UAE University

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

• Problem definition
• Objectives
• Process flow sheet
• Material balance
• Equipment design
• Plant cost estimation
• Process simulation
• Environmental impact
• Conclusions Recommendations

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• Refinery WW contains pollutants including
  solids, oil, organic and inorganic components.

• The composition of WW was adopted from Kurkkale
  Petroleum Refinery.

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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

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Process Flow Sheet
CPI Separator
Trickling Filter
Clarifier
DAF
Gravity Thickening
Belt filter press
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Material Balance

• material compatibility

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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

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

• Results

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Equipment Design
2. Dissolved air flotation

• The main required parameters
• Hydraulic loading
• Solid loading
• Air solid ratio

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

• Results

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2. Dissolved air flotation
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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

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3. Trickling filter
To Calculate the filter surface area
To Calculate the filter volume
Calculate the hydraulic and BOD loading
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3. Trickling filter
To calculate the efficiency of the filter
Calculate recirculation factor
Calculate the efficiency
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3. Trickling filter

• Results

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Equipment Design
4. clarifier

• The main required parameters
• Width
• Surface area
• Weir length
• detention time

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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)
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Equipment Design
5. Gravity thickening

• The main required parameter
• Area of thickener

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5. Gravity thickening
To calculate area of thickener
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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

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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 dosagepowdered
polymerdensity 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
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1. Purchase cost of the major equipment (PCE)
For Example - Purchase cost of Trickling filter
_at_ 1990 760,000 - _at_ 1998 the PCE 284,564 X
(109/100) 310,175 - Inflation
rate (1998-2002) 10.1 ? Cost _at_ 2002 310,175
X (1.101) 341,502
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? Total purchase cost of major equipment item
(PCE)
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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)
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For refinery wastewater treatment plant, only f1,
f2, f3, f4, f8
Fixed capital PPC (1 f10 f11 f12)
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• 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
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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

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? 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
labour costs
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• Variable costs

• Raw materials
• Utilities

Annual operating costs 20157201
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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
• Owners cost
• Contingency

Unit product cost, /m3
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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

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Process simulation
Influent characteristic
Influent environmental properties
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Process Description
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Process simulation
Volatile organic compounds (VOC) emission
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Plant cost estimation
Process performance

• The splitting as function of degradation

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Process simulation
Process performance

• The splitting as function of degradation

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Process simulation
4. Processes Performance
Process performance

• The kg/h of the biomass as degradation

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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

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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

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Piping Instrumentation

• It shows the engineering detailed of the
  equipment, instruments, piping, valves and
  fittings and their arrangements

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HAZOP analysis of DAF unit
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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

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