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Etp Process - Refinery

The BP Refinery in Kwinana, Western Australia generates waste water from its refining processes that comes into contact with hydrocarbons and other contaminants. It operates an advanced Waste Water Treatment Plant to clean the water before discharge. The multi-stage plant uses separators to remove oil and solids, followed by dissolved air flotation and activated sludge units to remove dissolved organics and nutrients. Continuous monitoring and improvements have reduced the refinery's emissions and improved water quality over time, giving it one of BP's best performing waste water treatment systems.

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267 views

Etp Process - Refinery

The BP Refinery in Kwinana, Western Australia generates waste water from its refining processes that comes into contact with hydrocarbons and other contaminants. It operates an advanced Waste Water Treatment Plant to clean the water before discharge. The multi-stage plant uses separators to remove oil and solids, followed by dissolved air flotation and activated sludge units to remove dissolved organics and nutrients. Continuous monitoring and improvements have reduced the refinery's emissions and improved water quality over time, giving it one of BP's best performing waste water treatment systems.

Uploaded by

sumit gulati
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Waste Water

Treatment
BP Refinery
Kwinana, Western Australia

Waste Water Treatment

BP Refinery Kwinana, Western Australia

The Kwinana Refinery has one of the best performing Waste Water Treatment Plants in all
of BPs global operations, and the Refinery openly shares its successes with its peers

BPs Kwinana Refinery uses water at every stage of the refining

Additionally, the Refinery has a cooling water system that uses

process. The most common water use is for cooling hydrocarbons,

salt water from Cockburn Sound to maintain hydrocarbons at

however water is also used for cleaning and other purposes. Water

steady temperatures as they travel through the refining units. The

is classified as waste water if it could have come in contact with

salt water is pumped through pipelines that wrap around tubes of

hydrocarbons or other contaminants.

hydrocarbons. Under normal circumstances the salt water does not


come into contact with any contaminants however a process is in

The Refinery operates two systems for cleaning water prior, one of

place to ensure the quality of cooling water.

which is a multi-stage Waste Water Treatment Plant.

What is in Waste Water?


How is Waste Water produced at the Refinery?

Waste water streams from the Refinery can contain a number of

Waste water is generated across the Refinery in the following ways:

chemicals which originate from crude oil. Typical contaminants include:

The Refinerys main input, crude oil, contains water from the

petroleum hydrocarbons

oil drilling process. This water must be removed before the

heavy metals

crude oil can be fed to the refining units.

phenolic compounds

sulfides

ammonia

Water is used to wash the holds of the ships that deliver

crude oil to the Refinery, so the ship can be loaded with its

next cargo.

Water is used within some refining processes, and some

of this water comes into direct contact with crude oil,

producing contaminated wastewater.

The Refinery has many sealed surfaces that will collect storm

water during a rainfall event; this water has the potential to be

contaminated so is also captured for treatment.

Waste Water Treatment

BP Refinery Kwinana, Western Australia

Waste Water Treatment Facilities at the Refinery

Waste Water Emissions - OIL

The Refinery has advanced systems in place to treat contaminated


waste water to standards set by the Department of Environment.
The salt cooling water is treated differently to other waste water
from the Refinery.

kg/day
1200

1000

1000
800

The Refinerys Waste Water Treatment Plant was commissioned in

600

1994, and was built in a dual train configuration, ensuring that the

400

Plant can operate effectively at all times, even during maintenance.

200

The first stage of the treatment process is the API separator, which
is named after the American Institute of Petroleum. As its name

A continually moving scraper system pushes oil to one end and the
solids to the other. Both are removed and the recovered oil is sent

37 17 11
1996

1 1 8 6
2 2 3 2 2 3 2 2 2
1998
2000
2002
2004
2006
2008
2010

Waste Water Emissions - NITROGEN

from the water. Gravity allows any oil in the water to rise to the
surface of the separator and any solid particles to sink to the bottom.

81
Cockburn 1993
Sound
Study
1978

suggests, the separator physically separates the free oil and solids

276

kg/day
400

350
300

300

back to the Refinery for reprocessing.


200

In the second stage, small suspended oil particles are removed


in the Dissolved Air Flotation unit. A polyelectrolyte chemical is
added to the waste water to help bind the small oil droplets into
larger ones, which will float. Air is also injected to lift the amassed
particles to the surface where they can be skimmed off.

100
0

57 41 38
Cockburn 1993
Sound
Study
1978

1996

22 33
1998

45

21 22 33 18 23 22 24 18 21 18 18
2000

2002

2004

2006

2008

2010

Both the API separator and the Dissolved Air Flotation Unit are

Performance and Control

covered processes, which prevents oil from evaporating and being

Each step of the waste water treatment process is monitored and

released into the atmosphere. In this way, the refinery has greatly

data recorded optimise the treatment process. Samples of the

reduced its emissions of volatile organic compounds.

treated waste water, taken by automatic samplers, are analysed for:


- hydrocarbons

- phenolics

The third treatment step is the removal of dissolved organic

- sulfides

- nitrogen

contaminants and nutrients in the Activated Sludge Units (ASUs).

- heavy metals

- pH

In this process, naturally occurring microorganisms feed on the

- temperature

- biological oxygen demand

dissolved organics in the waste water, and convert them to water,

- chemical oxygen demand - total suspended solids

carbon dioxide and nitrogen gas, which can be safely released into
the atmosphere.

Results are recorded and reported to the Department of


Environment and Conservation, who are the regulating body for the

In the final stage, waste water enters the clarifying tanks, where the

Refinerys environmental license.

microorganisms settle to the bottom while the treated waste water


flows away. An optional treatment step is to conduct further settling

Continuous Improvement

in the polishing ponds, or the water can be pumped back to the

The Refinery has worked hard to improve the quality of its treated

Activated Sludge Unit for retreatment.

waste water and the figures above show a steady improvement in


the average daily loads for oil and Nitrogen in waste water since the

Once water is cleaned to the appropriate standard it is discharged

late 1970s. The Kwinana Refinery has one of the best performing

directly to the Sepia Depression Ocean Outfall Line (SDOOL) which

Waste Water Treatment Plants in all of BPs global operations, and

is owned and managed by the Water Corporation.

the Refinery openly shares its successes with its peers.

Salt water used as cooling water is not contaminated under normal

The link to Cockburn Sound

circumstances, so is subject to a different treatment process. The

Since linking in with the Water Corporations Kwinana Water

heated water passes through three separators during which time it

Recycling Plant in 2009, BP no longer discharges any treated

cools down prior to discharge to Cockburn Sound. If oil is visible in

processed waste water into Cockburn Sound. Despite years of

any cooling water, actions are taken to isolate the source of the leak.

ongoing improvements in the quality of waste water, this is a


significant step forward for the Sound.

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