TREATMENTOF PETROCHEMICAL WASTEWATERS

Transcription

1 Report No. 80 TREATMENTOF PETROCHEMICAL WASTEWATERS by EARL D. OLIVER September 1972 A private report by the PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE I I MENLO PARK, CALIFORNIA

2 CONTENTS 1 INTRODUCTION SUMMARY... 3 General Aspects... 3 Technical Aspects INDUSTRY STATUS Waste Profiles Petroleum Industry Waste Profiles Petrochemical Industry Waste Profiles Wastewater Treatment Process Usage Petroleum Industry Petrochemical Industry EPA Guidelines Use of Municipal Sewers SIGNIFICANCE OF POLLUTIONAL PARAMETERS Oil Biochemical Oxygen Demand (BOD) Immediate Oxygen Demand (IOD) Chemical Oxygen Demand (COD) Theoretical Oxygen Demand (TOD) Total Organic Carbon (TOC) Toxic Metals Iron Phenols Cyanides Sulfides Free Chlorine Nitrogen and Phosphorus Dissolved Solids Suspended Solids ph Temperature Dams SEPARATION OF ENTRAINED LIQUIDS AND SOLIDS API Separators Baffled and Tubular Separators Review of Processes CPI Separator for 150-p Drops CPI Separator for 60-b Drops V

3 CONTENTS 5 (Continued) Coalescers Flotation Review of Processes Process Description Process Discussion Cost Estimates Flocculation and Sedimentation Chemistry and Physics of the Process Process Description Process Discussion Cost Estimates Comparison of Alternatives ACTIVATED SLUDGE Chemistry of Biological Processes Review of Processes Process Description Process Discussion Cost Estimates PURE OXYGEN ACTIVATED SLUDGE Review of Processes Process Description Process Discussion Cost Estimates AERATEDBASINS AND DITCHES Review of Processes Process Description Process Discussion Cost Estimates TRICKLING FILTERS Review of Processes Process Description Process Discussion Cost Estimates vi

4 CONTENTS OTHER BIOLOGICAL TREATMENTS... Anaerobic Lagoons or Ponds... Anaerobic Contact Units... Post Aeration... Spray-Irrigated Soils... CARBON ADSORPTION... Review of Processes... Process Description... Process Discussion... Cost Estimates... WET AIR OXIDATION... Chemistry... Sludge Treating... Process Description... Process Discussion and Economics... Combined Carbon and Biological Treatment... COOLING WATER BLOWDOWN TREATMENT... Chemistry... Review of Processes... Reduction and Precipitation... Process Description... Process Discussion... Cost Estimates... Ion Exchange Recovery... Process Description... Process Discussion... Cost Estimates APPENDIX A DESIGN AND COST BASIS AND DEFINITIONS... APPENDIX B EFFECTIVENESS OF PETROCHEMICAL WASTE TREATMENTS., APPENDIX C CARBON SPECIFICATIONS... CITEDREFERENCES... PATENT REFERENCES BY COMPANY vii

5 ILLUSTRATIONS Sequence/Substitution Diagram of Waste Treatment Processes API Oil-Water Separator API Separator Capacity on Operating Cost Module of Steeply Inclined Tubes Corrugated Plate Interceptor CPI Separator for 150-b Drops Capacity on Operating Cost CPI Separator for 60-b Drops Capacity on Operating Cost Air Flotation Processes Air Flotation Air Flotation Capacity on Operating Cost Flocculation and Sedimentation Flocculation and Sedimentation Capacity on Operating Cost Activated Sludge Processes Activated Sludge Aeration Basins Activated Sludge Capacity on Operating Cost UnoxSystem Unox Process Capacity on Operating Cost ix

6 ILLUSTRATIONS 8.1 Pasveer Sloot Oxidation Ditch Plan View., Oxidation Ditch Capacity on Operating Cost Trickling Filter,..., Trickling Filter Performance ,..... Trickling Filter Capacity on Operating Cost Carbon Adsorption Carbon Adsorption Capacity on Operating Cost Zimpro Wet Air Oxidation,...,....,..,,... Chromate Precipitation,....., ,... Chromate Precipitation Capacity on Operating Cost,.,., Chromate Recovery , Chromate Recovery Capacity on Operating Cost..,.,..., X

7 TABLES 2.1 Summary of Liquid Waste Treatment Evaluations Estimated Percentage of Petroleum Refineries Using Various Manufacturing Processes Waste Loadings and Volumes per Unit of Fundamental Process Throughput in Older, Typical, and Newer Technologies.,...,.....,....., Waste Loadings and Wastewater Volumes Associated with Fundamental Processes in Older, Typical, and Newer 100,000 bpsd Refineries, , Wastewater Characteristics Associated with Some Chemical Products ' Petrochemical Processes as Waste Sources Chemical Waste Characteristics Estimated Percentage of Petroleum Refineries Using Various Wastewater Treatment Processes Efficiency of Oil Refinery Waste Treatment Practices Based on Effluent Quality Reported Use of Wastewater Treatment Processes in Chemical Industries......,..., Frequent Pollutant Emissions from Some Commonly Encountered Hydrocarbon Processing Units Achievable Effluent Levels for the Petroleum Refining Industry Achievable Effluent Levels for the Organic Chemicals Industry Achievable Effluent Levels for the Plastic Materials and Synthetics Industry Achievable Effluent Levels for the Fertilizer Industry Achievable Effluent Levels for the Inorganic Chemicals, Alkali, and Chlorine Industry Achievable Effluent Levels for the Beverage Industry API Separators for 4 mgd Wastewater API Separator Major Process Equipment and Utilities Summary Xi

8 TABLES 5.3 API Separator 5.4 API Separator 5.5 CPI Separator for 150-p Drops Major Process Equipment and Utilities Summary CPI Separator for 150-u Drops 5.7 CPI Separator for 150-p Drops 5.8 CPI Separator for 6Cbp Drops Major Process Equipment and Utilities Summary CPI Separator for 6s~ Drops 5.10 CPI Separator for 60-p Drops 5.11 Coalescing Devices Patent Summary Dissolved Air Flotation Patent Summary Air Flotation Major Process Equipment and Utilities Summary Air Flotation 5.15 Air Flotation 5.16 Coagulants Patent Summary Sedimentation Patent Summary Flocculation and Sedimentation Major Process Equipment and Utilities Summary Flocculation and Sedimentation 5.20 Flocculation and Sedimentation Xii

9 TABLES 6.1 Activated Sludge Processes Patent Summary , Activated Sludge Apparatus and Aerators Patent Summary ,.,., Sludge Treatment Patent Summary Activated Sludge Major Process Equipment and Utilities Summary Activated Sludge Total Fixed Capital , Activated Sludge Operating Costs , Unox Process Major Process Equipment and Utilities Summary Unox Process Unox Process Aerated Basins and Ditches Patent Summary , Oxidation Ditch Major Process Equipment and Utilities Summary.., Oxidation Ditch Total Fixed Capital , Oxidation Ditch Operating Costs ; Trickling Filters Patent Summary Trickling Filter Major Process Equipment and Utilities Summary Trickling Filter Trickling Filter Carbon Adsorption Processes Patent Summary Xiii

10 TABLES B.l B.2 B.3 B.4 B.5 c.1 Carbon Adsorption Major Process Equipment and Utilities Summary Carbon Adsorption Carbon Adsorption Operating Costs Comparative Economics of Chemical Conditioning and Wet Air Oxidation..., Chromate Precipitation Major Process Equipment and Utilities Summary Chromate Precipitation Chromate Precipitation Chromate Recovery Major Process Equipment and Utilities Summary Chromate Recovery Chromate Recovery Activated Sludge Treatment of Petrochemical Wastes.... Trickling Filter Treatment of Petrochemical Wastes.... Aerated Lagoon Treatment of Petrochemical Wastes..... Waste Stabilization Pond Treatment of Petrochemical Wastes Petrochemical Waste Disposal by Deep Well Inject ion- Typical Installations , Specifications of Several Commercially Available Carbons..., xiv