Environmental Improvement Plan. Sohar Refinery
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- Carmella Hancock
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1 Environmental Improvement Plan Sohar Refinery Feb 2014 Page 1 of 18
2 Waste Water Treatment Plant Improvements Background The treatment of the waste water of the Refinery was malfunctioning for a long period. Almost no purification occurred and the water effluent quality was far away from the standards. The water also emitted vapours that caused strong odour. Page 2 of 18
3 WWTP 20 Projects Biological improvement (bio augmentation) by addition of special enzymes by KAM Biotechnology. Further cleaning and repairs of basins/equipment. Replacing sand and gravel in Sand Filters. Building of additional and more robust spent caustic treatment unit from in order to have a 100% back-up system. Replacing of gravel and activated carbon in Activated Carbon Filters. Optimization of the primary units (API and DAF) by different chemicals from different suppliers to select the best chemicals (on-going). Page 3 of 18
4 WWTP 20 Projects More tight control of waste water production and draining from the refinery plants. Continuous operation surveillance and monitoring of the WWTP. Ensure the implementation of preventive maintenance and repairs of all equipment in the refinery that have direct influence to WWT operation. Preparation to implement Zero Discharge Policy: Plan is to send SR treated effluent water from WWTP into Majis centralized treatment facility. Page 4 of 18
5 WWTP 20 Results All parameters are within standard except ammonia. Significant odour emissions reduction. Parameters/p pm COD 2011 >1,50 0 Standards/p 20 Feb Nov Nov 2012 pm Oil & grease TSS Phenols 56 <0.1 <0.1 < Ammonia Water quality into WWTP Water quality from WWTP Page 5 of 18
6 Odour Nuisance Reduction Background For mitigating odours from SR, the primary area for odour source has been the refinery Waste Water Treatment Plant. However Hydrocarbon emissions in other parts of the Refinery could also contribute to odour. Orpic is taking various actions for controlling odour emissions, generated from the refinery complex starting with WWTP. Orpic continues to identify the possible other sources of odour within the SR. Page 6 of 18
7 Odour Nuisance Reduction Installation of temporary spent caustic treatment unit. Installation of deodorizing additive in basins of WWTP that emit gases in December Use of E-noses for odour detection in September A project was launched to cover the WWTP basins, collect the gases and treat the gases to remove odour components. The project was divided into 3 phases. Phase-I is the coverage of the basins and has been completed in October Phase-II Odour control project of installing a ventilation system for some of the covered basins (API and DAF), completed and started up in August 20. An odour mapping study to identify all possible sources of odour within the SR was completed in July Sources other than the WWTP were identified, mainly vents of certain tanks and Oily Water sumps. Actions are being launched to equip all these sources with a system to collect the vapours. Installation of HC and H2S detectors at the impound basin November 20. Page 7 of 18
8 Odour Nuisance Reduction Phase-III Odour control project of installing scrubber and/or thermal oxidation (RTO) system by end of The EPC contract tender was floated and several offers were received. Currently in process to evaluate the offers and to select the EPC contractor. This last step will completely avoid any odour coming from the WWTP. As part of the odour reduction program, Orpic assigned a number of its engineers to work in shift along with the process Operators. Other initiative Orpic took to reduce odours is by launching the Coin Your Ideas campaign. Page 8 of 18
9 Odour Nuisance Reduction Results Odour emissions and hydrocarbon releases from the Refinery have decreased significantly, e-nose readings show less frequent peaks of emissions and also the intensity has decreased Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Phone Calls Statistics (Complaints) Date Phone call Validation 5/1/2014 One Not Valid 10/1/2014 One Valid 15/1/2014 One Not Valid 29/1/2014 One Not Valid 1/2/2014 One Not Valid 15/2/2014 One Not Valid Orpic hotline number: Page 9 of 18
10 Sohar Refinery Flaring Projects: A project was completed to connect the fuel gas system of the Refinery with Aromatics Plant. Continue to enhance chillers reliability and using both STG s to produce power. A study has started to recover the remaining low pressure gas that still is flared and that cannot be recovered by the means mentioned above. Results Routine flaring rate has been reduced by more than 60% from average of 12.5 tons/hr to 4.5 tons/hr. Sohar Refinery Flaring Long Term Trend Average 多項式 (Average) TPH YTD Page 10 of 18
11 SOx Emissions Reduction Background As part of the original Refinery construction, a Wet Gas Scrubber (WGS) was installed in Sohar Refinery to reduce Sulfur Dioxide (SO2) gas emissions from the RFCC unit. Due to the changes in RFCC feed quality (higher sulphur content) from the original design assumptions, Sohar Refinery experienced higher Sulfur Dioxide emissions than design. Also poor dispersion of the plume exiting from the WGS stack was an issue. Page 11 of 18
12 SOx Emissions Reduction Original Equipment Manufacturer (OEM) Alstom was contracted for debottlenecking the existing WGS. An EPC was awarded to Alstom to implement the modifications and to retrofit. GTB awarded the contract (19 M$) in September In October 2012, the packing material level in WGS increased to 100% as a first short term step. Higher scrubbing efficiency and lower emissions was observed. Inlet SO2 Outlet SO2 Efficiency Outlet SO2 After packing volume increased from 70% to 100% (mg/nm3) (mg/nm3) (%) (ppmv) 7,919 1, On 20 February 20, mobilization of manpower and lifting equipment started onsite, to implement planned WGS modifications. On 11 March 20, Fire incident occurred in the WGS Unit, resulting in major damage to the entire equipment. On 20 March 20, recovery plan started to re-build the damaged Wet Gas Scrubber, re-instate the sea water system and other utilities on a fast track. Page 12 of 18
13 SOx Emissions Reduction For a period of 2 months, the agreement was obtained from MECA/SEU to operate the refinery without the WGS but meeting a SOx limit which was similar to the emissions that Orpic had in first half of Orpic has taken measures (use of imported low sulphur feedstock and use of DeSox catalyst) and was able to stay below the agreed limit. On 24 May 20, the main parts of the Wet Gas Scrubber (Absorber Shell & Cone) were delivered to site, manufactured by local vendor. On 20 June 20, Completion of mechanical works with a three seawater booster pumps arrangement. On 3 July 20, Wet Gas Scrubber put in cold circulation with two seawater booster pumps. All systems were checked in detail. On 27 July 20, Wet Gas Scrubber put in operation with hot flue gases. Page of 18
14 mg/nm August August August 20 August August August August August September 06 September 10 September 14 September 18 September 22 September 26 September 30 September 04 October October October October October October October November 05 November 09 November November 17 November 21 November 25 November 29 November 03 December 07 December 11 December 15 December 19 December 23 December 27 December 31 December 04 January January January January January January January February February February 2014 February 2014 SOx Emissions Reduction October 20, the remaining external components (heater system of the flue gases coming from the WGS, fourth standby seawater booster pump) are installed. Results After WGS Revamp Inlet SO2 (mg/nm3) Outlet SO2 (mg/nm3) Efficiency (%) Outlet SO2 (ppmv) 7, SO2 of WGS SO2 Design SO2 Page 14 of 18
15 SOx Emissions Reduction A further reduction is expected after the implementation of the Sohar Refinery Improvement Project (SRIP). As a results of the new Refinery units that will be installed as part of the SRIP, the Sulfur in the RFCC feed will be lowered to 1.8 wt% which resulted in less SOx precursors. Also the amount of flue gases to be scrubbed will decrease. The impact on the WGS performance is that the 350 mg/nm3 will be met after start-up of New Units mid After SRIP Inlet SO2 (mg/nm3) Outlet SO2 (mg/nm3) Efficiency (%) Outlet SO2 (ppmv) 5, Page 15 of 18
16 Leak Detection and Repair (LDAR) Projects 20: An LDAR survey was conducted to all refinery units using best practices LDAR and Infrared camera scan. Result Page 16 of 18
17 Waste Management Export more than 19,000 tons of RFCC spent catalyst from Al Bhatinah facility and on-site. Construct on-site hazardous/non-hazardous waste storage facility. Continue to find more outlets for different type of waste. Accumulative tons 25,000 20,000 tons 15,000 10,000 5,000 0 Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr- May- Jun- Jul- Aug- Sep- Oct- Nov- Dec- Jan- Feb Accumulative tons ,430 2,010 3,190 4,210 5,430 6,750 9,570 10,31 10,61 11,33,27 15,43 17,57 18,83 19,14 19,52 Page 17 of 18
18 Waste Management RFCC spent catalyst stored on-site January 20, total of 8,600 tons. No RFCC spent catalyst stored onsite Feb 20. Page 18 of 18
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