UAE University Faculty of Engineering Graduation project II

1. UAE University Faculty of Engineering Graduation project II Refinery Wastewater Treatment Plant Advisors: Dr. Mohamed Abdul Karim Dr. Ibrahim Ashor Basma Maha Moza Noura

2. Presentation Layout • Problem definition • Objectives • Process flow sheet • Material balance • Equipment design • Plant cost estimation • Process simulation • Environmental impact • Conclusions & Recommendations

3. Refinery WW contains pollutants including solids, oil, organic and inorganic components. • The composition of WW was adopted from Kurkkale Petroleum Refinery.

4. Objectives • To design a plant for treatment of refinery WW Detailed Objectives: • Material balance calculation • Equipment design calculation • Cost estimation of the plant • Process simulation using Super Pro. • Environmental impact

5. Process Flow Sheet CPI Separator Trickling Filter Clarifier DAF Gravity Thickening Belt filter press

6. material compatibility Material Balance

7. Equipment Design 1. CPI Separator The main required parameters: • The effective surface area needed for separation • Rise velocity of oil globule • Number of packs • The separator depth

8. 1. CPI Separator To calculate the effective surface area required for separation Total surface area of the plates Projected surface area of the plates Effective surface area = Ap/1.12

9. 1. CPI Separator To calculate the no. of packs Calculate WW density Calculate horizontal surface area Calculate no. of packs

10. 1. CPI Separator Results

11. Equipment Design 2. Dissolved air flotation The main required parameters: • Hydraulic loading • Solid loading • Air solid ratio

12. Equipment Design 2. Dissolved air flotation Air solid ratio = 0.015 lbair/lbsolid Hydraulic Loading = 3.8 gal/min.ft2 To calculate solid loading Calculate surface area of flotation tank

13. Equipment Design 2. Dissolved air flotation To calculate power requirements for pumps Calculate surface area of flotation tank

14. 2. Dissolved air flotation Results

15. 2. Dissolved air flotation

16. Equipment Design 3. Trickling filter • The main required parameters: • Filter depth • Diameter, surface area of the filter • Hydraulic loading • BOD loading • Recirculation ratio • Mean detention time • Amount of oxygen required • Dosing rate and rotational speed

17. 3. Trickling filter To Calculate the filter surface area To Calculate the filter volume Calculate the hydraulic and BOD loading

18. 3. Trickling filter To calculate the efficiency of the filter Calculate recirculation factor Calculate the efficiency

19. 3. Trickling filter Results

20. Equipment Design 4. clarifier • The main required parameters: • Width • Surface area • Weir length • detention time

21. 4. clarifier To Calculate the tank surface area Surface area (ft2) = WW flow rate (gpd) / average overflow(gpd/m3) Width (ft) = Surface area(ft2)/ depth ft) Weir length (ft) = WW flow rate Detention time (hr) = clarifier volume (ft3)/ WW flow rate (ft3/hr)

22. Equipment Design 5. Gravity thickening • The main required parameter • Area of thickener

23. 5. Gravity thickening To calculate area of thickener

24. Equipment Design 5. Belt filter press • The main required parameters • Sludge feed rate • Hydraulic loading rate • Solid loading rate • Polymer dosage • SS in the WW • Solid recovery percentage

25. 5. Belt filter press Hydraulic loading rate = Sludge Feed rate Belt width Solid loading rate = Sludge flow rate * S.S in the feed *density of w.w Belt width Polymer dosage = Polymer dosage*powdered polymer*density of ww Solid loading * belt width The suspended solid in ww = wash-water solids + Filtrate solids Solid recovery % = (total solids in feed sludge )-(SS in wastewater) Total solids in feed sludge

26. 1. Purchase cost of the major equipment (PCE) For Example: - Purchase cost of Trickling filter @ 1990 = 760,000 $ - @ 1998 the PCE = 284,564 X (109/100) = 310,175 $ - Inflation rate% (1998-2002) = 10.1  Cost @ 2002 = 310,175 X (1.101) = 341,502 $

27.  Total purchase cost of major equipment item (PCE)

28. Estimation of total investment cost Total investment cost = Fixed capital + Working capital • Fixed Capital PPC = PCE (1+ f1 + f2 + f3 + f4 + f5 + f6 + f7 + f8 + f9)

29. For refinery wastewater treatment plant, only f1, f2, f3, f4, f8 Fixed capital = PPC (1+ f10 + f11 + f12)

30. Working Capital Working capital allows 5% of fixed capital  Working capital = $ 177,453  Total investment required for the project = $ 3,726,520 • Operating time allowing for plant attainment For 95% attainment  The operating time is 8322 hr/year

31. Operating cost Fixed operating costs: costs that do not vary with the production rate Variable operating costs: costs that are dependent on the amount of the product produced • Fixed costs • Maintenance • 2. Operating labour • 3. Laboratory costs • 4. Rates and any other local taxes • 5. Insurance • 6. Licence fees

32.  Maintenance, take as 5% of the fixed capital  Insurance cost approximated to be 1% of the fixed capital  Operating labour  laboratory costs, take as 20% of the operating labourcosts

33. Variable costs • Raw materials • Utilities Annual operating costs = $ 20157201

34. Direct capital cost • Well supply • Brine disposal • Land • Process equipment • Auxiliary building • Buildings • Membranes Annual operating cost • Electricity • Labor • Maintenance and spares • Insurance • Chemicals • Amortization Indirect capital cost • Freight and insurance • Construction overhead • Owner’s cost • Contingency Unit product cost, $/m3

35. Assumptions • Interest rate i = 5% • Plant life n = 30 yrs. • Plant availability = 0.9 • Amortization factor a = 0.08 yr-1 • Performance ratio = 7.5 kg fresh water/ kg steam • Average latent heat = 2,222.35 kJ/kg • Electric cost = $ 0.025/kWh • Heating steam cost = $ 1.5/m3 • Specific chemical cost = $ 0.025/m3 • Specific cost of operating labour = $ 0.1/m3 • Plant capacity = 32,732.64 m3/d

36. Process simulation Influent characteristic Influent environmental properties

37. Process Description

38. Process simulation Volatile organic compounds (VOC) emission

39. Plant cost estimation Process performance • The % splitting as function of % degradation

40. Process simulation Process performance • The % splitting as function of % degradation

41. Process simulation 4. Processes Performance Process performance • The kg/h of the biomass as % degradation

42. Environmental impact • The evaluation of the potential impacts of suggested projects that relative to the physical, chemical, and biological components of the total environment • To abide with both local and international standards

43. E1 E2 E3 E4 S1 M1 Clarifier CPI DAF M5 TF M2 M3 M4 E4 Thickening M6 Belt filter press S2 M7

44. Health concerns • Benzene • It is water-soluble • It can pass through the soil into underground water • At relatively high exposure levels, It is extremely toxic, even fatal to humans and other organisms • Carcinogenic • Phenol • It can cause muscle pain, liver damage, weight loss, and blood disorders • In animals, high exposure to phenols can result in muscle tremors, severe injury to the heart, kidneys, liver, and lungs, followed by death in some cases • Toluene • It has been linked to headaches, confusion, and memory loss • It can cause damage to the lungs, liver, and kidneys for humans • In animals, it was found that toluene has adversely effect the nervous system

45. Piping & Instrumentation • It shows the engineering detailed of the equipment, instruments, piping, valves and fittings and their arrangements

46. HAZOP analysis of DAF unit

47. Conclusions & recommendations • A survey is essential to recognize and estimate sources and treatment applied • Industrial wastewater plants should be designed for industrial area such as Jabal Ali and Al Ruwais industrial areas • Environmental agencies should conduct survey in order to identify status of industries generating wastewater • Environmental standards should be enforced on industries • Environmental impact assessment should be carried out for such industries • There is emission studies conducted on industries such studies are valuable to identify potential hazards