Whiting Business Unit ENVIRONMENTAL STATEMENT FOR YEAR 2015 (Review of Y2014 performance)
Introduction Recognizing the complex nature of petroleum refining operations and to ensure that we meet our stated goal of no damage to the environment, BP Whiting Refinery has implemented an Environmental Management System (EMS). The EMS has been certified under ISO 14001 since 2001 and is a formalized structure for ensuring that a facility prioritizes its environmental aspects and has plans in place to address and document progress toward improving environmental performance. The EMS works to achieve regulatory compliance and continually improve management of the environmental impacts of our operations. Our ISO 14001 certification covers the entire refinery, including our marine dock. The refinery s Site HSSE Policy focuses the organization on Safe, Compliant, and Reliable operations. 1
Description of our operations The scope of our EMS includes the activities, products and services of BP Whiting Business Unit (BP WBU), located in Whiting, Indiana. These activities include refining crude oil and processing chemical feedstocks. Built in 1889, the Whiting Refinery occupied 235 acres and processed 600 barrels of crude oil daily. Today, the crude units can process up to approximately 420,000 barrels of crude oil each day. Now located on 1,400 acres and stretching through three communities, the refinery has grown with its neighbors, employees, and customers. The refinery operates 24 hours a day, 365 days a year, and employs approximately 1,800 full-time employees, and over a thousand contractors. The refinery makes about 15 million gallons of product daily, about half of it gasoline. On an average day, the refinery produces enough fuel for about 430,000 automobiles, 10,000 farm tractors, 22,000 semi-trucks, 2,000 commercial jet liners, and to fill 350,000 propane cylinders. The refinery ships and receives hydrocarbons via barge, rail, truck and pipelines. Whiting Refinery Process Overview SRU VRU Refinery Fuel Gas Crude Oil Alkylation Isomerization OMD Reforming Cat Feed HT Catalytic Cracking Coker Asphalt Coke 2
How We Identify and Manage Important Environmental Impacts Environmental impacts are identified and managed through considering external stakeholders and internal processes. The Whiting Refinery reports all emissions to state and federal agencies. These agencies create regulations that control emissions and their impact to the environment. Regulations include requirements for the refinery to implement pollution control measures, as well as permit and operating conditions that limit emissions and/or require extensive monitoring and reporting. The refinery keeps local officials informed of emissions-related and other events that could impact the community. Whiting Refinery identifies and manages environmental impacts through BP s global as well site-specific processes. BP sets annual goals for Loss of Primary Containment Whiting Refinery includes these goals in BP s annual plan. The ISO 14001 process is used to annually evaluate the Environmental Aspects of its operations and to set Objectives and Targets. Management programs are established to achieve targets. The refinery monitors performance to ensure delivery of results. Our Impacts and Performance Air Quality As one of the largest refineries in the United States, we understand that Whiting Refinery can have a significant impact on the local air quality. We have made significant strides in the past decade to continue to reduce our emissions to the air. Through these actions, our air emissions are down since 2001. Continuous emission monitors (CEMs) exist on the refinery s largest emission sources of key pollutants. The refinery has more than 60 CEMs on sources throughout the refinery for various pollutants. This enables the refinery to establish baseline emissions and take corrective actions if emissions increase. As part of a voluntary agreement with the U.S. EPA to reduce emissions from BP refineries nationwide, Whiting Refinery implemented several actions to reduce air emissions from our facility: Hydrocarbon emissions were reduced through an enhanced valve monitoring program (2003), an enhanced pump monitoring and repair program (2006), and a program aimed at reducing hydrocarbon flaring (2003). Beginning in 2002, SO2 and NOx emissions were reduced through use of emission reducing additives at the Fluidized Catalytic Cracking units (FCUs), the installation of a Selective Catalytic Reduction system at one of the FCUs, elimination of oil burning in all refinery heaters and boilers, and installation of Ultra Low NOx burners at selected Power Station boilers. In addition to the above, the refinery has implemented other actions to continue to drive down air emissions from the facility. Our hazardous waste incinerator (FBI) and #3 Ultraformer Unit were shutdown in 2008. High efficiency drift eliminators were installed on cooling towers #2 and #3 in 2009 to reduce particulate emissions from those sources. The refinery ceased loading gasoline at our barge dock in 2009. A key activity in 2010 was installation of Selective Catalytic Reduction (SCRs) systems at one of our boiler houses (3SPS) to reduce NOx emissions. The last of these SCRs began operation in 2011. Additionally, we retired an older, less efficient boiler house in 2010. This resulted in over 600 tons of NOx reductions between 2009 and 2011. As part of our modernization project at Whiting Refinery, we invested more than $1 billion in environmental enhancements to the facility including waste water improvements, air emission reductions, and systems to remove sulfur from gasoline and diesel. These controls include technology to produce lower sulfur fuels, specialized burners and controls to reduce nitrogen oxide emissions from heaters and boilers, and improved automated controls that optimize process units for lower emissions. 3
As part of a 2012 agreement with USEPA and IDEM, we have installed equipment to ensure high flare combustion efficiency. Future work is scheduled to be completed in 2016 to install flare gas recovery on several flares and install ultra low NOx burners on additional heaters. \ Whiting refinery has also installed state-of-the-art fenceline monitoring systems. A fixed system was installed as part of our 2012 agreement. An open path monitoring system was installed as part of a voluntary agreement with the Calumet Project. The system provides data on concentrations of several hydrocarbons and sulfur compounds at the facility fenceline. The data is made available to the public at http://raqis.radian.com/pls/raqis/bpw.whiting. Water (use and discharge) The Whiting Refinery draws its intake water from Lake Michigan which is used in contact and non-contact cooling throughout the plant. Treated water discharges from our Waste Water Treatment Unit (WWTU) to Lake Michigan. The refinery continues to take steps to better understand and improve water management systems such as: In 2009, Whiting Refinery added capacity through startup of Tank 5052 to handle storm events and for equalization/stabilization of feed quality to the facility WWTU. In 2010, we completed a project to improve metering of stormwater in our tank fields, upgraded procedures to improve monitoring, implemented an internal plantwide permitting process for the sewer, implemented equipment to reduce the impact of our discharge, and improved measurement of discharge flows. In 2012, the refinery installed a new final effluent filter as an upgrade to the previous filter. 4
Additionally, BP funded independent academic work by Purdue University Calumet and Argonne National Laboratories on deployable technologies for the removal of total suspended solids, ammonia, mercury and vanadium from wastewater. The research has significantly contributed to the body of knowledge about the technologies, chemistry and analysis of wastewater treatment that is of interest to industries, municipalities, regulators and local communities. The above actions supplement but do not replace systems previously in place to maintain high quality water discharge. These systems include unit oil water separators to reduce total oil sent to the WWTU influent parameter monitoring, and tools to monitor and communicate wastewater treatment health. Discharge levels of Total Suspended Solid (TSS) in 2014 continued to show good treatment (following graph). As part of our NPDES permit renewal in 2013, the refinery requested that TSS discharge limits be lowered to those levels that we had committed to meeting in 2007. Since 2007, the annual TSS discharges was at approximately 30% of our lower commitment, and new permit limit, levels. The 2013 and 2014 average was approximately 10% of the permit limit level. Additional work is ongoing. As part of our 2012 agreement, Whiting Refinery is installing a new DNF unit, replacing the older AFU. This new DNF will be on-stream in 2016. Glossary Environmental aspects Components of the business unit s activities, products, and services that can interact with the environment Environmental Impacts Activities A change to the environment. Such change can be positive or negative. Environmental impacts are caused by environmental aspects. Processes and support functions including products and services that are directly or indirectly related to business unit operations 5
Products IDEM EMS SO2 NOx VOC CO2 GHG SCR 3SPS TSS WWTU DNF AFU Those materials produced (including by products) as a result of the process of crude oil refining and petrochemical processing operations Indiana Department of Environmental Management Environmental Management System Sulfur Dioxide Nitrogen Oxides (nitrogen oxide and nitrogen dioxide) Volatile Organic Compounds generally hydrocarbon emissions Carbon Dioxide a greenhouse gas Greenhouse gas primarily carbon dioxide and methane Selective Catalytic Reduction a technology that employs catalyst to reduce NOx emissions 3 Stanolind Power Station This is part of the refinery s power station that generates a significant portion of the plant s steam and energy demands. Total Suspended Solids - a water quality measurement Waste Water Treatment Unit - This is part of the refinery s operation that focuses treating process wastewater prior to discharge. Dissolved Nitrogen Floatation - This is part of the refinery s WWTU that removes dissolved organics in the wastewater. Air Floatation Unit - This unit performs the same function as the DNF, removing dissolved organics in the wastewater. The AFU was the former unit at the refinery. It used air as opposed to nitrogen to remove the organics. Further Information This is Whiting Refinery s annual Environmental Statement. This document was prepared by the Environmental Department at the Whiting Refinery. You can contact us at: Environmental Manager (Linda Wilson): 219-473-3287 Environmental Management System Coordinator (Janet Slupczynski): 219-473-2092 24-hour Alternate: 219-473-7700 Our verified Statement for Y2017 will be issued in 2018. Feedback Tell us what you think. Are our statements easy to understand? Is there any further information in which you are interested? Let us know what you think so we can improve our environmental reporting. If you have any queries about this report or general operations, please write or telephone us and we will be happy to assist. 6
Verification Statement During the course of conducting a periodic ISO 14001 conformance audit, DNV-GL has independently reviewed the Whiting Business Unit Environmental Statement and concludes it represents a true and fair reflection of the environmental programs and performance within 2013-2014. Within the audit samples performed by DNV-GL, and based on information provided by the plant, within the scope of the facility s ISO 14001 EMS, DNV-GL has found no statements in this report which we have been unable to substantiate and verify through observations, visits and review of the appropriate systems. Signed: Date: 11/13/2015 7