Waste management at Cosmo Refinery - Excess Activated Sludge Reduction of Waste Water Treating Unit - Waste management at Cosmo Refinery

Transcription

1 Waste management at Cosmo Refinery Waste management at Cosmo Refinery - Excess Activated Sludge Reduction of Waste Water Treating Unit -

2 Contents 1 1.Outline of Cosmo Oil Co., Ltd. 2. Waste materials from refinery 3. Typical waste water treatment flow 4. New reducing technology for excess activated sludge 5. Application of new technology to actual activated sludge process 6. Conclusions

3 Contents 2 1.Outline of Cosmo Oil Co., Ltd. 2. Waste materials from refinery 3. Typical waste water treatment flow 4. New reducing technology for excess activated sludge 5. Application of new technology to actual activated sludge process 6. Conclusions

4 Outline of Cosmo oil Co., Ltd. 3 Net Sales : 2,831,200,000,000- (Fiscal yearend March 31,2007) Employees : 1,916 (as of March 31,2007) Sakai Refinery 80,000BPSD Research and Development Center (Saitama Pref.) Sakaide Refinery 140,000BPSD Total CDU Capacity 635,000 BPSD Head Office Chiba Refinery 240,000BPSD Yokkaichi Refinery 175,000BPSD

5 Research and Development Center of Cosmo Oil 4 R&D Center Petroleum Products Group Hydroprocessing Technology Group Gasoline Production Technology Group Environmental Technology Group Treatment of wastewater, soil, etc. Specialty Chemicals Group New Energy Group Analytical Research Center General Affairs Group

6 Contents 5 1.Outline of Cosmo Oil Co., Ltd. 2. Waste materials from refinery 3. Typical waste water treatment flow 4. New reducing technology for excess activated sludge 5. Application of new technology to actual activated sludge process 6. Conclusions

7 Waste materials from refinery (All Japan) 6 Gross waste materials from refinery in Japan 556,000 Ton (All Japan, 2005) Spent acid 7% Spent alkali 4% Dust 16% Construction waste 2% Others 4% Waste oil 10% Spent catalyst 6% Sludge 51% Most of sludge is discharged from wastewater treating Unit

8 Contents 7 1.Outline of Cosmo Oil Co., Ltd. 2. Waste materials from refinery 3. Typical waste water treatment flow 4. New reducing technology for excess activated sludge 5. Application of new technology to actual activated sludge process 6. Conclusions

9 Typical waste water treatment flow 8 Waste Water Aeration Settling Guard Basin Treated Water Oil separation API: American Petroleum Institute PPI: Parallel Plate Intercepter CPI: Coagulated Plate Intercepter Dissolved-air flotation Coagulation etc Activated sludge process Coagulation Dissolved-air flotation Sand Filteration Activated Carbon treatment etc

10 Oil Separator 9 Dissolved-air flotation API PPI

11 Activated sludge process 10 Feed water (including organic compounds) CO 2 Activated Sludge Tank multiplication of microorganisms Sedimentation tank Treated water Settling section Outside Aeration section Return line for reused sludge Excess Sludge Dehydrator

12 Activated sludge process 11 Settling section Aeration section

13 Existing Treatment System of Excess Sludge 12 Excess Sludge (Cotaind water ratio:99mass%) CO 2 CO 2 Dehydrator Dehydrated Sludge (contained water ratio :85mass%) Incinerator Ash (Waste) CO 2 Landfill,

14 Sludge disposal cost in Japan 13 Waste disposal Difficulties to make a new land-filling Incineration Increasing of waste disposal cost Cost for sludge disposal in Japan currently $ /ton $380/ton? due to lack of landfilling sites Incinerator operation Refining cost increasing (include fuel cost) (Dioxin emission) Modification of incinerator New inexpensive reducing technology for excess activated sludge is requested.

15 Contents 14 1.Outline of Cosmo Oil Co., Ltd. 2. Waste materials from refinery 3. Typical waste water treatment flow 4. New reducing technology for excess activated sludge 5. Application of new technology to actual activated sludge process 6. Conclusions

16 New reducing technology for excess activated sludge 15 Feed water (including organic compounds) CO 2 Solubilized suludge Activated Sludge Tank Sedimentation tank Treated water Settling section Outside Aeration section Return line for reused sludge Excess Sludge Solubilization tank Alkaline substance Mashing pump

17 Solubilization of sludge Aerobic microorganism Microorganism cell wall (membrane) Cell nucleus 16 Microorganism Chemical treatment (Chemical addition and stirring) Microorganism can't eat easily Physical treatment (Mashing machine) Dissolution of cell wall CO 2 +H 2 O Fragments of cell nucleus Microorganism Microorganism can eat easily

18 The change of the sludge by the solubilization processing 17 Leaving for two hours sitting Leaving for two hours sitting Sludge Solubilization before Flocks of Sludge after

19 Contents 18 1.Outline of Cosmo Oil Co., Ltd. 2. Waste materials from refinery 3. Typical waste water treatment flow 4. New reducing technology for excess activated sludge 5. Application of new technology to actual activated sludge process 6. Conclusions

20 Application of new technology to actual activated sludge process Field Test at COSMO OIL refinery( in Sakaide) construction completion January, 2002 Funded by Petroleum Energy Center, Japan Purpose 1. an establishment of 50% reduction operation of excess sludge 2. a finding of operation condition more than 50% reduction of excess sludge 19 Location of Sakaide Refinery Sakai R&D Center (Saitama Pref.) Sakaide 140,000BPSD Yokkaichi Chiba Head Office

21 Aerial photograph of Sakaide refinery 20 Seto Ohashi bridge The Inland Sea of Japan (setonaikai) Sakaide refinery

22 Refinery layout of Sakaide refinery 21 Refinery site area; 798,700 m 2 N Ocean pier of crude oil Sea Berth 300,000 DWT GREEN BELT LCO2 SR VGO-HDS D-HDS HP DDS TOP/VAC HP GO-HDS Refining plants P/F FCC BOILER Crude oil tanks Land shipping LPG tanks Product and semi product tanks Pier 10 Product and semi product tanks Pier 4 Pier 3 5,400 DWT Pier 2 75,000 DWT Pier 7 5,400 DWT Pier 6 3,300 DWT Pier 5 5,400 DWT 5,000 DWT Domestic pier of product oils Wastewater treating unit

23 Process flow of Excess Sludge Reduction system 22 Extracting of excess sludge Feed water (1500-2,400 m 3 /day) Aeration Settling section section (600M 3 ) (450M 3 ) Returning of active sludge Treated water Returning of solubilized sludge LL HL TG FI Returning of excess sludge Circulation pump Solubilization Tank (3 m 3 ) Chemical Tank Chemical Lorry Injection pump Mashing machine

24 Panorama view of sludge solubilization unit 23 Solubilization Tank Chemical Tank 6M Circulation Pump Mashing Machine Chemical Injection Pump 9M

25 Mashing Machine and Solubilization Tank 24 Solubilization Tank Mashing Machine

26 The results of field test 25 Reduction Operation 100 Amount of excess sludge(%) % Reduction of excess sludge Operation Period (day) 50% Reduction of excess sludge continues stably until 2006.

27 Contents 26 1.Outline of Cosmo Oil Co., Ltd. 2. Waste materials from refinery 3. Typical waste water treatment flow 4. New reducing technology for excess activated sludge 5. Application of new technology to actual activated sludge process 6. Conclusions

28 Conclusions 27 Cosmo Oil has established the new excess sludge reducing technology for activated sludge process. ( Proprietary sludge solubilization system) The technology can be applied to existing activated sludge process with simple configuration, low operation cost, low investment, and easy maintenance. Cosmo Engineering Company (CEC) sales the system (CE-ESR system) using this new technology.

29 28 Thank you