational period - accomplished after regular or additional CEB;) may be used as a parameter for performance evaluation. B.) Trance Membrane Pressure should not exceed from designed parameter in order to avoid both intensified fouling and mechanical stress. C.) Membrane integrity - number of fiber breakages should not be too high in order to avoid Turbidity and an increased SDI. Nevertheless, the membrane elements with fiber breakages should be exchanged (or repaired) in order to maintain proper turbidity and SDI values, and subsequently to minimize the fouling potential of the RO membranes.
112
Loss 22
53
2 ROLoss 25 2.1
2.1.1 1652.1.1 530
6952.2
2.2.1 53CT 15 2.2.2 225
2.2.3 164CT 39 2.2.4 9
189 2.3 Total 451.2699152.4 Loss 2432.5 Total 695
Reject 25225
132LOSS
RO-1+RO3
RO to MBF RO for
RO to CTRO to DM
ETP newTotal IntakeConsumptio
Intake to ROETP old
9
DMF feed tank in m3/hr
RO flashing in m3/hr
RO feed tank in m3/hr
RO -1 process in m3/hr
River /open drain in MBF tank m3/hr
164 541 89
RO -1 permate tank in m3/hr
104
462RO -3 process tank
in m3/hr
434 530
RO -2 process in m3/hr
Effluent Generation in m3/hr 989
Clarifier O/L in m3/hr HRSCC I/L in m3/hr718
ETP Old TWP in m3/hr ETP new in m3/hr Backwash RO feed tank
45
WATER AUDIT AT HALDIA REFINERY
REPORT VERSION: 4, April 2015
Page
31
3.3. Process 3.3.1. Fuel oil block Process Description Fuel Oil block comprises of Crude Distillation Units (CDU I and CDU II), Catalytic Reforming Unit (CRU) and Kerosene Hydrodesulphurisation Unit (KHDS). CDU-I &II Water Use Scenario Water is majorly used mainly for the purpose of gland cooling and steam generation. Relatively small quantum of water is used, cleaning / product washing (service water), drinking and fire protection. Steam is used across these units for the purpose of heating and pumping (maintaining temperature and flow of hot streams). Crude oil received from crude storage tanks is heated to around 125 130°C by recovering process heat from the various hot streams in a series of heat exchangers. The temperature of crude is thereafter increased by heating it with medium pressure steam heater. Catalytic Reforming Unit (CRU) Water Use Scenario Water is majorly used across this unit for the purpose of gland cooling, cleaning (service water), drinking and firefighting. Steam is used across this unit for the purpose of heating and also maintaining temperature and flow of hot streams. Case Specific: 1. The reactor effluent after exchanging heat with the feed and subsequent cooling in water cooler is
sent to a High Pressure Separator Vessel. 2. The bottom stream from the stabiliser column, known as reformate, is cooled by exchanging heat
with the Cold feed and then with cooling water before routing to the MS Pool. Kerosene Hydro-desulphurization Unit (KHDS) Water Use Scenario Water is majorly used across this unit for the purpose of gland cooling, cleaning (service water), drinking and firefighting. Steam is used across these units for the purpose of heating and also maintaining temperature and flow of hot streams. Case Specific: 1. The reactor effluent is cooled in the feed preheat exchangers and water cooler and sent to a High
Separator Vessel 2. The stripper bottom (hydrotreated kero cut) is cooled in the feed/bottom exchangers and then in
water cooler and routed to respective storage tanks of Kerosene, ATF/RTF and MTO.
WATER AUDIT AT HALDIA REFINERY
REPORT VERSION: 4, April 2015
Page
32
Water supply Scenario Water required for the purpose of cooling is being supplied to units (CDU-I, CRU and KHDS) from DHDS and OHCU cooling tower. Recovered condensate is also being supplied for specific requirement. Water from OHCU cooling tower is supplied to CDU- 2 and from DHDS cooling tower to CDU-1 , CRU and KHDS. Water from cooling tower is supplied via main header to the units which is then subdivided to the respective locations depending upon the usage through sub headers.
Figure 155: Water supply network across FOB unit
CDU-1DHDS CT
CDU-2
OHCU CT CRU
KHDS
ETP
WATER AUDIT AT HALDIA REFINERY
REPORT VERSION: 4, April 2015
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33
Critical Observation 1. As indicated above a considerable amount of water
is being used for the purpose of bearing cooling. Pumps carrying hot and viscous fluid conduct some heat to its bearing. In-order to prevent bearing from damage this bearing is being cooled either by using water jacket or by injecting water (cooling water) on the bearing. The hot water is thereafter being drained to closed loop network which is being reused. The water used for the purpose of bearing cooling of the pumps are treated water and are least contaminated and can be reused. The water used for bearing quantified across the units are as follows:
FFigure 16: pump draining water to
drain in FOB Table 16: Water used in bearing cooling in CDU-2
Sl. No.
Pump/ Other device
Loss Sl. No.
Pump/ Other device
Loss ml/sec m3/hr ml/sec m3/hr
1 16PM26A 280.00 1.01 14 16PM109A 600.00 2.16 2 16PM26B 290.00 1.04 15 16PM109B 750.00 2.70 3 16PM26C 250.00 0.90 16 16PM02B 333.33 1.20 4 16PM03B 200.00 0.72 17 16PM02A 250.00 0.90 5 16PM107A 142.86 0.51 18 16PM01B 500.00 1.80 6 16PM08A 62.50 0.23 19 16PM107B 142.86 0.51 7 16PM10A 400.00 1.44 20 16PM106A 1000.00 3.60 8 16PM10B 333.33 1.20 21 16PM106B 1000.00 3.60 9 16PM110A 333.33 1.20 22 FIRE WATER 11.11 0.04
10 16PM104A 833.33 3.00 23 16PM26A 1566.67 5.64 11 16PM104B 250.00 0.90 24 16PM26B 1566.67 5.64 12 16PM105B 428.57 1.54 25 16PM26C 1566.67 5.64 13 16PM09A 600.00 2.16 26 Cooling Water
Back Lushing Line
33.33 0.12
Total quantity 49.41
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Table 17: Water used in bearing cooling in CDU-I
Sl. No.
Pump/ Other device
Loss Sl. No.
Pump/ Other device
Loss ml/sec m3/hr ml/sec m3/hr
1 11B112 & 11B113
125.00 0.45 13 11PM-10, HSDCR pump
140.00 0.50
2 11PM115A, VB to IP
125.00 0.45 14 11PM04, Kerosine pump
60.00 0.22
3 Heat exchanger 11E23A
500.00 1.80 15 11PM-05B HSD/Kero
165.00 0.59
4 11E11A,T-HSD CRS-Stabiliser bottom
1000.00 3.60 16 11PM-05A, HSD/Kero
125.00 0.45
5 S/S-16/DO22/21, 11-PM-102B
165.00 0.59 17 11PM-05C, HSD/Kero
45.00 0.16
6 11PM-102C, S/S-16/DO33/36
340.00 1.22 18 11PM06A, JBO pump
250.00 0.90
7 11PM-102A, crude oil pump
110.00 0.40 19 11PM06B, JBO pump
165.00 0.59
8 11PM-01, crude oil pump
165.00 0.59 20 11PM07A, RCO pump
165.00 0.59
9 11PM08A 200.00 0.72 21 11PM07B, RCO pump
230.00 0.83
10 11PM-08B 200.00 0.72 22 11PM07C, RCO pump
390.00 1.40
11 11PM109A, Hydrocarbon
500.00 1.80 23 11PM-01 100.00 0.36
12 11PM109B, Kero CR pump
500.00 1.80
Total quantity 20.75 Table 18: Water used in bearing cooling in Unit 21, 22 and 23
Sl. No.
Pump/ Other device
Loss Sl. No.
Pump/ Other device
Loss ml/sec m3/hr ml/sec m3/hr
Unit 21 Unit 23 1 21PM01C, LUBE
oil, S/S-68 (I/B+O/B)
250.00 0.90 9 23PM03A (closed)
200.00 0.72
2 21PM01C Feed pump-S/S-2/PC 23/22F
350.00 1.26 10 23PM03B (working)
60.00 0.22
3 21PM01D Feed pump
290.00 1.04
4 21PM-02A Reboiler pump
250.00 0.90
5 21PM-02B Reboiler pump
330.00 1.19
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Sl. No.
Pump/ Other device
Loss Sl. No.
Pump/ Other device
Loss ml/sec m3/hr ml/sec m3/hr
Unit 22 6 JB22PM04B
(Lube oil reserver) 230.00 0.83
7 22PM-202A, Feed pump
250.00 0.90
8 22PM-202B, Feed pump
250.00 0.90
Total quantity 8.86 Table 19: Estimation of Bearing Cooling water in FOB Sl. No Name of the Unit Total Loss (m3/hr) 1 CDU - 2 49.41 2 Unit 21,22 and 23 8.86 Total 58.27 The above converts to financial loss of INR 0.83 crore : Table 20: Total financial saving Sl. No Name of the Unit Total Loss (m3/hr) Total financial saving (INR in Crore/year)
1 CDU - 2 49.41 0.52 2 Unit 21, 22 and 23 8.86 0.09
Total 58.27 0.61 2. Steam loss: Steam is used for process heating, facilitation of pumping operation and
generating power. The recovered condensate across steam traps are purest form of water and should be reutilized. We have observed that in most cases the condensate recovery system is non functional and as such most of the condensates at the outlet of the steam trap is being drained out without being recirculated through condensate recovery piping network. Proper monitoring of the steam system in the refinery will help minimize the production of excess steam and minimize/ eliminate the need for venting. Moreover insulation leakage and leakage across the steam piping network results in loss of steam to the atmosphere.
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3.3.2. Lube oil block comprises of the following units: Vacuum Distillation Unit (VDU) Propane De-asphalting Unit (PDA) Furfural Extraction Unit Solvent Dewaxing Unit SDU Hydro finishing Unit Visbreaker Unit Lube Catalytic Iso Dewaxing Unit Water Use Scenario Water is majorly used across these units for the purpose of cooling, cleaning (service water), drinking and firefighting. Steam is used across these units for the purpose of heating and also maintaining temperature and flow of hot streams. Water supply Scenario Water required for the purpose of cooling is being supplied to units from PCT cooling tower. Recovered condensate is also being supplied for specific requirement. Water from cooling tower is supplied via main header to the units which is then subdivided to the respective locations depending upon the usage through sub headers.
Critical Observation
Figure 17: Water is being supplied to Pump No SS-121 under maintenance
During the study it was observed that water supply is unregulated in most cases. Water is continued to be supplied to the pump and equipments even if the system is idle.
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1. A considerable amount of water is used for the purpose of bearing cooling. Water after
cooling the bearing or coupling is being directed to the drain. Since this water neither contaminated nor is polluted it can be reused or recycled easily instead of directing the same to ETP. The oil or grease ingression if any can be removed from the water using arrestor and recycled for same use or as cooling tower makeup water. The quantification of water used as bearing cooling across the subunits are as follows:
Table 21: Water used in bearing cooling in unit 39 Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity ml/sec m3/hr ml/sec m3/hr
1 wax production to storage tank
3.00 0.01 9 HP Flare knockout drum
1.00 0.00
2 Steam Distribution Section(SDS)- 5
25.00 0.09 10 39 B 01 at Hydrogen knockout drum
5.00 0.02
3 Steam Condensate Section(SCS)- 8
10.00 0.04 11 Water vessel 50.00 0.18
4 39 C 02 Vacuum dry
10.00 0.04 12 Water vessel 50.00 0.18
5 SCS-5 20.00 0.07 13 39 B 01 at 39 KM 01B motor
30.00 0.11
6 SCS-4 25.00 0.09 14 SCS-10 20.00 0.07 7 SDS-3 0.50 0.00 15 SDS-9 30.00 0.11 8 SCS 2.00 0.01
Total quantity (m3/hr) 1.01 Table 22: Water used in bearing cooling in unit 84
Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity ml/sec m3/hr ml/sec m3/hr
1 84 PM 2A 750.00 2.70 8 84 PM 7A 20.00 0.07 2 84 PM 02 B 250.00 0.90 9 84 PM 18 B 1.00 0.00 3 84 PM 14 B 455.00 1.64 10 near pole no.
6F 6.00 0.02
4 VM condensate (near pole 21A)
5.00 0.02 11 84 PM 15 B 0.00 0.00
5 pole no. 21E 15.00 0.05 12 feed condenser (near 84 PM 1)
20.00 0.07
6 pole no. 21 F 23.00 0.08 13 feed condenser (near 84 PM 1) back side
0.00 0.00
7 84 PM 5A 16.00 0.06 14 84 GO 1A (feed filtration)
4.00 0.01
Total Quantity (m3/hr) 5.63
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Table 23: Water used in bearing cooling in unit 32 Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity ml/sec m3/hr ml/sec m3/hr
1 32KM01 (not operational)
1750.00 6.30 4 32P-110-C (SS-46-SP-46)
450.00 1.62
2 32-110D 1170.00 4.21 5 32P-110E 1150.00 4.14 3 32-PM-104
(centrifugal pump) 65.00 0.23 6 32-PM104 30.00 0.11
Total Quantity (m3/hr) 16.61 Table 24: Water used in bearing cooling in unit 31
Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity ml/sec m3/hr ml/sec m3/hr
1 31PM113 (125 centrifugal pump)- not working
200.00 0.72 4 31PM05R 100.00 0.36
2 31PM113R (125 centrifugal pump)
200.00 0.72 5 31PM103R 100.00 0.36
3 31PM06+B1PM06R
1000.00 3.60 6 31PM10 (Vacuum Residue)
625.00 2.25
Total quantity (m3/hr) 8.01 Table 25: Water used in bearing cooling in unit 37
Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity ml/sec m3/hr ml/sec m3/hr
1 37PM119A 30.00 0.11 2 37PM03 125.00 0.45 Total Quantity (m3/hr) 0.56
Table 246: Water used in bearing cooling in unit 33
Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quanity ml/sec m3/hr ml/sec m3/hr
1 33-PM-12A (hot water drain)
4.00 0.01 3 After steam trap nearby Redundan (33JBS-02A)
3.00 0.01
2 33E03 (valve leakage)
3.00 0.01
Total Quantity (m3/hr) 0.04 Table 27: Water used in bearing cooling in unit 35
Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity ml/sec m3/hr ml/sec m3/hr
1 35PM-102 220.00 0.79 4 35PM-01B Feed pump (not
50.00 0.18
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Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity ml/sec m3/hr ml/sec m3/hr
working) 2 Recycle com
(closed), Lube-CR case SP-150
330.00 1.19 5 35PM01A (working)
165.00 0.59
3 35KM-02B (working)
330.00 1.19
Total Quantity (m3/hr) 3.94 Table 28: Total water used for bearing cooling in LOB Sl. No Name of the Unit Total Quantity (m3/hr)
1 Unit 39 1.01 2 Unit 84 5.63 3 Unit 32 16.61 4 Unit 31 8.01 5 Unit 37 0.56 6 Unit 33 0.04 7 Unit 35 3.94
Total 35.8 The above converts to financial loss of INR 0.37 crore 2. Steam is used for process heating and facilitation of pumping operation. It was observed
steam leaking mostly due to insulation breakage, improper fixing of coupling/flanges and leakage across the steam piping network results in loss of steam to the atmosphere.
Figure 178: Steam condensate routed to drain
3. We have observed that in most cases due to the malfunction of condensate recovery system these condensates are drained out to the surface drain without being recirculated through condensate recovery piping network.
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Figure 19: Condensate drain across unit no 39
3.3.3. DHDS Block consists of the following process units DHDS Hydrogen Generation Unit (HGU) Sulphur Recovery Units , SWS and ARU Fluid Catalytic Cracking Unit (FCCU) VDU-2 MSQ Units Water Use Scenario Water is majorly used across these units for the purpose of cooling, cleaning (service water), drinking and firefighting. Steam is used across these units for the purpose of heating and also maintaining temperature and flow of hot streams. Water Supply Scenario Water required for the purpose of cooling is being supplied to units (HGU, DHDS, ARU, SWS, FCCU, VDU-II, MSQ ) from DHDS cooling tower. Water from cooling tower is supplied via main header to the units which is then subdivided to the respective locations depending upon the usage through sub headers. Critical Observation 1. A considerable amount of water is used for the purpose of bearing cooling. Water after
cooling the bearing or coupling is being directed to the drain. Since this water neither contaminated nor is polluted it can be reused or recycled easily instead of directing the same to ETP.
2. Lack of housekeeping resulting in loss of water from flanges
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Figure 20: Bearing cooling water drained to surface drain in Unit-82(VDU-2)
Table 259: Water used in bearing cooling in old HGU and DHDS (unit 24 and 25 )
Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity m3/hr m3/hr
1 24 PM 1 B 0.72 4 25 PM 4 B 1.80 2 24 PM 4 B 3.42 5 25 PM 4 A 1.19 3 25 PM 7 B 1.19
Total quantity (m3/hr) 8.32 Table 3026: Water used in bearing cooling in VDU-II (U-82)
Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity m3/hr m3/hr
1 82 PM 3 A & B 0.54 10 82 PM 4 A 0.30 2 82 PM8 B 0.54 11 82 PM 4 B 0.14 3 82 PM 8 A 1.62 12 82 PM 6 A 1.35 4 82 PM 10 B 0.65 13 82 PM 6 B 1.62 5 82 PM 10 A 0.72 14 82 PM 5 A 3.60 6 82 PM 9 B 2.16 15 82 PM 5 B 2.16 7 82 PM 9 A 2.88 16 82 PM 1 C 0.54 8 82 PM 7 B 0.72 17 82 PM 1 A 0.90 9 82 PM 7A 1.08
Total quantity (m3/hr) 21.52 Table 31: Water used in bearing cooling in MSQ units
Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity m3/hr m3/hr
1 85 K 21 A 0.45 17 85 PM 24 B 1.19 2 85 PM 4A 1.19 18 85 PM 24 A 0.20
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Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity m3/hr m3/hr
3 85 PM 4 B 1.19 19 85 PM 87 A (condensate)
0.01
4 85 PM 80 A 0.90 20 86 PM 3 B 0.90 5 85 PM 80 B 1.19 21 86 pm 3 A
(stand by) 0.90
6 85 PM 29 A 1.19 22 86 PM 1 B 0.72 7 85 PM 29 B 0.45 23 86 PM 1A 0.72 8 85 PM 3 A 1.80 24 86 PM 8A 0.96 9 85 PM 3 B 0.51 25 86 PM 7 A 0.54
10 85 PM 2 A 0.90 26 86 PM 7 B 0.04 11 85 PM 2 B 0.90 27 86 K 1 B 0.51 12 85 PM 1 B 1.19 28 87 PM 2A 0.72 13 85 PM 1 A 1.19 29 87nPM 53 B 0.60 14 85 PM 22 B 0.15 30 87 PM 51 B 0.72 15 85 PM 21 A 0.72 31 87 Pm 56A 0.16 16 85 PM 21 B 0.90
Total quantity (m3/hr) 23.71
Table 32: Water used in bearing cooling in FCCU
Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity m3/hr m3/hr
1 17 KM 1 A 0.90 12 18 PM 2 A 0.54 2 17 KM 1 C 0.30 13 Fire water 13 F 0.59 3 18 PM 29 A 1.26 14 18 PM 32 A 0.52 4 18 PM 12 A 0.72 15 18 PM 40 & 34
B 0.23
5 18 PM 12 B 1.08 16 18 PM 37 A 1.19 6 18 PM 14 B 2.38 17 18 PM 11 B 0.36 7 18 PM 15 A 2.70 18 18 PM 25 A 0.11 8 18 PM 15 B 2.70 19 18 PM 28 A 0.07 9 18 PM 16 B 0.59 20 18 PM 28 B 0.29
10 18 PM 16 A 0.59 21 18 PM 31 A 0.11 11 18 PM 2 B 1.80
Total quantity (m3/hr) 19.03 Table 33: Water used in bearing cooling in ARU and SWS unit
Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity m3/hr m3/hr
1 29 PM 51 B 0.04 2 29 PM 51 A 0.04 Total quantity (m3/hr) 19.03
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3.3.4. OHCU Block consists of the following process units Once Through Hydrocracker (OHCU) Hydrogen Unit(new) Table 34: Water used in bearing cooling in OHCU Block
Sl. No.
Pump/ Other device
Quantity Sl. No.
Pump/ Other device
Quantity m3/hr m3/hr
1 91 PM 2 A 0.54 29 91 PM 13 B 7.20 2 91 PM 2 B 4.79 30 91 PM 13 A 3.60 3 91 PM 42 B 0.45 31 91 PM 12 A 3.60 4 91 PM 43 0.04 32 91 PM 12 B 4.68 5 91 PM 44 0.04 33 91 PM 9 A 4.32 6 91 PM 19 B 0.27 34 91 PM 9 B 3.60 7 91 PM 19 A 0.54 35 91 PM 14B 0.54 8 91 PM 22 B 1.08 36 91 PM 17 B 1.44 9 91 PM 22 A 0.90 37 91 PM 17 A 1.44
10 91 PM 20 B 0.14 38 92 PM 15 A 0.72 11 91 PM 20 A 0.36 39 92 PM 14 A 0.54 12 91 PM 18 B 0.36 40 92 PM 14 B 0.36 13 91 PM 18 A 0.54 41 92 PM 2 A 0.27 14 91 PM 3 B 0.54 42 92 PM 11 A 0.27 15 91 PM 3 A 0.54 43 92 PM 11 B 0.27 16 91 PM 6 B 0.54 44 92 PM 13 A 0.90 17 91 PM 6 A 0.54 45 92 PM 13 B 0.72 18 91 PM 7 B 0.90 46 92 PM 1 B 1.08 19 91 PM 4 B 0.54 47 92 PM 12 C 1.19 20 91 PM 4 A 0.09 48 92 PM 12 B 0.59 21 91 PM 26 B 0.36 49 92 PM 12 A 0.90 22 91 PM 26 A 0.54 50 92 PM 16 B 1.19 23 91 PM 5 B 2.16 51 92 PM 16 A 0.90 24 91 PM 5 A 1.73 52 92 PM 22 A 0.01 25 91 PM 10 B 1.08 53 92 PM 21 B 0.04 26 91 PM 10 A 1.62 54 92 PM 21 A 0.01 27 91 PM 16 B 3.60 55 92 K 1 A 0.07 28 91 PM 16 A 2.52
Total quantity (m3/hr) 40.45
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Table 35: Total water used for bearing cooling in all the units Sl. No Name of the Unit Total Quantity (m3/hr)
1 CDU - 2 49.41 2 Unit 21,22 and 23 8.86 3 DHDS (24,25) 8.32 4 VDU (82) 21.52 5 FCCU (17,18,19) 19.04 6 ARU & SWS 0.07 7 OHCU (91,92) 40.45
Total 143.1 The above quantity converts to financial amount of INR 1.6957 crore Table 36: Estimation of financial amount Sl. No Name of the Unit Total Loss (m3/hr) Total financial saving (INR in Crore)
1 CDU - 2 49.41 0.52 2 Unit 21, 22 and 23 8.86 0.09 3 DHDS (24,25) 8.32 0.08 4 VDU (82) 21.52 0.20 5 FCCU 19.04 0.18 6 ARU & SWS 0.07 0.0007 7 OHCU (91,92) 67.79 0.625
Total 143.1 1.6957
3.4 DM Plant The DM plant is the most critical unit in a process industry requiring treated water either for process or for generation of high pressure steam. The DM plant through use of ion exchange technique results in fixation of ionic impurities of water in a dynamic manner, on the ion exchange resin beds, to improve the quality of water progressively, until completely demineralised water, having the highest degree of chemical purity is achieved. The existing DM plant includes five demineralization chains in parallel, with array of essential accessories. Each demineralization chain consists of two cation units in series ( Strong acid cation + Weak acid cation ) , one (common) degasser unit, one weak base anion unit, one strong base anion unit and one mixed bed unit. The cation units contain strongly acidic cation exchange resin beds and weak acid cation exchange resin beds which accommodated all the metallic ions of the influent water and in exchange, release hydrogen ions in equivalent amount. Thus the mineral salts of the water are converted into corresponding acids leaving practically no metal ions in the effluent from cation units. Water balancing for the DM utility is presented below. Water generation and condensate recovered from different units and directed to DM plant are as follows:
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Table 37: DM Water generation & Condensate recovery from different units Sl. No.
DM Water generation & condensate receiving form different unit
Unit/Area Tag Number
DM water in m3/hr
DM water in m3/month
1 DM Water from DM Plant/tank DM Plant 55FI-06 371 267120 2 DM Water from MB-6 99FI-
0601 0 0
3 DM Water from MB-7 99FI-0602
0 0
4 Total Condensate recovery from Units Different Unit 51FI-21 145 104400 Total DM water Generation + condensate Received 516 371520 DM water supply to units and processes: Table 278: DM water supply to units and processes Sl. No.
DM Water Consumption in Unit Unit/Area Tag Number
DM water in m3/hr
DM water in m3/month
1 Dearator No.-1 Make Up Flow TPS 51FI-29A 46 33120 2 Dearator No.-2 Makeup Flow 51FI-29B 38 27360 3 Unit Feed pump flow 51FI-22 11.05 7956 4 TPS Area dosing pump + Caustic
Preparation No Tag 1.75 1260
5 OHCU DM Water Tank 92T01 OHCU 92FI-4101 105 75600 6 OHCU Stand By DM Water Tank 91T02 No Tag 0 0 7 OHCU Unit-91 DM consumption as wash
water 91FIS-701 14 10080
8 92P-16A/B Pump Jacket Cooling No Tag 3 2160 9 SRU-IV DM Water For Process SRU-IV 95FI-5201 0 0
10 DM Water To Hydrogen Unit Tank No.-24T01
OLD HGU 24FI-3201 0 0
11 DM Water Flow to HRSG-1&2 Tank No.59-T01
GT/HRSG 59FI-51A 108 77760
12 DM Water Flow to HRSG-3 Tank No.59-T05C
59FI-9822C 40 28800
13 DM Water through VDU-2 finally reach to HRSG/Dearator-1/2
59FC-11A 75 54000
14 HRSG area dosing pump No Tag 2 1440 15 Ammonia dosing near VDU-2 No Tag 0.5 360 16 DM Water flow to FCCU Tank no. 18-T11 FCCU/MSQ 18FI-6601 18 12960 17 DM Water flow to MSQ 85FI-2201 27 19440 18 DM Water to ARU UNIT-29 No Tag 1 720 19 DM Water used for Process Steam in
LOB/Unit-37 LOB/Unit-37 37FI-01 6 4320
20 37FI-706 0.43 309.6 21 37FI-705 0.46 331.2
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Sl. No.
DM Water Consumption in Unit Unit/Area Tag Number
DM water in m3/hr
DM water in m3/month
22 37FI-708 3.3 2376 23 DM Water to maintain level
31B105,31H01A& 31H01B LOB/Unit-31 31FI-34 3.7 2664
24 DM Water To Maintain Level of C-03 LOB/Unit-84 FC-2401 3.85 2772 25 DM Water flow to Tank 32-B11 LOB/Unit-32 No Tag 1 720 26 DM Water to Vessel 39B08 LOB/Unit-39 39FI-801 1 720 27 DM Water filling in DM Water Storage
Tank in T/Hr 5.96 4291.2
Total Consumption 516 3,71,520 DM Plant water balance diagram
16.90%
1.40%
67.25% 15.50%
46.50%0.02%
0.50%32.72%
19.10%
0.10%Hydro test/ Chem
prepn/Alkali boilout
DM Plant
DM Water Produced
DM water from Tank
DE oily condensate
To Deaerator
FOB and LOB
DHDS and FCC
GT
TG make up
OHCU and HGU
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CHAPTER 4: WATER CONSUMPTION REDUCTION OPPORTUNITIES
4.1. Water conservation across Process Units Critical observation 1. Bearing cooling and jacket water is being directly drained to surface drain 2. Water and steam being always injected to the backup pump so as to facilitate zero down time
at the same rate at which it is injected when at use. 3. Water loss from valve, coupling and flanges 4. Steam leaks from valves, coupling and flanges Recommendation 1. Recycle of pump bearing cooling water and jacket cooling water should be undertaken. The
water that is being drained out after each pump can be collected in existing or newly constructed pit near the unit. The water stored in this storage pit can be pumped again to bearing cooling water piped network of the particular units or to cooling water return line.
2. Condensate recovery should be maximized: . Best practices towards condensate recovery are outlined as follows: The refinery should monitor the condensate balance in the refinery on an ongoing basis
and efforts should be made to maximize recovery. The quantity of blow-down taken at each boiler or steam generator in the refinery should
be monitored and minimized. The blow-down from each location or a group of locations should be collected and sent to
a flash drum where the pressure is let down to atmospheric pressure before being discharged. The flashed blow-down should then be cooled with a heat exchanger. This will prevent deterioration of the sewers and also avoid heating and vaporizing of any hydrocarbons that might be present in the sewer. The discharge should not be cooled by directly adding water (such as utility water) because this could require the addition of a substantial quantity of water to adequately cool the stream. This will also result in an increase of the total flow of wastewater to the treatment plant.
Perform steam trap surveys and implement recommendations for repair and replacement Install new steam traps and return the condensate to the boiler house
3. The effective way to reduce freshwater consumption is to maximize the recycle and reuse of
the treated wastewaters. In the Refinery, the extent of wastewater generation and their quality depends on the type of pollutants and composition. One of the broad categorization is that the wastewater can be segregated as on the basis of total dissolved solids and is subjected to the pre-treatment/treatment of the specific pollutants. The treated wastewater can thereafter be used in the cooling towers where maximum consumption is for cooling water and next maximum utilization through Tertiary Treatment Plant. The waste water generated from some of the units can be pre-treated prior to discharge to waste water treatment.
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Desalter oil / water separation techniques may be upgraded from the existing ETP configuration.
Primary Treatment in ETP: To upgrade the API system because Emulsified or dissolved oil that is usually
present which cannot be removed by an API system High pH at the API separator can stabilize emulsions. Spent caustic streams should be
either neutralized or routed directly to equalization in order to reduce pH at the API separators.
Use of DAF versus IAF based on the influent conditions and the required outlet condition may be decided. Advantages of IAF technique are compact size, low capital cost and the effective removal of free oil & suspended materials.
The possibility for installing the Equalization & Holding tank in downstream of the DAF may be evaluated to protect the downstream equipment (basically Biological System) from wide variations in flow and concentration.
Secondary treatment: Activated sludge with Powdered Activation Carbon (PACT) Treatment may be
adopted for better efficiency: In this treatment system both Biological oxidation and carbon absorption occur simultaneously, thus enhancing the removal of contaminants in the waste water. Most of the carbon is recycled with the activated sludge.
Aerated lagoons system can be developed in the Guard pond to enhance biological treatment
Tertiary Treatment: Chemical oxidation can be enhanced by the use of UV light as a catalyst Chemical oxidant (Hydrogen Per-oxide, Chlorine dioxide etc.) must be prepared
afresh to maintain reactivity 4. Complete mixing of returned sludge in Aeration tank, use of Ferro bacteriological process or
multistage activated sludge systems or UNOX (Pure oxygen input instead of air) process for aeration may be provided for better treatment of wastewater.
5. Reducing leaks and over flows from overground and underground fire water lines. 6. As a practice, waste water obtained across the plant is directed towards the ETP for
treatment. The degree of treatment is function of the level of contamination. In the current practice of handling waste water, even the water with lower level of contamination gets highly contaminated in contact with hydrocarbon. It is therefore recommended that separate infrastructure be planned to treat water with different level of TDS or at-least broadly segregating the waste water as low and high TDS contained and facilitating treatment.
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Water/ condensate with oil contamination and TDS below 500 mg/l and the chloride content below 300 mg/l can be treated easily and used for cooling water make up or fire water. The oily wastewater from the crude unit, desalters containing dissolved salts such as sodium chloride, neutralized spent caustic and contaminated cooling water blow-down can be considered for rigorous treatment.
4.2 Cooling Tower Critical observation 1. Drift eliminators at the top of the tower minimize the amount of water lost. Drift eliminator
as seen in PCT and TPS cooling tower is underperforming. 2. Mist eliminator (Used to minimize the amount of water carried out by wind at the top of the
tower) in PCT and TPS cooling tower are damaged Fills (Fills are wooden or plastic splash plates designed to increase the amount of water surface exposed to the surrounding air. Splash fills breaks the falling water into finer droplets) in PCT and TPS cooling tower are damaged in many areas .
3. Cooling towers louvers (louvers allow proper air passage & to control loss of water spillage through cooling tower) are damaged in many areas.
4. Biological growth/algae formations are observed. Such growth reduces cooling tower efficiency.
Recommendation 1. Repair and replace drift eliminator. While replacing the drift eliminator it is recommended to
replace the same with rigid PVC made eliminator. These standard drift eliminators are cellular multipass type, with a wave sheet between each corrugated sheet to impart extra structural integrity for beam strength and durability.
2. Repair and replace mist eliminator. 3. Fills to be repaired in PCT and TPS cooling tower and other cooling tower. 4. Louvers to be repaired in PCT and TPS cooling tower and other cooling tower. 5. It is recommended to install FRP based louvers if possible. These louvers reduce by far the
need for anti-biocide chemicals to overcome the biocide and algae problem created by the sun; the louvers serve as a filter to prevent any particles (e.g., birds or plastic bags) from entering the tower, as well as reducing noise by three decibels.
6. Dosing of chlorine or biocides as part of advanced cooling water treatment in the cooling water system should be done to take care of biological growth
7. Cooling towers are normally designed for a COC of around 5. By increasing COC, the blow down quantity can be reduced by external water treatment and adding water treatment chemicals, COC of even 10 can be reached. Increasing COC can result in significant saving of water. However since the plant is operating at COC level of 2 it is recommended to improve the COC to at least at the level of 5.
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4.3 DM Plant Critical Observation 1. There are leakage across different couplings /flanges leading to water loss 2. Water leakage from across seal of pumps 3. Tank overflow Recommendation towards water conservation 1. Continuous monitoring and vigilance to identify leaks and measures undertaken to ascertain
that there is no leak in the system. 2. Demineralization by the ion exchange process generates strong effluents which require
dilution with fresh water or other streams low in dissolved solids prior to discharge. However water can be recovered from the effluents generated in a DM plant by installing a water recovery plant for reuse in the plant. Some plants use the strongly acidic effluents in cooling water for pH control in place of acid.
4.4 Monitoring Recommendation 1. The detailed record of raw water intake at refinery (for processes, CT, makeup, fire water,
green belt development and sanitary and drinking purpose) as well as township complex and wastewater generation from different sources should be maintained on daily/regular basis w.r.t. flow rates and characteristics. These details will be useful in preparing comprehensive water balance at the site and also for identification and implementation of reuse/recycle practice of treated effluent at project site leading to mitigation of effluent discharges.
2. Frequent in house water audit be undertaken.
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CHAPTER 5: CONCLUSION The basis of the effective conservation of water is not only about reducing water loss, monitoring and verification but establishing the framework of integrated water management. Effective utilisation and management of water resources needs a foresight of the critical challenges of competing water demand in light of extrinsic factors like regional water quality & availability, regional policies & regulations, socio-economic setup, and stakeholders (Govt. agencies, local community, including the industrial value chain etc.) views and a multifarious approach towards not only improving the in-plant water use efficiency, but also to foresee beyond the paradigm of in-situ water management. This calls for a holistic approach towards management of water resources necessitating formulation of an integrated water management framework, as a first step, with responsive corporate water policies and programs in order to respond to the potential challenges related to water within and outside the plant boundaries. It is also recommended to implement integrated water management framework: An integrated water management framework is an essential step towards effective water management and conservation. The water management framework needs to be integrated within the sustainability and resource conservation policy of the organisation. The effective steps towards integrated water management framework are outlined below:
Water use mapping Water quality assessments Availability/ Supply Assessment Regulatory risk assessment Stakeholder need assessment
Assessment
Set benchmark for the water usage Making the source sustainable Reducing specific water consumption and implementing conservation interventions Aiming for zero liquid discharge Integrating ICT for efficienct water use planning
Identify Intervention
Prioritizing material issues Sensitize and capacitate internal stakeholders Engaging with community Implement high priority interventions
Prioritise and implement
Develop systems for internal audit Conduct external audit Evaluate and benchmark performance Take remedial measures
Monitor and evaluate
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Monitoring/Measurement Monitoring and measurement are two most important things in effective industrial water management. Good water management requires accurate water measurement. Some benefits of water measurement are:
Accurate accounting and good records help allocate equitable shares of water between competitive uses both on and off the plant.
Good water measurement practices facilitate accurate and equitable distribution of water. Proper recording and monitoring leads to develop a clear Water balance which is the
primary key to water conservation programme For effective water use it is important to integrate integrated water management tools discussed above in with planning which will include Management Information System and, Decision Support System, etc. Adopting of effective water management framework will help in reducing water consumption and improving specific water consumption. This will not only enhance the industrial sustainability but will also lower the unprecedented stress on the finite and fragile water resources that are on the verge of depletion on account of overexploitation coupled with mismanagement.
Annexure - IV