Enhancing Nitrification in an Oil Refinery WWTP with IFAS
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1 Enhancing Nitrification in an Oil Refinery WWTP with IFAS Wayne J. Flournoy (2), Russ Grillo (1), *Sarah B. Hubbell (2), Ramesh Kalluri (3), Casey Mueller (1) (1) Frontier Refining, Inc. (2) Entex Technologies Inc. (3) Kalluri Group, Inc. ABSTRACT The Frontier Oil refinery in Cheyenne, WY had a great deal of trouble meeting a new effluent permit limit of 2.18 mg/l monthly average ammonia nitrogen, mainly due to large fluctuations in the strength and type of influent wastewater. The company decided to become the first documented oil refinery to use the Integrated Fixed-Film/ Activated Sludge process to upgrade their exisitng WWTP for better nitrification. Frontier added 240 m 3 (13% fill fraction) of high surface area plastic carrier elements to each of their two parallel activated sludge aeration basins, and have since acheived consistant nitrification despite several major refinery process changes and corresponding wastewater plant upsets. KEYWORDS: Refinery, IFAS, Ammonia, Nitrogen, Industrial, Media INTRODUCTION Frontier Refining and Marketing operates a 52,000 bpd oil refinery in Cheyenne, Wyoming. Frontier is an independent oil company that primarily markets gasoline and diesel in the Rocky Mountain and Plains states. The Cheyenne refinery has a coking unit, which allows it to process up to 100% heavy or sour crude oil, which does not flow as easily and is higher in sulfur content and is available locally and imported via pipeline from Canada. This coking unit, as well as other complex process units such as a HF acid alkylation unit produce a complicated and fluctuating blend of process wastewater, which must be treated and is discharged to the Crow Creek in Cheyenne.
2 Figure 1. The Frontier Oil Refinery in Cheyenne, WY At the refinery s discharge outfall, Crow Creek is only three feet wide and the treated wastewater makes up approximately half of the Creek s seven year low flow. In August of 2006, Wyoming reclassified the Creek as a trout habitat, and consequently issued the refinery a new permit that required greater ammonia removal than the plant had historically been able to maintain. The WWTP consists of two parallel activated sludge processes (called the North plant and the South plant) and discharges approximately 1.7 m 3 /m to Crow Creek. The plant s process is shown in Figure 1.
3 Figure 2. Frontier Oil Refinery WWTP Process Flow Plan The facility previously had a mass based limit that required a maximum monthly average effluent concentration of about 20 mg/l NH3-N. The receiving stream was reclassified as a trout habitat and the new permit limited the effluent ammonia to 2.18 mg/l as a monthly average and 5.45 mg/l as a daily maximum. A review of the existing WWTP process and operating data indicate that the existing WWTP was unable to sustain MLSS concentrations high enough to maintain the required Food/Microorganism (F/M) ratio in the Bio-Reactors. In the past, several different polymers were tested in order to improve settling properties of the sludge in the Clarifiers, but the results were unsatisfactory. Historically the North side of the WWTP always performed worse than the South side of the plant, but it was unclear the reason for this. This is clearly seen in Figure 3.
4 Figure 3. Effluent ammonia-nitrogen from the North and South WWTPs Methodology The staff of Frontier Oil and their consulting engineer did an extensive literature search to select the most feasible technology that could be easily implemented so that the WWTP would comply with the NPDES permit requirements. Based on the available information, literature review, implementation schedule and considerations for ease of operations, a combined suspended growth and attached growth nitrification processes were determined to be the most suitable cost-effective technology for upgrading the existing Bio-Reactors at Frontier Cheyenne Refinery. The hybrid systems are also referred to as Integrated Fixed Film/ Activated Sludge (IFAS) process. IFAS systems add the benefits of fixed film systems into the suspended growth activated sludge process. Activated sludge not only provides process flexibility but also a high degree of treatment. Fixed film processes are inherently stable and resistant to organic and hydraulic shock loadings. Placing fixed film media into the activated sludge tanks (Bio- Reactors) combines the advantages of both of these systems. The City of Cheyenne, where the refinery is located, has an IFAS process using plastic Bio- Carriers as moving bed media to achieve nitrification at their municipal wastewater treatment plant, which also discharges to Crow Creek. Based on the successful operation of IFAS system at the City s WWTP, Frontier decided to upgrade their wastewater plant to an IFAS process. The staff from Frontier visited the City s plant and heard positive remarks about the floating carrier media as compared to the alternative of fixed IFAS media. Research into industrial applications of IFAS was done but they were unable to find any uses of IFAS in a petroleum refinery WWTP. This caused some concern because of the complex nature of the refinery, which includes process units that produce wastewater with significant concentrations of hydrocarbons, phenols, sulfides, toluene and amines. Since adequate design data was not available for refinery type wastewater, a bio-carrier loading rate of 0.42 g NH3-N/m 2 /day (typical for municipal wastewater) was used to determine the minimum amount of moving bed media required to achieve nitrification. Based on this loading rate, the minimum required surface area of the bio-carriers was calculated. With the help of their engineer, Frontier examined a number of IFAS suppliers and selected BioPortz TM carrier media, which has a protected specific surface area in excess of 576 m 2 /m 3,
5 and they planned to fill each of the bioreactors in their North and South wastewater plants with 240 m 3 of media, which is only a 13% fill fraction. Because of its larger diameter, BioPortz employs stainless steel screens with wider openings (10 mm) than other IFAS systems to retain the media in the basins. A major challenge for the project was designing and building the necessary piping and weir changes to accommodate the new retention screens in such a way that they could be installed without taking their system offline. In June of 2007 during a regularly scheduled refinery turnaround, the Bioreactors were retrofitted with effluent screens in the North plant as shown in Figure 4 in order to convert the existing Bioreactors to an IFAS system. Figure 4. BioPortz Stainless Steel Media Retention Screens Being Installed The BioPortz media was slowly added to the bioreactor beginning in early July. By mid-august the reactor contained 93 m 3 (approximately 54,000 square meters) of media and the effects of the additional fixed biomass were already being seen in the plant performance.
6 Figure 5. BioPortz Media Being Added to North Bioreactor Results As previously noted, the North plant had always performed worse than the South plant, but after the addition of just half of the designed media fill fraction the North plant appeared to nitrify better than the South bioreactor, as shown in Figure 6. Figure 6. Ammonia Removal After Media added to North plant
7 The ammonia removal data reported a 73% improvement in the IFAS bioreactor with only a small fill fraction of media. Figure 7 shows the improved performance and the more rapid recovery after an upset in the North bioreactor with the media. Figure 7. Ammonia Removal, North and South Bioreactors The IFAS upgrade has helped the plant recover more quickly from major upsets which are a chronic problem due to the complex nature of the refining process. The Cheyenne refinery processes 50,000 barrels per day of crude. Of this, about 80-85% is sour Canadian; the remainder being a blend of locally produced crudes and condensates which are known to be difficult to treat. The refinery is fully integrated, and has Coker and HF Alkylation Units, which produce especially difficult wastewater streams. In the fall the refinery experienced some heat exchanger leaks which contributed a lot of amines to the wastewater and caused the plant to lose nitrification. Because of the fixed biomass on the media in the North bioreactor, the North plant recovered nitrification much more quickly than previously, and continued to perform better than the South plant. The remaining media was installed in the North and South bioreactors in early 2008.
8 Figure 8. Frontier s North WWTP Ammonia removal before and after IFAS upgrade Conclusions Integrated Fixed-Film/ Activated Sludge proved to be an excellent and quick solution to the new nitrification challenge faced by the Frontier refinery. With only a small fill fraction of biocarrier media the plant was able to meet their very low effluent ammonia limit and the attached growth biomass helped the plant recover quickly from major refinery process upsets that affected the wastewater plant. Frontier Oil demonstrated that IFAS is a cost- effective technology for quick upgrade solutions for oil refinery and other industrial wastewater treatment systems. In summary, the benefits of the Frontier IFAS system are: Maintains a high density of biomass population. Increases the efficiency of the system without the need for increasing the Mixed Liquor Suspended Solids (MLSS) concentration. Performance of the Secondary Clarifiers becomes less critical in maintaining the desired biomass in the Bio-Reactors. Improved process stability.
9 Relative ease in retrofitting the existing plant. No significant operational changes are required to the current practices.
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