Saudi Aramco Project Development
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1 Saudi Aramco Project Development Wastewater Treatment Facilities Jeddah Refinery And Marine Area December 2007 Facilities Planning Dept.
2 OBJECTIVE: Provide an overview of the complexities of developing a project scope for Upgrading the Industrial and Sanitary Wastewater Treatment Facilities at Jeddah Refinery attributed to: Difficult to treat industrial oily wastewater stream requiring multiple studies Multiple changes in the future operations of the Jeddah Refinery
3 PRESENTATION OUTLINE Background Initial Study Conventional Biological Treatment Second Study Physical Chemical Treatment 1 st Revised Operating Scenario for Jeddah Refinery Third Study Membrane Bio-Reactor 2 nd Revised Operating Scenario for Jeddah Refinery Overall summary of the project development
4 BACKGROUND General Information Environmental Master Plan (EMP) issued by Company in 2001 EMP indicates that upgrades required for Jeddah Refinery Industrial Wastewater Treatment System and Sanitary Sewage System Consultant contracted in 2002 to perform field evaluation and tests and recommend upgrade requirements
5 BACKGROUND (cont d) Location & Existing Facilities Jeddah Refinery: Located adjacent to the Islamic Port in Jeddah Commissioned in 1982 Currently operating at 90,000 barrel crude oil refinery producing gasoline, fuel oil, and asphalt Major process units include crude distillation, vacuum, platformer unit, naphtha hydrotreating, fluid catalytic cracker (FCC) Tank Farm for Crude and Product and Terminal Facilities Provides feedstock/some utilities and treats wastewater from adjacent Luberef Plant
6 BACKGROUND (cont d) Location & Facilities (cont d) Existing Industrial Wastewater Treatment Facilities, Jeddah Refinery Located adjacent to the refinery in the Marine Area Holding Basin for incoming wastewater flow conditions API Separators for removal of oil & grease and solids Media Filter for removal of total suspended solids (TSS) All equipment more than 25 years old Treats wastewater from the refinery, tank farm, & Luberef Design wastewater flow 2.66 million gpd (10,000 M 3 /d) Existing Sanitary Wastewater System Sewage collected from buildings into holding tanks Sewage removed via vacuum trucks and sent to Saudi Aramco s Al-Rehab Community Center STP Approximate quantity of sewage generated: 12,000 gpd (45 M 3 /d)
7 Red Sea Jeddah Refinery Tank Farm Area Marine Area Lagoons Industrial WWTP Luberef Jeddah Refinery & Marine Area
8 Industrial & Sanitary Wastewater Treatment Existing Flow Scheme Jeddah Refinery Refinery Tank Farm, and Luberef Plant Wastewater, Stormwater Holding Basin Oil & Grease Removal API Separators Suspended Solids Removal Sand Filtration To Effluent Lagoons/ Red Sea Solids Oil to Slop Oil System Industrial Wastewater Treatment Sanitary Wastewater Septic Tanks Vacuum Tank Trucks To Al-Rehab STP Sanitary Wastewater Handling
9 JRMA - Holding Basin
10 JRMA - API Separators
11 JRMA - Sand Filters
12 INITIAL STUDY (2002) FINDINGS Major Deficiencies with JR Industrial Wastewater Treatment and Sewage System API Separators at end of useful life Separator solids difficult to remove Media Filters in constant state of repair and often unavailable Removal of Organic/Inorganic contaminants not possible No onsite sanitary waste treatment facility
13 INITIAL STUDY (2002) FINDINGS PME Discharge Limits are not met Chemical Constituent PME Discharge Limits JR Industrial Wastewater Discharge Max Max Avg ph, units BOD5, mg/l COD, mg/l TOC 150 Phenol, mg/l Oil & Grease, mg/l Total Suspended Solids, mg/l Ammonia, mg/l Cyanide (T/F), mg/l / / 0.05
14 INITIAL STUDY (Cont d) FINDINGS Other Physical Characteristics of Wastewater Highly Variable Total Dissolved Solids, up to 16,000 ppm Extreme Variability of Wastewater Parameters High Temperatures o C Highly Variable Flow Rate
15 INITIAL STUDY (Cont d) Treatment Alternatives Industrial Wastewater Treatment Conventional Biological Treatment Physical Chemical Treatment (Steam Stripping) Sanitary Wastewater Treatment Conventional Biological Treatment
16 INITIAL STUDY (Cont d) Recommended Industrial Wastewater Treatment Scheme Conventional Biological Treatment Storm Water Basin To Effluent Lagoons/ Red Sea Oil to Slop Oil System Skim Tanks Suspended Solids Removal Primary Oil & Grease Removal API Separators Sand Filters Refinery Tank Farm, and Luberef Plant Wastewater, Stormwater Chlorination Dissolved/ Air Flotation Dewatered Biosludge to Disposal Secondary Oil & Grease Removal Removal of Organic & Inorganic Compounds; ph Adjustment Chiller Sanitary Wastewater Methanol & ph Control Activated Sludge with Nitrification Biosludge Thickening & Dewatering
17 INITIAL STUDY (Cont d) Issues with Recommended Biological Treatment Advantages Most commonly used process for normal industrial oily wastewater streams Can be also used to treat sanitary waste Disadvantages Difficult to sustain biomass due to high swings in wastewater concentrations, TDS, and temperature Requires complex operations (as currently experienced at Rabigh Refinery) Not supported by EPD
18 SECOND STUDY (2003) Background Information EPD Identify Simpler Treatment Process R&DC Recommended resins for treatment via polymeric adsorption of contaminants Consultant Contracted to perform bench testing & field pilot tests Physical Chemical Treatment Proposed scheme developed
19 Second Study (Cont d) Recommended Physical Chemical Treatment Resin Adsorption Storm Water Basin API Separators Primary Oil & Grease Removal Refinery Tank Farm, and Luberef Plant Wastewater, Stormwater Skim Tanks Secondary Oil & Grease Removal Dissolved/ Air Flotation To Sanitary Wastewater Treatment Plant Cartridge Filters To Effluent Lagoons/ Red Sea Oil to Slop Oil System Suspended Solids Removal ph Adjust Sand Filters Chlorination Phenol & Organics Removal Ammonia Removal Steam ph Adjust Air Stripper Resin Columns GAC Columns
20 Second Study (Cont d) Recommended Sanitary Wastewater Treatment Scheme Membrane Bio-Reactor (MBR) Sanitary Wastewater Regenerant from Industrial Wastewater Plant Existing Septic Basins w/new Pumps & Lines Main Collection Sump* New MBR Treatment Plant Treated Water Sludge To Landfill To Effluent Lagoons *With Grit Chamber & Screens Irrigation
21 Second Study (Cont d) Physical Chemical Treatment - Resin Adsorption Advantages Simple unit operations High tolerance to swings in effluent conditions Easy to restart after shutdown Disadvantages High steam requirements Frequent replacement of GAC (Regeneration possible) Requires separate sanitary wastewater treatment plant
22 1 st Revised Operating Scenario for Jeddah Refinery (2004) New Rabigh Refinery/Petrochemical Complex may affect future operation of Jeddah Refinery Jeddah Refinery partial or complete shutdown of process units; study being performed by Facilities Planning Dept. (FPD) Industrial Wastewater Treatment Plant (IWTP) for Jeddah Refinery capacity & treatment scheme could vary with process units remaining in operation Two - Phase Implementation of IWTP at Jeddah Refinery Phase 1 install equipment for removal of oil & grease and total dissolve solids from the industrial wastewater to meet PME regulations Phase 2 based on FPD study results and management recommendations, install remaining equipment for removal of all other contaminants from the industrial wastewater and provide onsite sanitary sewage to meet PME regulations
23 1 st Revised Operating Scenario for Jeddah Refinery Phase 1 Industrial Wastewater Treatment Facilities Design Capacity: flexibility to allow for any changes in the operation of Jeddah Refinery Project Proposal Engineering: commenced on August 2004 Detailed Engineering: commenced on December 2005 Construction: currently under Plant Start Up: July 2008
24 1 st Revised Operating Scenario for Jeddah Refinery (Cont d) Phase 1 Industrial Wastewater Treatment Facilities Refinery Tank Farm, and Luberef Plant Wastewater, Stormwater Storm Water Tank Oil to Slop Oil System API Separator Primary Oil & Grease Removal Skim Tanks Secondary Oil & Grease Removal and TSS Walnut Shell Filters To Effluent Lagoons/ Red Sea
25 1 st Revised Operating Scenario for Jeddah Refinery FPD Study Results for Future Operations of Jeddah Refinery Released in Early 2005 Based on study recommendations and management decision in May 2005, Jeddah Refinery process units to be shutdown in 2010 Jeddah Refinery Tank Farm (including marine area) and Luberef to remain in operation Proceed with implementation of Phase 2 Wastewater Treatment Facilities
26 Third Study (2005) Phase II Industrial Wastewater Treatment Facilities Shutdown of Jeddah Refinery expect lower concentrations of phenols and ammonia in wastewater cooler wastewater temperatures wastewater flowrate reduced by 33% Membrane Bio-Reactor (MBR) EPD recommends the evaluating the use of an MBR in lieu of physical chemical treatment for industrial wastewater and sanitary sewage at Jeddah Refinery Consultant contracted to perform bench testing and conducts pilot plant evaluation Test Results indicate MBR viable & economical process
27 Third Study Phase 2 Industrial Wastewater Treatment Facilities (Base) Refinery Tank Farm, and Luberef Plant Wastewater, Stormwater Storm Water Tank API Separators Skim Tanks Walnut Shell Filters To Effluent Lagoons/ Red Sea Oil to Slop Oil System Granulated Activated Carbon Units Phase 1 Equipment MBR Units From Sanitary Waste Collection System To Sludge Pit/ Sludge Beds Equalization Tanks
28 Third Study Phase 2 Industrial Wastewater Treatment Facilities (Alternate) Refinery Tank Farm, and Luberef Plant Wastewater, Stormwater Storm Water Tank API Separators Skim Tanks Walnut Shell Filters To Effluent Lagoons/ Red Sea Oil to Slop Oil System Powder Activated Carbon MBR Units From Sanitary Waste Collection System Equalization Tanks Phase 1 Equipment To Sludge Pit/ Sludge Beds
29 2nd Revised Operating Scenario for Jeddah Refinery (2007) Future Operation of Jeddah Refinery In lieu of shutting down the Jeddah Refinery process units, the JR is to continue to run as a topping refinery until 2014 for the production of fuel oil and asphalt only Jeddah Refinery Tank Farm (including marine area) and Luberef to remain in operation Impact on Phase 1 & 2 Wastewater Treatment Facilities Phase 1 Facilities: none, except install 2 nd API Separator in Phase 2 Phase 2 Facilities: re-size equipment to handle 33% more flow & provide wastewater cooling Project Proposal: commenced on September 2007 Plant Start-Up: March 2011
30 Currently Proposed Facilities Phase 1 & 2 Industrial & Sanitary Wastewater Treatment Facilities Refinery Tank Farm, and Luberef Plant Wastewater, Stormwater Storm Water Tank API Separators Skim Tanks Walnut Shell Filters To Effluent Lagoons/ Red Sea Oil to Slop Oil System Powder Activated Carbon MBR Units From Sanitary Waste Collection System Equalization Tanks Chiller Design Capacity: ~ 2MM gpd (7900 M3/d) To Sludge Pit/ Sludge Beds
31 PROJECT DEVELOPMENT SUMMARY JEDDAH REFINERY WASTEWATER TREATMENT FACILITIES Pre-2001: Company conducts survey of all major plants and facilities for environmental compliance 2001: Company issues Environmental Master Plan 2002: Initial Study for Jeddah Refinery with conventional biological treatment recommended 2003: EPD recommends physical chemical treatment to facilitate operations (2 nd Study) 2004: Future continued operations of Jeddah Refinery under study 2004: Implementation of JR WWTP in two phases; Phase I treatment for oil & grease and TSS only; Phase I engineering commences 2005: Management decision to discontinue operation of process refining units at Jeddah Refinery (1 st Operational Change)
32 PROJECT DEVELOPMENT SUMMARY (Cont d) JEDDAH REFINERY WASTEWATER TREATMENT FACILITIES 2005: EPD recommends MBR for treatment of industrial wastewater & sanitary sewage (3 rd Study) 2006: Evaluation of MBR treatment indicates viability 2007: In lieu of shutting down the Jeddah Refinery process units, the JR is to continue to run as topping refinery until 2014 (2 nd Operational Change) 2007: Commence with engineering of Phase 2 wastewater treatment facilities 2008: 3 rd Operational Change????? 2008: Startup of Phase : Startup of Phase 2
33 Thank you
34
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