Kwinana Refinery 2007 2009

BP Refinery (Kwinana) Mason Road, Kwinana, WA 6167
Public Environmental Report Jan 2007 Dec 2009
Public Environmental Report 2009
TABLE OF CONTENTS 1 INTRODUCTION ..............................................................................................11 1.1 Aim and Scope of the Public Environmental Report ...............................11 1.2 General information on BP Refinery (Kwinana).......................................11 1.3 Environmental Management System .....................................................14 1.4 Objectives and targets............................................................................14 1.5 Major modifications since the 2006 Public Environmental Report..........15 1.6 New Significant Environmental Aspects.................................................17 PETROLEUM REFINING ..................................................................................18 2.1 History of BP Refinery Kwinana..............................................................18 2.2 Crude processing at BP Kwinana Refinery .............................................20 ENVIRONMENTAL MANAGEMENT SYSTEM...............................................29 3.1 Policy ......................................................................................................29
Kwinana Refinery Environmental Policy ............................................................30 3.2 Legal and other requirements.................................................................32 3.3 Environmental Aspects...........................................................................32 3.4 Objectives and Targets ...........................................................................32 3.5 Environmental Management Program ....................................................33 3.6 Audits .....................................................................................................34 3.7 Non-conformance Reporting and Incident Investigation .........................34 3.8 Management Review .............................................................................34 4 ENVIRONMENTAL NOTIFICATIONS..............................................................35 4.1 The Structure of Environmental Enforcement ........................................35 4.2 BP Refinery (Kwinana) Environmental Notification History .....................35 SIGNIFICANT ENVIRONMENTAL ASPECTS .................................................37 AIR EMISSIONS...............................................................................................41 6.1 Introduction ............................................................................................41 6.2 Particulates .............................................................................................42 6.3 Sulphur Dioxide (SO2) .............................................................................50 6.4 Oxides of Nitrogen (NOX)........................................................................56 6.5 Carbon Dioxide (CO2)..............................................................................60 6.6 Hydrogen Sulfide (H2S) ...........................................................................72 6.7 Volatile Organic Compounds (VOC) ........................................................75 6.8 Carbon Disulphide (CS2)..........................................................................81 6.9 Odour .....................................................................................................84 6.10 Odour - Carbonyl Sulphide (COS)............................................................87 6.11 Noise ......................................................................................................90 6.12 Smoke ....................................................................................................94 6.13 Hydrogen fluoride (HF)............................................................................97 6.14 Methane ...............................................................................................100 6.15 Carbon Monoxide (CO) .........................................................................102
5 6
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6.16 Benzene................................................................................................108 6.17 Heavy metals........................................................................................112 6.18 1,3 Butadiene .......................................................................................122 7 WATER EMISSIONS......................................................................................125 7.1 Introduction ..........................................................................................125 7.2 Waste Water Treatment Plant (WWTP)................................................127 7.3 Hydrocarbons .......................................................................................128 7.4 Sulphides ..............................................................................................134 7.5 Fluoride.................................................................................................138 7.6 Phenolics ..............................................................................................142 7.7 Nitrogen................................................................................................145 7.8 Heavy metals........................................................................................150 7.9 Arsenic..................................................................................................151 7.10 Cadmium ..............................................................................................154 7.11 Chromium.............................................................................................157 7.12 Cobalt ...................................................................................................160 7.13 Copper ..................................................................................................163 7.14 Lead......................................................................................................166 7.15 Mercury ................................................................................................169 7.16 Nickel....................................................................................................172 7.17 Vanadium..............................................................................................175 7.18 Zinc .......................................................................................................178 7.19 pH.........................................................................................................181 7.20 Temperature .........................................................................................185 7.21 Total Suspended Solids ........................................................................188 7.22 Chemical oxygen demand (COD) / Biological oxygen demand (BOD) ..192 7.23 Refinery Water Use ..............................................................................197 SOLID WASTE ...............................................................................................201 8.1 Background...........................................................................................201 8.2 Management Systems & Waste Facilities............................................203 8.3 Current Wastes Produced & Disposal Routes ......................................208 8.4 Performance .........................................................................................211 8.5 Future Plans..........................................................................................212 SOIL AND GROUNDWATER .........................................................................213 9.1 Historical Background ...........................................................................213 9.2 Setting ..................................................................................................215 9.3 Subsurface hydrocarbon .......................................................................217 9.4 Recent Investigations ...........................................................................229 9.5 LNAPL Recovery Methods ...................................................................234 9.6 Subsurface product recovery................................................................238 9.7 Treatment of Contaminated Soil...........................................................240 9.8 Historical contaminated sites................................................................241 9.9 Future Plans..........................................................................................246
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10 11
BIODIVERSITY ...............................................................................................247 VERIFICATION STATEMENT ........................................................................249
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LIST OF FIGURES Figure 1: Location of BP Refinery (Kwinana) in relation to Australia. .........................12 Figure 2: Location of BP Refinery (Kwinana) within the Kwinana Industrial Area...................................................................................................................13 Figure 3: Location plan of BP Refinery (Kwinana). .....................................................18 Figure 4: Simplified flowchart of crude processing at the BP Refinery (Kwinana), from the Crude Distillation Units to the resulting products..............20 Figure 5: The two Crude Distillation Units at the BP Refinery (Kwinana), with the Residue Cracking Unit in the distance. .......................................................21 Figure 6: The Catalytic Reformer (CR3) at BP Refinery (Kwinana). ............................24 Figure 7: The Bitumen Unit at BP Refinery (Kwinana). ..............................................25 Figure 8: The East flare at BP Refinery (Kwinana). ....................................................26 Figure 9: The Waste Management Area at BP Refinery (Kwinana). ..........................27 Figure 10: Salt Cooling Water Circulars .....................................................................28 Figure 11: Flow chart of the BP Refinery (Kwinana) Environmental Management System (EMS). ............................................................................29 Figure 1: Filter elements from the Pall Filter being lifted into place...........................43 Figure 13: Particulate Emissions from BP Refinery (Kwinana) from 1992 to 2009. .................................................................................................................45 Figure 14: Visible Particulate Emissions prior (left) and After the Installation of the Pall Filter (right). ......................................................................................46 Figure 15: Hourly average particulate emissions for BP Refinery (Kwinana) 2007 and 2009 [see Note below]. .....................................................................47 Figure 16: Yearly SO2 Emissions...............................................................................54 Figure 17: Sources of NOX Emissions from BP Refinery (Kwinana) in 2009..............57 Figure 18: The NOX Emissions from the BP Refinery 1990 to 2009 (Kwinana). ........59 Figure 19: The Greenhouse Effect that creates a blanket of warm air around the Earth. ..........................................................................................................60 Figure 20: Cogeneration Plant (COGEN) next to the Refinery that produces steam and electricity used by the Refinery. ......................................................62 Figure 21: BP Kwinana Continuous Catalytic Reformer (left) and VDU furnace (right).................................................................................................................63 Figure 22: Plantation of Maritime Pines in the South-West of Western Australia. ...........................................................................................................64 Figure 23: Decommissioned Inefficient Boiler (left) and Mission Energys Cogeneration Plant (right)..................................................................................65 Figure 24: New Induced Draft Fan on Crude Distillation Unit One (left) and New Stripper Structured Packing Prior to Installation on Crude Distillation Unit Two (right). ...............................................................................66 Figure 25: Energy Efficient Hydrofiner 3 Unit. ...........................................................67 Figure 26: CO2 Emissions from BP Refinery (Kwinana). ............................................68 Figure 27: CO2 Emissions from BP Refinery (Kwinana) (t/yr) per unit throughput (t/yr). ...............................................................................................69 Figure 28: The Energy Intensity Index Performance at BP Refinery (Kwinana) for the Past 8 years. The Lower the EII the Better the Performance................70
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Figure 29: Hydrogen Sulphide Emissions from BP Refinery (Kwinana). ....................74 Figure 30: Aerial View of the Tank Storage Facility at BP Refinery (Kwinana). ..........76 Figure 31: (left) The Inlet of the API (where the Oily Water Sewer Enters the Waste Water Treatment Plant) is Open to Atmosphere, (right) Sewer Box with Open Vent to Atmosphere. ................................................................76 Figure 32: VOC Emissions (tonnes) from Different Sources Within the BP Refinery (Kwinana) in 2009. ..............................................................................77 Figure 33: Leak Detection Monitoring at the Waste Water Treatment Plant.............78 Figure 34: Total VOC Emissions from the BP Refinery (Kwinana) since 1993. ..........79 Figure 35: Emissions of Carbon Disulphide from BP Refinery (Kwinana) 20072009. .................................................................................................................82 Figure 35: BP Refinery (Kwinana) Land Farm cell and Waste Water Treatment Plant (WWTP). .................................................................................85 Figure 37: COS Emissions from BP Refinery (Kwinana) 2004-2009. .........................88 Figure 38: RCU Silencer installed in 2008 at BP Refinery (Kwinana). ........................91 Figure 39: VDU Furnace.............................................................................................95 Figure 40: The new Rapid Acid Dump system, installed in 2008...............................99 Figure 41: Carbon Monoxide Emissions from BP Refinery (Kwinana) from 1995 to 2009. ..................................................................................................104 Figure 42: Contributors of CO to the Local Airshed of Rockingham, Cockburn and Kwinana for 2008-2009. ...........................................................................105 Figure 43: Number of Days of Unplanned Shutdown of the CO Burner at BP Refinery (Kwinana) Compared to the Target to Achieve 98% Reliability.........106 Figure 44: Benzene Emissions by Source for 2009 from BP Refinery (Kwinana). .......................................................................................................109 Figure 45: Benzene Emissions from BP Refinery (Kwinana)....................................110 Figure 46: Emissions of 1,3 Butadiene from BP Refinery (Kwinana). ......................123 Figure 47: Aerial photograph of the Waste Water Treatment Plant.........................126 Figure 48: Annual Average Daily Hydrocarbon Emissions to Cockburn Sound from BP Refinery (Kwinana) from Treated Process Wastewater. ...................130 Figure 49: Daily Hydrocarbon Emission in Process Water to Cockburn Sound........131 Figure 50: Monthly Averaged Hydrocarbon Emissions in Process Water to Cockburn Sound..............................................................................................132 Figure 51: Quarterly Emissions of Sulphide (kg/day) to Cockburn Sound from BP Refinery (Kwinana).....................................................................................135 Figure 52: Annual Average Daily Emissions of Sulphide from BP Refinery (Kwinana) to Cockburn Sound. ........................................................................136 Figure 53: BP Refinery (Kwinana) Alkylation Unit. ...................................................139 Figure 54: Quarterly Average Fluoride Emissions to Cockburn Sound from BP Refinery (Kwinana) Process Wastewater from 2007 to 2009. ........................140 Figure 55: Quarterly Average Phenol Emissions (kg/day) to Cockburn Sound from BP Refinery (Kwinana) Process Wastewater. .........................................143 Figure 56: Nitrogen Daily Load to Cockburn Sound (kg/day) from BP Refinery (Kwinana) Process Wastewater. .....................................................................147 Figure 57: Nitrogen Quarterly Average Emissions (kg/day) to Cockburn Sound from BP Refinery (Kwinana) Process Wastewater. .........................................147
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Figure 58: Annual Average Daily Total Nitrogen Emissions to Cockburn Sound from BP Refinery (Kwinana) Process Wastewater...............................148 Figure 59: Monthly Average Arsenic Concentrations (mg/L) in Process Wastewater from January 2007 July 2009...................................................152 Figure 60: Cadmium Concentrations in Wastewater from BP Refinery (Kwinana) from 2007 to 2009. .........................................................................155 Figure 61: Chromium Concentrations in Wastewater from BP Refinery (Kwinana) from 2007 to 2009. .........................................................................158 Figure 62: Cobalt Concentration in Wastewater from BP Refinery (Kwinana) from 2007 to 2009. .........................................................................................161 Figure 63: Copper Concentration in Wastewater from BP Refinery (Kwinana) from 2007 to 2009. .........................................................................................164 Figure 64: Lead Concentration in Wastewater from BP Refinery (Kwinana) from 2007 to 2009. .........................................................................................167 Figure 65: Mercury Concentration in Process Wastewater from BP Refinery (Kwinana) from 2007 to 2009. .........................................................................170 Figure 66: Nickel Concentration in Process Wastewater from BP Refinery (Kwinana) from 2007 to 2009. .........................................................................173 Figure 67: Vanadium Concentration in Process Wastewater from BP Refinery (Kwinana) from 2007 to 2009. .........................................................................176 Figure 68: Monthly Average Zinc Concentration (mg/L) in Process Wastewater from BP Refinery (Kwinana) from 2007 to 2009. ........................179 Figure 69: pH Measurements of the Process Wastewater from BP Refinery (Kwinana) to Cockburn Sound. ........................................................................183 Figure 70: BP Refinery (Kwinana) Salt Cooling Water flow diagram. .......................186 Figure 71: Salt Cooling Water Outfall Temperature Differences from BP Refinery (Kwinana) 2007 to 2009. ...................................................................187 Figure 72: Monthly Average Daily Concentrations of Total Suspended Solid (TSS) in Process Wastewater from BP Refinery (Kwinana) Discharged to Cockburn Sound..........................................................................................190 Figure 73: The Annual Average Concentration of Total Suspended Solids (TSS) in Process Wastewater from BP Refinery (Kwinana) Discharged to Cockburn Sound..........................................................................................191 Figure 74: Average Monthly Concentrations of Chemical Oxygen Demand and Biological Oxygen Demand from BP Refinery (Kwinana), 2007 to 2009. ...............................................................................................................194 Figure 75: Annual Average Concentrations of BOD (mg/L) in Process Wastewater Discharged from BP Refinery (Kwinana).....................................195 Figure 76: Annual Average Concentrations of COD (mg/L) in Process Wastewater Discharged from BP Refinery (Kwinana).....................................195 Figure 77: Annual Average Daily Water Use at BP Refinery (Kwinana) and Water Use Efficiency (expressed as kL water use / tonne crude throughput). ....................................................................................................199 Figure 78: Old Landfarm (left) and the Current Waste Management Area (right)...............................................................................................................202 Figure 79: Plan of the Waste Management Area (WMA). .......................................205
Figure 80: (a) The Use of the Rotary Hoe to Incorporate Oily Solids into the Landfarm for Bio-remediation (left); (b) and Spreading Oily Solids onto the Landfarm...................................................................................................206 Figure 81: Biopile Cells at BP Refinery (Kwinana)....................................................207 Figure 82: Evidence of Subsurface Hydrocarbon Staining. ......................................214 Figure 83: Photograph of NAPL (degraded diesel) Recovered from a Groundwater Well (Courtesy of CSIRO)..........................................................218 Figure 84: BP Refinery (Kwinana) 900 Series Monitoring Bores..............................219 Figure 85: Location of the PICL and Dune Sparge Lines. ........................................223 Figure 86: Extent of LNAPL Plume..........................................................................225 Figure 87: The Dye Facility Prior to being Upgraded................................................227 Figure 88: The Dye Facility After being Upgraded. ..................................................227 Figure 89: Total Corrosion Control Yard Prior to Upgrade. .......................................228 Figure 90: Total Corrosion Control Yard After Being Upgraded. ..............................228 Figure 91: Location of PB8. .....................................................................................229 Figure 92: Benzene Concentration Contours for PB8 Investigation.........................231 Figure 93: Location of the Southern Dune Dissolved Phase Plume. .......................232 Figure 94: Schematic of Passive Recovery Trench Design......................................234 Figure 95: Location of Passive Trenches at BP Refinery (Kwinana).........................235 Figure 96: Schematic and Photographs of Single Phase Skimmers. .......................236 Figure 97: Solar Powered Air Compressor Units used for Product Recovery. .........236 Figure 98: Schematic and Photographs of Dual Phase Recovery Systems. ............237 Figure 99: Photographs of VER System and Generator...........................................238 Figure 100: Historical Sub-surface Product Recovery..............................................238 Figure 101: Location of BP Refinery (Kwinana) Contaminated Sites .......................245
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LIST OF TABLES Table 1: The Environmental Aspects for BP Refinery in 2009. ..................................38 Table 2: The standards for SO2 concentrations in the air for Western Australia (information from DEC 2009)..............................................................52 Table 3: Emission limits (hourly averages) set by the licence issued to BP Refinery (Kwinana) to maintain SO2 concentrations set by the EPP.................53 Table 4: Performance against operational targets to control SO2 emissions. ...........54 Table 5: Assigned noise levels from the Environmental Protection (Noise) Regulations 1997. .............................................................................................92 Table 6: Emissions of heavy metals to air from BP Refinery (Kwinana) from 2007 2009. ...................................................................................................120 Table 7: Heavy metal emissions from BP Refinery (Kwinana) as a percentage of the total emissions of the substance to the local airshed of Rockingham, Cockburn and Kwinana and the Perth & Rockingham airshed in 2008-2009.......................................................................................121 Table 8: Licence Limits for Hydrocarbon Discharge from BP Refinery (Kwinana). .......................................................................................................130 Table 9: Heavy Metal yearly average load to Cockburn Sound from 2007 to 2009 from BP Refinery (Kwinana) process wastewater..................................150 Table 10: Solid Wastes at BP Refinery (Kwinana)....................................................204 Table 11: Waste Produced by BP Refinery (Kwinana) by Category (tonnes/year). ..................................................................................................211 Table 12: Status of the Refinery Historical Contaminated Sites. .............................241
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LIST OF ABBREVIATIONS BOD Biological Oxygen Demand BPRK BP Refinery (Kwinana) BTEX Benzene, toluene, ethyl benzene and xylene CDU Crude Distillation Unit CR3 Catalytic Reformer 3 COD Chemical Oxygen Demand C3 Hydrocarbon consisting of 3 carbon atoms (eg propane) C4 Hydrocarbon consisting of 4 carbon atoms (eg butane) DEC Department of Environment and Conservation EMS Environmental Management System Hyd3 - Hydrofiner No.3 HSE Health, Safety and Environment LNAPL Light Non Aqueous Phase Hydrocarbons OWS Oily Water Sewer ppmw parts per million by weight RCU Residue Cracking Unit TPH Total Petroleum Hydrocarbons TSS Total Suspended Solids WMA Waste Management Area WWTP Waste Water Treatment Plant
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1 INTRODUCTION
1.1 Aim and Scope of the Public Environmental Report
As part of the BP HSE commitment to openly report our performance, good or bad, all major business operations will periodically produce a public environmental report that is externally verified. The aim of this report is to openly report against BP Refinery (Kwinana) significant environmental aspects. Environmental aspects are identified by the Refinery Environmental Management System (certified to ISO 14001:2004), and are defined as an element of an organisations activity, product or service which can have a beneficial or adverse impact on the environment. This externally verified report covers the performance of the Refinery for the Significant Environmental Aspects for the period 2007 2009. This information is presented with a historical context where appropriate. The aspects have been grouped into the major categories of air emissions, water emissions, soil and groundwater. Where appropriate any Regulatory Notices or Licence exceedances will be discussed (see section 4.1 for further definition of scope in this area). Additional information is also provided on solid waste and biodiversity as there are no significant environmental aspects in these areas. It is not within the scope of this report to cover the health and safety performance of BP Refinery (Kwinana). The scope does not include any external pipelines or BP property leased to third parties. 1.2 General information on BP Refinery (Kwinana)
Located on the edge of the magnificent natural deep-water harbour of Cockburn Sound, Western Australia (see Figure 1: LOaction of BP Refinery (Kwinana) in relation to Australia), the BP Refinery (Kwinana) has been processing crude oil since 1955. The Refinery is approximately 35 km south-west of the City of Perth; the capital city of Western Australia. The majority of the population of Western Australia (~ 2.5 million) live within a 50 km radius of Perth. BP Refinery (Kwinana) is the only refinery in Western Australia and one of only seven in Australia.
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Figure 1: Location of BP Refinery (Kwinana) in relation to Australia.
Currently the Refinery processes approximately 6 million tonnes of crude oil per year. Approximately 65 percent of the Refinery products are transported by pipeline to Fremantle and Kewdale for distribution throughout Western Australia. The remaining 35 percent of products are exported by ship to markets in the remainder of Australia and internationally to South East Asia, New Zealand, the South West Pacific and Japan. The Refinery is located in the Kwinana Industrial Area (see Figure 2: Location of BP Refinery (Kwinana) within the Kwinana Industrial Area.) and is the most isolated refinery in the world. Crude oil is delivered to BP Refinery (Kwinana) mostly by ship, with a small proportion arriving via road transport.
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Figure 2: Location of BP Refinery (Kwinana) within the Kwinana Industrial Area.
The assets of the Refinery have a replacement cost of $2.5 billion, and are operated and maintained by a permanent BP staff of 410 people who are supported by contractors as required. For further information on the history of the Refinery and crude processing please refer to Section 2.
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1.3
Environmental Management System
An Environmental Management System (EMS) is a structured framework to manage environmental issues. It is a commitment of BP Corporate for each major Business Unit to have a certified Environmental Management System. An EMS based on ISO 14001 aims to achieve: Compliance with legislation and regulations, Continual improvement, Management of significant environmental issues and Prevention of pollution.
BP Refinery (Kwinana) first achieved certification of its EMS in 1999, was recently recertified in January 2009 (ISO14001:2004), and will continue to undergo regular audits to maintain this certification. For further information on the EMS at BP Refinery (Kwinana) please refer to Section 3. 1.4 Objectives and targets
The Senior Leadership Team of BP Refinery (Kwinana) set objectives and targets every year for Significant Environmental Aspects. The objectives and targets can be set to maintain business as usual performance, investigate, or implement an improvement. A single Significant Environmental Aspect can have a number of targets associated with it, as targets can be applied to any activity or outcome. Multiple targets may be set, for example, on the inputs that may manage a particular aspect such as equipment reliability and availability; operational conditions such as flow and temperature; emissions monitoring system reliability and on the outputs such as actual emissions. Generally targets will aim to control a particular piece of refinery equipment (and therefore also control the performance), to achieve a task by a particular time (a likely example is to commission a piece of equipment), or a target can directly state a limit to the emission/occurrence of the Significant Environmental Aspect. Targets originate from a number of sources, both internal and external. These include; Licensing requirements, Works Approval documentation, EMS (Environmental Management System) and BP corporate guidelines. An example of a significant environmental aspect that has a number of targets associated with it is particulate emissions. The Environmental Licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation (DEC) requires that particulate emissions from the Refinery never exceed 250 mg/m3, and
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for 95% of the time emissions must not exceed 150 mg/m3. The Refinery has set internal targets on the air velocity in the regenerators, as this partially controls what the particulate emissions will be, as well as targets to ensure compliance with the licence emission limits. The Public Environmental Report reports on the performance of the Refinery for the period 2007 - 2009. It is intended that a Public Environmental Report will be updated every three years and be made available to the public via the Internet. 1.5 Major modifications since the 2006 Public Environmental Report
A number of Refinery modifications have taken place since 2006. These include the: KWRP Tie In, SDOOL Output, Cracker Revamp, Alky RAD, Naptha Splitter, Mercaptan Crudes, Bitumen Plant and Building Changes. KWRP Tie In The tie in to the Kwinana Water Reclamation Plant (KWRP) was completed in 2008. This project involved piping high grade tertiary treated munici0ple wastewater from KWRP into the Refinery. The KWRP purification process treats wastewater from the Water Corporation Woodman Point treatment plant by intense microfiltration and reverse osmosis. This water is then piped into the Refinery where it is used for industrial processes such as steam generation and cooling. BPs investment in the reclaimed water project has freed up nearly two GL - or 800 Olympic size swimming pools - of potable water each year for public use. Furthermore, a future proposal to extend the use of KWRP water for firefighting and other industrial purposes could see this increase. SDOOL Output The second phase of the KWRP upgrade was the connection to the Sepia Depression Ocean Outlet Landline (SDOOL). This connection was completed in July 2009, resulting in no process wastewater being discharged into Cockburn Sound from the Refinery. All BP process water undergoes rigorous treatment prior to discharge. This treated wastewater is now piped through the Water Corporation wastewater infrastructure to the Sepia Depression, 4.1 km offshore from Point Peron. This is preferable to Cockburn Sound discharge as the Sepia Depression has higher dilution and better assimilative capacity than the relatively poorly flushed waters of the Sound.
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Cracker Revamp The Residue Cracking Unit (RCU) is a key unit for the Refinery as it plays a significant role in upgrading less valuable residue into valuable products. Furthermore products from the RCU are processed in five other Refinery units, so availability is crucial to the Refinery. The 2008 revamp of this unit centred on modifications to improve the reliability, yield, process safety and reduce the environmental impacts of the RCU. The environmental improvements achieved through the cracker revamp included: a decrease in Refinery sound power level (a reduction in the Refinery noise impact on the community), improvement to the storage of spent catalyst (eliminating the potential for runoff from the storage pit to contaminate groundwater), a reduction in particulate emissions under startup conditions and the amount of small particulates released into the atmosphere and a reduction in Refinery water usage. Alky RAD HF Alkylation is one of the chemical processes required within the Refinery. This process uses a highly toxic catalyst, hydrofluoric (HF) acid. In 2007 the Alky RAD project reduced the risk associated with this catalyst by introducing a RAD (Rapid Acid Deinventory) system and an Emergency Shutdown System onto the Unit. Although the project was primarily safety based there were also environmental improvements through reduced risk of toxic spills, reduced quantities for any potential leaks and ensuring a reduction in potential environmental impacts for such events. Naptha Splitter The new naptha splitter was built in 2008 to improve feed flexibility and throughput to the Refinery octane upgrading unit, the Catalytic Reformer Three (CR3). The new column was sized for optimal performance on any crude feedstock to ensure crude scheduling optimisation opportunities. Furthermore, the new unit also produces lower benzene levels in reformate. This project had a minor environmental impact with some increases in air emissions. These increases included: NOx (0.25%), VOC (0.01%), particulates (0.7%), CO (0.15%), metals (0.2%), SO2 (0.42%) and CO2 (0.39%). The changes resulted from improved process efficiency and a resulting increase in average feed rate. To offset the increase in CO2, off-site carbon sinks were used. The establishment of tree plantations on salt affected farm land in the south-west of Western Australia mitigates the effects of land salinisation and salinisation of adjacent water bodies, and offsets the Refinery CO2 emissions. The tree plantations provide carbon sequestration rates in the order of twenty tonnes CO2/hectare/year.
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Mercaptan Crudes In 2008 the Mercaptan Crudes project reinstated the capability and flexibility of the Refinery to process crude containing up to 600ppm weight mercaptan. The improvements included reducing the volume of spent caustic generated whilst processing mercaptan crude on the PPU1 (thus ensuring LPG product quality [residue and sulphur] was maintained), changing the catalyst type on the Jet Merox Unit and ensuring that there was no odour risk associated with the handling, storage and processing of mercaptan crude. This project had predominantly economic impacts. Bitumen Plant The Bitumen Emulsions plant was shut down in early 2009 resulting in a reduction in water use for the Refinery. Furthermore, there are plans to decommission the entire plant in the near future. Building Changes Between 2007 and 2009 a number of building renovations and works have been in progress. The Central Control Building (CCB) was completed in 2008 with an extension and blast proof cladding installed appropriate to its location within the Refinery. The Canteen (new building) and Administration building was completed in 2008 and 2009 respectively. The Canteen is at a location further removed from the Refinery and both have been fitted with appropriate protective materials in the structure (ie window coverings and new roofing material (tin)). Further to this, the old canteen building was demolished in late 2009 and a new laboratory building is in the planning stage. These new buildings have a number of environmental improvements including energy efficient lighting, water saving fixtures & fittings and infrastructure to recycle water for garden use. 1.6 New Significant Environmental Aspects
The Refinery has identified numerous new significant environmental aspects since the 2006 Public Environmental Report. These new aspects include numerous category three aspects for air, category four aspects for water and new waste and clean fuel aspects. These new additions are the result of external regulatory obligations and the Refinerys own internal targets and objectives. The Refinery significant environmental aspects are detailed in Section 5.
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2 PETROLEUM REFINING
2.1 History of BP Refinery Kwinana
Figure 3: Location plan of BP Refinery (Kwinana).
In the post World War Two era, Western Australia rapidly developed its manufacturing industries. This industry was important to enable the state to provide for itself and create employment opportunities for a population boosted by post-war immigration. In 1952 the Anglo-Iranian Oil Company, later to become BP, acquired land at Kwinana, and within the same year, site preparation began with clearing and fencing for the construction of an oil Refinery. On the 23rd of January 1953 work officially began with the then Premier of Western Australia, Sir Ross McLarty, turning the first soil. The first piece of Refinery equipment was erected in September of 1953. Construction continued throughout 1954 under the direction of the American firm Kellogg, with the labour force peaking at almost 3,500. In this year an average of three ships per week were arriving from the United Kingdom with equipment and materials, with additional ships also arriving from the eastern states of Australia. On the 11th January 1955 the first crude oil arrived in the ship British Crusader, and at one minute past midnight on February the 1st, crude processing began over three months ahead of schedule.
The Refinery at that time consisted of two Crude Distillation Units (CDU), a Vacuum Distillation Unit (VDU), a Catalytic Reformer (CRU), Fluid Catalytic Cracker, Hydrofiner (Hyd), Bitumen Plant and associated support equipment. At the time the Refinery was built it was the largest industrial engineering project undertaken in Australia and had a design capacity of three million tonnes of crude per year. Since its original construction the Kwinana Refinery has undergone many upgrades and additions to improve the range of crudes it can process, the range and quality of products it can produce and improve the environmental performance of the Refinery. Currently the Kwinana Refinery processes approximately six million tonnes of crude per year and improvements are continuing to be made towards clean fuel production. A simplified flow chart outlining the main processing units and products is shown in Figure 4.
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2.2
Crude processing at BP Kwinana Refinery
BP Kwinana Refinery Flow Diagram

Refinery Fuel Gas Gas Amine & Merox Unit LPG Recovery PPU1 Isomerisation Naphtha Crude Distillation Units Kero/Jet Gas Oil Hydrofiners Catalytic Reformer Jet Merox Sweetening Propane Butane Gasoline Gasoline
Kero/Jet Diesel Diesel
Sulphur Recovery Units

CCS Minalk
Refinery Fuel Gas Sulphur Gasoline Gasoline
Atmos Residue
Residue Cracker PPU2
Vacuum Distillation Unit
Alkylation Cat Poly
Fuel Oil Bitumen Oxidiser Bitumen
Figure 4: Simplified flowchart of crude processing at the BP Refinery (Kwinana), from the Crude Distillation Units to the resulting products.
2.2.1 Distillation Crude oil is not one chemical compound but a combination of hydrocarbons (carbon and hydrogen atoms bonded in various configurations) each with a unique boiling point. Before any other treatment crude is first distilled in the Crude Distillation Units (CDU). Distilling is simply a boiling process that physically separates the crude into a number of fractions and a less volatile residue, by boiling them off at different temperatures. There are two Crude Distillation Units, CDU1 and CDU2, which function in a very similar way. The crude oil is pumped from storage tanks into the CDU and heated, which removes the lighter material from the crude oil. These lighter ends consist of products like Liquid Petroleum Gas (LPG) that is fed to the Propane Production Unit One (PPU1) for separation into propane and butane. The remainder of the crude is further heated in stripping columns, which separates the side stream products according to their different boiling temperatures. These products include kerosene and light and heavy gas oils. The unvapourised residue (atmospheric residue) of the crude oil that remains after the other products that have been removed forms the
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feedstock for the Vacuum Distillation Unit Two (VDU2) or the Residue Cracking Unit (RCU). (See Figure 5).
Figure 5: The two Crude Distillation Units at the BP Refinery (Kwinana), with the Residue Cracking Unit in the distance.
2.2.2 Cracking Residue from the Crude Distillation Units is fed into the Residue Cracking Unit (RCU) where it is converted to lighter components that are more valuable. The heavy residue is fed onto tiny spheres of alumina silica catalyst at high temperatures which crack the long chain molecules of the residue. The products from the reaction are then distilled into cracked spirit, a material suitable for blending in motor spirit (petrol), and other components for gas oils and fuel oils. During the process of cracking large molecules, small amounts of carbon form a layer over the catalyst. This is referred to as coke and if left in the system it will foul the process. The coke is removed by burning the catalyst in the regenerators, and the catalyst can be circulated back to the reactor section of the Residue Cracking Unit. The RCU has two regenerators, one converts the coke directly to carbon dioxide through a combustion reaction that is supplied with excess oxygen. The other regenerator converts the coke to carbon monoxide first by limiting the oxygen
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supply to the combustion. The CO is then converted to CO2, which is an exothermic reaction (i.e. the reaction produces heat), and this heat is used as an energy source to produce steam. 2.2.3 Sweetening The term sweetening refers to the conversion of mercaptans in motor spirit into less odorous disulphides (Leffler 2000). This is done through a series of units that perform in slightly different ways depending on the specific product being produced, but in this report are discussed under the same general heading. There are two Propane Production Units, referred to as PPU1 and PPU2. The PPU1 takes overhead product from the Crude Distillation Units and removes the hydrogen sulphide (H2S). The lighter ends then go to the Refinery fuel gas main for energy production within the Refinery, while the bottom product goes to the Merox Section. Here the mercaptans are extracted from the LPG and oxidised to disulphide oil, and the remaining LPG is separated into propane and butane for sale. The PPU2 takes LPG from the Residue Cracking Unit and removes hydrogen sulphide and mercaptan sulphur. The mixed LPG is then split into C3 and C4 streams, which are then further treated. The C3 stream can be sold directly from this stage, or be passed to the Catalytic Polymerisation Unit (CPU). The bulk of the C4 stream goes to the Alkylation Unit while the remainder goes to the CPU. The CPU takes the C3 and C4 streams from the Propane Production Units and converts them to Polygas, which is used for motor spirit blending. This is done by diluting the feed with LPG, then heating it and passing it into a reactor. The reactor has beds of solid phosphoric acid catalyst, and the reaction produces excess heat. Then Polygas is separated from the C3 and C4 in the Debutaniser, after which the Polygas can be used for blending. The C4 product generally flows to the Alkylation Unit (Butane Splitter), while the C3 product goes directly to sale. The Hydrofiners (Hydrofiner 2 and 3) enable the Refinery to process sour crudes (higher sulphur content). Hydrofiner Unit 2 takes Light Cycle Oil from the Residue Cracking Unit and both take Gas Oil from the Crude Distillation Units. Sulphur is removed through a hydrotreating process, which involves contacting the feedstock with an alumina catalyst in the presence of hydrogen. This converts the existing organic sulphur, nitrogen and oxygen compounds in the feed to hydrogen sulphide, ammonia, water and hydrocarbons. The result is sweetened oil that is blended to make diesel. The Merox Unit takes Jet from the Crude Distillation Units and removes the mercaptans. The process involves treating the Jet with a caustic soda solution in the presence of Merox catalyst and a controlled amount of air injection. After reaction the Jet is fed through sand and clay filters to remove traces of water and surfactants prior to being pumped to storage.
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The Catalytic Reformer upgrades the gasoline and naphtha from the Crude Distillation Units to make them suitable components for blending into motor spirit. There are three parts to the Catalytic Reformer, the first section, the Naphtha Hydrotreater (NHT) is designed to clean-up the naphtha by the removal of sulphur, oxygen and nitrogen compounds. From this process both Light and Heavy Hydrotreated Naphtha are produced, the Light Hydrotreated Naphtha is sent to the Isomerisation unit for upgrading, while the Heavy Hydrotreated Naphtha is sent to the next stage of the Catalytic Reformer. The Heavy Hydrotreated Naphtha is converted to a high octane motor spirit component. This section of the Catalytic Reformer unit is the continuous Catalyst Regenerator that regenerates the reformer catalyst allowing the unit to run continuously. The Isomerisation Unit uses a process designed to upgrade the octane number of Light Hydrotreated Naphtha from the Catalytic Reformer. This conversion occurs in a hydrogen rich atmosphere, over a fixed bed of catalyst. The reaction is exothermic, with the heat of the products being used to preheat the incoming feed. The gas is separated from the liquid product and the resulting Isomerate is moved to storage. The Alkylation Unit produces high-octane motor spirit by reacting butylenes (C4) from the Residue Cracking Unit with isobutene from the Crude Units, Catalytic Reformer and Residue Cracking Unit. Alkylation is the reverse process of cracking, as it takes small molecules and combines them together to make larger ones. This is done using hydrofluoric acid (HF) as a catalyst, and produces a motor spirit component called alkylate. The alkylate has superior stability and anti-knock qualities, therefore when blended into aviation gasoline (Avgas) it improves the environmental and mechanical performance. (See Figure 6).
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Figure 6: The Catalytic Reformer (CR3) at BP Refinery (Kwinana).
2.2.4 Bitumen Plant The heavy ends of crude oil are very complex molecules with high carbon to hydrogen ratios. Bitumen is made from this substance after it is extracted in the Vacuum Distillation Unit. The residue from the Vacuum Distillation Unit enters the blowing tower of the Bitumen Unit and compressed air is injected into the base of the tower. The air causes a chemical reaction, some lighter ends are carried through the vents to the fume disposal incinerator. Different grades/hardness of bitumen are produced by varying the quantity of air and the temperature. (See Figure 7).
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Figure 7: The Bitumen Unit at BP Refinery (Kwinana).
2.2.5 Environmentally related units/areas 2.2.5.1 Sulphur Recovery Unit The Refinery has two Sulphur Recovery Units that remove sulphur from gas streams that could otherwise contribute to atmospheric emissions. The units receive H2S rich gas from various areas of the Refinery, which is absorbed into a solvent and heated to generate a feed gas. The H2S reacts to produce sulphur that is condensed and stored as a hot liquid. The gas can then be used within the Refinery as an energy source and molten sulphur is sent offsite for use in the manufacture of fertilizer and other products. 2.2.5.2 Refinery Flares The Refinery flare is an essential relief system that can safely dispose of any excess gas produced by short duration surges within the Refinery process units. This prevents the dangerous build-up of pressure, and ensures the gases are combusted to less harmful products. (See Figure 8).
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Figure 8: The East flare at BP Refinery (Kwinana).
2.2.5.3 Waste Management Area The Refinery has a specifically built Waste Management Area (WMA) for the handling, storage and treatment of solid wastes produced by the Refinery. The handling and storage facilities in the WMA consist of a Solid Waste Shed, a Drum shed, an Oily Waste Dewatering Shed and a Hazardous Waste shed for the separate undercover storage of solid waste. The WMA also has a large bunded weathering slab constructed of concrete with a leachate collection drain and a High Density Poly-Ethylene (HDPE) liner to prevent contamination of the underlying soil. The weathering slab is used for the mixing, storage and weathering of solid waste. The WMA has lined calcium fluoride dewatering pits and bunded concrete drying slabs for the treatment of calcium fluoride prior to disposal and a landfarm facility for the bio-remediation of oily sludges and oil contaminated soils.
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Figure 9: The Waste Management Area at BP Refinery (Kwinana).
Wastes are tracked by the Environment and Dangerous Goods Team through a permit system controlling the movement of wastes both onsite and offsite. (See Figure 9). 2.2.5.4 Waste Water Treatment Plant The Waste Water Treatment Plant treats wastewater produced by the process units, storm water runoff and maintenance work. The water flows to the plant via the Oily Water Sewer network. The first stage of treatment is the API (American Petroleum Institute Oil Water Separator) which uses gravity, density variation and time to physically separate the free oil, sludge and water. The free oil is returned to the system for reprocessing and the water is pumped to the Equalization Tank to homogenise the flow to the remainder of the plant. From this tank the water is treated in the Dissolved Air Flotation Unit (DAF) for removal of fine suspended oil particles, then the dissolved phase oil and other organic contaminants (e.g. phenolics) are removed in the Activated Sludge Units (ASU). The wastewater is clarified and polished before disposal. Under normal circumstances disposal of treated wastewater occurs through the Sepia Depression Ocean Outlet Landline (SDOOL). The SDOOL is a pipeline that ends 4km offshore at the Sepia Depression. This location has a much higher rate of dilution than within Cockburn Sound and is subject to an extensive monitoring program. A number of industries share the SDOOL pipeline and extensive environmental conditions are a requirement of its use.
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The Refinery also has a once through Salt Cooling Water stream that under normal conditions does not come into contact with hydrocarbons. This water stream is only required to undergo primary treatment in the Salt Cooling Water oil/water separators before the water is returned to Cockburn Sound.
Figure 10: Salt Cooling Water Circulars
See Figure 10 of the Waste Water Treatment Plant at BP Refinery (Kwinana). On the left are two Salt Cooling Water circulars, on the right the two Activated Sludge Units and clarifiers are visible.
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3 ENVIRONMENTAL MANAGEMENT SYSTEM

An Environmental Management System (EMS) is a structured approach to managing environmental issues. BP Refinery (Kwinana) has an EMS based on the international standard ISO 14001:2004, therefore the system is structured, transparent and auditable. This provides the framework for the continual improvement of environmental performance. BP Refinery (Kwinana) achieved its first certification of the EMS in 1999 based on the international standard ISO 14001. The basic structure of the EMS for BP Refinery (Kwinana) is outlined in the Figure 11 below).
1. ENVIRONMENTAL POLICY
2.1. LEGAL AND OTHER REQUIREMENTS 2.2. ENVIRONMENTAL ASPECTS 4.1. .ACTION PLANS FOR TARGETS 4.2. OPERATIONAL CONTROL (Procedures and practices) 4.3. EMERGENCY MANAGEMENT 4.4. TRAINING 4.5. ENVIRONMENTAL RESPONSIBILITIES MATRIX 4.6. COMMUNICATION 4.7. PERFORMANCE MONITORING 6. NON-CONFORMANCE REPORTING & INCIDENT INVESTIGATION
3. OBJECTIVES AND TARGETS
4. ENVIRONMENTAL MANAGEMENT PROGRAMME
5. AUDITING
4.8. RECORDS
7. MANAGEMENT REVIEW
Figure 11: Flow chart of the BP Refinery (Kwinana) Environmental Management System (EMS).
3.1
Policy
The Environmental Policy establishes the overall direction and principles of the Refinery EMS, reflecting the culture and value system of the Refinery. BP Refinery (Kwinana) Policy is aligned with the broader HSE BP Corporate policy of no harm to people, no accidents and no damage to the environment. The BP Refinery (Kwinana) Environmental Policy for 2009 is shown below:
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Kwinana Refinery
Environmental Policy At BP Refinery Kwinana, we are committed to the BP HSE Policy and its stated expectation of no damage to the environment. The prevention of pollution resulting from our operations is of the highest priority to us. We are committed not only to meeting the requirements of our Environmental Protection Act licence and all other environmental legal obligations, but also to the concept of best practice environmental performance. To us, this means managing our operations to the highest standard possible to minimise our potential environmental impact at all times. To provide assurance both to ourselves and our community that we are managing our significant environmental issues effectively, our environmental management system is based upon the requirements of the international standard ISO 14001:2004. It is therefore structured, transparent and auditable and provides the framework for the continual improvement of our environmental performance. We focus our efforts on those environmental issues which we have identified as being most significant to the community and the receiving environment. We set ourselves objectives and targets to manage these significant issues, which address contributing factors within our operations as well as the emissions themselves. All employees and contractors on our site have a role to play in our environmental management system. We are therefore committed to training all personnel to an appropriate level to ensure the effectiveness of our environmental systems and procedures, and to ensure an acceptable level of environmental awareness across our site. Our key environmental goals include: Protecting Cockburn Sound and water resources We protect our groundwater resources by managing our wastes effectively and by our programmes to eliminate oil and chemical spills and improve our chemical storage systems. We aim to eliminate oil and chemical spills from our operation and activities. We will record and measure spills as far as possible to enable us to prioritise our efforts in engineering out problem areas and improving procedures and practices which may result in oil or chemical spills to the ground or water. We aim to reduce our water consumption and manage our sewer discharges and wastewater treatment plant operation to minimise impacts on the receiving water of
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Cockburn Sound. We will work towards zero discharge of process water to Cockburn Sound by participating in the Kwinana Water Recycle Programme (KWRP). Reducing greenhouse gas emissions We participate in the Federal Government Greenhouse Challenge and set ourselves emissions reduction and energy efficiency targets. This includes forestry trials for carbon sequestration in salt affected areas of the State. Furthermore, we will eliminate deliberate operation of refinery process units in a manner which causes production of gases excess to requirements for fuel consumption, sales to Cogen, or other sales, resulting in the disposal of the excess gases to flare. We accept the cost penalties associated with this mode of operation. Reducing Volatile Organic Compounds (VOC) emissions We aim to continually reduce our VOC emissions by the use of best practice equipment and systems and by monitoring and controlling our emissions sources. We have programmes to install closed loop sampling systems, use environmentally friendly valve packings, reduce emissions from our sewers and reduce emissions from tanks storing volatile products. Other Atmospheric Emissions We recognise that sulphur dioxide and nitrogen oxides have the potential to impact on the environment, and we are therefore committed to reducing these emissions. We will operate our plant so as to keep SO2 emissions to the lowest practicable levels and aim to reduce NOx emissions by optimising furnace performance and efficiency and selecting low NOx burners for new furnaces and when existing furnace burners are upgraded. We will continue to manage our particulate emissions. Supplying Clean Fuels We are committed to playing a role in improving Perth air quality by supplying the cleanest possible fuels consistent with market expectations. We will continue to work with our environmental regulator and other stakeholders to move the fuel quality agenda forward in this state.
Des Gillen March 2010 Business Unit Leader
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3.2
Legal and other requirements
It is a requirement of ISO 14001 to identify, and have access to, the legal and other requirements that the Refinery believes are applicable to the environmental aspects of its activities, products and services. The sources of these requirements include legislation, agreements with regulators, international agreements and voluntary commitments. All legal and other requirements for BP Refinery (Kwinana) are compiled in the Environmental Legal Register, and responsibilities to meet these requirements are allocated to members of the leadership team. 3.3 Environmental Aspects
An Environmental Aspect is defined by the ISO 14001 Standard as an element of an organizations activity, product or service which can have a beneficial or adverse impact on the environment. BP Refinery (Kwinana) has environmental aspects relating to air emissions, solid wastes, wastewater discharges, soil and groundwater contamination, resource usage (water and energy), nuisance (odour and noise), product quality and biodiversity. 3.4 Objectives and Targets
BP Refinery (Kwinana) annually sets objectives and targets for environmental performance based on legal and other requirements, technology options, financial, operational and business requirements and the views of the local community and the regulators. All Significant Environmental Aspects have objectives and targets that reflect the policy of the Refinery. There are three types of objectives and targets; business as usual targets that are achieved by managing day-to-day activities, investigation targets that are set when there is not enough information to make a change and improvement targets that are set when a change can be implemented.
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3.5
Environmental Management Program
This is the part of the Environmental Management System that outlines how it should be run. 3.5.1 Action Plans for targets The Environment Management Program requires the Senior Leadership Team to develop action plans to meet improvement and investigation targets. 3.5.2 Operational Control Operations and activities related to significant environmental aspects have been identified, and the engineering and operational control used to manage each significant environmental aspect have been documented. Each of the identified operations and activities are required to have a working procedure that sets operating envelopes for emission control. 3.5.3 Emergency Management All personnel must be aware of their function in an emergency situation, as set out in the Emergency Management Plan, which provides the structure, process and information to respond to emergencies onsite. 3.5.4 Training The environmental training requirements for each role in the Refinery have been determined and new appointees are required to complete their environmental training before acting in the position. 3.5.5 Environmental Duties and Responsibilities Matrix A duties and responsibilities matrix is maintained so the training requirements and responsibilities for each position are recorded. 3.5.6 Communication Internal and external communication is an important part of the Environmental Management System. Internal reporting is required to understand the environmental performance and successfully manage the significant environmental aspects. External reporting provides transparency and demonstrates good citizenship. 3.5.7 Performance monitoring The Refinery has established procedures to monitor and measure the key characteristics of its operations and activities that may have a significant impact on the environment.
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3.5.8 Records The Refinery has established an Environmental Records Procedure to ensure records are securely stored and maintained. This is done by many teams within the Refinery, not only the Environmental Team. 3.6 Audits
An essential component of the ISO 14001 Standard for Environmental Management System is the process of auditing. Internal audits are conducted by the Refinery to ensure the program is working effectively and to correct any non-conformances. Surveillance audits and re-certification audits are carried out six-monthly and threeyearly respectively by an accredited third party organization (NATA Certification Services International) to ensure compliance with the standard. 3.7 Non-conformance Reporting and Incident Investigation
A non-conformance occurs when a requirement of the Environmental Management System is not fulfilled, for example failure to follow a procedure. When an environmental incident is identified it is reported and investigated with the actions arising from the investigation tracked to ensure adequate completion within the nominated time frame. The Refinery has established a procedure defining the responsibility and authority for handling and investigating incidents. The Senior Leadership Team will determine the level of investigation required and will appoint Investigation Team Leaders. The recommendations resulting from the investigation will be assigned to relevant areas and dates for completion set. 3.8 Management Review
The Annual Management Review allows the Senior Leadership Team to evaluate the performance of the EMS and establish the EMS future direction, including the objectives and targets for the coming year.
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4 ENVIRONMENTAL NOTIFICATIONS
4.1 The Structure of Environmental Enforcement
The enforcement guidelines of the Environmental Protection Act 1986 describe the structure of the tiered offences and penalties regime. There are three levels of offence under the Act reflecting the relative seriousness of offences. Tier one offences are committed intentionally, or with criminal negligence, resulting in actual damage to the environment or a serious breach of trust. Tier two consists of statutory offences, such as a breach of licence condition. There is an option to deal with a Tier two offence with a modified penalty if the Chief Executive Officer of the DEC has the opinion it is more appropriate than a prosecution. Tier three offences consist of minor technical offences, and may be dealt with by an infringement notice and the payment of a fine. A licence exceedance is defined as exceeding a numerical threshold. Licence noncompliance relates to any other requirements within the Licence. Please note Licence non-compliances are only included in this document where they are considered to have impacted on the environment. A DEC inspector or authorized officer may also issue an Environmental Field Notice, which is essentially a warning. Warnings may be issued in cases of minimal potential/actual environmental damage, of a minor technical breach of instrument or regulation, or if the matter can be quickly corrected. 4.2 BP Refinery (Kwinana) Environmental Regulatory Notices
BP Refinery (Kwinana) received two Infringement Notices and two Environmental Field Notices between 2007 and 2009. The first infringement notice was from the 11th November 2007 when 70L of hydrocarbon was released from a pipeline on the Kwinana Bulk Berth #2 (formally the AIS jetty), north of BP Refinery. This release occurred from a disused bunkerline, not used by BP Refinery since the early 1990s. The hydrocarbon release resulted in an oil slick of 100m by 10m in Cockburn Sound. This oil was subsequently broken up by boat. The DEC issued an infringement notice of $250 based on the risk being known to the Refinery. The Refinery had attempted to access the jetty on previous occasions to remove any remaining oil but was unable to do so due to the owner activities. An investigation into the incident highlighted that the pipeline had been blanked without allowing for a thermal relief valve. This resulted in a boxed in line and a
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resulting valve leak. To reduce the risk of reoccurrence the investigation ensured internal procedural changes. These changes involved formal reviews for all activities that modify a process or instrumentation and a review of all Kwinana Bulk Berth jetty pipelines to assess their status and remove any residual oil. The second infringement notice related to the discharge of firefighting foam concentrate from the Refinery jetty on 19th October 2008. This resulted in 800L of firefighting foam entering Cockburn Sound. This release occurred due to a hole in the jetty foam concentrate line. The concentrate entered the water beneath the pipeline and dissipated without foaming. The leak was stopped by relieving pressure in the line and isolating it prior to repairs to reinstate it. The DEC issued an infringement notice of $500 for the release of concentrate containing zinc oxide into Cockburn Sound. An investigation into the incident found that the pipeline had some areas of corrosion and that the timeframe for assessment of the line was too long. To prevent such incidents reoccurring procedural changes were implemented for improved inspection within shorter timeframes and improved risk assessment and notification. The two field notices issued between 2007 and 2009 were both related to an inspection on the 10th July 2008; 1) in breach of Regulation 8 of the Environmental Protection (Abrasive Blasting) Regulations 1998 for not removing abrasive blasting waste from the blasting area as required by the Regulations (this was rectified through an update to the appropriate procedure). 2) in breach of Regulation 10 of the Environmental Protection (Metal Coating) Regulations 2001 for not using compliant storage for chemicals/paints (rectified through moving the chemicals/paint into the bunded, compliant storage area that was already present and updating the procedure to ensure this becomes mandatory within 24 hours of delivery). BP Refinery (Kwinana) had four Licence limit exceedances and one Licence Target exceedance during the peroid 2007 to 2009. All Licence exceedances were attributed to Particulate emissions from the Residue Cracker Unit (RCU), these are discussed in Section 6.2. The Licence target exceedance was attributed to Biochemical Oxygen Demand (BOD) from treated process wastewater, this is discussed further in Section 7.22.
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5 SIGNIFICANT ENVIRONMENTAL ASPECTS

An Environmental Aspect is defined by the ISO 14001 Standard as an element of an organizations activity, product or service which can have a beneficial or adverse impact on the environment. The general categories of environmental aspects of BP Refinery (Kwinana) are air emissions, solid wastes, wastewater discharges, soil and groundwater contamination, resource usage (water and energy), nuisance (noise and odour), product quality and biodiversity. BP Refinery (Kwinana) has developed a ranking system that classifies each aspect in Categories One through to Four. The aspects that qualify as a Category One are the most Significant Environmental Aspects and are typically regulated, have a high profile and have a licence limit on emissions. The Refinery must consider its activities, products and services, present and relevant past activities, direct and indirect impacts, and normal, abnormal and emergency conditions when identifying environmental aspects. Once identified, Environmental Aspects are assigned to a category using a number of rules specific to if it is an air/water/soil and groundwater, solid waste or historical contaminated sites aspect. Examples of rules that determine the category level are the licence conditions or regulations that apply to the aspect, the potential to cause external complaints and the potential to cause impacts on human health. The environmental aspects for 2009 are shown in Table 1: The Environmental Aspects for BP Refinery in 2009. Significant Environmental Aspects have objectives and targets set for performance each year. Some of the significant environmental aspects are also licensed by DEC. This report compares the performance for significant environmental aspects against licence limits and objectives and targets where appropriate. Some additional Environmental Aspects that are of public interest are also included to provide a complete picture of the Refinery environmental performance, however many of these additional Environmental Aspects do not have set formal objectives and targets. These have been identified in Table 1: The Environmental Aspects for BP Refinery in 2009.
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Table 1: The Environmental Aspects for BP Refinery in 2009.
AIR EMISSIONS
Category 1 SOX NOX VOCs CO2 Particulates Odours Odours (COS) H 2S CS2 HF Smoke Noise Methane Category 2 CO Benzene Heavy metals PAHs Chlorine Acid gases Dioxins F Halons Ammonia Category 3 Toluene Xylene 1, 3 Butadiene 1, 2 Dibromoethane Acetaldehyde Cumene Cyclohexane Ethyl Benzene Formaldehyde n-Hexane Phenolics Styrene Category 4 H2 Organic Pb
WATER EMISSIONS
Category 1 Oil Sulphides Fluoride Phenols Nitrogen Arsenic Cadmium Chromium Cobalt Copper Lead Nickel Vanadium Zinc pH Temperature Category 2 MBAS Halogenated Organics Chlorine/ Bromine Phosphorous Dioxins Aluminium Iron Manganese Selenium Ammonia MTBE Category 3 Category 4 PAHs Benzene Total Dissolved Solids Toxicity Toluene Xylene Hexane Cumene Styrene Ethyl Benzene Ethylene Glycol Cyanide Metals (other than those individually listed)
total Suspended Solids COD/BOD Refinery Water Use Mercury
SOLID WASTE
Category 1 Category 2 Alky Holding Basin Sludge Alky Cooling Tower Sludge CDU 1 Desalter Sludge CDU 2 Desalter Sludge SGA Cooling Tower Sludge Category 3 Alky Cooling Tower Scrap Wood Bitumen Waste Bitumen Hotmix CDU Filter Salt Alky Feed Drier Alumina Category 4
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Category 1
Category 2 Acid Tank Bottoms Caustic Tank Bottoms PCB Oily Sump Sludge HX Cleaning Solids Pyrophoric Scale Refractory Brick TEL Scale CPU Catalyst Hydrotreater Catalyst White Oil Tank Bottoms Dark Oil Tank Bottoms Slops Recovery Basin Bottoms WWTP Biosludge BPRK Contaminated Soil
Category 3 Air Drier Alumina Chloride Treater Reformer Catalyst Reduction Gas Filter Cartridges Filter Clay Coalescer Coalescer Cartridges Activated Alumina Isom Catalyst Merox Catalyst Charcoal Merox Filter Sand Activated charcoal PPU Molecular Sieve PPU Filter Sand
Category 4
PPU Amine Filter Cartridge RCU Coke Main Fractionator Sludge RCU Oily Catalyst RCU/Minalk Catalyst Air Drier Desiccant Water tank Bottoms Zeolite Resin Contaminated Sulphur SRU Amine Filter Activated Carbon SRU Amine Precoat Filter Sludge SRU Amine Storage Sludge SRU Catalyst Defluorinator Alumina Calcium Fluoride Spent Caustic Tank Bottoms Oily WWTP Algae Scum Polymer Sludge Combustion Soot and Ash Rubble - Bitumen/Concrete Support Balls Unit TAR Scale Unit TAR Sludge Garnet Asbestos General Waste - Non Recycleable General Waste Recycleable Scrap Wood - General Waste Scrap Wood - Recycleable Pallets Used Empty Drums Scrap Metal - HF Service
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SOLID WASTE contCategory 1 Category 2 Category 3 Scrap Metal - TEL Service Clean Fill Vegetation Circular Bottom Sludge Polishing Pond Sludge RCU Spent E-Catalyst RCU Catalyst Fines Category 4
CLEAN FUELS
Category 2 Category 3 Category 4
Category 1 Particulates (managed by sulphur concentration in diesel and petrol) VOC (managed by RVP) Benzene Lead Aromatics Phosphorous Olefins MTBE
SOIL AND GROUNDWATER

Category 1 Sub-surface Oil Category 2 Sub-surface Chemicals Category 3 Category 4
BIODIVERSITY
Category 1 Category 2 Category 3 Biodiversity Category 4
HISTORICAL CONTAMINATED SITES

Category 1 Old Drum Yard Category 2 Category 3 Old Sand Blast Yard* Category 4
Old Scrap Metal Yard RCU Catalyst (600s) Old Flare Site* Old RCU Catalyst Disposal Area PB8 Area
*
Indicates that the site was remediated during 2007-2009
Please note the historical contaminated sites are categorised by area and not by contaminants, this is due to the multiple analytes, above the assessment criteria.
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6 AIR EMISSIONS
6.1 Introduction
At a Petroleum Refinery atmospheric emissions primarily result from the many combustion processes that are used in the processing of crude oils. Heaters (furnaces), sulphur recovery units and catalytic cracking are the main point sources of oxides of carbon, nitrogen and sulphur; and particulates. On the other hand volatile organic compound emissions are sourced mainly from oil storage and handling facilities, flare systems and wastewater treatment. Oil refinery processes require a significant amount of energy; with typically more than 60% of refinery air emissions being related to the production of energy (IPPC 2003). The BP Refinery (Kwinana) has in place licence conditions associated with maintaining emissions below certain thresholds as well as Continuous Emissions Monitoring equipment reliability limits. A licence exceedance is defined as exceeding a numerical threshold value, for example <250mg/m3 particulate concentration out the RCU stack or reliable Continuous Emission Monitor (CEM) data for 90% of the month. On the other hand, licence non-compliances are related to textual conditions, for example not following a specified USEPA test method when carrying out stack testing. During the 2007-2009 period the key area for licence exceedances and noncompliances for the Refinery was Particulates and the associated opacity analyser availability limits (see section 6.2 for further information). The Public Environmental Report reports against the Significant Environmental Aspects of atmospheric emissions. The air emissions section discusses the parameters in order of significance with category one parameters being addressed first.
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6.2
Particulates
6.2.1 What is it? Particulate matter is any solid or liquid airborne substance. There are two common size fractions for particulate matter; less that ten micrometers in diameter (PM10), and less than two and half micrometers (PM2.5). These definitions are not absolute, as thin longer flakes or fibres may be included in either classification. Currently the majority of attention on particulate issues is related to the PM10 size fraction although focus on the PM2.5 size fraction has significantly increased. The values in this report refer to total particulates which includes both size fractions. 6.2.2 Impacts There are two issues to be considered for particulates, the impacts of the particulate itself and the chemical composition of the particulates. The impacts of the particulate itself on humans can include impeeding vision and irritating respiratory passages. Emissions can also affect the aesthetics and utility of an area. The chemical composition of the particulates can have a wider range of effects on humans depending on their nature, ranging from toxic effects, allergic effects, fibrosis (e.g. asbestos) or cancer. Environmental effects are also dependant on the chemical composition as the continual addition of particulates can raise the concentration of substances in water or soils. 6.2.3 Why do we emit it? Particulates are produced in every combustion process. However, different fuels produce different types and amounts of particulates. The amount can be controlled through the conditions of combustion. As well as during combustion, particulates can also be produced from the attrition of solid substances exposed to high wind velocities as small pieces are broken off and carried by the air. 6.2.4 Sources There are many naturally occurring sources of particulates including soil particles carried by wind, sea salt spray, fires and volcanic activity. Since urbanisation new sources have been generated including lawn mowing, vehicle emissions and dust from turbulence on roads. BP Refinery (Kwinana) produces particulates from the Residue Cracking Unit (RCU), Alkylation Unit cooling tower, flares and furnaces. The flares and furnaces are relatively minor sources of particulates with only intermittent emissions when smoke is produced during process upsets. Particulates from the cooling tower are water droplets produced as the water is sprayed during the cooling process.
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The Residue Cracking Unit (RCU) contributes the largest amount of particulates to the total emissions for BP Refinery (Kwinana). The RCU uses a zeolite catalyst to facilitate catalytic cracking reactions. As a result of processing, a waste product called coke (a dense coating of carbon) deposits on the catalyst. In the regenerators coke is burnt off the catalyst to allow the catalyst to be returned to the system to be reused. Due to the high velocities and temperatures the catalyst experiences, small pieces of the catalyst are broken off forming particles. Cyclones are used to prevent this catalyst being lost from the process with the RCU flue gas. However, due to the size of the particulate matter, there are some inadvertent losses to atmosphere carried with the waste flue gas. This waste is emitted from the stacks on both of the Regenerators on the RCU, Regenerator No.One (R1) and Regenerator No.Two (R2). The median flue gas particulate concentrations from the R1 were 73mg/m3 over 2007-2009 and R1 was the largest point source of particulates from the Refinery over this period. For the R2 the median flue gas particulate concentrations over the same period were 30mg/m3. The difference between the two regenerators is due to the Pall filter system which filters out most higher fraction particulates. During short and infrequent unit upset and during RCU startup, the hourly average concentration from R1 and R2 can reach levels of over 1000 mg/m3.
Figure 12: Filter elements from the Pall Filter being lifted into place.
6.2.5 How is it managed? Over the past decade significant improvements have been made in reducing particulate emissions from the Residue Cracking Unit; the main significant contributor to particulate emissions. The Regenerators of the RCU had existing primary cyclones, and R1 had secondary cyclones. Cyclones operate by creating a
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whirlpool effect (centrifugal force) that separates the particulates from the rest of the gas. The particulates are then collected and are available for reuse. In 1992 a secondary cyclone, called a Polutrol, was installed on R2 to reduce emissions. The design specification of the secondary cyclone was to reduce the particulate concentration to 150 mg/m3. The cyclone did at the time reduce the particulate concentration significantly, from 1200 mg/m3 to 200-400 mg/m3. Further process modifications have been made to the RCU since that have reduced particulate concentrations to below 150mg/m3. In 1994 the Riser Termination Device and the Main Fractionator were replaced to enable an increase in RCU throughput. Due to the increase in throughput careful management of the superficial velocity was required to minimise the particulate emissions. The superficial velocity is the velocity of the gas inside the Regenerators, and if this speed is too high there will be an increased incidence of disintegration of the catalyst into finer particles. Alternatively the superficial velocity cannot be too low as then the catalyst will not regenerate as there is insufficient oxygen to burn off the layer of coke and the cyclones do not work as effectively. Management of the superficial velocity could maintain the particulate emissions but it was not able to reduce them significantly, therefore in 1998 feed injectors were replaced and air-rings were modified. These changes to the RCU were not as successful as hoped, and therefore in 2000 the air-rings were replaced in both Regenerators with the aim of reducing particulate concentrations below 250 mg/m3.
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Particulate Emissions from BP Refinery (Kwinana)

1200
Emissions (tonnes/year)
1000 800 600 400 200 0

92 95 96 97 98 99 00 01 03 02 04 05 06 07 08 20 19 19 19 19 19 19 20 20 20 20 20 20 20 20 20
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Figure 13: Particulate Emissions from BP Refinery (Kwinana) from 1992 to 2009.
Currently BP Refinery (Kwinana) is operating below 150 mg/m3 most of the time. As illustrated in Figure 13, there was a significant reduction in 2005 and 2006 from previous years. This was due to the installation of a Pall Filter on the Regenerator Two. In June 2004 BP Refinery (Kwinana) commissioned the Pall Filter with the aim to virtually eliminate visible emissions from R2. Prior to installation of the filter, fine catalyst dust particles formed a visible plume from the stack. Commissioning of the filter has eliminated all visible catalyst dust emissions to the atmosphere from the R2 stack (see Figure 14). In January of 2007 the RCU experienced a process upset and an estimated 45 tonnes of catalyst entered the atmosphere; this contributed to the increase in the RCU particulates emitted during 2007 compared to previous years. During 2009 the Pall filter was offline for a significant period of time undergoing its four yearly clean; hence emissions during this year are also higher than the expected baseline with the Pall filter online.
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09
Figure 14: Visible Particulate Emissions prior (left) and After the Installation of the Pall Filter (right).
The Refinery has a Durag D-R 290 Opacity analyser on both the R1 and R2 regenerators. Opacity is the visual obscurity that appears at the stack discharge point, and is scaled from 0%, when no obscurity occurs, to 100% when the emissions totally obscure any background. Opacity gives an indication of the variation of concentration of particulates leaving a stack. The greater the amount of light blocked, the higher the opacity percentage, and therefore the greater the concentration of particulate emissions through the stack. Particle concentration can be correlated with stack opacity and the Refinery developed a specific equation that is used to calculate the particulate emissions from the opacity readings. Emissions of PM10 at the Refinery are calculated using emission factors and Continuous Emissions Monitoring (CEM) using the RCU opacity meters. The emission factors that are used for this calculation are those recommended as part of the NPI Emission Estimation Techniques Manual for Petroleum Refining (1999), which is based on USEPA standard AP-42 (1998). Emission factors are provided for furnaces, flares, cooling tower aerosols and the SRU. The calculation multiplies the emission factor by the feed flow rate of that unit. In other areas of the Refinery the more minor particulate emissions are controlled by controlling combustion conditions. For example, to prevent excess particulate emissions and black smoke from the flare, the steam flow is controlled. 6.2.6 Context about emissions Data from the National Pollutant Inventory shows that BP Refinery (Kwinana) emitted 0.97% of the total particulate emissions less than 10 micron meters (PM10) to the Perth and Rockingham airsheds in 2008-2009 and 1.52% in 2007-2008. BP Refinery (Kwinana) individually contributed 3.98% of the total particulate emissions to the smaller local airshed of Rockingham, Cockburn and Kwinana in 2009.
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6.2.7 Context about targets There are several targets the Refinery aims to comply with to further reduce the Refinery contribution to particulate emissions in Perths airshed. Some targets are set by the licence issued by the DEC, others are internal EMS targets set by the Refinery. The Refinery licence requires that particulate emissions from the Residue Cracking Unit remain less than 150 mg/m3 (one hour average) for 95% of the operational time, and never exceed 250 mg/m3 (one hour average at any time). 6.2.8 Performance
Figure 15: Hourly average particulate emissions for BP Refinery (Kwinana) 2007 and 2009 [see Note below].
Note: No emissions were reported from 19/08/2008 until 05/05/2009 as a result of unreliable data due to issues with the correlation between measured opacity and particulates concentration. All attempts to rectify the correlation were not successful and it was decided to wait until the major shutdown at the end of 2008 to resolve the problem. During this continuous data outage the Refinery undertook additional stack tests for particulate concentration. The RCU was offline from the 1st October 2008 until 14th December 2008; hence emitting zero particulate emissions during this time. The data shows that generally the Refinery particulate concentration (average of R1 and R2) is operating within the licence limits. The BP Refinery (Kwinana) had a total of four Licence particulate concentration threshold exceedances during the three year period of 2007 to 2009: January 2007
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and February 2008 (both associated with a Main Air Blower Trip), June 2009 and July 2009 (due to a hole on the RCU which required RCU shut-down for repair). All of these Licence exceedance events were reported to the DEC and formally investigated in compliance with the BP Refinery (Kwinana) DEC Licence. Corrective actions which came out of the investigation reports included improvements to procedures, operating conditions and hardware. All actions were all closed out within the required due dates. The BP Refinery (Kwinana) also had three Licence Availability Exceedances during 2007-2009, related to the opacity analysers providing unreliable data (May 2008, August 2008 and June 2009). These exceedances did not result in an actual release of excess contaminants into the atmosphere but were attributed to unreliable analyser equipment. During 2007-2009, in addition to the licence exceedances above, there were also several other minor licence non-compliances as outlined below: 2007 stack sampling ports non-compliance with USEPA Method One. In 2007 it was identified that not all of the Refinery stack sampling ports were fully compliant with USEPA requirements for stack testing. During major, planned maintenance outages in 2008, the Refinery installed new sampling locations on both the Sulphur Recovery Plants and the RCU (Regenerators one and two); these are fully compliant with USEPA Method 1 and AS4323.1. 2009 RCU Regenerator 2 stack testing non-compliance. During the year 2009, compliance stack tests carried out on the Regenerator two stack of the RCU were non compliant with US EPA Method One, due to the fact that the stack diameter was incorrectly measured. This meant that only a proportion of the stack diameter was sampled as opposed to the whole stack. Once the error was identified the data was recalculated. An investigation was carried out and the required corrective actions implemented to avoid similar incidents in the future.
6.2.9 Comments on performance Majority of the licence threshold exceedances occurred during RCU start-up operations. Formal investigations recommended changing the way the start-up of the RCU is conducted to minimise the impact of emissions during these periods. 6.2.10 Future plans It is acknowledged by the Refinery that R1 is the single largest emitter of particulates. Future efforts will be focused on reducing particulate emissions from R1.
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6.2.11 References National Pollutant Inventory (1999) Emission Estimation Technique Manual for Petroleum Refining[online]. Available from: http://www.npi.gov.au/publications/emission-estimationtechnique/pubs/petroleum.pdf. [Accessed 30/11/2010]. Emission Estimation Techniques Manual for Petroleum Refining. Environment Australia. 50pp. USEPA (1998) Compilation of Air Pollutant emission Factors. USEPA Report No. AP-42, Storage of Organic Liquids.
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6.3
Sulphur Dioxide (SO2)
6.3.1 What is it? Sulphur dioxide (SO2) is a colourless gas with a sharp irritating odour. SO2 reacts with other substances to form different compounds, such as sulphuric acid, sulphurous acid and sulphate particles (Environment Australia, 2001). 6.3.2 Impacts Sulphur dioxide reacts directly on the respiratory system as you breathe it in, with the most common symptoms of exposure being coughing, wheezing and shortness of breath. The symptoms can be more pronounced in asthmatics, with the maximum effect occurring within 10 to 15 minutes of exposure (Department of Environmental Protection, 2000). The environmental impact of SO2 is both direct and indirect. SO2 can damage vegetation leaf tissue and affect crop yields. Indirectly atmospheric SO2 has wider affects as it can react with vapour in clouds to form sulphuric acid (H2SO4), commonly known as acid rain. 6.3.3 Why do we emit it? SO2 is produced during the combustion of sulphur containing fuels. This is due to the sulphur naturally occurring in these materials (e.g. coal and oil) being exposed to oxygen during combustion and processing, which allows the sulphur to combine with oxygen to form the atmospheric gas sulphur dioxide. 6.3.4 Sources Natural sources of SO2 are volcanoes, hot springs and the natural decay of vegetative matter. BP Refinery (Kwinana) has two main sources of SO2, the Residue Cracking Unit (RCU) and the Sulphur Recovery Units. The Residue Cracking Unit is a source of SO2 emissions as the coke is burnt off the catalyst to allow reuse. The Residue Cracking Unit uses an alumina silica based catalyst to break long chain hydrocarbons into smaller, more valuable components. As a by-product of this reaction a coating of coke is deposited on the catalyst, which is mainly a dense layer of carbon atoms, however it does contain some sulphur. As the coke is burnt off the catalyst (to allow it to be recycled), the sulphur forms SO2. The Refinery has two Sulphur Recovery Units that receive H2S rich gas from the Refinery fuel gas, sour water stripper off gas and the amine regeneration system. The H2S rich gas is partially converted to SO2 in the muffle furnace, and the SO2 then reacts with the remaining H2S to produce elemental sulphur, these units are designed to recover 95% of the input sulphur.
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The unreacted H2S and SO2 from this reaction is then incinerated at high temperature to SO2 which is then released to atmosphere. 6.3.5 How is it managed? The way in which SO2 emissions are currently managed at the Refinery is based on: Feedstock selection; sour or sweet crudes will have different sulphur contents (sour containing higher sulphur concentrations); Refinery process configuration (for example a product with low sulphur will require additional sulphur removal); Refinery throughputs (volume of); and Scrubbing of H2S from the Refinery Fuel Gas (RFG).
In 1987 the Refinery changed from using fuel oil that contained sulphur compounds to natural gas as a supplementary fuel source, a change that resulted in a 25% reduction in sulphur dioxide emissions. In 1989 and 1992 two Sulphur Recovery Units (SRU) were commissioned to remove sulphur from the Refinery fuel gas and convert it to liquid sulphur, which is then recycled and used by other companies. The Sulphur Recovery Units have the capacity to remove as much as 70 tonnes per day of sulphur from the Refinery fuel gas and other sour gas streams. In 1993 monitoring of SO2 emissions was improved by the installation of Continuous Emissions Monitors (CEM) that give a continous reading of the current emission rates, and work is continuing to ensure the availability and reliability of this data. Management of SO2 occurs on a daily basis through planing the sulphur content of feedstock and monitoring the reliability of the Sulphur Recovery Units to minimise the SO2 emissions from the Refinery. 6.3.6 Context about emissions There are two standards that control the SO2 emissions in Western Australia; the Air National Environment Protection Measure (NEPM) has standards for hourly, daily and yearly averages that apply to the whole of the Perth metropolitan region (excluding the Kwinana Industrial Area), and the Environmental Protection Policy (EPP) has standards and limits for the Kwinana Industrial Area. (refer to Table 2: The standards for SO2 concentrations in the air for Western Australia). The EPP also prescribes the maximum permissible quantities of sulphur dioxide which may be discharged from significant industrial sources in the policy area.)
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Table 2: The standards for SO2 concentrations in the air for Western Australia (information from DEC 2009).
Area A: industry; Area B: buffer zone; Area C: rural/residential. Information from Perth Air Quality Management Plan 2000.
Averaging period 1 hour Air NEPM Standards Kwinana EPP Area A standard Area B standard Area C standard 0.20ppm 700g/m3 500g/m3 350g/m3 24 hour 0.08ppm 200g/m3 150g/m3 125g/m3 200g/m3 1 year 0.02ppm 60g/m3 50g/m3 50g/m3 60g/m3
Residential ....................................................................................................... 700g/m3
The National Pollutant Inventory data shows that in 2008-2009 BP Refinery (Kwinana) was contributing 26.73% of the total SO2 emitted to the local Kwinana, Rockingham and Cockburn airshed, and 23.19% of the emissions to the Perth and Rockingham airsheds. 6.3.7 Context about targets The Department of Environment and Conservation used the standards set out in the Kwinana Environmental Protection Policy to assign SO2 limits to the industries in the area with the aim of maintaining the ambient SO2 levels within the standards. BP Refinery (Kwinana) has licence conditions for SO2 emission control. Licence conditions are applied to total Refinery SO2 emissions as per the relevant SO2 redetermination (DEC 2009) (Table 3: Emission limits (hourly averages) set by the licence issued to BP Refinery (Kwinana) to maintain SO2 concentrations set by the EPP).
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Table 3: Emission limits (hourly averages) set by the licence issued to BP Refinery (Kwinana) to maintain SO2 concentrations set by the EPP.
Column A Maximum Permissible Quantities (g/s) Column B % of time in any 12 months for which total site emissions may exceed the emission rate in Column A. 90.00% 70.00% 2.11% 0.83% 0.49% 0.00%
150.1 200.1 300 350.1 400.1 1000.1
BP Refinery (Kwinana) has set internal targets to limit the amount of trips per year of the Sulphur Recovery Units, as with each unit trip there is a spike in the SO2 emissions. The current targets are to have less than fifteen trips per year associated with mechanical issues and less than ten trips per year associated with operational issues. The Refinery also has targets for the availability and reliability of the continuous emission monitoring system (CEM) and the backup process emission monitoring system that is used if the CEMs are unavailable. 6.3.8 Performance
The total SO2 emissions have been steadily increasing since 1999 (Figure 16). This is due to an increase in Refinery crude throughput as well as processing a greater proportion of sour crude (crude oil containing elevated sulphur contents).
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7000.00
SO2 Emissions and Refinery Throughput by BP Refinery (Kwinana)
6400000 6200000 6000000
SO2 emissions (tonnes/year)
6000.00 5000.00
5800000 4000.00 3000.00 2000.00 5000000 1000.00 0.00

19 94 19 95 19 96 19 97 19 98 19 99 20 00 20 01 20 02 20 03 20 04 20 05 20 06 20 07 20 08 20 09
5600000 5400000 5200000
4800000 4600000
Total SO2 Emissions
Linear (Refinery total throughput)
Figure 16: Yearly SO2 Emissions.
The Performance represented by the number of SRU trips and number of hours above normal emissions.is presented in Table 4: Performance against operational targets to control SO2 emissions. The total number of SRU trips per year has been within the Refinery targets for the last three years.
Table 4: Performance against operational targets to control SO2 emissions.
Emission source Target 2007 2008 2009
SRU1
<15 trips (Mechanical) <10 trips (Operational)
SRU2
<15 trips (Mechanical) <10 trips (Operational)
There were no licence exceedances of emission limits for the period between 2007 and 2009. BP has made a commitment to control the amount of sulphur emissions during the use of its products through the Clean Fuels program. This program commits to supplying petrol and diesel to the market at a lower sulphur content, therefore reducing the emissions from the use of its products. Implementing the Clean Fuels project was predicted to bring a reduction of 5,800 tonnes/year of sulphur dioxide
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Refinery throughput (tonnes/year)
emissions that would otherwise have been emitted to the Perth airshed (BP Refinery (Kwinana) 2000. 6.3.9 Comments on performance BP Refinery (Kwinana) continues to strive to improve its performance against SO2 limits by learning from previous incidents and taking proactive measures. 6.3.10 Future plans The tightening of world crude supplies may require the Refinery to process more sour crude putting pressure on SO2 emissions. BP Refinery (Kwinana) will aim to improve monitoring of emissions and processes, improve the reliability of process units and update technology as required. 6.3.11 References Department of Environment and Conservation (DEC), W.A., July 2009, Redetermination of maximum permissible quanitties of sulphur dioxide under the Environmental Protection (Kwinana) (Atmosperic Wastes) Policy 1999. Environment Australia (2001) Fact sheet Sulphur Dioxide [online]. Atmosphere. Available from: http://www.ea.gov.au/atmosphere/airquality/sulphurdioxide.html [Accessed 10/03/2003]. BP Refinery Kwinana (2000) Clean Fuels Project Phase 2. Environmental Referral Document.
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6.4
Oxides of Nitrogen (NOX)
6.4.1 What is it? The oxides of nitrogen (written as NOX) have different physical and chemical properties, however generally all are gases that have a strong odour and colours that can range from dark brown to colourless. The main oxides of nitrogen are nitrogen oxide (NO) and nitrogen dioxide (NO2). 6.4.2 Impacts Oxides of nitrogen can enter the human body through the lungs, skin or moist surfaces such as the eyes or mouth (Department of the Environment and Heritage, 2003) and have been identified as contributing to respiratory illness, including asthma. The oxides of nitrogen are essential in the upper atmosphere as nitrogen dioxide and oxygen react to form ozone, one of the naturally occurring Greenhouse Gases that maintain the Earth temperature. When present in the lower atmosphere the oxides of nitrogen can react with Volatile Organic Compounds (VOC) to form ozone at ground level where it does not naturally occur. The effect is commonly known as smog, a problem commonly experienced in Perth. Smog is ground-level ozone which is a brownish, toxic gas causing severe lung irritation and an unaesthetic staining in the sky. 6.4.3 Why do we emit it? Combustion reactions convert the nitrogen contained in fuel into nitrogen oxides (known as feed NOX) and at high temperatures the nitrogen naturally contained in the air can also be changed to nitrogen oxides (referred to as thermal NOX). 6.4.4 Sources Natural sources of nitrogen oxides include lightning and biological cycling, which have been enhanced through agriculture. The largest modern source is the burning of fossil fuels; coal, oil and gas. Vehicle exhausts are the largest emitters of NO2 in cities, and gas heaters and cookers are the major source in homes (Department of the Environment and Heritage, 2003). The main sources of NOX gases at BP Refinery (Kwinana) in 2009 were the furnaces (67%) and the Residue Cracking Unit (31%). Other comparatively minor sources were combustion engines, flares and the Sulphur Recovery Units (see Figure 28).
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Contributors to the Total NOx Emissions from BP Refinery (Kwinana) 2009

0% 2% 31%
Furnaces RCU Flares Combustion Engines
67%
Figure 17: Sources of NOX Emissions from BP Refinery (Kwinana) in 2009.
NOX is produced from the furnaces as the fuel gas is burnt and reacts with oxygen. The RCU emits NOX from the Regenerators as the waste product coke is burnt off the catalyst, so that the catalyst can be recycled. 6.4.5 How is it managed? Management of NOX emissions at BP Refinery (Kwinana) involves a combination of emissions monitoring techniques and ongoing design reviews to ensure that the processes and equipment used onsite deliver minimum emissions of NOX. In 1985 the Refinery changed the fuel for the furnaces from fuel oil to fuel gas (a mixture of Refinery Fuel Gas and natural gas), and as this has a lower content of nitrogen the NOX emissions (feed NOX) are reduced. As the Refinery installs new equipment or performs furnace upgrades the traditional Burners are replaced with Low NOX Burners. The Continuous Catalytic Reformer (CR3) is an example of a unit that was built with all low NOX Burners to reduce emissions. Nitrogen oxide emissions from traditional furnaces can be controlled to an extent by the excess oxygen in the flue gas. If there is not enough oxygen the temperature in the furnace will be higher and more of the nitrogen in the air will be converted to NOX. If there is an excess of oxygen in the furnace flue gas then too much cooling will be occurring and the furnace will be energy inefficient, requiring more fuel gas to be burnt for the same amount of heating, which results in increased fuel (feed) NOX emissions. Emissions from furnaces are therefore controlled by balancing oxygen in every furnace to minimize the conversion of nitrogen to nitrogen oxides and maximize the furnace efficiency. Low NOX Burners reduce NOX emissions from improved design characteristics by allowing for reduced peak temperatures, reduced oxygen concentration in the combustion zone and a shorter time at elevated temperatures. At BP Refinery
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(Kwinana) low NOX Burners are currently operating in the CR3, VDU2, Isom Rerun and the Hyd3 unit. The NOX emissions at BP Refinery (Kwinana) are only measured directly and on a continous basis on the Residue Cracking Unit. Other NOX emissions are calculated using emission estimation factors based on stack testing. The emission factors used are those recommended as part of the NPI Emission Estimation Technique Manual for Petroleum Refining (1999). Stack testing is carried out at the Refinery on a yearly basis to determine the parameters needed to calculate NOX emissions. 6.4.6 Context about emissions BP Kwinana is a comparatively minor source of NOX emissions, during the 20082009 reporting year, contributing 1.06% of the NOX emissions to the Perth and Rockingham airsheds, and 4.17% of the emissions to the local airshed of Rockingham, Cockburn and Kwinana. 6.4.7 Context about targets BP Refinery (Kwinana) has set internal targets unique to each furnace to minimize the NOX emissions. The commitment to replace traditional Burners with low NOX Burners ensures that the Refinery will continue to reduce its contribution of nitrogen oxides to the airsheds. 6.4.8 Performance The Refinery NOX emissions have been steadily decreasing over the last 20 years. The NOX emissions reached a record low in 2008, this can be predominately attributed to the large shutdown period during 2008 which meant that the major NOX emitting sources were not operational for a sigificant proportion of the year.
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NOx Emissions from BP Refinery (Kwinana)

3500 3000
(tonnes/year)
2500 2000 1500 1000 500
Figure 18: The NOX Emissions from the BP Refinery 1990 to 2009 (Kwinana).
6.4.9 Comments on performance Emissions over the period 2007 2009 were relatively flat and on average significantly lower when compared to the previous three years of 2004 -06 (Figure 29). 6.4.10 Future plans Over 90% of Refinery NOX emissions come from the RCU and Furnaces (mainly the Reformer and Crude Distillation units); therefore NOX emissions reduction options will be targeted on these units. Options under consideration include the installation of low NOX Burners on the Crude Distillation Units and redesigning the RCU Regenerator One reactor hardware.
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19 90 19 91 19 95 19 96 19 97 19 98 19 99 20 00 20 01 20 02 20 03 20 04 20 05 20 06 20 07 20 08 20 09
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6.5
Carbon Dioxide (CO2)
6.5.1 What is it? Carbon dioxide (CO2) is a colourless gas that has no odour.
6.5.2 Impacts The impact of carbon dioxide on human health is mostly associated with the reduced oxygen availability for breathing when large concentrations of CO2 are present. This can occur in confined spaces with a constant source of CO2. The environmental impacts of carbon dioxide are based on the changes of concentration in the atmosphere. The sunlight that enters the atmosphere warms the Earths surface. Heat energy is then released from the surface to the atmosphere and some gases, known as greenhouse gases, absorb part of this heat. The major greenhouse gases are water vapour, ozone and carbon dioxide, and they are responsible for the natural process called the Greenhouse Effect, as they act like the glass of the greenhouse. Elevated concentrations of carbon dioxide in the atmosphere contribute to the Enhanced Greenhouse Effect, where more heat is being trapped and the temperature of the atmosphere increases.
Some heat reflected by the earth is lost to space
SUN
ATMOSPHERE
Most of the heat is absorbed by the earth's surface
Some heat is trapped by the atmosphere
EARTH
Figure 19: The Greenhouse Effect that creates a blanket of warm air around the Earth.
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The exact degree and time scale of climate change are not known, but it is predicted that the average global temperature rise may lead to extreme weather conditions, with intense rainfall and flooding in some areas, and droughts and increased fire risks in other areas. Figure 19 illustrates the Greenhouse Effect. 6.5.3 Why do we emit it? Carbon dioxide is formed when substances containing carbon are burnt in the presence of oxygen. This is an essential part of the refining process to provide energy. 6.5.4 Sources Natural sources of CO2 include volcanoes, fire, and the decay of organic matter. The Earths atmosphere has a natural concentration of approximately 280 ppm, which has been increased to current levels of around 370 ppm (Atmosphere, Climate & Environment Information Program, 2001). Human activities such as burning fossil fuels and deforestation are believed to be responsible for additional emissions of carbon dioxide in the past 200 years. BP Refinery (Kwinana) produces carbon dioxide from two main sources; the combustion of fuel gas in furnaces for the production of energy and the combustion of coke laid down on the catalyst in the Residue Cracking Unit. 6.5.5 How is it managed? The ongoing management of CO2 emissions from BP Refinery (Kwinana) is performed through an Energy Strategy that monitors the Refinery energy performance and implements projects to improve energy efficiency that lead to reductions in direct or indirect CO2 emissions. Direct carbon dioxide emissions are emissions made from the Refinery stacks or furnaces, and indirect emissions are those that are emitted by a third party in producing steam and electricity that the Refinery purchases (see Figure 20).
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Figure 20: Cogeneration Plant (COGEN) next to the Refinery that produces steam and electricity used by the Refinery.
In the past decade projects have been implemented at the Refinery to reduce both direct and indirect carbon dioxide emissions. This has resulted in a significant net decrease in the CO2 emissions per unit of throughput. In 1996 BP Refinery (Kwinana) in conjunction with Mission Energy LTD, currently International Power LTD, commissioned a cogeneration facility. This plant provides 100% of the Refinery electricity needs as well as steam. The combined production of electricity and steam increased the energy efficiency of electricity production from 47% to 62% (Mission Energy Development 1994), and reduced the Refinery direct CO2 emissions by 42,000 tonnes as inefficient onsite steam boilers were decommissioned. In 1997 a no economic flaring policy was implemented at BP Kwinana, requiring the Refinery to only operate to the level where it can use all fuel gas produced. This requires careful management of all units to optimise throughputs to achieve the reduction in flaring. This policy reduced CO2 emissions by approximately 16,600 tonnes per annum. Modifications to the air system on the Catalytic Reformer were completed in 1997 and considerably improved the furnace efficiency, therefore resulting in reduced CO2 emissions. In 1998 major modifications were carried out on the Vacuum Distillation Unit, including the installation of a new, more efficient, furnace that resulted in reductions in CO2 emissions per unit throughput. (See Figure 21).
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Figure 21: BP Kwinana Continuous Catalytic Reformer (left) and VDU furnace (right).
6.5.5.1 Carbon offsetting BP Refinery (Kwinana) is also actively involved in a carbon offsetting project in the southwest of Western Australia, through the establishment of tree plantations. By carbon offset, the impact of emitting a tonne of CO2 is negated by avoiding the release of a tonne elsewhere, or absorbing a tonne that would have otherwise remained in the atmosphere. Trees can be used to offset CO2 emissions as they remove CO2 from the atmosphere and store it as carbon in their roots, stems, leaves, twigs and in the soil. Since 1997, BP Refinery (Kwinana) have planted more than 2600 ha of trees, predominantly maritime pines (Pinus pinaster), Western Australian Sandalwood (Santalum spicatum) and local native species on farmland in the Katanning area, Western Australia. (See Figure 22). The planting of these trees allows for the sequestration of carbon dioxide. This is due to the fact that the trees absorb carbon dioxide from the atmosphere and convert it into wood. Through this project, BP Refinery (Kwinana) also has the unique opportunity to contribute to the solution of salinity, one of the most serious environmental problems in WA. Western Australia has over 70% of Australias reported dryland salinity, which renders the soil virtually useless with few species of plants being able to tolerate the harsh conditions. Planting of deep rooted tree species in strategic locations allows control of groundwater fluctuations and lowers the water table, therefore reducing the seepage of saline waters to the soil surface.
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Figure 22: Plantation of Maritime Pines in the South-West of Western Australia.
The following information provides a summary of other programs undertaken at the Refinery to reduce its energy use, thereby reducing CO2 emissions. 6.5.5.2 Decommissioning off inefficient boilers Originally the Refinery produced its own steam using relatively inefficient steam boilers. Between 1996 and 1999 these boilers were gradually decommissioned and steam was instead sourced from the neighbouring cogeneration plant where the boilers are 20-30% more energy efficient. (See Figure 23).
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Figure 23: Decommissioned Inefficient Boiler (left) and Mission Energys Cogeneration Plant (right).
6.5.5.3 Crude Distillation 1 & 2 upgrades In March 2000 the furnace on the Crude Distillation Unit One, one of the biggest energy users on the Refinery, was upgraded to a higher efficiency design. The upgrade involved modifying the convection tube configuration and adding an induction fan (Figure 24: New induced draft fan on Crude Distillation Unit One (left) and New stripper structured packing prior to installation on Crude Distillation Unit Two (right)) to allow greater heat recovery from the flue gas. The modifications improved the units overall efficiency by 8-12%. In 2002, modifications were carried out to the crude preheat exchanger network and to the preflash column on the Crude Distillation Unit Two. These changes improved heat recovery from waste heat resulting in a decrease in the fuel gas firing on the furnace. New stripper structured packing was also used to enhance performance and reduce steam usage.
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Figure 24: New Induced Draft Fan on Crude Distillation Unit One (left) and New Stripper Structured Packing Prior to Installation on Crude Distillation Unit Two (right).
6.5.5.4 Vacuum Distillation Unit upgrades Major modifications to the Vacuum Distillation Unit were undertaken in 1998, including the installation of a new, state of the art furnace and upgrades to the main distillation tower internals. These modifications gave rise to a 20-30% increase in the units furnace efficiency and a 5-10% increase in steam generation from waste energy streams. 6.5.5.5 Decommissioning Lubricants Units The Kwinana Refinery Energy Usage and Future Strategy indicated that the lubricants operation was highly energy intensive and inefficient. Given these problems, along with issues around the commercial viability of lubricants, it was decided to decommission the lubricants units. This process took place mainly in 2002 and was completed in 2003. 6.5.5.6 Hydrofiner 3 In 2005 the refinery built a new diesel hydrotreater unit to allow the refinery to produce lower sulphur content diesel (Figure 25). This unit furnace was built with the aim of achieving high energy efficiency and at the time was best in class in terms of other BP furnaces globally. A hot separator option was adopted, versus the conventional burner design, to reduce energy use.
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Figure 25: Energy Efficient Hydrofiner 3 Unit.
6.5.5.7 Alkylation Unit upgrades In 1999 a new pre-treatment unit (Hydro-Isomerisation) was added to the Alkylation Unit. By removing key contaminants from the feed and enhancing the feed composition to the unit, it enabled the Alkylation Unit to be run at lower severity and higher throughputs. This had a dramatic effect on unit energy usage per ton of feed. In addition, some innovative optimisation work led to additional energy savings through changes to the octane operating philosophy on the unit. 6.5.6 Context about targets In 1997 the Climate Change Conference in Kyoto established the Protocol for reduction targets of CO2 over the period of 2008 2012. Following this BP Group set its own target of reducing its global greenhouse emissions by 10% of the 1990 baseline over the period to 2010. This target exceeded the reduction targets set for industrialised nations in Kyoto, and was achieved by 2001, nine years early. Following this achievement BP set a new target to hold net emissions at 10% below 1990 levels over the next decade while allowing for business growth. BP Refinery (Kwinana) has an internal target to hold CO2 emissions at a baseline value while
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continuing business growth, where the baseline value is the average of the 19982002 direct CO2 emissions of 695,000 tonnes (including offsets). BP Refinery (Kwinana) strategy to ensure compliance with this involves both operational and capital improvements to increase energy efficiency and reduce onsite CO2 emissions; and a carbon offset programme through tree planting. As well as the total emission target for CO2, BP Refinery (Kwinana) has other targets that have the aim of keeping CO2 emissions minimised. The first of these targets is the Energy Intensity Index (EII). EII is a tool that is used to monitor and highlight energy inefficiencies. The Refinery also has various targets to control the combustion conditions in the furnaces on site, most commonly through control of the amount of oxygen supplied to the furnace. By controlling the efficiency of the combustion process, waste products such as CO2 can also be controlled. 6.5.7 Performance CO2 emissions for the period 2007 2009 were below the target of 695,000 tonnes, when taking into account the carbon offsets from forestry sequestration. The 2007 CO2 emissions were approximately 4500 tonnes above the target. The amount of CO2 sequestration by the forest plantations is modelled at approximately 50,000 tonnes per year.
CO2 Emissions from BP Refinery (Kwinana) tonnes/year
900000 850000 CO2 (tonnes/year) 800000 750000 700000 650000 600000
19 90 19 9 19 1 9 19 5 96 19 9 19 7 98 19 9 20 9 00 20 0 20 1 0 20 2 03 20 0 20 4 05 20 0 20 6 0 20 7 08 20 09
6500000 6000000 5500000 5000000 4500000 4000000 3500000 Throughput (tonnes/year)
CO2 Emissions
Refinery Throughput
Figure 26: CO2 Emissions from BP Refinery (Kwinana).
Note, in Figure 26 and Figure 27 carbon offsets by forestry have not been deducted from the total CO2 emissions to allow for fair comparison to historical data (which excludes offsets).
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Over the past decade the Refinery has followed an overall decreasing trend emissions of carbon dioxide (see Figure 26). The increase in emissions during 2007 is related mainly to the increase in Refinery throughputs that year. The drop in emissions in 2008 is related to a large shutdown period during which the Refinery was completing maintenance work on key process units. Emissions during 2009 returned to expected levels, with an improved efficiency of CO2 emissions against Refinery throughput. The efficiency of CO2 emissions per unit of Refinery throughput are shown in Figure 27.
CO2 Emissions from BP Refinery (Kwinana) (per tonne of crude throughput)
CO2 (tonnes) / tonne of crude throughput
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0.17 0.16 0.15 0.14 0.13 0.12 0.11 0.1

19 90 19 91 19 95 19 96 19 97 19 98 19 99 20 00 20 01 20 02 20 03 20 04 20 05 20 06 20 07 20 08 20 09
Figure 27: CO2 Emissions from BP Refinery (Kwinana) (t/yr) per unit throughput (t/yr).
BP Refinery Kwinana have steadily improved the energy efficiency performance since 2002 (see Figure 28). This improvement is measured against the energy intensity index, an industry benchmark which reflects energy consumption, the relative complexity of making a range of products and the overall utilization of Refinery capacity. These reductions in energy consumption have resulted from upgrades to process units (such as those which have improved heat recovery) and efforts to better understand where energy is used and lost within the plant.
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Energy Intensity Index Performance for BP Refinery (Kwinana)

110.0 108.0 Solomon Energy Intensity Index 106.0 104.0 102.0 100.0 98.0 96.0 94.0 92.0 90.0 88.0 2002 2003 2004 2005 Date 2006 2007 2008 2009
Figure 28: The Energy Intensity Index Performance at BP Refinery (Kwinana) for the Past 8 years. The Lower the EII the Better the Performance.
The Refinery has been operating a tree planting program in the south west of Western Australia since 1997, with over 2,600 ha of trees planted to the end of 2009. The program has multiple benefits including targeting dryland salinity, socioeconomic benefits to rural communities and providing carbon offsets. 6.5.8 Comments on performance BP Refinery (Kwinana) was part of the BP Group commitment to reduce CO2 emissions by 10% from the 1990 baseline, and the Refinery set reduction targets to help BP achieve this goal globally. BP Refinery (Kwinana) met each of the targets, and continues to support the commitment that BP will hold its global emissions at 10% below the 1990 baseline until 2012. The Refinerys EII performance continues to improve even though the Refinery is now producing energy intensive, cleaner fuels. 6.5.9 Future plans BP Refinery (Kwinana) will continue to investigate options and implement projects to increase energy efficiency and decrease CO2 emissions.
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6.5.10 References BP Refinery (Kwinana) Pty Ltd and Mission Energy Development Australia Pty Ltd (1994) Cogeneration Project Works Approval Documentation. Atmosphere, Climate & Environment Information Program (2001) Carbon Dioxide [online]. Encyclopedia of the Atmospheric Environment. Available from: http:www.doc.mmu.ac.uk/aric/eae/Global_Warming/Older/Carbon_Dioxide.html [Accessed data 27/03/2003].
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6.6
Hydrogen Sulfide (H2S)
6.6.1 What is it? Hydrogen Sulfide (H2S) is a colourless gas that is commonly described as having a smell of rotten eggs. The gas is flammable and corrosive to metals (Department of the Environment and Heritage, 2006). 6.6.2 Impacts H2S is an extremely toxic substance that enters the human body through the lungs, and due to its offensive smell in very low concentrations can be the cause of odour complaints. In low concentrations (5 to 50 parts per million) H2S can cause irritation of the eye, nose and throat. At high concentrations (100 to 200 parts per million) exposure may cause sleeplessness, blurred vision, and haemorrhage possibly leading to death. At the extremely high levels of 1,000 to 2,000 parts per million respiratory failure may be experienced immediately, leading to collapse, coma and death (Department of the Environment and Heritage, 2006). Hydrogen sulfide in the environment usually exists in the atmosphere as a gas, and will react with other chemicals to be broken down. H2S is toxic to aquatic life, plants, animals and birds, however the exact concentrations and levels of effect are not as well quantified as they are for humans (Department of the Environment and Heritage, 2006). 6.6.3 Why do we emit it? Hydrogen sulfide is contained in crude oil and therefore must be extracted during the refining process as it is unsafe to allow H2S to remain in the finished products. 6.6.4 Sources Natural sources of hydrogen sulfide are coal pits, volcanic gases and sulphur springs. The decaying process of organic matter that contains sulphur can also release H2S (Department of the Environment and Heritage, 2006). H2S is used in the manufacture of paper, in tanneries, in fertiliser production and glue manufacturing (Department of the Environment and Heritage, 2006). The processing of ores (lead, gold and copper) can also produce H2S. Hydrogen sulfide is contained in crude oil and must be extracted from the final products and recycled. Hydrogen sulfide is emitted from the Refinery from the Sulphur Recovery Units. H2S rich gas is sent to the SRU to be converted to elemental sulphur to reduce SO2 emissions when combusted, however a trace amount of H2S is not reacted and remains in the waste gas emitted from the SRU incinerators.
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6.6.5 How is it managed? BP Refinery (Kwinana) disposes of H2S by converting it to elemental sulphur in the Sulphur Recovery Units (SRU), which is then recycled and used in the manufacture of products by another company. The first Sulphur Recovery Unit was commissioned in 1989 and the second in 1992. A small amount of H2S can remain in the tail-gas of the Sulphur Recovery Units, however this is burnt in the SRU incinerator with excess oxygen to ensure that only trace amounts of hydrogen sulfide are emitted into the air. BP Refinery (Kwinana) monitors the amount of hydrogen sulphide emissions from the SRU by using a H2S analyser that was commissioned in October 2005. This analyser continually records the amount of H2S (high range only) in the two SRU stacks, alternating between the two, every six minutes. 6.6.6 Context about targets BP Refinery (Kwinana) targets are set against oxygen concentrations in the incinerator flue gas to ensure sufficient oxygen is present to allow combustion of the H2S. Refinery has in place a set of internal targets to ensure that consistently high levels of oxygen are maintained in the flue gas of the SRU: SRU and incinerator gas oxygen concentration to be greater than 1 vol% (dry basis) over 1 hour average; and No more than two incidents (with a four hour limit on each incident) wherethe SRU and incinerators combusted gas oxygen concentration is less than 1.5 vol% (dry basis) over one hour average.
To reduce the emissions of H2S from the RCU the Refinery has in place a target to maintain the COB online. The target states that the shutdown of the CO Burner is to be no more than 2% per year of RCU operating time. There are currently no licence limit requirements for H2S emissions. 6.6.7 Performance In 2008 BP Refinery (Kwinana) developed a calculation method for estimating H2S emissions from the Residue Cracking Unit (RCU), prior to this time this source was not quantified. During normal RCU operation off-gases on the Regenerator No. One pass through the CO Burner before exiting out the stack. The combustion process of the COB converts most of the H2S to SO2. On occasions when the COB is offline, off-gases exit directly out the stack, these may contain higher levels of H2S.
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Hydrogen Sulphide Emissions BP Refinery (Kwinana)

30000 H2S Emmissions (kg/yr) 25000 20000 15000 10000 5000 0 2005 2006 2007 2008 2009
Figure 29: Hydrogen Sulphide Emissions from BP Refinery (Kwinana).
6.6.8 Comment on performance The apparent large increase in emissions between 2007 and 2008 (see Figure 29) is due to the introduction of a calculation method for RCU emissions (as per mentioned in section 6.8.7). Emissions from the RCU are dependent on the number of days that the COB is offline. During 2008 the COB was offline for twenty days compared to zero days offline in 2009, this explains the large difference between these two years. The other underlaying increase in H2S emissions from the lower baseline of 2005-07 to 2009 was associated with a previous error in the Sulphur Recovery Unit calculations. 6.6.9 Future plans The Refinery will manage the Sulphur Recovery Units for the maximum possible reliability to prevent H2S breakthrough, and therefore minimise adverse health impacts and odour issues for the surrounding community. The Refinery aims to focus on improving the measurement capability and reliability of the H2S analysers on the SRU. 6.6.10 References Department of the Environment and Heritage (2006) National Pollutant Inventory Substance Profile [online]. Australian Government. Available from www.npi.gov.au/ [Accessed 20/06/06].
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6.7
Volatile Organic Compounds (VOC)
6.7.1 What is it? Volatile Organic Compounds (VOCs) are a broad group of compounds consisting of hydrocarbons which vaporise at ambient temperature and pressure, excluding methane. As this is a grouping of compounds, the chemical properties can vary widely and may contain nitrogen, oxygen and other elements in addition to carbon and hydrogen. 6.7.2 Impacts The health impacts of VOCs vary with the chemical content, however generally at low concentrations eye, nose and throat irritation may occur, and other symptoms such as headaches, nausea and loss of coordination could be experienced. VOCs are one of a number of substances identified as a trigger for asthma and other respiratory illness (Department of the Environment and Heritage, 2010). The major environmental significance of VOCs is the formation of photochemical smog, which doesnt naturally occur at ground level. Smog is formed when VOCs are exposed to nitrogen oxides, heat and strong sunlight, which allows them to breakdown to produce ozone and other compounds. 6.7.3 Why do we emit it? Petroleum fuels are moderate to highly volatile, therefore fugitive emissions can be produced during the cycle of refining, combustion of carbon containing fuels, petroleum distribution and use. 6.7.4 Sources Natural sources of VOCs are areas of native bush that emit volatile oils, and other diffuse sources include vehicle exhausts, painted surfaces, fabrics, carpets, printed paper and cut lawns. At BP Refinery (Kwinana) the main sources of VOC emissions are: tankage, process areas, fugitive emissions, sewer system and loading and unloading of ships. Emissions from storage tanks (see Figure 30) occur through two mechanisms, evaporation and flash losses. Evaporation can occur anywhere a tank is not completely sealed to the atmosphere due to the volatile nature of hydrocarbons. Flash losses are specific to the storage tanks for the products of the Minalk treatment unit. In the Minalk the removal of H2S and mercaptan is facilitated by the injection of air. After the product is moved to the storage tanks this air then flashes out of solution, taking with it some hydrocarbons (in vaporised form are Volatile Organic Compounds).
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Figure 30: Aerial View of the Tank Storage Facility at BP Refinery (Kwinana).
VOC emissions from process areas are usually from furnaces and also include emissions from the Flare. The design of some units require some process venting to release pressure for safety, which emits a small amount of VOCs. Fugitive emissions are from plant components such as valves, flanges, pumps and seals and will leak hydrocarbon vapour to the atmosphere at rates determined by process parameters (for example temperature and pressure), equipment design, and duty.
Figure 31: (left) The Inlet of the API (where the Oily Water Sewer Enters the Waste Water Treatment Plant) is Open to Atmosphere, (right) Sewer Box with Open Vent to Atmosphere.
The Oily Water Sewer (OWS) transports liquid contaminated with hydrocarbon from the process units to the Waste Water Treatment Plant for treatment. The OWS is open to the atmosphere at many locations, including the inlet to the API of the Waste Water Treatment Plant (see Figure 31). The Refinery sewer system was the largest source of VOC emissions from BP Refinery (Kwinana) in 2009, making up nearly a quarter of total VOC emissions (see Figure 32).
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Major VOC Emission Sources Within the BP Refinery (Kwinana) 2009

Sew ers Process Vents Loading Losses Tanks Leaks Other Flares Furnaces Lab Venting Marketing Soils Tank 802 Combustion Engines Spills Underground Storage CCS Flash Losses
Figure 32: VOC Emissions (tonnes) from Different Sources Within the BP Refinery (Kwinana) in 2009.
6.7.5 How is it managed? Emissions of Volatile Organic Compounds are managed through a VOC Reduction Program, which was implemented in 1995 with the aim of reducing emissions to a quarter of the emission rate recorded in 1994 (a base line of 18,745 tonnes/year). This was reached by the target date of 1998, and projects to reduce emissions further are continuing. The VOC Reduction Program reduced tank emissions by installing secondary seals on all external floating roof tanks that stored motor spirit and crude, and installing covers and seals on still wells. One of the Minalk units was decommissioned which significantly reduced the flash losses of VOCs. Fugitive emissions have been targeted through the Leak Detection and Repair (LDAR) program, where fugitive VOC leaks are systematically detected and leaking equipment repaired or replaced (see Figure 33). The program also ensures that all new valves are of environmentally friendly valve design.
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Figure 33: Leak Detection Monitoring at the Waste Water Treatment Plant.
The VOC emissions from the Oily Water Sewer have been controlled by reducing the amount of oil entering the sewer system, by improving control systems and the education of Refinery personnel. 6.7.6 Context about emissions There are currently no standards or guidelines set for ambient levels of Volatile Organic Compounds in Western Australia, however the Department of Environment (now DEC) first began monitoring photochemical smog (ground level ozone formed by the reaction between VOCs and the oxides of nitrogen) north east of Perth city at Caversham in 1989. Results at this time found that the city was sometimes subjected to smog levels which exceeded the guidelines recommended at the time by the National Health and Medical Research Council of Australia (DEP b 2000). In 2000 the Department of Environmental Protection released the Perth Air Quality Management Plan that was developed with the objective to ensure that acceptable air quality is achieved and maintained throughout the Perth metropolitan area over the next 30 years (DEP a 2000 p.8). The Management Plan acknowledged substantial improvements in tank and fugitive emission control and stated an objective to continue to work with BP Kwinana Refinery to ensure continuous improvement in VOC control measures (DEP a 2000 p.61) National Pollutant Inventory data from 2008-2009 show that the largest source of VOCs to the Perth and Rockingham airsheds were motor vehicles, emitting 42% of the total emissions, while the BP Refinery (Kwinana) contributed 3.59% of the total emissions to the Perth and Rockingham airsheds. In the smaller local airshed of Rockingham, Cockburn and Kwinana the Refinery had a larger contribution of 25.71% of VOC emissions to the airshed.
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6.7.7 Context about targets BP Refinery (Kwinana) reviews and sets targets on a yearly basis. Long term goals are being established to ensure the VOC Reduction Program will deliver the desired emission reductions and financial savings. Over the period 1995 to 2006 the refinery has been setting itself more challenging and decreasing VOC emissions targets and this has driven the gradual decrease in emissions over that time. A second target was also set to attempt repair of all major leaking valves found through the Leak Detection and Repair (LDAR) program within seven days. 6.7.8 Performance
The refinery met its current target of 1750 tonnes per year for two out of the three years in the 2007-2009 period. (see Figure 34).
VOC Emissions by BP Refinery Kwinana

20000
VOC emissions (tonnes/year)
Target
15000
VOC emission
10000
5000
Figure 34: Total VOC Emissions from the BP Refinery (Kwinana) since 1993.
Note: In 2009 a decision was made to retrospectively apply a more current and reliable methodology of calculating the VOC emissions from the year 2000 onwards, hence data in Figure 34 will differ slightly from numbers provided in previous copies of the PER.
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6.7.9 Comments on performance The target of reducing VOC emissions to 1,750 tonnes was achieved with emissions for the years 2007 through to 2009 being below the 1,750 tonnes. Over the ten year life of the LDAR program there has been a four-fold decrease in the number of leaking valves found. Additionally since 2002 there has been order of magnitude improvement in meeting the target of repairing leakers within seven days. 6.7.10 Future Plans The largest VOC emission source from BP Refinery (Kwinana) are the sewer systems. In the future the sewer system will be the focus of reducing VOC emissions. Ultimately the aspiration of BP Refinery (Kwinana) is to reduce VOC emissions to less than 1,000 tonnes per annum. 6.7.11 References Department of the Environment and Heritage (2003) National Pollutant Inventory Substance Profile [online]. Australian Government. Available from www.npi.gov.au/ [Accessed 18/03/03]. Department of Environmental Protection (a) (DEP) 2000. Perth Air Quality Management Plan Consultation Draft. Department of Environmental Protection (b) (DEP) 2000. Perth Air Quality Management Plan State of Knowledge.
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6.8
Carbon Disulphide (CS2)
6.8.1 What is it? Pure Carbon Disulphide (CS2) is a colourless liquid with an odour similar to chloroform. CS2 is a highly reactive molecule that is dangerous when exposed to heat, flames, sparks or friction. 6.8.2 Impacts CS2 can enter the human body through inhalation, ingestion or contact with the skin. Chronic (long term) CS2 poisoning can cause a number of problems including sensory changes, memory loss, kidney and liver damage, weakness and mental deterioration. At high concentrations, CS2 can be life threatening, affecting the nervous system and the heart (Department of the Environmental and Heritage, 2010). In the environment, chronic exposure to CS2 can cause reproductive and fertility problems in animals (including humans), and lower growth rates in plants. 6.8.3 Why do we emit it? CS2 is formed during the refining process and can be emitted from the RCU, SRU incinerators and the flares. 6.8.4 Sources Small amounts of CS2 are found naturally in coal tar and crude oil, and it is a natural product of anaerobic biodegradation. The ocean, coastal marshlands and areas of high biological activity are major sources of CS2. The main sources of CS2 from BP Refinery (Kwinana) are the RCU and the SRU. In the muffle furnace of the SRU, the combination of temperature, oxygen, H2S and hydrocarbons form some CS2, This is then released from the incinerator when its capacity is exceeded. Similarly, in the RCU the combustion process leads to the formation of CS2, which is released via the Regenerator one stack if the CO Burner is offline. Small amounts of CS2 may be emitted from the Flare when a SRU trips. There are no typical emissions of CS2 from the Refinery under normal operating conditions. Abnormal emissions of Carbon Disulfide from the Refinery can range from 400 to 1400 kg/year. This includes emissions from the SRU and the RCU. Note there is currently no emission estimation techniques for the RCU. 6.8.5 How is it managed? There is currently no direct monitoring of CS2 emissions from BP Refinery (Kwinana). Only emissions from the SRU are reported to the National Pollutant Inventory (NPI). Emissions of CS2 from the SRU are estimated using approved NPI estimation techniques.
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6.8.6 Context about emissions Under the Refinery certified Environmental Management System (EMS), objectives and targets are set each year for availability of the CO Burner and number of SRU2 trips. This ensures there are internal management processes and procedures in place to maintain current performance and promote continuous improvement in terms of minimising CS2 emissions. 6.8.7 Performance
Emissions of Carbon Disulphide from BP Refinery (Kwinana)
Carbon Disulphide kg/yr
35000 30000 25000 20000 15000 10000 5000 0 2007 2008 2009
Figure 35: Emissions of Carbon Disulphide from BP Refinery (Kwinana) 2007-2009.
Emissions of Carbon Disulphide from the Refinery are dependent only on the flows through the Sulphur Recovery Units (SRU). The big increase in emissions between 2007 and 2008 is attributed to a previous error in the calculation method. The incorrect flows through the unit were used which resulted in an under estimation of the emissions. Data presented here in Figure 35 is as per reported to the NPI. BP Refinery (Kwinana) is the largest emmitter of CS2 to the Perth and Rockingham airsheds, contributing 99.7% of emissions during the 2008-2009 NPI reporting year. 6.8.8 Comments on performance The major source of CS2 emissions from the Refinery is the RCU if the CO Burner is offline, this source is not currently quantified. The Refinery has targets to limit the amount of time the CO Burner is offline in order to minimise this emission. 6.8.9 Future plans Emissions from the SRU will continue to be estimated. A method will be developed to estimate CS2 emission from the RCU and the Refinery plans to validate this with stack testing results over the next few years.
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6.8.10 References Department of the Environment and Heritage (2003) National Pollutant Inventory Substance Profile [online]. Australian Government. Available from www.npi.gov.au/ [Accessed 20/06/06].
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6.9
Odour
6.9.1 What is it? Odour is a sensory response to the trapping of odorant molecules in the mucous layer covering the olfactory epithelium. The odorant is recognised by olfactory receptor cells which send neural signals to the brain. How the receptor cells and the brain determines the unique properties of each odour is not well known, however it is clear that individuals perceive odours differently and have different detection levels. The character of refining odours is not well defined because refineries are complex facilities with many processes that may cause odours (PERF, 1994). 6.9.2 Impacts The impact of human exposure to odours generally has one of the three general responses; health effects, annoyance or stress (behavioural). An odour is often the first indicator of exposure to a chemical, however the ability to smell the presence of a chemical does not itself indicate toxicity or a health risk (PERF, 1994). 6.9.3 Why do we emit it? A refinery is a complex facility with a number of possible offensive odour emission sources. This is due to the range of different substances used in the refining process that are highly volatile (that is they exist as a gas at ambient temperatures). These potentially odorous substances can include crude oil, catalysts, cleaning agents, wastes, by-products and final products. Typical odour causing compounds commonly encountered in refining processes include H2S and mercaptans. 6.9.4 Sources There are many natural and human sources of odour that are encountered in everyday life. BP Refinery (Kwinana) has identified eight gases that could be responsible for causing an offsite incident of offensive odour in the Refinery internal procedure; Odour Management at BP Refinery. If the characteristics of the odour can be identified this is then used to trace the odour back to units that are likely to be responsible. Hydrogen Sulfide (H2S) has the characteristic odour of rotten eggs. The flare, SRU stacks, amine sump, sulphur pit, RCU stack (when the CO Burner is offline), jetties or the 300 series of storage tanks are all potential sources of H2S odour. Mercaptans are generally described as a stench, and the source within the Refinery can be LPG (to which mercaptans must be dosed), spent caustic intertankage or the 300 series of storage tanks.
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The Waste Water Treatment Plant (WWTP) and the Land Farm (see Figure 40) areas can be responsible for an odour resembling musty old socks, which is due to the presence of a mercaptan type species
Figure 36: BP Refinery (Kwinana) Land Farm cell and Waste Water Treatment Plant (WWTP).
Ammonia has the characteristic odour of bleach, which may be emitted from the Sour Water Stripper. An odour of rotten cabbage is usually from a hydrocarbon/sulphurous compounds mix, which can be emitted from the flare seal pot drainings. An odour of firecrackers/gun smoke indicates carbonyl sulphide (COS), which can be emitted from the Residue Cracking Unit when the CO Burner is offline. Light hydrocarbons resemble a sweet oily smell, which can be from a range of sources within the Refinery, including CDU, PPU, 500 and 600 series tanks or the Residue Cracking Unit when it is steaming out. 6.9.5 How is it managed? Odours from the Refinery are managed according to the procedures that outline how to avoid producing odours, and how to respond in the case of odour detection. The Breaking Odorous Lines Procedure provides a general overview of the actions to consider for activities that could result in the venting of odorous substances to atmosphere, including consideration of weather conditions and methods to prevent odours (e.g. venting to flare, flushing lines prior to work and the use of odour neutralising compounds). Two odours can be emitted from the Residue Cracking Unit when the CO Burner is offline. These odours are due to H2S and COS, therefore to manage these odours the reliability of the CO Burner is managed. The Odour Management procedure at the Refinery details the types of odours that may be detected with a description and possible sources to allow efficient and correct identification in the event of an odour emission.
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6.9.6 Context about targets Specific targets for odour emissions are difficult to set as they are sensory perceptions. Individuals have different detection thresholds; therefore what is offensive to one person may not be detected by another. This problem is intensified by the puff phenomena, that is the odour is perceived for a short period of time (PERF, 1994). As part of its current environmental licence the Refinery is required to manage and operate the premises such that odours emanating from the premises do not unreasonably interfere with the health, welfare, convenience, comfort or amenity of any person at an odour sensitive premise. BP Refinery (Kwinana) complies with this licence condition as well as having internal targets in place to limit the specific odour emissions from the SRU and the RCU. These targets are based around maintaining CO Burner reliability and preventing H2S breakthrough from the SRU. 6.9.7 Performance During 2007-2009 there were three substantiated odour complaints in relation to the BP Refinery (Kwinana). These were all from neighbouring industries in Kwinana. 6.9.8 Comment on Performance The external complaints concerning BP Refinery (Kwinana) were from within the industrial area (from neighbouring facilities). No impact was registered from the surrounding residential areas in the period 2007-2009. 6.9.9 Future plans The Refinery continues to manage potentially odorous sources and activities to eliminate any off-site impact. Refinery Turnarounds (large maintenance activities) are a time when odour management is especially required. Incorporating these activities into the Environmental Management Plan (EMP) for the maintenance activity will continue to be a focus. 6.9.10 References Petroleum Environmental Research Forum (PERF) 1994, Odours From Petroleum Refineries: A Reference Document. IIT Research Institute, Chicago.
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6.10 Odour - Carbonyl Sulphide (COS) 6.10.1 What is it? Carbonyl sulphide (COS) is a highly reactive, flammable and colourless gas with an odour similar to rotten eggs. 6.10.2 Impacts Exposure to COS may cause irritation to the respiratory tract and damage to the central nervous system. It is currently suspected that COS is a neurotoxicant and a skin or sense organ toxicant. 6.10.3 Why do we emit it? A Refinery is a complex facility with a number of possible offensive odour emission sources. This is due to the range of different substances used in the refining process that are highly volatile (that is they exist as a gas at ambient temperatures). In the muffle furnace of a Sulphur Recovery Unit (SRU), the combination of temperature, oxygen, H2S and hydrocarbons result in the formation of some COS. The RCU may be a source of COS if the CO Burner is offline. 6.10.4 Sources COS is mainly formed in the oceans, by the action of sunlight on sulphur-containing organic matter. Due to its low solubility in water, COS easily enters the atmosphere and is hence is the dominant sulphur gas in the atmosphere. The main sources of COS from BP Refinery (Kwinana) are the: Residue Cracking Unit (RCU), Sulphur Recovery Unit (SRU) and Flare. All significant COS emissions are the result of abnormal operating conditions (i.e. SRU incinerators being overloaded, the Carbon Monoxide Burner (CO Burner) being offline with the RCU operational, and SRU tripping to Flare). 6.10.5 How is it managed? In the muffle furnace of a Sulphur Recovery Unit (SRU), the combination of temperature, oxygen, H2S and hydrocarbons result in the formation of some COS. This is then combusted in the incinerator. The combustion of COS in the SRU Incinerator is expected to be 98-99% efficient resulting in negligible emissions under normal operating conditions. If the SRU incinerator becomes overloaded then its combustion efficiency drops and higher COS emissions result. Similarly, in the RCU the combustion process leads to the formation of COS, which is released via the Regenerator one stack, when the CO Burner is offline. Under the Refinery EMS, objectives and targets are set each year for availability of the CO Burner and number of SRU trips. This ensures there are internal
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management processes and procedures in place to maintain current performance and promote continuous improvement in terms on minimising COS emissions. The Refinery also manages COS emissions by ensuring that there is always low sulphur (<1% S) RCU feedstock available and if the CO Burner shuts down then low sulphur feed is processed on the RCU as quickly as possible. Experience has shown that impacts on the community (odour) are avoided if the sulphur content of the RCU feed is <1% when the CO Burner offline. 6.10.6 Performance The levels at which BP Refinery (Kwinana) emits COS are currently only quantifiable for the Sulphur Recovery Units using an emission factor derived from Paskall & Sames 1998. Refinery emissions of COS as per reported to the DEC for the last six years are show in Figure 37). The large jump in emissions between 2008 and 2009 is due to a previous error made with regards to the flow used in the emission calculations.
Emissions of COS from BP Refinery (Kwinana)
9000 8000 7000 6000 5000 4000 3000 2000 1000 0 2004 2005 2006 2007 2008 2009
Figure 37: COS Emissions from BP Refinery (Kwinana) 2004-2009.
6.10.7 Comment on performance The Refinery met its target aimed at preventing Sulphur Recovery trips for the last three years (see Table 3). For two out of the last three days The Refinery did not manage to meet the target to keep the COB online operating 98% of the RCU operating time due to mechanical failure issues (as per discussed in section 6.1).
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6.10.8 Future plans The Refinery continues to manage potentially odorous sources and activities to eliminate any off-site impact. Refinery Turnarounds (large maintenance activities) are a time when odour management is especially required. Incorporating these activities into the Environmental Management Plan (EMP) for the maintenance activity will continue to be a focus. 6.10.9 References Paskall, H. G & Sames, J.A. 1998, Sulphur Recovery, Sulphur Experts Inc. Western Research.
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6.11 Noise 6.11.1 What is it? Sound is any variation in pressure that the ear can detect, and noise is often described as a subjective term of unwanted or excessive sound. The Environmental Protection Act 1986 defines noise to include vibration of any frequency, whether transmitted through air or any other physical medium. Sound measurements are commonly expressed as decibels (dB); a compression of the range of sound intensities and pressures (NVMS, 2002). Different weightings are used to represent different noise levels, and it is widely accepted A-weighting gives the best approximation to the human ear, with units of measurement expressed as dB(A) (NVMS, 2002 6.11.2 Impacts The impacts of noise can vary greatly depending on the level and type of noise emitted, and in what context. Possible impacts can range from behavioural effects such as increasing aggressiveness, reduced attention, reduced problem solving capabilities and disturbed sleep to more serious hearing impairments and hypertension. 6.11.3 Why do we emit it? The process of refining crude oil to useful products is complex and requires equally complex equipment that produce noise simply due to the fact that there are moving mechanical parts, pressure drops across equipment such as valves and jet noise from high gas/steam flow rates exiting stacks. 6.11.4 Sources The major sources of noise from the Refinery have been identified as the Residue Cracking Unit (RCU), Catalytic Reformer No3 (CR3), the Crude Distillation Units (CDUs) and the Flares. The Residue Cracking Unit produces noise due to the high air velocities required in the unit, and the sound of combustion gases being released through the stack. The largest noise emitters on the Catalytic Reformer Unit are the fin fans, piping and gas compressors. The location of the unit on the eastern boundary of the Refinery exaggerates the boundary noise issue. Noise from the Crude Distillation Units is attributed to the crude heaters and the forced draft fans. The Refinery flares are a noise source during high volumes of gas flow, as not only the gas to be combusted goes through the flare but also steam to aid the combustion and prevent black smoke.
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6.11.5 How is it managed? Noise emissions from the Refinery are managed using engineering solutions and managing the operation of equipment. Engineering solutions to noise control are applied to both new and existing equipment. As new equipment is installed at the Refinery its potential as a noise emitter is considered, and if necessary noise control devices are used to control noise emissions (for example pump enclosures and fin fan silencers). Also, BP Refinery (Kwinana) has in the past implemented several changes to minimise its noise emissions including the following: Shutting down of three noisy process units and noisy furnaces (Propane Deasphalting (PDA) Unit, Furfural Unit and the Ferrofiner); Restricting the steam flow to the East Flare to 100 tonnes per day; and Carrying out hydroblasting (high pressure water jet cleaning) in enclosures with special acoustic curtains across the front to mitigate noise.
The Residual Cracker Unit (RCU) exhaust stack had been identified as a dominant noise source within the BP Kwinana refinery facility following a noise survey carried out by SVT in 2005-2006. As a result, in 2008, BP Refinery (Kwinana) installed a silencer in the upstream ducting of the Residual Cracker Unit (RCU) exhaust stack to reduce the noise levels from the stack, see Figure 38.
Figure 38: RCU Silencer installed in 2008 at BP Refinery (Kwinana).
Following the installation BP Kwinana contracted SVT to measure the noise levels from the exhaust stack and hence quantify the noise reduction achieved by the silencer. Noise surveys were conducted in February 2009, September 2009,
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February 2010, March 2010 and June 2010. As a result of the noise surveys, SVT concluded that the silencer provides a net reduction of 10 dB in the noise emissions from the exhaust stack (based on the A-weighted sound power levels); and, with the silencer installed, the exhaust stack is no longer a major contributing noise source within the refinery and at far field locations such as the Kwinana Industries Council monitoring points (SVT 2010). Noise is an important consideration in the internal approvals process. Any new projects or existing equipment design changes are assessed in terms of possible noise emissions. When equipment is replaced or updated; low noise generating alternatives are always the preferred options. 6.11.6 Context about targets The Environmental Protection (Noise) Regulations 1997 came into effect on the 31st January 1998. The regulations of 1997 set out what the acceptable noise levels are for different times of the day considering the location and landuse. A summary of the permitted noise levels for noise sensitive premises is outlined in Table 5.
Table 5: Assigned noise levels from the Environmental Protection (Noise) Regulations 1997.
Type of premises receiving noise Time of day Assigned level (dB) LA10 Noise sensitive premises at locations within 15 meters of a building directly associated with a noise sensitive use 0700 to 1900 hours Monday to Sunday 0900 to 1900 hours Sunday and public holidays 1900 to 2200 hours all days 2200 hours on any day to 0700 hours Monday to Saturday and 0900 hours Sunday and public holidays 45* LA1 55* LA max 65*
40*
50*
65*
40* 35*
50* 45*
55* 55*
*plus the influencing factor for the premises, takes into account the amount of industrial and commercial land and the presence of major roads around the noise receiver. LA10: a noise level that is not to be exceeded for more than 10% of the time; LA1: a noise level that is not to be exceeded for more than 1% of the time; and LA
max:
a noise level not to be exceeded at any time.
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In addition to these noise levels for noise sensitive premises the 1997 Regulations also apply assigned levels for industrial premises receiving noise of 65 dB for LA10, 80dB for LA1 and 90dB as LA max. These limits therefore apply to the boundary of the Refinery, as all neighbours are industrial premises. 6.11.7 Performance Noise surveys carried out in 2006 indicated that locations near the northeast corner of refinery are at risk for exceeding noise levels above the Environmental Protection (Noise) Regulations 1997 of levels above 65dB at the site boundary. As a result, the refinery decided to proceed with the project to reduce noise emissions from its major noise point source emitter, the RCU. This led to the installation of the RCU Silencer in 2008 (see Figure 38). As well as direct measurment using noise meters and modelling noise emissions, BP Refinery Kwinana performance can also be assessed by the number of complaints received regarding noise from the Refinery per year. 6.11.8 Comment on performance In the last three years, there have been no substantiated noise complaints made against the Refinery from its neighbours or from the local residential area. The Refinery is currently in the process of re-assessing its compliance with the Environmental Protection (Noise) Regulations 1997 following the installation of the RCU silencer. 6.11.9 Future Plans BP Refinery (Kwinana) plans to continue making improvements in reducing noise emissions from the Refinery, focussing on installing noise efficient devices on new projects and adressing high noise point sources onsite. 6.11.10 References Department of Environmental Protection (1997) Environmental Protection (Noise) Regulations 1997 Summary of the Regulations. McLoughlin J (2002) Boundary Noise Measurements at the Kwinana Refinery for BP Refinery (Kwinana) Pty Ltd Report No. AV/02/06/002. Engineering Consultants. Noise & Vibration Measurement Systems (NVMS) (2002) Environmental Noise Course. SVT Engineering Consultants (2010) Residue Cracker Unit Exhaust Stack Silencer Performance Report No. 01-0951847-Rev0-11Nov 10.
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6.12 Smoke 6.12.1 What is it? Smoke is a cloud of particulates suspended in the air after incomplete combustion, and black smoke is produced when the particles are a carbon dust (DEP, 2000). 6.12.2 Impacts As smoke is a cloud of suspended particulates the impact can be the same as those described in the Particulates significant environmental aspect (see Section 6.2). Smoke can also have an impact on the aesthetics of an area, as an accumulation of smoke on still days can contribute to a haze (accumulation of very small suspended particles in concentrations large enough to impede vision) in the atmosphere, or as an isolated event (DEP, 2000). Smoke may also cause an odour depending on the fuel source. 6.12.3 Why do we emit it? There are a number of combustion processes that occur within the Refinery. As no combustion process is complete these all are capable of producing some smoke during process upsets. Due to the high carbon content of what is being combusted this smoke can appear as black smoke in severe refinery upsets. 6.12.4 Sources There are natural sources of smoke from bushfires or volcanoes. Human sources include smoke produced from wood-fired heaters and energy production. The Refinery uses combustion to produce heat in furnaces (see Figure 39), to dispose of waste gas through the Refinery flare(s) and as part of the emergency response training methods
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Figure 39: VDU Furnace.
6.12.5 How is it managed? Visual smoke from the furnaces does not occur under normal refinery operation as the variables of the combustion are able to be controlled (for example the fuel feed and oxygen availability). Smoke from the refinery flare is controlled by injecting steam at the flame creating a greater mix of air within the gas to improve the combustion and therefore preventing visible black smoke. The flare does have a limit to the amount of gas it can burn without producing smoke, the smokeless capacity is determined by steam availability. The Refinery has a purpose built fire training facility to give personnel experience in simulated emergency situations. Part of this training program involves the use of oil fires which can produce black smoke before the fires are extinguished. These smoke events are limited, and the DEC are notified before each training session. Smoke emissions from the Refinery are currently managed under the Environmental Protection (Unauthorised Discharges) Regulations (2004), which state that it is an offence to burn any material that allows dark smoke to be discharged for more than 4 minutes in any hour. BP Refinery (Kwinana) monitors its major stacks and records the times during which smoke is generated. 6.12.6 Context about targets As specified by the Unauthorised Discharges Regulations (2004), the Refinery has a requirement to control any black smoke emissions to four minutes in an hour.
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6.12.7 Performance The flares are generally the only source of black smoke that has the potential to exceed the 4 minutes in an hour requirement. The central control building operations centre has a continous live shot of the flare at all times, to help ensure that generation of black smoke is quickly spotted and attended to. Fire training is a planned event and oil fires are extinguished within the four minute limit. 6.12.8 Comment on Performance BP Refinery (Kwinana) views large flare incidents as regrettable, however as the purpose of the flare is to be a safety release for gas production there are occasions (for example during an process unit upset) where this gas needs to be released through the Flare. On occasions of large flaring, control of black smoke is quickly achieved by altering the rate of steam injection. 6.12.9 Future plans The Refinery will continue its management of the potential sources of black smoke. 6.12.10 References Department of Environmental Protection (DEP) (2000) Perth Air Quality Management Plan.
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6.13 Hydrogen fluoride (HF) 6.13.1 What is it? Hydrogen fluoride (HF) is a highly corrosive, colourless and pungent gas. 6.13.2 Impacts HF is a highly toxic gas. Inhalation, ingestion or dermal contact of hydrogen fluoride can be fatal. Permanent eye damage, including blindness, can occur as a result of contact to the eyes. Insufficient data is available to predict the short-term or long-term effects of hydrogen fluoride on aquatic life, plants, birds or land animals. Concentrated hydrogen fluoride is very corrosive and would badly burn any plants, birds or land animals exposed to it. The concentrations of hydrogen fluoride found in close proximity to sources may adversely affect some species of plants. Hydrogen fluoride can exist as an aerosol or mist in the air if released to the atmosphere. Industrial emissions of fluoride compounds can produce elevated concentrations in the atmosphere. Hydrogen fluoride will exist as a particle, which may dissolve in clouds, fog, rain, dew or snow. In clouds and moist air it will travel along the air currents until it is deposited as wet acid deposition (acid rain, acid fog, etc). In waterways it readily mixes with water. 6.13.3 Why do we emit it? HF is used as a catalyst in the Refinery Alkylation Unit (see Figure 45). Alkylation is a process for producing high-octane gasoline by reacting olefins with isobutane in the presence of a HF acid catalyst. Unplanned HF emissions can occur due to leaks and equipment malfunctions on the Alkylation Unit. 6.13.4 Sources There are potentialyl unplanned leaks from the multiple pieces of equipment carrying hydrogen fluoride due to equipment malfunction and pipe faults. 6.13.5 How is it managed Due to its high potential health and environmental risks HF acid is amongst one of the most stringently monitored and managed emissions at BP Refinery (Kwinana). Regular risk assessments are conducted to ensure that emissions are prevented onsite. The Refinery has a Dangerous Goods management plan which covers the potential emissions of HF gas from the Alkylation unit, ensuring that all correct measures are in place to prohibit such emissions from occurring. There are also detailed emergency response procedures, as well as a specific first aid procedure for the
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treatment of any personnel that come into direct contact with the HF acid/gas while working onsite. There are several monitoring measures in place at the Alkylation unit to ensure that potential emissions of HF are quickly identified and resolved. All of the pipe-work and equipment is coated with a special type of paint which changes colour when exposed to HF gas. This allows for immediate visual identification of any leaks of HF to atmosphere during routine inspections of the unit. Any such leaks are immediately fixed with sections of the plant being taken out of commission until repairs are complete. Furthermore, HF detectors and alarms are installed around the Alkylation unit to immediately detect and notify of any potential leaks. 6.13.6 Context about emissions The Refinery is licensed under the Dangerous Goods Safety Act 2004 and the Dangerous Good Safety (Storage & Handling of Non-Explosives) Regulations 2007. The licence is administered by Resources Safety Division (RSD) and the Department of Petroleum and Mines (DMP), and specifies conditions and procedures that must be followed in regards to Hydrogen Fluoride Anhydrous (HF) storage and use onsite. The Refinery has a Dangerous Goods Management Plan that embraces the Dangerous Goods Storage legislative requirements and manages risk to an acceptable level. Personnel handling and working on equipment in HF service must undergo adequate and regular training to be familiar with Material Safety Datasheets (MSDS)s and emergency plans. In the event of a major HF acid release, there is an Emergency Response Procedure that is activated and implemented in accordance with existing Major Hazards Facility requirements. Spills of HF to the environment are communicated to RSD, DMP in accordance with their incident reporting criteria. 6.13.7 Performance Over a one year period approximately 80 tonnes of HF acid is used on the Alkylation unit and it is approximated that less than half a tonne (0.63% of use) of this is lost as a result of sampling and other fugitive leakages. 6.13.8 Comments on performance Since the Refinery first began operating there have been no catastrophic releases of HF acid gas, with only negligible emissions occuring in the past. 6.13.9 Future plans The Refinery is continually investigating options for increasing the safety of the Alkylation unit and this naturally leads to a decrease in HF emissions. BP Refinery (Kwinana) is currently investigating options to replace the manual HF gas sampling
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practice with the use of automated analysers and this will decrease the emissions of HF associated with this routine procedure. The Refinery has also recently, in 2008, implemented a new Rapid Acid Dump (RAD) system (see Figure 40), which has improved both safety and environmental protection in the event of an HF release. In case of an emergency this is a secure holding vessel for HF acid contained in the unit.
Figure 40: The new Rapid Acid Dump system, installed in 2008.
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6.14 Methane 6.14.1 What is it? Methane (CH4) is a colourless, odourless gas. 6.14.2 Impacts The environmental impacts of methane are due to its contribution to the Enhanced Greenhouse Effect. The Earths atmosphere naturally contains greenhouse gases (for example carbon dioxide, ozone and water vapour) that absorb part of the heat radiated from the Earths surface. This natural process is known as the Greenhouse Effect, an essential process to maintain the Earths temperature. Human activities have increased the amount of greenhouse gases in the atmosphere; and this is causing an Enhanced Greenhouse Effect, as too much heat is being trapped and the temperature of the atmosphere is increasing. The exact degree and time-scale of climate change is not known, but it is predicted that the average global temperature rise may lead to extreme weather conditions, with intense rainfall and flooding in some areas, and drought and increased fire risks in other areas. Methane is over 20 times more effective in trapping heat in the atmosphere than carbon dioxide (CO2) (US EPA, 2006). 6.14.3 Why do we emit it? Methane forms when organic (carbon containing) material is broken down in the absence of oxygen (Holper, 2002). The process of refining crude oil (which contains carbon) into useful products requires several combustion processes which produce methane, due to no combustion process being totally complete. Methane is also emitted from the Refinery as fugitive emissions. 6.14.4 Sources Methane is naturally occurring as a main constituent of natural gas, and is emitted from swamps, the general degradation of organic substances in the absence of oxygen and fires. Sources such as cattle, sheep and rice paddies are natural sources enhanced by humans through agriculture. Sources of methane from BP Refinery (Kwinana) are from the burning of refinery fuel gas in furnaces, the flare and from fugitive emissions. 6.14.5 How is it managed? The Refinery has a policy to control the operation of the plant to minimise the excess gas production, therefore minimising flaring.
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BP Refinery (Kwinana) has a Leak Detection and Repair program where approximately 50,000 points (for example valves, flanges) are tested each year for leaks of fugitive emissions (for more information see Volatile Organic Compounds). As these fugitives may contain some methane, locating and repairing leaking equipment minimises these emissions. 6.14.6 Context about targets Methane is not a significant environmental aspect for BP Refinery (Kwinana). However, as most atmospheric methane is converted to carbon dioxide, the Refinery has included methane in the target for carbon dioxide emissions by converting methane emissions to equivalent tonnes of carbon dioxide (Holper, 2002). 6.14.7 Performance For the period 2007 2009 methane emissions ranged between 27 to 32 tonnes/year, this equates to a carbon dioxide equivalent emission of 563 to 666 tonnes/year. 6.14.8 Comment on Performance The methane emissions were fairly steady during the period 200709. 6.14.9 Future plans BP Refinery (Kwinana) will continually aim to minimise methane emissions by controlling the amount of gas burnt at the flare through the No Economic Flaring Policy, and through the continuing program to reduce fugitives by the Leak Detection and Repair Program. 6.14.10 References Holper, Paul (2002) The Greenhouse Effect [online]. CSIRO Atmospheric Research. Available from www.dar.csiro.au/publications/holper%5F2001b.html [Accessed 15/08/06]. US Environmental Protection Agency (EPA) (2006) Methane and other gases [online]. US Environmental Protection Agency. Available from: http://yosemite.epa.gov/oar/globalwarming.nsf/content/emissions.html [Accessed 15/08/06].
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6.15 Carbon Monoxide (CO) 6.15.1 What is it? Carbon monoxide is a colourless, odourless gas. It is highly flammable and when emitted to atmosphere it is eventually converted into carbon dioxide. 6.15.2 Impacts Carbon monoxide enters the body through the lungs, where it is absorbed into the bloodstream. Carbon monoxide takes up space on the red blood cells that would otherwise carry oxygen, therefore less oxygen can be supplied to the bodies vital organs. The concentration of carbon monoxide normally present in the atmosphere is approximately 0.2 parts per million, a level that is not harmful to humans (Department of the Environment and Heritage, 2005), however in a confined space concentrations may reach higher levels. The first effects noticeable in humans from low concentrations of carbon monoxide may be difficulty concentrating, memory and vision problems and reduced motor skills. At moderate levels of exposure (200 parts per million for 2 3 hours) headaches, nausea and/or fatigue may be experienced, and levels of 1,200 parts per million exposure becomes life threatening (NPI, 2010). Exposure over a long period of time may produce heart disease, damage to the nervous system and low birth weights and defects in offspring (NPI, 2010). The impacts of carbon monoxide on the environment include animal health and reproduction rate as all animals experience similar effects of exposure as humans. The other environmental impact of carbon monoxide is the contribution to Greenhouse Gases in the Earths atmosphere. Carbon monoxide is not a Greenhouse Gas but it is the precursor to one, carbon dioxide (see significant environmental aspect Carbon Dioxide for information). 6.15.3 Why do we emit it? When any combustion process takes place the oxidation process is not complete, therefore the burning of any carbon-based fuel (e.g. gas, wood, coal, or petrol) will result in the production of some carbon monoxide. Under controlled conditions, such as at the Refinery, temperature and oxygen levels can be managed to maximise the extent of combustion and minimise the production of waste products. 6.15.4 Sources Carbon monoxide is emitted from natural sources such as volcanoes, lightning and fires. In Perth up to 80% of all carbon monoxide emissions are from vehicle exhausts (Department of Sustainability, Environment, Water, Population and Communities, 2010).
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The sources of carbon monoxide within the Refinery are furnaces, flares, the CO Burner and the Sulphur Recovery Units. The main source of carbon monoxide from BP Refinery (Kwinana) is the CO Burner (COB) on the Residue Cracking Unit (RCU). A by-product of breaking down the carbon chains into smaller molecules is coke, a solid consisting mainly of densely packed carbon atoms. To remove the coating of coke from catalyst a specific amount of oxygen is supplied to convert the coke (carbon) into carbon monoxide in the Regenerator No.One (R1). The carbon monoxide can then be converted to CO2 in the CO Burner, which is an exothermic reaction (i.e. a reaction that produces heat). The Residue Cracking process at the Refinery deliberately controls an incomplete combustion reaction to convert coke into CO. The CO is then directed to a boiler, and the energy produced from converting CO to CO2 is used to produce steam for heating in the RCU. This approach is used as a means of raising energy efficiency and heat integration in the RCU. If the CO Burner is offline and the RCU continues to operate then emissions of CO from the RCU are increased. The Sulphur Recovery Units (SRU) are also sources of CO. The SRU converts hydrogen sulphide (H2S) from the refinery fuel gas and other sour gas sources around the refinery to liquid sulphur. This removes sulphur which would otherwise contribute to atmospheric emissions; however the process is not complete, producing a small amount of tail-gas. This gas must be burnt in the incinerator for safe disposal. The tail-gas contains some hydrocarbon carryover and carbon monoxide that is present due to some remaining hydrocarbon from the production process, which cannot be combusted at this temperature and is therefore emitted to air. 6.15.5 How is it managed? BP Refinery (Kwinana) achieved significant reductions in the amount of carbon monoxide released to atmosphere in the mid 1990s (see Figure 41: Carbon Monoxide Emissions from BP Refinery (Kwinana) from 1995 to 2009), mainly through increasing the reliability of the CO Burner. Recently, during 2007 and 2008, the Refinery has experienced reliability issues with the CO Burner associated with fouling of the internal tubes leading to mechanical failure. This contributed to an increase in CO emissions during these years
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CO Emissions by BP Refinery (Kwinana)

6000
CO (tonnes/year)
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5000 4000 3000 2000 1000 0
Figure 41: Carbon Monoxide Emissions from BP Refinery (Kwinana) from 1995 to 2009.
When the CO Burner is not operating and while the RCU is running, carbon monoxide is emitted directly to atmosphere. In 2008 when the RCU was operating without the CO Burner an average of 3.84 tonnes/day of CO was emitted. When operational, the CO Burner lowered the average emission of carbon monoxide to 0.44 tonnes/day. Overall, carbon monoxide emissions from the CO Burner in 2008 made up 63% of the total carbon monoxide emissions from the BP Refinery (Kwinana). In 1997 the CO Burner underwent an upgrade to minimize the risk of mechanical failures, and further modifications to the design were completed by 1999 to improve the reliability and limit the time the CO Burner spent offline. During 2008, the Boiler Feed Water to the COB was changed over to the cleaner supply of water from the Water Corporations Kwinana Water Reclmation Plant (KWRP) and improvements were made to the monitoring of the quality of this supply. Good quality, clean water helps to prevent fouling and build up of contaminants on the COB tubes which helps prevent fouling and mechanical failure. The Refinery is currently investigating the reasons for the mechanical failures of the COB. The Sulphur Recovery Units are designed to operate with a maximum of 1% CO in the flue gas. Monitoring has found that the actual operating value is slightly below 1%, which leads to a relatively small emission of carbon monoxide due to the low flue gas flows. 6.15.6 Context about emissions The National Environment Protection Council has established the standard for ambient air quality for carbon monoxide, which is 9 ppm over an eight hour averaging period (NEPC, 2006). The Perth Air Quality Management Plan (EPA, 2007) found the carbon monoxide concentrations experienced in Perth are decreasing with more
19 95 19 96 19 97 19 98 19 99 20 00 20 01 20 02 20 03 20 04 20 05 20 06 20 07 20 08 20 09
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detail statistical analysis required to confirm these trends. Data from the National Pollutant Inventory in 2008-2009 shows that BP Refinery (Kwinana) emitted 0.96% of the total CO emitted to the Perth and Rockingham airsheds. The National Pollutant Inventory data also shows in 2008-2009 BP Refinery (Kwinana) contributed 7.86% of the CO emitted to the smaller local airshed of Rockingham, Cockburn and Kwinana. By far the majority of CO emissions to the local airshed in 2008-2009 were motor vehicles, accounting for 59% of the total emissions (see Figure 42).
CO Emissions to Rockingham, Cockburn and Kwinana Airshed 2008-2009 Motor vehicles

Basic chemical manufacturing 1% 1% 1% 4% 2% 7% Law n mow ing 6% 5% Cement, Concrete manufacture Other Petroleum & Coal Product Manufacturing 59% Fuel Combustion 6% 8% BP Refinery (Kw inana) Electricity supply Iron and Steel Manufacturing Solid fuel burning (domesic)
Figure 42: Contributors of CO to the Local Airshed of Rockingham, Cockburn and Kwinana for 2008-2009.
6.15.7 Context about targets BP Refinery (Kwinana) sets internal targets to ensure continuing improvement in reducing carbon monoxide emissions. These targets are based on the control of emissions by managing the CO Burner reliability. As the largest source of carbon monoxide emissions is from the RCU when it is operating without the CO Burner, this time is managed by a target of no more than 2% per year of unplanned RCU operating time without the CO Burner. The Refinery also has an internal target to maintain excess oxygen levels in the flue gas between 0.75% and 3% for 99% of the time to ensure optimal conditions to convert CO to CO2.
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6.15.8 Performance The target of 98% reliability for CO Burner availability has been met every year since 1999, excluding 2007 and 2008. (see Figure 43: Number of Days of Unplanned Shutdown of the CO Burner at BP Refinery (Kwinana) Compared to the Target to Achieve 98% Reliability). As previously mentioned the COB experienced significant fouling leading to mechanical failure and an extended offline period in both 2007 and 2008. The Refinery is currently investigating measures to improve the reliability of the COB in the future.
COB Reliability at BP Refinery (Kwinana)
45
Number of days unplanned shutdown
40 35 30 25 20 15 10 5 0 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Target
Figure 43: Number of Days of Unplanned Shutdown of the CO Burner at BP Refinery (Kwinana) Compared to the Target to Achieve 98% Reliability.
During 2008 and 2009 the target of excess oxygen in the flue (stack) gas of the CO Burner was to remain between 0.75% and 3%, this was met 99.13% (2008) and 100% (2009) against the target of 99% for these years. 6.15.9 Comments on performance The Refinery has met the current targets for CO Burner reliability for the 9 of the last 11 years (Figure 43). The Refinery has also met the excess oxygen in flue gas target for the last 2 years. 6.15.10 Future plans To maintain its performance BP Refinery (Kwinana) will continue to focus on monitoring and reporting of CO Burner reliability and excess oxygen levels in the flue gas.
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6.15.11 References Environmental Protection Authority (EPA) (2007) Perth Air Quality Management Plan: Five-Year Review [online]. Available from: http://www.epa.wa.gov.au/docs/2583_AQMP_Review_Draft_3.pdf [Accessed 24/11/2010]. Department of the Environment and Heritage (2005) Air Quality Fact Sheet Carbon Monoxide [online].Available from: http://www.environment.gov.au/atmosphere/airquality/publications/carbonmo noxide.html [Accessed 30/11/2010]. National Environment Protection Council (NEPC) (2006) Ambient Air Quality [online]. Environment Protection and Heritage Council. Available from: http://www.ephc.gov.au/nepms/air/air_nepm.html [Accessed 14/06/06]. Department of Sustainability, Environment, Water, Population and Communities (2010) National Pollutant Inventory 2008/2009 data within the Perth airshed [online]. Available from:http://www.npi.gov.au/npidata/action/load/emission-by-substanceresult/criteria/year/2009/destination/ALL/airshed-catchment/31/ [Accessed 24/11/2010]. National Pollutant Inventory (NPI) (2010) Carbon Monoxide [online]. Substance Fact Sheet. Available from: http://www.npi.gov.au/substances/carbon-monoxide/index.html [Accessed 30/11/2010].
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6.16 Benzene 6.16.1 What is it? Benzene is a clear to light-yellow liquid with a sweet aromatic odour. It evaporates into the air very quickly and is highly flammable. Benzene can pass from the air to soil and water through rain. 6.16.2 Impacts The health impacts of inhaling small amounts of benzene can include skin and eye irritations, headaches and vomiting. High levels of exposure to benzene can cause dizziness, rapid heart rate, confusion and unconsciousness. Very high levels can result in death, while long term exposure, affects bone marrow and can cause anaemia and leukaemia. Benzene in the environment is a precursor to the formation of photochemical smog, and usually breaks down within a few hours due to photo oxidation. Benzene can be dissolved out of the air by rain, but as it is highly volatile it will evaporate again, however it does not accumulate in plants or animals over time. 6.16.3 Why do we emit it? Benzene is naturally contained in crude oil, which means that some emissions can occur during the processing of the crude and from fugitive sources. Benzene is also emitted through the combustion process, from both the benzene in the fuel and from benzene that is formed from other components during combustion. 6.16.4 Sources Natural sources of benzene are volcanoes and forest fires. Human sources of benzene include the manufacture of chemicals used to make plastics, nylon and synthetic fibres. Benzene is released to air primarily from fumes and vehicle exhaust. Sources of benzene emissions to air from BP Refinery (Kwinana) are fugitives from tankage, sewers, soil remediation, spills and loading losses. The biggest emissions are sourced from the Refinery sewers and tanks, while combustion emissions at the Refinery are comparatively small (see Figure 44).
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Benzene Emissions by Source from BP Refinery (Kwinana) 2009
CCS Flash Losses T802 Underground Tanks Spills Furnaces Combustion Engines Flares Marketing Soils Leaks Loading Losses Tanks Sewers
Figure 44: Benzene Emissions by Source for 2009 from BP Refinery (Kwinana).
6.16.5 How is it managed? Over the past decade the Refinery has taken steps to reduce VOC emissions, (see significant environmental aspect Volatile Organic Compounds). This has been accomplished through large scale projects, such as improving seals on storage tanks, and through an ongoing Leak Detection and Repair program that systematically tests potential fugitive emission points such as valves and flanges. This focus on reducing volatile emissions has resulted in a net reduction of benzene emitted from BP Refinery (Kwinana) since 1998 (see Figure 45). Emissions increased in 2009 predominantly due to a change in the emission estimation factor used to calculate sewer emissions.
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Benzene Emissions from BP Refinery (Kwinana)

26000
Benzene (kg/yr)
21000 16000 11000 6000 1000

19 98 19 99 20 00 20 01 20 02 20 03 20 04 20 05 20 06 20 07 20 08 20 09
Figure 45: Benzene Emissions from BP Refinery (Kwinana).
Benzene emissions from the Refinery are relatively minor when compared to emissions produced as a result of the use of the products, therefore the most effective management of benzene emissions is to manage the fuel quality specifications. Data from the National Pollutant Inventory shows that in 2008 2009 motor vehicles emitted 56.4% of the total benzene to the Perth and Rockingham airsheds, compared to the contribution by BP Refinery of 0.2%. In the smaller local airshed of Rockingham, Cockburn and Kwinana, the contribution to total benzene emissions by BP Refinery was 2.5%. The quality of fuel supplied to the market is strictly controlled through fuel specifications. In 1999 regulations were introduced to reduce the maximum benzene content in gasoline from 5% to 1%, the most stringent regulations in Australia at the time, thereby reducing the benzene emissions from the motor vehicle fleet, as well as reduced emissions from storage of the product within the Refinery. 6.16.6 Context about targets As benzene emissions to air are not a significant environmental aspect for the Refinery there are no specific benzene emissions targets, however BP Refinery (Kwinana) does have the compliance requirement to supply all batches of petrol at 1% (v/v) concentration of benzene. 6.16.7 Performance In 2009 all batches of petrol were supplied within the compliance value of 1% benzene concentration.
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Total benzene emissions have been reduced by more than 40% since 2000. 6.16.8 Future plans The ongoing program to control VOC emissions from the Refinery through continuing the Leak Detection and Repair program for fugitive emissions and implementing improved environmental design for new equipment will continue to reduce benzene emissions
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6.17 Heavy metals 6.17.1 What is it? BP Refinery (Kwinana) emits a number of heavy metals to air, and although heavy metals to air are not significant environmental aspects for the Refinery, all heavy metals reported to the National Pollutant Inventory are discussed here in view of community interest in these emissions. Heavy metals are the stable metals or metalloids that are standard constituents of the earths crust. They are stable and cannot be degraded or destroyed, and therefore they tend to accumulate in soils and sediments (Anderson, 2003). Human activities have drastically altered the biochemical and geochemical cycles and balance of some heavy metals, with principal man-made sources being industrial point sources as well as combustion by-products (Anderson, 2003). Relatively volatile heavy metals and those that become attached to air-borne particles can be widely dispersed on very large scales and can therefore can have an impact on areas large distances away from the emitting source. The specific health and environmental impacts of each particular heavy metal varies, and the metals are therefore discussed individually below. The Refinery emits several heavy metals to the atmosphere as a result of the Refinery combustion sources, maintenance activities, and as attached constituents to the particulates released from the Residue Cracking Unit (RCU). Heavy metals emitted from BP Refinery (Kwinana) contribute varying amounts to the total local and Perth airshed. As of mid 2004, BP Refinery Kwinana emissions of heavy metals decreased significantly due to the installation of the Pall filter on Regenerator No. Two (R2) on the Residue Cracking Unit (RCU). This filter decreased the particulates emitted from the R2 stack by tenfold, which in turn reduced the heavy metals emissions from that unit by 74%. 6.17.1.1 Arsenic Pure arsenic is silver-grey in colour and has both metallic and non-metallic properties. Arsenic is odourless and in nature is usually found combined with one or more other elements (Department of Environment and Heritage, 2003). 6.17.1.2 Antimony Antimony is a brittle, silvery-white substance that has both metallic and non-metallic characteristics. Antimony metal is stable under normal atmospheric conditions and is not readily attacked by air or water (Department of Environment and Heritage, 2003).
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6.17.1.3 Beryllium Pure Beryllium is a hard, brittle silvery metal. Beryllium can often exist in compound form, and therefore the properties vary depending on the particular compound. 6.17.1.4 Chromium Chromium is a white, hard, lustrous and brittle metal. The most stable oxidation state of the element chromium is chromium (III), another oxidation state of importance is chromium (VI) (Department of Environment and Heritage, 2003). 6.17.1.5 Cadmium Pure Cadmium is a soft silver white colour, however it is most often found combined with other elements producing compounds. Cadmium and its compounds are stable (Department of Environment and Heritage, 2003). 6.17.1.6 Cobalt Cobalt metal is an odourless shiny, silvery metal, when first exposed to air. Cobalt is a metal that occurs naturally in many different forms (Department of Environment and Heritage, 2003). 6.17.1.7 Copper Copper is a reddish-brown, odourless metal that becomes dull when exposed to air. Copper is malleable and ductile, and can form compounds of copper(I) and copper (II) (Department of Environment and Heritage, 2003). 6.17.1.8 Lead Lead is a soft, blue-grey metallic solid, and compounds of lead have varying chemical and physical properties (Department of Environment and Heritage 2003). 6.17.1.9 Manganese Manganese is a very brittle, hard metal of white-grey colour. Manganese can form compounds with different properties depending on the particular form (Department of Environment and Heritage, 2003). 6.17.1.10 Mercury
Mercury is an odourless, silver white liquid metal at ambient conditions. It is very heavy and is slightly volatile at ambient temperatures. Mercury will form alloys with most metals, and is an excellent conductor of electricity (Department of Environment and Heritage, 2003).
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6.17.1.11
Nickel
Nickel is a hard silvery-white metal. It is malleable and ductile, and is a good conductor of electricity and heat (Department of Environment and Heritage, 2003). 6.17.1.12 Selenium
Selenium has both metallic and non-metallic properties. The most metallic form is grey in colour, and is the most stable form, however selenium can also be found as a red or black solid (Department of Environment and Heritage, 2003). 6.17.1.13 Zinc
Zinc is a bluish-white, lustrous metal that is brittle at ambient temperatures, although when heated to 100 to 150C it becomes malleable and can be rolled out. Zinc forms many alloys, the properties of which vary greatly (Department of Environment and Heritage, 2003). 6.17.2 Impacts The specific health and environmental impacts of each particular heavy metal varies, and are therefore discussed individually below. 6.17.2.1 Arsenic Low levels of exposure of arsenic may cause nausea, vomiting, diarrhoea and abnormal heart rhythm as some of the possible health effects. Long term exposure can result in stomach disorders, anaemia, skin lesions, liver and kidney damage. Arsenic is a known carcinogen (Department of Environment and Heritage, 2003). Arsenic is toxic to birds and land animals, and reduced plant growth is seen in soils with high arsenic content (Department of Environment and Heritage, 2003). 6.17.2.2 Antimony Antimony has similar toxic properties to arsenic, although this depends on the chemical form and the oxidation state. Breathing high levels of antimony for a long period of time can irritate eyes and cause heart and lung problems, diarrhoea and vomiting as some of the possible health effects. Conclusions have not been made as to whether antimony is a human carcinogen or not (Department of Environment and Heritage 2003). When released to air, antimony can attach itself to small airborne particles allowing potential transportation over long distances (Department of Environment and Heritage, 2003).
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6.17.2.3 Beryllium The health effects of beryllium on humans are currently not well understood, and not all forms are equally toxic. Breathing high levels of beryllium dust or fumes may irritate the respiratory tract, which may heal when exposure is ceased. Inhalation of beryllium and its compounds are considered to have cancer causing potential in humans (Department of Environment and Heritage 2003). Currently no data is known on the effects of beryllium on plants, birds or land animals (Department of Environment and Heritage, 2003). 6.17.2.4 Chromium In very small amounts Chromium (III) is beneficial in a human diet, however high levels can be toxic. The health effects of Chromium (VI) are very different, with compounds usually highly toxic. Inhaling chromium (VI) can damage and irritate the nose, throat, lungs, stomach and intestine. Breathing in chromium (VI) can also lead to asthma and kidney and liver damage. Long term exposure to chromium (VI) can result in reduced immune systems and cause cancer (Department of Environment and Heritage, 2003). No data are currently available on the long term effects of chromium on plants, birds or land animals (Department of Environment and Heritage, 2003). 6.17.2.5 Cadmium Repeated low exposures of cadmium to humans can cause permanent kidney damage that may go unnoticed. High exposures can cause rapid lung damage, shortness of breath and chest pain as some of the possible effects. Long term exposures can cause anaemia, fatigue and loss of the sense of smell. There is evidence of cadmium causing prostate and kidney cancer in humans (Department of Environment and Heritage 2003). No data is currently available for the effects on plants, birds or land animals, however test animals did develop lung scarring at very high doses (Department of Environment and Heritage, 2003). 6.17.2.6 Cobalt The health effects of cobalt can be beneficial, as it forms part of the vitamin B-12. Adverse effects of exposure to high levels of cobalt can include different forms of respiratory irritation (coughing, asthma and pneumonia) and can be responsible for damage to the heart (Department of Environment and Heritage, 2003). There is currently no data on the effects on plants, birds or land animals (Department of Environment and Heritage, 2003).
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6.17.2.7 Copper Copper is a necessary part of the human diet, with a daily intake of 1-2 milligrams required to stay healthy. Larger daily intakes over time or single very large doses can have adverse health effects such as liver and kidney damage, anaemia and even death. Long term exposure to copper dust can cause irritation of the nose, mouth and eyes, and cause headaches, dizziness, nausea and diarrhoea. (Department of Environment and Heritage 2003). The environmental effects of copper are often reduced as it strongly attaches to other particles which reduces the toxicity. Currently no data is available on the toxicity of copper on plants, birds or land animals (Department of Environment and Heritage, 2003). 6.17.2.8 Lead The ingestion of a large amount of soluble lead or lead compound may cause poor appetite, nausea, leg cramps, muscle weakness, damage to brain, kidneys and reproductive organs and death. Exposure can also have behavioural effects (Department of Environment and Heritage, 2003). The environmental effects of exposure to lead can include death of animals, birds and death or low growth rate of plants (Department of Environment and Heritage, 2003). 6.17.2.9 Manganese Manganese is essential for human health, and relatively large doses can be tolerated without adverse effects. Long term exposure of substantial amounts can cause bronchitis/pneumonitis after the inhalation of manganese dust, or disease called manganism. The first signs of manganism are psychological, which are followed by neurological symptoms such as muscular weakness and speech disturbances as some of the possible effects. If exposure ceases once these symptoms begin the individual generally recovers. (Department of Environment and Heritage, 2003). Manganese is a naturally occurring element that is essential to all living organisms, therefore the environmental effects are when the concentrations are altered significantly. Plants generally have a very high tolerance for manganese (Department of Environment and Heritage, 2003). 6.17.2.10 Mercury
Exposure to high levels of mercury can permanently damage the brain, and this can lead to irritability, shyness, tremors, changes in vision or hearing and memory problems. Exposure can also result in damage to the kidneys and a developing foetus. Long term exposure may cause a clouding of the eyes, and mercury accumulates in the body (Department of Environment and Heritage, 2003).
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When mercury is released into the environment it is oxidised into other compounds of mercury. Animals (birds, land animals) can be exposed by eating contaminated fish and can suffer from similar health effects as humans. Mercury emitted to the environment will remain for many years (Department of Environment and Heritage, 2003). 6.17.2.11 Nickel
The most common health impact of nickel on humans is an adverse skin reaction (usually a skin rash) from exposure to jewellery or other products containing nickel. Nickel dust can cause irritation to the eyes, nose and throat, and a variety of lung effects, including chronic bronchitis, reduced lung function and lung cancer. (Department of Environment and Heritage 2003). There is currently insufficient data on the effects of nickel on plants, birds and land animals (Department of Environment and Heritage, 2003). 6.17.2.12 Selenium
Selenium has a beneficial health impact in trace amounts, and most healthy diets provide enough to meet the daily requirements. Consuming too much selenium over long periods of time can result in excessive tooth decay, discolouration of skin and teeth, brittle hair, fatigue, irritability and depression. Exposure of high levels of selenium can produce symptoms such as headaches, dizziness, fatigue, irritation (of the eyes, nose and throat) and severe bronchitis. (Department of Environment and Heritage, 2003). The environmental impact of selenium depends if it is present in the biologically active oxidised form. In this form the uptake by plants is increased, and plants are known to accumulate selenium. Animals that consume plants containing high levels of selenium have been observed to suffer from the short term effects of impaired vision, reduced consumption of food and water and paralysis. Consuming plants containing selenium over a long period produces symptoms such as hair loss, erosion of the joints and bones, anaemia and effects on the heart, kidney and liver. Selenium has a high toxicity to mammals, and a moderate toxicity to birds (Department of Environment and Heritage, 2003). 6.17.2.13 Zinc
Zinc is an essential trace element in the diet of all living organisms, and either too little or too much zinc can cause health effects in humans. The recommended dietary allowance (RDA) for zinc is 15 milligrams a day for men, 12 milligrams a day for women and 10 milligrams a day for children. Not getting enough zinc can produce symptoms such as a loss of appetite, a reduced sense of taste and smell, slow wound healing or a damaged immune system. Harmful effects of too much zinc are generally seen at levels of 100 to 250 milligrams a day. Health effects can include
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stomach cramps, nausea and vomiting. Long term exposure can cause anaemia and pancreas damage. Zinc dust is irritating to the eyes, nose and throat, however the long term effects of inhaling high levels are unknown (Department of Environment and Heritage, 2003). Zinc is unlikely to build up in plants, however soils with very high zinc levels can be toxic to plants, especially in conditions of lower pH. There is currently insufficient data on the effects of zinc on birds and land animals (Department of Environment and Heritage, 2003). 6.17.3 Why do we emit it? Heavy metal emissions from the Refinery are due to the combustion of refinery fuel gas that originates from crude oil that naturally contains these elements, and from emissions of catalyst from the Residue Cracking Unit. 6.17.4 Sources Natural sources of heavy metals are volcanoes and the weathering of ores and minerals that naturally occur in the earths crust. Common human sources of heavy metals to air are coal fired power plants, mining of ores and vehicle exhausts. Sources of arsenic from within the Refinery are the flare, furnaces, the Residue Cracking Unit and sandblasting. The flare and furnaces emit heavy metals as gas generated from crude oil that contains these is combusted. Emissions from the Residue Cracking Unit (RCU) are due to the heavy metals being laid down on the catalyst during the reaction, and some catalyst released to atmosphere during the catalyst regeneration process. Heavy metal emissions occur from sandblasting as this cleaning process will result in the emission to the atmosphere of some of the metal surface of the item being blasted or corrosion products on the surface of the item. 6.17.5 How is it managed? Heavy metal emissions from the Refinery are managed by minimising the gas burnt in the flare, through the No Economic Flaring Policy. BP Refinery (Kwinana) have committed to a flaring policy, this requires the Refinery to be run so that the gas generated is used for heating rather than burnt at the flare during planned operations. Managing the emissions of particulates from the Residue Cracking Unit also manages the emissions of heavy metals, which includes controlling the velocity, or wind speed inside the regenerator, and installing cyclones to collect catalyst particulates (for more information see significant environmental aspect Particulates).
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As of mid 2004, BP Refinery (Kwinana) emissions of heavy metals decreased (see Figure 38) due to the installation of the Pall filter on Regenerator No. 2 (R2) on the Residue Cracking Unit (RCU). This filter decreased the particulates emitted from the R2 stack by tenfold (for more information see Section 6.2), which in turn reduced the heavy metals emissions from that unit. Emissions from BP Refinery (Kwinana) are managed mainly by minimising particulate emissions from the Residue Cracking Unit (RCU), this includes: Controlling the velocity, or wind speed inside the regenerators, Installing cyclones to collect catalyst particulates, and Installing the Pall filter on Regenerator No Two.
The Refinery also manages it environmental emissions from sandblasting activities onsite using methods outlined in the Management of Sandblasting Facilities procedure. The procedure includes carrying out of blasting in enclosed areas to limit air-borne atmospheric contamination. Fuel gas flows to furnaces are minimised, as this is the main source of emissions for some metals (i.e. cadmium), to ensure they are constantly run at maximum efficiency. In addition, the Refinery monitors the heavy metal content in crude oil to limit emissions in the refining process. 6.17.6 Performance The heavy metal emissions from the Refinery from 2007 to 2009 are outlined in Table 6.
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Table 6: Emissions of heavy metals to air from BP Refinery (Kwinana) from 2007 2009.
Heavy metal Arsenic Antimony Beryllium Cadmium Cobalt Chromium Chromium Copper Lead Mercury Manganese Nickel Selenium Zinc
2007 (kg)
1.16 15.82 0.03 3.28 1.76 1.18 0.06 6.37 8.39 0.77 6.23 38.77 0.07 143.94
2008 (kg)
0.91 7.36 0.03 3.26 0.97 0.78 0.06 4.55 6.58 0.76 5.06 21.65 0.07 142.16
2009 (kg)
0.66 5.31 0.06 3.39 6.39 2.16 0.2 525.04 13.4 0.98 6.6 52.91 0.1 207.97
The heavy metals with the highest loads are zinc, copper and nickel. The increase in both Cobalt and Copper emissions in 2008 is due to the increased concentration of these metals in material used for sand-blasting purposes (garnet). The concentrations of metals in garnet are measured by laboratory solids analysis typically each batch of spent garnet is analysed. 6.17.7 Comment on performance To put the emissions data into the context of the Perth airshed and the local airshed of Rockingham, Cockburn and Kwinana, the total emissions of heavy metals to the airshed were calculated from the information available from the National Pollutant Inventory, and BP Refinery (Kwinana) as a percentage of this total. Of the fourteen heavy metals emitted to air by BP Refinery (Kwinana) the contribution all of these emissions were less than 1% (excluding cadmium, antimony and zinc) of the emissions made to the Perth and Rockingham airsheds.
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Table 7: Heavy metal emissions from BP Refinery (Kwinana) as a percentage of the total emissions of the substance to the local airshed of Rockingham, Cockburn and Kwinana and the Perth & Rockingham airshed in 2008-2009.
Heavy metal Arsenic Antimony Beryllium Cadmium Cobalt Chromium (III) Chromium (VI) Copper Lead Mercury Manganese Nickel Selenium Zinc BPs contribution to local airshed 0.70% 26.20% 0.34% 2.34% 0.34% 0.22% 0.09% 1.23% 0.11% 0.22% 0.19% 1.49% 0.07% 4.73% BPs contribution to Perth airshed 0.28% 24.67% 0.25% 1.85% 0.31% 0.09% 0.05% 0.45% 0.01% 0.14% 0.02% 0.76% 0.07% 1.20%
(Source: National Pollutant Inventory)
6.17.8 Future plans It is acknowledged by the Refinery that Regenerator No.One (R1) is the single largest emitter of particulates, therefore heavy metals. As a result, all efforts will be focused on reducing emissions from R1. 6.17.9 References Anderson, D. (2003) Introduction to Heavy Metals Monitoring [online]. Centre for Ecology and Hydrology. Available from www.heavymetals.ceh.ac.uk [accessed 5/12/2006]. Department of the Environment and Heritage (2006) National Pollutant Inventory Substance Profile [online]. Australian Government. Available from www.npi.gov.au/ [Accessed 20/07/06].
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6.18 1,3 Butadiene 6.18.1 What is it? 1,3-Butadiene is a colourless gas with a smell similar to petrol. 6.18.2 Impacts Exposure to 1,3-Butadiene at low levels can irritate the eyes, nose and throat. At higher concentrations the gas can cause central nervous system damage, blurred vision, nausea, fatigue, headache, decreased pulse rate and unconsciousness. Long term exposures can cause an increase in heart and lung damage, and 1,3-Butadiene is classified as a probable human carcinogen (Department of Environment and Heritage, 2003). The environmental impacts of 1,3-Butadiene are not as well documented, as for human health, however there is a moderate short-term toxicity to aquatic life, and a slight long term toxicity. 1,3-Butadiene is not expected to accumulate in fish, and while effects on animals are not as well documented there are reports of developmental and reproductive effects (Department of Environment and Heritage, 2003). 1,3-Butadiene is a precursor to photochemical smog which is a problem in many cities. 6.18.3 Why do we emit it? 1,3-Butadiene is a compound made from the processing of crude oil, and small levels remain in gasoline. 6.18.4 Sources Natural sources of 1,3-Butadiene include forest fires, as it is emitted to air as a product of incomplete combustion. Human sources can involve the burning of tobacco and emissions from motor vehicles. Sources from within BP Refinery (Kwinana) are the refinery fuel gas and the flare gas, as well as some fugitive emissions, tank and sewer emissions and combustion engines. 6.18.5 How is it managed? 1,3-Butadiene is volatile at ambient temperatures, therefore the management techniques for Volatile Organic Compounds also controls these emissions. These management techniques include large scale projects to reduce emissions from storage tanks and a Leak Detection and Repair Program to systematically check possible fugitive emission points for leaks (for more information see Volatile Organic Compounds Section 6.5).
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The Refinery No Economic Flaring Policy that limits the amount of gas burnt at the flare also manages the emissions of 1,3-Butadiene. 6.18.6 Context about targets As this is not a category one significant environmental aspect, BP Refinery (Kwinana) does not have a specific target for emissions of 1, 3-Butadiene. Data from the National Pollutant Inventory shows that in 2008-2009 BP Refinery (Kwinana) contributed 3.77% of the total emissions of 1,3-Butadiene to the local airshed of Rockingham, Cockburn and Kwinana and the contribution to the Perth and Rockingham airsheds was only 0.3%. 6.18.7 Performance The emissions of 1,3-Butadiene have remained constant at about 200 kg/yr for the years 2004 to 2007 after a steady decline from 2000 when emissions were about 1200 kg/yr. (see Figure 46). The increase in emission during 2009 was due to an improved calculation method for estimating emissions from loading and unloading of products, previously this was not calculated.
Emissions of 1,3-Butadiene from BP Refinery (Kwinana)
1400
1,3-Butadiene kg/yr
1200 1000 800 600 400 200 0 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
Figure 46: Emissions of 1,3 Butadiene from BP Refinery (Kwinana).
6.18.8 Future plans The ongoing campaigns to reduce spills and the amount of oil discharged to the Refinery sewer will aid in achieving further reductions in emissions of 1,3-Butadiene. 1,3-Butadiene emissions will continue to be managed through controlling VOC emissions at the Refinery (see the significant environmental aspect Volatile Organic Compounds Section 6.7).
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6.18.9 References Department of Environment and Heritage (2003) National Pollutant Inventory Substance Profile [online] Available from: www.npi.gov.au/database/substanceinfo/profiles/16.html [Accessed on 15/08/06].
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7 WATER EMISSIONS
7.1 Introduction
BP Refinery (Kwinana) uses four different streams of water within the Refinery; potable (scheme) water, process water, salt cooling water, and recycled water from the Kwinana Water Recycling Plant since 2008. The Kwinana Water Reclamation Plant (KWRP) takes secondary treated wastewater from the Woodman point Wastewater Treatment Plant and uses microfiltration and reverse osmosis to produce a high quality industrial grade recycled water that can be used in place of potable water. KWRP water was commissioned to the Refinery in 2008, and is used in Alkylation Unit Cooling Tower and as boiler feed water for steam production replacing potable water. Potable water since 2008 has been mainly used for domestic purposes within the offices and safety showers at the Refinery, with only small or sporatic uses in the refining process as required. Process water is groundwater extracted onsite that is made-up with potable water if necessary. Process water is used throughout the Refinery for purposes that do not require high quality water such as sample cooling, pump jacket cooling, pump water seals, closed loop cooling circuits, process wash waters and fire water. The Refinery has an Oily Water Sewer (OWS) system that collects process water, storm water run off and tank drainings and takes it to the Refinery Waste Water Treatment Plant (see section 7.2 for further details). Salt cooling water is sea water extracted from Cockburn Sound and is used in a once through cooling stream. Salt cooling water does not require treatment through the Waste Water Treatment Plant (Figure 47) as the closed system generally prevents contamination, however the salt cooling water is passed through two circulars and an API separator to give the water a larger residence time to check for potential heat exchanger leaks and if so capture any hydrocarbon.
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Figure 47: Aerial photograph of the Waste Water Treatment Plant.
The Public Environmental Report reports against the Significant Environmental Aspects of water emissions, which are the measured parameters of the quality of the water discharged from the Refinery Waste Water Treatment Plant.
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7.2
Waste Water Treatment Plant (WWTP)
BP Refinery (Kwinana) was commissioned in the year 1955 with the standard environmental emission control technology available at the time. Since 1985 the Refinery has progressively been updating its emissions control technologies. In particular with regards to its wastewater, the Refinery commissioned a wastewater treatment facility in 1994 to treat the waste water leaving the Refinery prior to discharge. The Wastewater Treatment Plant (WWTP) employs a combination of physical, physio-chemical and biological processes to treat the contaminants in the wastewater. Process water, storm water run off and tank drainings are directed to the WWTP by the Oily Water Sewer (OWS). The first stage of treatment is primary oil removal, where gross oil and solids are removed. All wastewater then passes through the Equalisation Tank, which aims to homogenise the quality of water flowing through to the remaining units to avoid shock upsets in the biological section of the plant. Following equalisation, the water enters the secondary deoiling section of the plant, which removes suspended oil particles. After passing through the secondary deoiling section, the wastewater passes through the biological section (Activated Sludge Units), which removes dissolved phase contaminants, such as sulphides, phenols and nitrogen present in the water. The water then passes through the Clarification section, which removes any suspended solids from the water before discharge. Historically the Refinery has discharged all process wastewater to Cockburn Sound, however on the 1st August 2009 the connection to the Sepia Depression Ocean Outfall Line (SDOOL) was commissioned. SDOOL discharges into the Sepia Depression 4.1km off the coast where the level of mixing and flushing is much higher than in Cockburn Sound. As a consequence the Refinery will no longer discharge treated process water to Cockburn Sound under normal operation. Only Salt Cooling Water will continue to be discharged into Cockburn Sound. Discharges from the Wastewater Treatment Plant are reported to the Department of Environment and Conservation according to the requirements of the Licence, and emissions are calculated according to the Waste Water Quality Assurance Procedure (QAP).
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7.3
Hydrocarbons
7.3.1 What is it? Hydrocarbons are any organic compounds comprised of hydrogen and carbon, which can include crude oil, natural gas and coal (Leffler, 2000). Unless otherwise specified when BP Refinery (Kwinana) uses the term hydrocarbon it is referring to the liquid form, that is either the crude oil or as a general term for the refined products, rather than gas or solid hydrocarbon. 7.3.2 Impacts There are four main groups of hydrocarbons contained in crude oil and refined products, which are alkanes, olefins, alicyclics and aromatics. These different groups have different health effects on humans at certain exposure levels. Alkanes are straight-chain hydrocarbons, and olefins are unsaturated aliphatic hydrocarbons that both have relatively low toxicities. Alicyclic hydrocarbons have a low degree of shortterm toxicity with the effects of acting as a depressant on the central nervous system. Aromatic hydrocarbons generally have the most health effects, with low levels of exposure include headache, nausea, irritation to the eyes, nose and respiratory tract. Benzene is a component of aromatic hydrocarbons and has been classified as a known human carcinogen (Sherertz, 1998). The impacts of a large volume release of hydrocarbon to water, for example those seen for a spillage from a ship, are dramatic due to the high volume of free oil, however very small releases of dissolved phase hydrocarbon within large volumes from an outfall is very different. Some components of hydrocarbons are biodegraded rapidly, however aromatics are generally slower to biodegrade and can be absorbed onto particulates and therefore be accumulated in filter feeders and the sediments (Petroleum Geochemistry Group WAIT, 1982). 7.3.3 Why do we emit it? The refining process utilises water in various parts and therefore the water may become contaminated. BP Refinery (Kwinana) has a Waste Water Treatment Plant to remove this contamination before the wastewater is discharged, however a small amount of dissolved hydrocarbon may remain in the discharged water. These emissions are measured daily. 7.3.4 Sources Hydrocarbons are naturally occurring, formed by the degradation of organic matter, however they are generally located deep beneath the earths crust, therefore generally it is human actions that bring them to the surface. Although there are natural seeps that release hydrocarbons to the marine environment.
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Hydrocarbon that arrive at the Waste Water Treatment Plant can be from various sources including the washing down of oily areas, tank draining, salt filter brine pots on the Merox and Crude Distillation Units, desalter effluent from the Crude Distillation Units and from the Fire Training Ground. Refinery upsets can be caused by power dips or failures, or mechanical failure, and during these circumstances there are a variety of other possible sources of hydrocarbon to the Waste Water Treatment Plant. 7.3.5 How is it managed? Emissions of hydrocarbon to Cockburn Sound or SDOOL are minimised by optimising the treatment efficiency of the Waste Water Treatment Plant and reducing the amount that is received at the plant. This is achieved through process changes and waste minimisation, and for notification to be given to the WWTP when the inputs to the WWTP varies from normal. Primary oil removal at the WWTP occurs at the API and secondary oil removal at the Dissolved Air Floatation. These processes remove free oil and return it to the system for reprocessing. The later stage of treatment is to remove the dissolved phase hydrocarbon through biodegradation by microorganisms in the Activated Sludge Units. The oxygen and pH conditions of these units are controlled to optimise this process. There are also opportunities in the treatment process to recirculate any water that still contains an unsatisfactory amount of contaminants for further treatment prior to discharge. 7.3.6 Context about limits and targets In the early 1970s there was growing concern about the water quality in Cockburn Sound, with increasing algal problems and a reduction in the sea grass beds. This resulted in a detailed environmental study of Cockburn Sound which was released in 1979. One of the many findings was that there were hydrocarbon biomarkers present in the fish. At this time BP Refinery (Kwinana) estimated its hydrocarbon input to the Sound was approximately 1,000 kg/day, and no specific targets were in place for hydrocarbon content of discharge water (see Figure 48).
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Process Water Hydrocarbon Emissions from BP Refinery (Kwinana) 1000 36

10 9 8 7
kg/day
6 5 4 3 2 1 0
19 73 19 94
4.7
5.3
2.8 2.0 1.8
2.4 1.9
2.8
2.4
2.4
20 00
20 07
20 08
20 01
20 02
20 03
20 04
20 05
Figure 48: Annual Average Daily Hydrocarbon Emissions to the Environment from BP Refinery (Kwinana) from Treated Process Wastewater.
The licence issued to the Refinery by Department of Environment and Conservation sets a limit and target on total hydrocarbon emissions from the process wastewater and the Salt Cooling Water (see Table 8). BP Refinery (Kwinana) has set an internal target of < 5 kg/day of hydrocarbon in the process wastewater averaged over a month period, and <45kg/day of hydrocarbon in the Salt Cooling Water over a month average.
Table 8: Licence Limits for Hydrocarbon Discharge from BP Refinery (Kwinana).
Daily load (kg/day) 120 n/a Monthly average load (kg/day) 15 n/a Concentration per volume of flow (mg/L) n/a 0.1
Process SCW
20 06
For the 24 hr period when a heat exchanger leak is identified the target is 1mg/L.
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7.3.7 Performance All process waste water hydrocarbon emissions for the period of 2007 to 2009 were below the daily licence limit of 120kg/day (see Figure 49) and were also below the licence target of 15 kg/day of hydrocarbon (monthly average), (see Figure 49).
Daily Process Water Hydrocarbon Emissions from BP Refinery (Kwinana) 140

120 100
kg/day
80 60 40 20 0
20 06 20 07 20 09 20 08
licence limit
Figure 49: Daily Hydrocarbon Emission in Process Water to Cockburn Sound.
The Refinery met the internal target of controlling hydrocarbons in the process wastewater to less than 5 kg/day averaged over a month (see Figure 50) for the period 2007 2009.
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Process Water Hydrocarbon Emissions from BP Refinery (Kwinana)

6.0 Internal Target 5.0 4.0 kg/day 3.0 2.0 1.0 0.0 2005 2006 2007 2008 2009
Figure 50: Monthly Averaged Hydrocarbon Emissions in Process Water to Cockburn Sound.
Note Figure 49 and Figure 50 do not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August 2009, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The hydrocarbon emissions from 1st August 2009 to the end of the year were within the Licence limit and target. Typically there are no detectable emissions of hydrocarbons in the Refinery Salt Cooling Water, with concentrations being below the laboratory reporting limit of 0.1mg/L. Abnormal emissions of Hydrocarbons into the Salt Cooling Water (SCW) occur in the event of a heat exchanger leak. These emissions can vary depending on the duration and severity of the leak. In the period from 2007 to 2009 there were two occasions when the hydrocarbon was measured above the detection limit. On both occasions the hydrocarbon emissions were within the Licence requirements, and the internal target to maintain emissions <45kg/day as a monthly average was also met. 7.3.8 Comments on Performance All process wastewater and Salt Cooling Water Licence Limits and Targets were met for the period 2007 - 2009, as well as the internal Refinery targets. BP Refinery (Kwinana) has seen a large reduction in hydrocarbon emissions since 1979 as a result of the commissioning of the Waste Water Treatment Plant and improved processes and practices. The average daily load of hydrocarbon discharged in the period 2007 2009 was approximatly 2.5kg/day which represents a very high level of treatment performance.
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7.3.9 Future plans In 2011 the Refinery plans to conduct an upgrade on the secondary oil removal section (Dissolved Air Floatation Unit) of the Wastewater Treatment Plant, with the aim to improve the availablity of both DAF units, which is expected to improve the performance of the Activated Sludge Unit. 7.3.10 References Leffler W.L. (2000) Petroleum Refining In Nontechnical Language (3rd edition). PenWell Corporation, Tulsa. Petroleum Geochemistry Group WAIT (1982). Petroleum Hydrocarbons In Cockburn Sound A report to BP Refinery (Kwinana) and the Department of Conservation and Environment Western Australia (Bulletin 125). Department of Conservation and Environment, Perth Western Australia. Sherertz, P.C (1998) Petroleum Products [online]. Virginis Department of Health Division of Health Hazards Control. Available from www.vdh.state.va.us/HHControl/petrofac.PDF [Accessed 26/09/06].
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7.4
Sulphides
7.4.1 What is it? Sulphide is a compound of sulphur and another element. Soluble sulphide salts dissociate into sulphide ions that react with the hydrogen ions in water to form the hydrosulphate ion (HS-) or hydrogen sulphide (H2S) (Health Canada, 1992). 7.4.2 Impacts Ingestion of sulphides has been linked to nausea, vomiting and epigastric pain in humans (Health Canada, 1992). Natural waters containing elevated concentrations of hydrogen sulphide are used for therapeutic baths and have been consumed for medical purposes (Health Canada, 1992). The toxicity of sulphide to aquatic animals is dependant on the temperature, pH and dissolved oxygen concentration of the water (ANZECC, 1992). Fish usually show a strong avoidance reaction to sulphide (ANZECC, 1992). 7.4.3 Why do we emit it? Sulphides are naturally contained in crude oil. As a result some will remain in the products produced and in the waste streams generated by the Refinery. 7.4.4 Sources Natural sources of sulphides in aquatic environments are bacteria decomposing organic matter, especially in stagnant conditions (Health Canada, 1992). This source can be exaggerated by human impacts such as the degradation of sewage. Sources of sulphides from within the Refinery are sour water streams (that is streams containing sulphur) from the Residue Cracking Unit, Hydrofiners, Catalytic Reformer and the Vacuum Distillation Unit. These units have sour water streams as they remove sulphur from the crude oil and intermediate products during the wash water phase. 7.4.5 How is it managed? In 1978 the Refinery built a Sour Water Stripper on the Residue Cracking Unit as part of an expansion project. The Sour Water Stripper was designed to remove 99% of hydrogen sulphide, therefore significantly reducing the Refinery sulphide emissions from this source. In 1992 another larger Sour Water Stripper was commissioned and again significantly reduced the sulphide content of water discharged to Cockburn Sound. The emissions of sulphide from the Refinery are managed by optimising the Sour Water Stripper performance and Waste Water Treatment Plant availability and performance.
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A Sour Water Stripper removes sulphides and ammonia by feeding water into the stripping column and injecting steam which produces an overhead gas which is directed to the muffle furnace under normal operation, and a stripped sour water effluent which can be reused in other refinery processes to reduce fresh water usage, with the balance treated through the WWTP. 7.4.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a daily discharge limit of 10kg/day on the emissions of sulphide from treated process wastewater and a target to discharge less than 1kg/day on a quarterly average. BP Refinery Kwinana has set an internal target to discharge less than 0.5kg/day sulphide in process wastewater on a monthly average. 7.4.7 Performance The quarterly average emissions (kg/day) for treated process wastewater were well within the licence target of 1kg/day averaged over a quarter (see Figure 51), and also within the daily Licence Limit of 10kg/day.
Quarterly Average Sulphide Emissions (kg/day) from BP Refinery (Kwinana) 2006 - 2009
1.0
Sulphide (kg/day)
0.8
0.6
0.4
0.2
0.0
Figure 51: Quarterly Emissions of Sulphide (kg/day) to Cockburn Sound from BP Refinery (Kwinana).
Note Figure 51 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August 2009, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The sulphide emissions
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20 06 20 - Q 06 1 20 - Q 06 2 20 - Q 06 3 20 - Q 07 4 20 - Q 07 1 20 - Q 07 2 20 - Q 07 3 20 - Q 08 4 20 - Q 08 1 20 - Q 08 2 20 - Q 08 3 20 - Q 09 4 20 - Q 09 1 -Q 2
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from 1st August 2009 to the end of the year were within the Licence limit and target. 7.4.8 Comments on Performance BP Refinery (Kwinana) met the licence limit and target and the internal target for sulphide emissions from 2007 to 2009, and has achieved a significant reduction in emissions since the Cockburn Sound Study (see Figure 51).
Annual Average Daily Sulphide Emissions from BP Refinery (Kwinana)
592 10 39
Sulphide (kg/day)
8 6 4 2 0
1991 1994 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Cockburn Sound Study 1978
4.50
0.35 0.00 0.44 0.00 0.01 0.02 0.03 0.03 0.03 0.04
Figure 52: Annual Average Daily Emissions of Sulphide from BP Refinery (Kwinana) to Cockburn Sound.
Note Figure 52 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The sulphide emissions from 1st August 2009 to the end of the year were within the Licence limit and target. 7.4.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound.
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7.4.10 References Health Canada (1992) [online] Guidelines for Canadian Drinking Water Quality Supporting Documents. Available from http://www.hc-sc.gc.ca/ewhsemt/alt_formats/hecs-sesc/pdf/pubs/water-eau/doc-sup-appui/sulphidesulphure/sulphide-sulphure_e.pdf [Accessed 25/09/06].
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7.5
Fluoride
7.5.1 What is it? Fluoride compounds are all related by containing fluorine. Fluorine (F), a yellow-green gas, combines with hydrogen to make hydrogen fluoride (HF) (Department of Environment and Heritage, 2006). 7.5.2 Impacts Fluorides are found in the environment but at levels not believed to be harmful. Sodium fluoride is used in small amounts to prevent tooth decay, but in high levels may be harmful. Excessive fluoride may cause dental problems such as fluorosis which visibly changes the teeth. Exposure to high levels of fluoride over time may lead to skeletal fluorosis which causes denser bones, joint pains and limited joint movement (Department of Environment and Heritage, 2006). High levels of fluorine or hydrogen fluoride gas can harm the lungs, heart and even cause death. At low levels they can irritate eyes (potentially causing blindness), skin and lungs (Department of Environment and Heritage, 2006). Hydrogen fluoride can exist as an aerosol or mist in the air if released to the atmosphere. Industrial emissions of fluoride compounds can produce elevated concentrations in the atmosphere. Hydrogen fluoride will exist as a particle, which may dissolve in clouds, fog, rain, dew or snow. In clouds and moist air it will travel along the air currents until it is deposited as wet acid deposition (acid rain, acid fog, etc). In waterways it readily mixes as it dissolves when combined with water. 7.5.3 Why do we emit it? HF is used as a catalyst in the Refinery Alkylation Unit (see Figure 53). Alkylation is a process for producing high-octane gasoline by reacting olefins with isobutane in the presence of a HF acid catalyst. Unplanned HF emissions can occur due to leaks and equipment malfunctions on the Alkylation Unit. The released HF may dissolve into another substance (i.e. water) and enter the Waste Water Treatment Plant via the oily water sewer. The other source of fluoride is Acid Soluble Oil which forms during the alkylation process. The acid soluble oil is treated with caustic to neutralise the acid and then the solution containing fluoride is treated with calcium to precipitate out calcium fluoride (CaF2) which is highly insoluble. Post treatment some fluoride ions remain in solution and this liquid is discharged to the WWTP.
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Figure 53: BP Refinery (Kwinana) Alkylation Unit.
7.5.4 Sources The settling basin on the Alkylation Unit is the major source of fluoride in wastewater. The settling basin is used to settle out the precipitated calcium fluoride, and the water is drawn off and treated through the waste water treatment plant. 7.5.5 How is it managed? Due to its high potential health and environmental risks HF acid is amongst one of the most stringently monitored and managed substances at BP Refinery (Kwinana). Regular risk assessments are conducted to ensure that the emissions are adequately controlled onsite. The concentration of fluoride in the wastewater discharged from the wastewater treatment plant is managed by ensuring that the correct dosing of calcium chloride occurs when treating caustic neutralised wastewaters from the Alkylation Unit. 7.5.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a quarterly average target concentration of 20 mg/L on fluoride in process wastewater discharged to Cockburn Sound. Fluoride conditions were first introduced into the licence in 2005. The Refinery has an internal target of maintaining fluoride concentrations in the treated process wastewater below 16mg/l as a quarterly average.
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7.5.7 Performance In 2007 to 2009 all process wastewater quarterly averages were below the licence target of 20mg/L and the Refinery internal target of 16mg/l (see Figure 53).
Quarterly Average Fluoride Emissions from BP Refinery (Kwinana)
20
(mg/L)
10
20 08
20 08
20 08
20 08
20 07
20 07
20 09 1Q
20 07
20 07
3Q
1Q
2Q
4Q
3Q
1Q
2Q
4Q
Licence Target
Figure 54: Quarterly Average Fluoride Emissions to Cockburn Sound from BP Refinery (Kwinana) Process Wastewater from 2007 to 2009.
Note Figure 54 does not contain the emission results from 1st August 2009 to 31 December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The fluoride emissions from 1st August 2009 to the end of the year were within the Licence target. There is no Licence limit for Flouride. 7.5.8 Comments on Performance BP Refinery (Kwinana) met the licence target for fluoride concentrations in 2007 to 2009. The internal target to maintain emissions of fluoride in treated process wastewater <16mg/L as a quartely average was also met from 2007 to 2009. 7.5.9 Future plans BP Refinery (Kwinana) will continue to aim for a high level of treatment of water with calcium prior to discharge from the Alkylation Unit. This process is controlled by setting targets for fluoride concentration, and communication if results our outside of the expected range. BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by
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setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound. 7.5.10 References Department of Environment and Heritage (2006) National Pollutant Inventory Substance Profile [online] Available from: http://www.npi.gov.au/database/substance-info/profiles/44.html [Accessed on 3/10/06].
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7.6
Phenolics
7.6.1 What is it? Phenol is a colourless to pink solid or thick liquid with a characteristic sweet tar like odour (Department of Environment and Heritage, 2003). 7.6.2 Impacts The health impacts of exposure to phenol may be irritation of the nose, throat eyes and skin. A short exposure to a high level of phenol may result in a decreased respiration rate and body temperature, muscular weakness, with death usually the result of respiratory failure. Long term exposure to smaller amounts of phenol can have the symptoms of headaches, vertigo and digestive difficulties (Department of Environment and Heritage, 2003). The environmental impacts of phenol can include death of fish, birds or animals with a high exposure. Longer term exposures at lower levels may result in a shortened lifespan, reproductive problems, and changes in appearance or behaviour. Phenol does not tend to bioaccumulate in plants or animals (Department of Environment and Heritage, 2003). Phenols in marine waters are broken down by bacteria, but fish in phenol contaminated waters can have a strong kerosene flavour. 7.6.3 Why do we emit it? Phenolics are naturally contained in crude oil, therefore as the oil is refined into useful products some remains dissolved in wastewater streams. Phenolics are also formed in the refining process. 7.6.4 Sources Phenol is naturally found in animal wastes, pine needles and decomposing organic material (Department of Environment and Heritage, 2003). Phenol is contained in many consumer products such as red wine, disinfectants, paint and varnish removers, rubber adhesives and office wood surfaces (Department of Environment and Heritage, 2003). Sources of phenolics within BP Refinery (Kwinana) include drainings from storage tanks as water separates out of crude oil or finished products, and caustic from the Minalk on the Residue Cracking Unit. 7.6.5 How is it managed? The Cockburn Sound Environmental Study from 1976-1979 reported BP Refinery was emitting 514kg/day of phenolics to Cockburn Sound.
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In 1992 the Refinery built a new Minalk (Minimum Alkalinity) Unit that uses a reduced caustic strength, therefore reducing the phenolics present in the wastewater. In 1994 the Waste Water Treatment Plant was commissioned with the capability to treat phenols in the Activated Sludge Units (ASU) by biodegradation. 7.6.6 Context about limits and targets The Cockburn Sound Environmental Study reported BP Refinery to be the largest emission point of phenolics, contributing 514kg/day to Cockburn Sound, while the only other recorded source contributed a load of 1.1kg/day (Department of Conservation & Environment, 1979). Since this time the Refinery has reduced emissions significantly. The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets the limit for the discharge of phenolics at 20kg/day for process wastewater, and sets a licence target of 1kg/day (quarterly average). The Refinery has an internal target to maintain phenolic emissions in process wastewater below 0.5kg/day (monthly average). 7.6.7 Performance The Refinery met the licence limit applied to emissions as well as the internal target set by the Refinery for 2007 - 2009. As can be seen in Figure 55 phenolic compounds have been barely detectable between 2007 and 2009 and are two orders of magnitude less than the Refinery licence limit and target.
Quarterly Average Phenol Emissions (kg/day) From BP Refinery (Kwinana)
0.05 0.04 (kg/day) 0.03 0.02 0.01 0.00
1 -Q 09 20 09
-Q
-Q
-Q
-Q
-Q
-Q
-Q
-Q
-Q
06
06
06
06
07
07
07
07
08
08
08
-Q
20
20
20
20
20
08
20
20
20
20
20
20
Quarter
Figure 55: Quarterly Average Phenol Emissions (kg/day) to Cockburn Sound from BP Refinery (Kwinana) Process Wastewater.
Note Figure 55 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are
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20
-Q
-Q
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-Q
calculated separately as required by the Quality Assurance Procedure. The phenolic emissions from 1st August 2009 to the end of the year were within the Licence limit and target. 7.6.8 Comments on Performance The reduction of phenolic emissions from over 182 500 kg/year in the late 1970s to approximately 10 kg/year is a significant achievement by the Refinery, achieved by cleaner production upstream of the WWTP and treatment at the WWTP. 7.6.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound. 7.6.10 References Department of Conservation & Environment (1979) Cockburn Sound Environmental Study 1976-1979 (report No 2). Department of the Environment and Heritage (2003) National Pollutant Inventory Substance Profile [online]. Australian Government. Available from www.npi.gov.au/ [Accessed 3/12/03].
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7.7
Nitrogen
7.7.1 What is it? Nitrogen in its standard state is a colourless, odourless gas that is generally inert, and makes up approximately 78% of the atmosphere by volume (Winter 2003). In water nitrogen exists in various forms; the total nitrogen in water is the sum of the ammonium and ammonia nitrogen, nitrate/nitrite nitrogen and organic nitrogen. 7.7.2 Impacts Nitrogen is an essential nutrient for humans, and there are no specific health effects directly associated with nitrogen (Department of the Environment and Heritage 2003). Nitrogen can have indirect effects on human health through the potential to cause toxic algal blooms in waterways (see below). Nitrogen emissions to natural waterways can have varied effects, depending on the previous nutrient levels and the amount of nitrogen being emitted. Nitrogen is naturally occurring in water, however increased levels can lead to excessive growth (bloom) of algae, which can reduce the amount of light reaching benthic plants and algae, and may cause these to die. This process, as well as the decay of the bloom, can create reduced dissolved oxygen conditions that can lead to fish kills. 7.7.3 Why do we emit it? Nitrogen is a component of many process chemicals and it is also present in crude oil. The BP Refinery (Kwinana) WWTP is designed to remove nitrogen, however a small amount can still remain in the process wastewater discharged. 7.7.4 Sources Nitrogen is naturally fixed from the atmosphere by bacteria in the roots of certain plants, and is a vital component of food (Winter 2003). Humans have enhanced this process through agriculture and the application of fertilisers. Nitrogen, in the form of amine is used in the refining process to absorb H2S and CO2, occasionally amine may be drained to the Waste Water Treatment Plant which significantly contributes to nitrogen loading. Other sources of nitrogen within the Refinery are the Sour Water Stripper effluent or fire fighting foam from the fire training ground. 7.7.5 How is it managed? In 1994 the Refinery commissioned the Waste Water Treatment Plant to improve the quality of the wastewater discharged from the Refinery. The Waste Water Treatment Plant has two Activated Sludge Units (ASUs) that are responsible for conversion of nitrogen in the water to N2 gas, a natural component of the atmosphere. The ASUs at Kwinana are quite unique in that the denitrification process
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takes place in the same basin as nitrification. Kwinana Refinery was only the second oil refinery in the world to actually remove nitrogen from the wastewater via denitrification. To ensure effective removal of the nitrogen the process conditions in the ASUs must be carefully controlled. Nitrogen is also managed prior to the Waste Water Treatment Plant by minimizing the amount of amine drained to the sewer and optimising the efficiency of the Sour Water Stripper Unit. 7.7.6 Context about limits and targets The Cockburn Sound Study conducted between 1976 - 1979 reported that BP Refinery was discharging 322kg/day of nitrogen (Department of Conservation & Environment, 1979). The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a limit on the nitrogen discharge in process water at 200kg/day and a quarterly average target of 60kg/day. The Refinery has an internal target to have less than 50kg/day of nitrogen in the treated process wastewater discharge on a monthly average. 7.7.7 Performance From 2007 to 2009 nitrogen emissions from BP Refinery (Kwinana) were within the licence limit of 200kg/day (see Figure 55) and within the target of 60kg/day on a quarterly average (see Figure 56). The Refinery also met its internal target of discharging less than 50kg/day (monthly average) from 2007 to 2009.
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Nitrogen Daily Load (kg/day) from BP Refinery (Kwinana)

250 200
kg/day
150 100 50 0
1/ 01 /2 00 6 1/ 07 /2 00 6 1/ 01 /2 00 7 1/ 07 /2 00 7 1/ 01 /2 00 8 1/ 07 /2 00 8 1/ 01 /2 00 9 1/ 07 /2 00 9
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Final Effluent To tal Nitro gen Daily Lo ad (kg/day) Final Effluent To tal Nitro gen Daily Lo ad limit (kg/day)
Figure 56: Nitrogen Daily Load to Cockburn Sound (kg/day) from BP Refinery (Kwinana) Process Wastewater.
Nitrogen Quarterly Averages (kg/day) from BP Refinery (Kwinana) 2006 to 2009

70 60 50 40 30 20 10
20 0 2Q 6 20 0 3Q 6 20 0 4Q 6 20 0 1Q 6 20 0 2Q 7 20 0 3Q 7 20 0 4Q 7 20 0 1Q 7 20 0 2Q 8 20 0 3Q 8 20 0 4Q 8 20 0 1Q 8 20 0 2Q 9 20 09
kg/day
1Q
License Target
Figure 57: Nitrogen Quarterly Average Emissions (kg/day) to Cockburn Sound from BP Refinery (Kwinana) Process Wastewater.
Note Figure 56 do not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The phenol emissions from 1st August 2009 to the end of the year were within the Licence limit and target.
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7.7.8 Comments on Performance BP Refinery (Kwinana) met the licence limit and licence target and the internal targets for nitrogen emissions from 2007 to 2009. Process wastewater nitrogen emissions have been significantly reduced from the levels recorded in 1979, and the annual average emissions have been relatively consistent in the period from 2007 - 2009 (see Figure 58).
Annual Average Nitrogen Emissions from BP Refinery (Kwinana)
350
Nitrogen (kg/day)
300 250 200 150 100 50 0
19 79
19 96
19 99
20 00
20 01
20 02
20 03
20 04
20 05
20 06
20 07
20 08
Figure 58: Annual Average Daily Total Nitrogen Emissions to Cockburn Sound from BP Refinery (Kwinana) Process Wastewater.
Note Figure 58 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The phenol emissions from 1st August 2009 to the end of the year were within the Licence limit and target. 7.7.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound.
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7.7.10 References Department of the Environment and Heritage (2003) National Pollutant Inventory Substance Profile [online]. Australian Government. Available from www.npi.gov.au/ [Accessed 3/12/03]. Winter M (2003) Chemistry WebElements Periodic Table (Nitrogen) [online] Webelements. Available from www.webelements.com/webelements/elements/text/N/key.html [Accessed 12/12/03].
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7.8
Heavy metals
7.8.1 Introduction Treated process wastewater is sampled daily, with a 24 hour composite made up of samples taken every hour. The daily samples are then made into a weekly composite sample which is analysed for heavy metals. Prior to this, the daily samples were composited for 28 days then analysed. Table 9 shows a summary of the annual heavy metal emissions in process wastewater for the period 2007 2009 against the yearly average Licence Limits. Each metal is discussed individually in the following sections along with performance against Licence and internal targets.
Table 9: Heavy Metal yearly average load to Cockburn Sound from 2007 to 2009 from BP Refinery (Kwinana) process wastewater.
2007 performance (kg/day) 2008 performance (kg/day) 2009 performance (kg/day) Licence Limit (yearly average) (kg/day) 0.4 0.08 0.16 0.16 0.16 0.16 0.008 0.16 0.16 0.8
Heavy metal
Arsenic Cadmium Chromium Cobalt Copper Lead Mercury Nickel Vanadium Zinc
0.055 0.003 0.007 0.007 0.008 0.013 0.0002 0.008 0.061 0.077
0.039 0.003 0.007 0.007 0.007 0.014 0.0002 0.015 0.026 0.076
0.041 0.003 0.016 0.007 0.007 0.014 0.0002 0.019 0.016 0.065
Note Table 9 does not contain the emission results from 1st August 2009 to 31 December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The 2009 annual average emissions are based on data from 1/1/09 to 31/7/09. The heavy metal emissions from 1st August 2009 to the end of the year were within the Licence limit and target.
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7.9
Arsenic
7.9.1 What is it? Pure arsenic is silver-grey in colour and has both metallic and non-metallic properties. Arsenic is odourless and in nature is usually found combined with one or more other elements (Department of Environment and Heritage, 2003). 7.9.2 Impacts Arsenic has a high short and long term toxicity to aquatic life, and fish and shellfish can build up organic arsenic compounds (Department of Environment and Heritage, 2003). Arsenic has high toxicity for both acute and chronic exposure, is very persistent and is expected to bioaccumulate in fish and shellfish, although not in elemental form (NPI, 2006). 7.9.3 Why do we emit it? Arsenic is naturally contained in water, soil and crude oil. Concentrations of arsenic vary between crudes, and may enter the Wastewater Treatment Plant via the Oily Water Sewer (OWS). Effluent from the Crude Distillation Units (CDU) is likely to be the key source of arsenic. 7.9.4 Sources Natural sources of heavy metals to water are weathering of rocks, soils and minerals, and volcanic activity. Human activity has increased these emissions through heavy metal emissions from sources such as the combustion of fossil fuels (including vehicle emissions) and industry. Approximately 90 percent of industrial arsenic in the U.S. is currently used as a wood preservative, but arsenic is also used in paints, dyes, metals, drugs, soaps and semi-conductors (US EPA, 2005). Heavy metal emissions from the Refinery occur either as the metal is added or used to assist the refining process or is naturally contained in the crude oil itself, such as arsenic, and therefore a small amount may remain in the wastewater. 7.9.5 How is it managed? By managing what is discharged to the oily water sewer the emissions of heavy metals can be controlled to an extent, as some discharges can contain metals. Arsenic is a difficult heavy metal to remove from waste water due to the high solubility of some forms of arsenic. The Dissolved Air Flotation (DAF) units remove suspended solids, fine droplets of oil and other materials. The majority of arsenic is in solution and passes through the DAF; whereas other metals which are in particulate form are largely removed in this unit.
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7.9.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a limit on arsenic discharge in process wastewater as an annual average of 0.4kg/day, and a monthly average target of 0.1mg/L. The Refinery has an internal target of <0.32kg/day as a yearly average, and <0.08mg/L as a monthly average. 7.9.7 Performance The arsenic annual average loads in process wastewater from 2007 to 2009 were below the Licence limit (see Table 9), and were also below the internal target of <0.32kg/day. Monthly average arsenic concentrations were below the licence target of 0.1 mg/l (see Figure 58), and also below the internal target of 0.08mg/L. Monthly Arsenic Average Effluent Concentrations from BP Refinery (Kwinana) 2007 to 2009
0.15
Comment [BU1]: What about monthly average data???
Concentration (mg/L)
0.1
0.05
2007
2008
Target
2009
Figure 59: Monthly Average Arsenic Concentrations (mg/L) in Process Wastewater from January 2007 July 2009.
Note Figure 59 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The arsenic emissions from 1st August 2009 to the end of the year were within the Licence limit and target. 7.9.8 Comment on performance For the period of 2007 - 2009 the arsenic emissions from process wastewater were below the licence limit and licence target. The emissions for the same period were also below the internal targets for annual load and monthly average concentration.
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7.9.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound. 7.9.10 References Department of the Environment and Heritage (2003) National Pollutant Inventory Substance Profile [online]. Australian Government. Available from www.npi.gov.au/ [Accessed 20/11/03]. National Pollutant Inventory (NPI) (2006). Available: www.npi.gov.au (accessed 9/1/2006). US Environmental Protection Agency (US EPA) (2005). Available: www.epa.gov (accessed 12/12/2005). Gehle, K., Harkins, D., Johnson, D., Rosales-Guevara, L. (2000) Case Studies in Environmental Medicine: Arsenic Toxicity. Agency for toxic Substances and Diseases Registry, Atlanta, United States.
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7.10 Cadmium 7.10.1 What is it? Pure cadmium is a soft silver white colour, however it is most often found combined with other elements producing compounds. Cadmium and its compounds are stable. Cadmium is highly persistent in the environment and will concentrate or bioaccumulate in aquatic animals (Department of Environment and Heritage, 2003). 7.10.2 Impacts Cadmium has high short and long term toxicity to aquatic life, and will accumulate in aquatic animals. Cadmium compounds do bind to the sediments in rivers and lakes and they become less bioavailable (Department of Environment and Heritage, 2003). 7.10.3 Why do we emit it? Cadmium is naturally contained in crude oil, generally in extremely low (ultra trace) concentrations. 7.10.4 Sources Cadmium may enter the Waste Water Treatment Plant as it is naturally contained in trace concentrations in crude oil. 7.10.5 How is it managed No other source of cadmium is present in the refining process. Cadmium is used as a component of some metal alloys but leaching rates from these are extremely low. Therefore no management of emissions is necessary as no measurable concentrations are present. 7.10.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a limit on cadmium discharge in process wastewater at an annual average of 0.08kg/day, and a target monthly average concentration of 0.2mg/L. The Refinery has set an internal target for cadmium emissions in the process wastewater to remain <0.064kg/day as a yearly average, and <0.16mg/L as a monthly average. 7.10.7 Performance The cadmium annual average loads in process wastewater from 2007 to 2009 were below the Licence limit, and were also below Licence target (see Figure 59) and the Refinery internal targets.
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0.3
Monthly Cadmium Average Effluent Concentrations from BP Refinery (Kwinana) 2007 to 2009
0.2
0.1 Limit of Reporting <0.02 mg/L
2007
2008
Target
2009
Figure 60: Cadmium Concentrations in Wastewater from BP Refinery (Kwinana) from 2007 to 2009.
Note Figure 60 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The cadmium emissions from 1st August 2009 to the end of the year were within the Licence limit and target. 7.10.8 Comments on performance For the period of 2007 - 2009 the cadmium emissions from process wastewater were below the licence limit and licence target. The emissions for the same period were also below the internal targets for annual load and monthly average concentration. 7.10.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound.
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7.11 Chromium 7.11.1 What is it? Chromium is a white, hard, brittle silvery metal. The most stable oxidation state of the element chromium is chromium (III), another oxidation state of importance is chromium (VI) (Department of Environment and Heritage, 2003). 7.11.2 Impacts In very small amounts chromium (III) is beneficial in a human diet, however high levels can become toxic. Some forms of chromium are highly toxic to aquatic organisms. 7.11.3 Why do we emit it? Chromium is naturally contained in crude oil, present in some chemicals and metal alloys- used within the Refinery, and is present in timber used in the cooler tower onsite. Wastewater entering the WWTP could therefore contain some chromium. 7.11.4 Sources The main emission sources of chromium from the Refinery include particulate emissions from process units, flares, furnaces and sandblasting activities. Chromium is present in the crude oils processed at the Refinery, chemicals and cooling tower timber and therefore can be contained in wastewater streams. 7.11.5 How is it managed By managing what is discharged to the oily water sewer the emissions of heavy metals can be controlled to an extent, as some discharges can contain metals. The Dissolved Air Flotation (DAF) unit at the Wastewater Treatment Plant is responsible for removing the majority of suspended solids, fine droplets of oil and other materials from the wastewater. The DAF is where the majority of metals removal takes place. 7.11.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a limit on chromium discharge in process wastewater at 0.16kg/day, and a monthly average target of 0.1mg/L. The Refinery has an internal target to maintain chromium emissions from process wastewater <0.128kg/day as an annual average, and <0.08mg/L as a monthly average. 7.11.7 Performance The chromium annual average loads in process wastewater from 2007 to 2009 were below the Licence limit (see Table 2), and the monthly average concentrations in process wastewater were generally below the laboratory reporting limit of 0.005
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mg/l with the expection of three months (see Figure 60). For the period 2007 - 2009 the monthly average concentration was within the Licence target, and also within the Refinery internal targets.
Monthly Chromium Average Effluent Concentrations from BP Refinery (Kwinana) 2007 to 2009
0.15
0.1
2007
2008
Target
2009
Figure 61: Chromium Concentrations in Wastewater from BP Refinery (Kwinana) from 2007 to 2009.
Note Figure 61 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The chromium emissions from 1st August 2009 to the end of the year were within the Licence limit and target. 7.11.8 Comments on performance For the period of 2007 - 2009 the chromium emissions from process wastewater were below the licence limit and licence target. The emissions for the same period were also below the internal targets for annual load and monthly average concentration. 7.11.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater
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discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound. 7.11.10 References Department of the Environment and Heritage (2003) National Pollutant Inventory Substance Profile [online]. Australian Government. Available from www.npi.gov.au/ [Accessed 20/11/03].
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7.12 Cobalt 7.12.1 What is it? Cobalt metal is an odourless shiny, silvery metal, when first exposed to air. Cobalt is a metal that occurs naturally in may different forms (Department of Environment and Heritage, 2003). 7.12.2 Impacts The environmental effects of cobalt are high short term and long term toxicity effects on aquatic life, and accumulation in the tissues of fish can occur (Department of Environment and Heritage, 2003). 7.12.3 Why do we emit it? Cobalt is present in catalysts used within the Refinery and is present in trace amounts in crude oil. 7.12.4 Sources Cobalt catalysts are used within the Refinery, therefore effluent, containing small amounts of cobalt, from the process units may enter the Waste Water Treatment Plant. 7.12.5 How is it managed By managing what is discharged to the oily water sewer the emissions of heavy metals can be controlled to an extent, as some discharges can contain metals. The Dissolved Air Flotation (DAF) unit at the Wastewater Treatment Plant is responsible for removing the majority of suspended solids, fine droplets of oil and other materials from the wastewater. The DAF is where the majority of metals removal takes place. Cobalt removal in the Waste Water Treatment Plant is typically very high. 7.12.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a limit on cobalt discharge in process wastewater at 0.16kg/day (annual average), and a monthly average target concentration of 0.1mg/L. The Refinery has set internal targets for cobalt emissions from process wastewater at <0.128 kg/day as an annual average, and <0.08mg/L as a monthly average. 7.12.7 Performance The cobalt annual average loads in process wastewater from 2007 to 2009 were below the Licence limits (see Figure 62), and the monthly average concentrations in process wastewater were all below the laboratory reporting limit of 0.005mg/L (see
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Figure 61). For the period 2007 - 2009 the monthly average concentration was within the Licence target, and also within the Refinery internal targets.
Monthly Cobalt Average Effluent Concentrations from BP Refinery (Kwinana) 2007 to 2009
0.2
0.1
Limit of Reporting <0.005 mg/L
2007
2008
Target
2009
Figure 62: Cobalt Concentration in Wastewater from BP Refinery (Kwinana) from 2007 to 2009.
Note Figure 62 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The cobalt emissions from 1st August 2009 to the end of the year were within the Licence limit and target. 7.12.8 Comments on performance For the period of 2007 - 2009 the cobalt emissions from process wastewater were below the Licence limit and Licence target. The emissions for the same period were also below the internal targets for annual load and monthly average concentration. 7.12.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound.
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7.13 Copper 7.13.1 What is it? Copper is a reddish-brown, odourless metal that becomes dull when exposed to air. Copper is malleable and ductile, and can form compounds of copper (I) and copper (II) (Department of Environment and Heritage, 2003). 7.13.2 Impacts The environmental effects of copper are often reduced as it strongly attaches to other particles which reduces the toxicity, however free copper ions are potentially very toxic to aquatic life and are expected to accumulate in fish (Department of Environment and Heritage, 2003). 7.13.3 Why do we emit it? Copper is naturally contained in crude oil and is commonly used in alloy pipes. 7.13.4 Sources Copper may enter the Waste Water Treatment Plant from water coming into contact with crude oil which naturally contains some copper, or effluent from process units may contain small concentrations of copper as copper is common in metal alloyed pipes. The alloyed metals may weather and leach copper, thus it may enter the Waste Water Treatment Plant. 7.13.5 How is it managed By managing what is discharged to the oily water sewer the emissions of heavy metals can be controlled to an extent, as some discharges can contain metals. The Dissolved Air Flotation (DAF) unit at the Wastewater Treatment Plant is responsible for removing the majority of suspended solids, fine droplets of oil and other materials from the wastewater. The DAF is where the majority of metal removal takes place. Copper removal in the Waste Water Treatment Plant is typically very high. 7.13.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a limit on copper discharge in process wastewater at 0.16kg/day (annual average), and a monthly average target concentration of 0.21mg/l. The Refinery has set internal targets for copper emissions from process wastewater at <0.128 kg/day as an annual average, and <0.168mg/L as a monthly average. 7.13.7 Performance The copper annual average loads in process wastewater from 2007 to 2009 were below the Licence limit (see Figure 62), and the monthly average concentrations in
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process wastewater were all below the laboratory reporting limit of 0.005 mg/l (see Figure 63) with one exception. For the period 2007 - 2009 the monthly average concentration was within the Licence target, and also within the Refinery internal targets.
Monthly Copper Average Effluent Concentrations from BP Refinery (Kwinana) 2007 to 2009
0.3
0.2
2007
2008
Target
2009
Figure 63: Copper Concentration in Wastewater from BP Refinery (Kwinana) from 2007 to 2009.
Note Figure 63 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The copper emissions from 1st August 2009 to the end of the year were within the Licence limit and target. 7.13.8 Comments on performance For the period of 2007 - 2009 the copper emissions from process wastewater were below the Licence limit and Licence target. The emissions for the same period were also below the internal targets for annual load and monthly average concentration. 7.13.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater
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discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound. 7.13.10 References Department of the Environment and Heritage (2003) National Pollutant Inventory Substance Profile [online]. Australian Government. Available from www.npi.gov.au/ [Accessed 20/11/03].
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7.14 Lead 7.14.1 What is it? Lead is a soft, blue grey metallic solid, and compounds of lead have varying chemical and physical properties (Department of Environment and Heritage, 2003). 7.14.2 Impacts The environmental effects of lead can include death of fish, and the death or low growth rate of plants. Lead will remain in sediments for long periods, therefore it is expected it can accumulate in the tissue of fish living in lead polluted water (Department of Environment and Heritage, 2003). 7.14.3 Why do we emit it? Lead is naturally contained in crude oil and is an additive to aviation gasoline in organic form. 7.14.4 Sources Lead may enter the Waste Water Treatment Plant as it is naturally contained in trace concentrations in crude oil. Tetra-ethyl lead was previously a common additive in most hydrocarbon fuels to increase the fuels octane number. Due to the associated environmental and health impacts of lead emissions, the addition of lead to fuels (with the exclusion of Aviation Gasoline, or Avgas) was ceased in the late nineties. Lead is only added to Avgas suitable for use in aircrafts with piston engines. Other potential sources of lead in wastewater are spills of the lead additive, water draining from Avgas tanks, and slop oil from tanks containing Avgas. 7.14.5 How is it managed By managing what is discharged to the oily water sewer the emissions of heavy metals can be controlled to an extent, as some discharges can contain metals. The Dissolved Air Flotation (DAF) unit at the Wastewater Treatment Plant is responsible for removing the majority of suspended solids, fine droplets of oil and other materials from the wastewater. The DAF is where the majority of metals removal takes place. Lead removal in the Waste Water Treatment Plant is typically very high. 7.14.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a limit on lead discharge in treated process wastewater at 0.16kg/day (annual average), and a monthly average target of 0.1mg/L. The Refinery has set internal targets for lead emissions from process wastewater of <0.128kg/day as an annual average, and <0.08mg/L as a monthly average.
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7.14.7 Performance The lead annual average loads in process wastewater from 2007 to 2009 were below the Licence limit (see Table 9: Heavy Metal yearly average load to Cockburn Sound from 2007 to 2009 from BP Refinery (Kwinana) process wastewater. ), and the monthly average concentrations in process wastewater were all below the laboratory reporting limit of 0.010mg/l (see Figure 64). For the period 2007 - 2009 the monthly average concentration was within the Licence target, and also within the Refinery internal targets.
Monthly Lead Average Effluent Concentrations from BP Refinery (Kwinana) 2007 to 2009
0.2
0.1
2007
2008
Target
2009
Figure 64: Lead Concentration in Wastewater from BP Refinery (Kwinana) from 2007 to 2009.
Note Figure 64 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The lead emissions from 1st August 2009 to the end of the year were within the Licence limit and target. 7.14.8 Comments on performance For the period of 2007 - 2009 the lead emissions from process wastewater were below the licence limit and licence target. The emissions for the same period were also below the internal targets for annual load and monthly average concentration.
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7.14.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound. 7.14.10 References Department of the Environment and Heritage (2003) National Pollutant Inventory Substance Profile [online]. Australian Government. Available from www.npi.gov.au/ [Accessed 20/11/03].
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7.15 Mercury 7.15.1 What is it? Mercury is an odourless, silver white liquid metal. It is very dense and is slightly volatile at ambient temperatures. Mercury will form alloys with most metals, and is an excellent conductor of electricity (Department of Environment and Heritage, 2003). 7.15.2 Impacts When mercury is released into the environment it is oxidised into other compounds of mercury. Mercury bio-accumulates and can remain in the environment for many years (Department of Environment and Heritage 2003). 7.15.3 Why do we emit it? Mercury is naturally contained in crude oil. 7.15.4 Sources Mercury may enter the Waste Water Treatment Plant as it is naturally contained in crude oil. As a result, effluent from process units containing small concentrations of mercury may enter the Waste Water Treatment Plant. 7.15.5 How is it managed By managing what is discharged to the oily water sewer the emissions of heavy metals can be controlled to an extent, as some discharges can contain metals. The Dissolved Air Flotation (DAF) unit at the Wastewater Treatment Plant is responsible for removing the majority of suspended solids, fine droplets of oil and other materials from the wastewater. The DAF is where the majority of metals removal takes place. Mercury removal in the Waste Water Treatment Plant is relatively high. 7.15.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a limit on mercury discharge in process water at 0.008kg/day (annual average), and a monthly average target of 0.01mg/l. The Refinery has set internal targets for mercury emissions from process wastewater of <0.0064kg/day as an annual average, and <0.008mg/L as a monthly average. 7.15.7 Performance The mercury annual average loads in process wastewater from 2007 to 2009 were below the Licence limit (see Table 9) and the monthly average concentrations in process wastewater were all below the laboratory reporting limit of 0.010mg/l (see
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Figure 65). For the period 2007 - 2009 the monthly average concentration was within the Licence target, and also within the Refinery internal targets.
0.0150 0.0125 Concentration (mg/L) 0.0100 0.0075 0.0050 0.0025 0.0000
Monthly Mercury Average Effluent Concentrations from BP Refinery (Kwinana) 2007 to 2009
2007
2008
Target
2009
Figure 65: Mercury Concentration in Process Wastewater from BP Refinery (Kwinana) from 2007 to 2009.
Note Figure 65 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The mercury emissions from 1st August 2009 to the end of the year were within the Licence limit and target. 7.15.8 Comments on performance For the period of 2007 - 2009 the mercury emissions from process wastewater were below the licence limit and licence target. The emissions for the same period were also below the internal targets for annual load and monthly average concentration. 7.15.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound.
Comment [BU2]: this data came from outfalls2
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7.16 Nickel 7.16.1 What is it? Nickel is a hard silvery-white metal. It is malleable and ductile, and is a good conductor of electricity and heat (Department of Environment and Heritage, 2003). 7.16.2 Impacts The environmental impact of nickel is high short and long term toxicity on aquatic life (Department of Environment and Heritage, 2003). The majority of nickel in aquatic environments is associated with particulate matter or sediments, with only a small portion remaining in the dissolved phase (ANZECC, 1992). 7.16.3 Why do we emit it? Nickel is naturally contained in crude oil, and is present in a catalyst used within the Refinery. 7.16.4 Sources Nickel may enter the Waste Water Treatment Plant from a number of sources. Nickel is naturally contained in crude oil and concentrations of nickel can vary widely between crudes. Effluent from the Crude Distillation Units (CDU) is likely to be the main source of nickel. Nickel is used as catalyst on the Hydrofiner Two and Three, and Catalytic Reformer (CR3) process units. Nickel Molybdenum (NiMo) is used as a hydrotreating catalyst to remove sulphur in a hydrogen rich environment. 7.16.5 How is it managed By managing what is discharged to the oily water sewer the emissions of heavy metals can be controlled to an extent, as some discharges can contain metals. The Dissolved Air Flotation (DAF) unit at the Wastewater Treatment Plant is responsible for removing the majority of suspended solids, fine droplets of oil and other materials from the wastewater. The DAF is where the majority of metals removal takes place. Nickel removal in the Waste Water Treatment Plant is relatively high. 7.16.6 Context about limits ands targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a limit on nickel discharge in process wastewater at 0.16kg/day (annual average), and a monthly average target of 0.11mg/l. The Refinery has set internal targets for nickle emissions from process wastewater of <0.128kg/day as an annual average, and <0.088mg/L as a monthly average.
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7.16.7 Performance The nickel annual average loads in process wastewater from 2007 to 2009 were were below the Licence limits (see Table 9), and the monthly average concentrations in process wastewater were all below Licence target (see Figure 66). For the period 2007 - 2009 the nickel emissions from the process wastewater were within the Refinery internal targets.
Monthly Nickel Average Effluent Concentrations from BP Refinery (Kwinana) 2007 to 2009
0.2
0.1
2007
2008
Target
2009
Figure 66: Nickel Concentration in Process Wastewater from BP Refinery (Kwinana) from 2007 to 2009.
Note Figure 66 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The nickel emissions from 1st August 2009 to the end of the year were within the Licence limit and target. 7.16.8 Comments on performance For the period of 2007 - 2009 the nickel emissions from process wastewater were below the licence limit and licence target. The emissions for the same period were also below the internal targets for annual load and monthly average concentration. 7.16.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by setting internal objectives and targets. These objectives and targets will be reviewed
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annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound. 7.16.10 References Australian and New Zealand Environment and Conservation Council (ANZECC) (1992) Australian Water Quality for Fresh and Marine Waters. Department of the Environment and Heritage (2003) National Pollutant Inventory Substance Profile [online]. Australian Government. Available from www.npi.gov.au/ [Accessed 20/11/03].
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7.17 Vanadium 7.17.1 What is it? Vanadium is a silver-grey metal that is rare, soft and ductile. Vanadium is found combined in certain minerals and is used mainly to produce certain alloys. 7.17.2 Impacts Vanadium having oxidation states of 0, +1, +2, +3, +4 and +5 occurs in nature in oxidised forms as metal vanadates. Dissolved vanadium is usually in the pentavalent form. Vanadium pentoxide has a water solubility of 7mg/l. Little information is available on the bioaccumulation of vanadium, although some marine benthic invertebrates, particularly tunicates, accumulate vanadium to levels five to six orders of magnitude those found in the marine environment. 7.17.3 Why do we emit it? Vanadium is naturally contained in crude oil.
7.17.4 Sources Vanadium may enter the Waste Water Treatment Plant as it is naturally contained in crude oil. As a result, effluent from process units containing small concentrations of vanadium may enter the Waste Water Treatment Plant. 7.17.5 How is it managed By managing what is discharged to the oily water sewer the emissions of heavy metals can be controlled to an extent, as some discharges can contain metals. The Dissolved Air Flotation (DAF) unit at the Wastewater Treatment Plant is responsible for removing the majority of suspended solids, fine droplets of oil and other materials from the wastewater. The DAF is where the majority of metals removal takes place. Vanadium removal in the Waste Water Treatment Plant is high. 7.17.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a limit on vanadium discharge in process wastewater at 0.16kg/day (annual average), and a monthly average target concentration of 0.1mg/l. The Refinery has set internal targets for vanadium emissions from process wastewater of <0.128kg/day as an annual average, and <0.08mg/L as a monthly average.
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7.17.7 Performance The vanadium annual average loads in process wastewater from 2007 to 2009 were below the Licence limit (see Table 9), and the monthly average concentrations in process wastewater were all below Licence target (see Figure 67). Vanadium concentration did increase from historical levels from late 2007 to early 2008, it is suspected this increase was due to a particular crude slate being run during this period. For the period 2007 - 2009 the vanadium emissions from the process wastewater were within the Refinery internal targets.
Monthly Vanadium Average Effluent Concentrations from BP Refinery (Kwinana) 2007 to 2009
0.2
0.1
2007
2008
Target
2009
Figure 67: Vanadium Concentration in Process Wastewater from BP Refinery (Kwinana) from 2007 to 2009.
Note Figure 67 does not contain the emission results from 1st August 2009 to 31 December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The vanadium emissions from 1st August 2009 to the end of the year were within the Licence limit and target. 7.17.8 Comments on performance For the period of 2007 - 2009 the vanadium emissions from process wastewater were below the licence limit and licence target. The emissions for the same period were also below the internal targets for annual load and monthly average concentration.
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7.17.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound. 7.17.10 References Department of the Environment and Heritage (2003) National Pollutant Inventory Substance Profile [online]. Australian Government. Available from www.npi.gov.au/ [Accessed 20/11/03].
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7.18 Zinc 7.18.1 What is it? Zinc is a bluish-white, lustrous metal that is brittle at ambient temperatures, although when heated to 100 to 150C it becomes malleable and can be rolled out. Zinc forms many alloys, the properties of which vary greatly (Department of Environment and Heritage, 2003). 7.18.2 Impacts Zinc has high short and long term toxicity to aquatic life, and it is moderately accumulated in fish. Zinc is unlikely to build up in plants (Department of Environment and Heritage, 2003). 7.18.3 Why do we emit it? Zinc is naturally contained in crude oil, and is added to water systems for corrosion control. 7.18.4 Sources Zinc may enter the Waste Water Treatment Plant from a number of sources. Zinc is naturally contained in crude oil, as a result effluent containing small concentrations of zinc may enter the Waste Water Treatment Plant. Zinc is widely used as a chemical treatment in water systems for corrosion control. Also galvanised metals are coated with ZnO to prevent corrosion and the coating may weather leaching zinc which may find a pathway to the Waste Water Treatment Plant. 7.18.5 How is it managed By managing what is discharged to the oily water sewer the emissions of heavy metals can be controlled to an extent, as some discharges can contain metals. The Dissolved Air Flotation (DAF) unit at the Wastewater Treatment Plant is responsible for removing the majority of suspended solids, fine droplets of oil and other materials from the wastewater. The DAF is where the majority of metals removal takes place. Vanadium removal in the Waste Water Treatment Plant is very high. 7.18.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a limit on zinc discharge in process wastewater at 0.8kg/day (annual average), and a monthly average target concentration of 0.213mg/L. The Refinery has set internal targets for zinc emissions from process wastewater of <0.64kg/day as an annual average, and <0.1704mg/L as a monthly average.
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7.18.7 Performance The zinc annual average loads in process wastewater from 2007 to 2009 were below the Licence limit (see Table 9), and the monthly average concentrations in process wastewater were all below Licence target (see Figure 68). For the period 2007 2009 the vanadium emissions from the process wastewater were within the Refinery internal targets.
Monthly Zinc Average Effluent Concentrations from BP Refinery (Kwinana) 2007 to 2009
0.3
0.2
0.1
2007
2008
Target
2009
Figure 68: Monthly Average Zinc Concentration (mg/L) in Process Wastewater from BP Refinery (Kwinana) from 2007 to 2009.
Note Figure 68 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The zinc emissions from 1st August 2009 to the end of the year were within the Licence limit and target. 7.18.8 Comments on performance For the period of 2007 - 2009 the vanadium emissions from process wastewater were below the licence limit and licence target. The emissions for the same period were also below the internal targets for annual load and monthly average concentration. 7.18.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by
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setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound. 7.18.10 References Department of the Environment and Heritage (2003) National Pollutant Inventory Substance Profile [online]. Australian Government. Available from www.npi.gov.au/ [Accessed 20/11/03].
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7.19 pH 7.19.1 What is it? pH is a unit of measure for the amount of hydrogen ions in a solution. It is a measure of acidity or alkalinity, seven is neutral, above a pH of seven is basic and below is acidic. Natural marine waters usually have a pH close to 8.2 (ANZECC, 1992). 7.19.2 Impacts Marine waters are naturally highly buffered from changes in pH, therefore even a slight change in a water body indicates a major change in the system (ANZECC, 1992). A change in pH can have direct and indirect effects, that is the change in pH can directly affect egg production and the emergence of aquatic organisms, and a pH change can also release contaminants previously bound to sediments or increase toxicity (ANZECC, 1992). 7.19.3 Why do we emit it? Refining crude oil to useful products is a complex process that requires the use of acid (low pH) in some areas to be used as a catalyst, and bases (high pH) in other areas to remove impurities. When process water comes into contact with either of these substances the pH is altered. 7.19.4 Sources There are natural causes for changes in pH, for example the anaerobic degradation of organic matter and the weathering of rocks and soils, however these changes are generally very slow, allowing systems to adjust. Human influences such as the clearing of native vegetation leading to dryland salinity have caused natural streams and rivers to be subject to relatively rapid changes in pH. Continuous or daily sources of variation of pH to the Waste Water Treatment Plant (WWTP) within BP Refinery (Kwinana) are water draining from storage tanks, caustic draining from the Residue Cracking Unit Minalk and the wash water from the Merox Unit water column. Water draining from storage tanks is required as water separates out of the crude oil or the petroleum products. The water drained to the WWTP for processing can have a high pH. The Residue Cracking Unit Minalk and the Merox Unit use small amounts of caustic soda to extract mercaptans from motor spirit components, jet fuel and LPG due to their offensive smell and corrosive properties that can affect engines. Following extraction the caustic solution can be regenerated for further use, however a small amount is drained to the Waste Water Treatment Plant during this process.
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Potential sources of pH variation that are less regular are drainings from the Alkylation Unit Holding Basin (which receives process water from the unit as well as storm wash water), and acidic wash water from Catalytic Polymerisation Unit catalyst changes. 7.19.5 How is it managed? Water received at the Waste Water Treatment Plant (WWTP) is first directed to the API separator, where an analyser provides an online indication of the pH of the water. If the water is outside the expected range the source can then be investigated, and the water segregated for later treatment. In the feed line to the Dissolved Air Floatation Unit (DAF) the pH is adjusted, either raising or lowering the pH as required via an online control system to achieve a relatively neutral feed for the rest of the plant. This process can be easily controlled when there is warning of any unusual substances discharged to the WWTP. 7.19.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) specifies that the Refinery shall ensure that the pH of process wastewater shall be in the range of 6 to 9.5. The Refinery has set an internal target to maintain pH of the process wastewater emissions between 6.5 and 9. 7.19.7 Performance The pH of the Refinery process wastewater was within the Licence requirement of 6 to 9.5 from the period 2007 to 2009, the results from the daily measurements are shown in Figure 69. The internal target was met, with the highest pH result recorded equal to the target of nine on the 30th November 2008.
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pH Levels in Process Wastewater from BP Refinery (Kwinana)

10.00
9.00
8.00
pH
7.00 6.00 5.00 2005
2006 pH
2007 Low er limit
2008 Upper limit
2009
Figure 69: pH Measurements of the Process Wastewater from BP Refinery (Kwinana) to Cockburn Sound.
Note Figure 69 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The pH results from 1st August 2009 to the end of the year were within the Licence limit and target. 7.19.8 Comments on Performance From 2007 to 2009, all results were within the pH licence limit range of 6 to 9.5, and the internal Refinery target was met. 7.19.9 Future plans BP Refinery (Kwinana) will maintain a designated Process Engineer to optimise the performance of the Wastewater Treatment Plant. The Refinery endeavours to achieve continuous improvement in wastewater environmental performance by setting internal objectives and targets. These objectives and targets will be reviewed annually and performance against the benchmarks monitored regularly. Emissions to Cockburn Sound will be minimised by maintaining treated process wastewater discharge to the Sepia Depression, 4.1km offshore, where the level of mixing and flushing is much higher than in Cockburn Sound.
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7.19.10 References Australian & New Zealand Environmental Conservation Council (ANZECC) (1992) Australian Water Quality Guidelines for Fresh and Marine Waters. Australian & New Zealand Environmental Conservation Council (ANZECC) (2000) Australian Water Quality Guidelines for Fresh and Marine Water Quality. National Water Quality Management Strategy Paper No. 4, Vol 1.
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7.20 Temperature 7.20.1 What is it? Temperature is a physical property that determines whether heat energy can be transferred from one object on contact with another object. 7.20.2 Impacts The temperature of the water discharged from the Refinery into the Cockburn Sound is at levels elevated from ambient sea temperatures. A change from ambient temperature may have detrimental impacts on the local marine environment, as it can disturb the physiology of marine biota. Increased temperatures in summer can increase growth of algal blooms; and very high temperatures can be close to the thermal tolerance limit of some marine biota. 7.20.3 Why do we emit it? The Refinery Salt Cooling Water (SCW) is a once through system where sea water from Cockburn Sound is pumped in to circulate and cool down process liquids at the Refinery. The outlet is at elevated temperatures compared to Cockburn Sound. The SCW is discharged into Cockburn Sound via three discharge points (Outfalls North, Centre and South) (see Figure 70). Under normal operation the SCW does not come into contact with process liquids.
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Marine Water Intake
Salt Cooling Water
API 2
North Outfall
North Circular Seperator
Salt Cooling Water

(gravity)
Salt Cooling Water

(pressure)
Centre Outfall
Process Waste Water API 3

DAF
South Circular Seperator Activated Sludge Units Polishing Ponds
South Outfall
Figure 70: BP Refinery (Kwinana) Salt Cooling Water flow diagram.
7.20.4 Sources SCW with an elevated temperature is emitted into the Cockburn Sound via the three outfalls from the Refinery, North, Center and South Outfalls. 7.20.5 How is it managed? Temperature of the SCW discharge, at each of the circular separators and the API2 system, is monitored on a daily basis from grab samples in accordance with the Refinery Licence. The Refinery conducts maintenance of heat exchangers to ensure optimum performance is achieved, and new equipment is designed to meet temperature specifications. 7.20.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) states the target for Salt Cooling Water discharge should not be more than 15C above the inlet temperature averaged over a quarterly period.
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7.20.7 Performance From 2007 to 2009 the Refinery was within the licence target of the Salt Cooling Water discharge being < 15C higher than the inlet temperature (see Figure 71: Salt Cooling Water Outfall Temperature Differences from BP Refinery (Kwinana) 2007 to 2009. ).
Salt Cooling Water Outfall Temperature Differences from BP Refinery (Kwinana)
20
Temperature (celcius)
15
10
0
1/ 01 /2 00 6 1/ 01 /2 00 7 1/ 01 /2 00 8 1/ 01 /2 00 9
North outfall
South Outfall
Centre Outfall
Licence target
Figure 71: Salt Cooling Water Outfall Temperature Differences from BP Refinery (Kwinana) 2007 to 2009.
7.20.8 Comments on performance From 2007 to 2009 the difference between the outfalls and the inlet were within the Licence target of not more than 15C.
7.20.9 Future plans The Refinery will continue to maintain its good performance.
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7.21 Total Suspended Solids 7.21.1 What is it? Total Suspended Solids (TSS) is a measure of the mass of fine particles suspended in the water. Suspended solids can include phytoplankton, zooplankton and suspended silt and clay particles (ANZECC, 2000). 7.21.2 Impacts The impact of suspended solids in waterways on human use and enjoyment is related to aesthetic appearance and safety, as visual clarity is important so that swimmers can estimate depth and see submerged hazards easily (ANZECC, 2000). Suspended solids in aquatic ecosystems can have an impact both when in suspension and when the particles settle. When in suspension particles can reduce light penetration, therefore affecting the growth of aquatic plants, and as they settle they may interfere with the feeding mechanisms of benthic filter feeding organisms (ANZECC, 1992). 7.21.3 Why do we emit it? The Waste Water Treatment Plant receives water from the oily water sewer that may contain suspended solids. These are removed in the first stages of the treatment process, however later treatment can add some solids in the form of suspended micro-organisms and organic matter. 7.21.4 Sources Natural sources of suspended solids to water are bank and catchment erosion, which has been exaggerated in many areas by clearing and other human impacts. Sources of suspended solids to the Waste Water Treatment Plant are dirt/dust from slabs and other open areas that require washing down within the Refinery, and sediment contained in the crude oil that is removed during the refining process. The main source of TSS from the Refinery is from the wastewater treatment process itself. Wastewater entering the Treatment Plant first enters the API for the separation of free oil, sludge and water. The water is then homogenised in Tank 801 before being treated in the Dissolved Air Floatation Unit (DAF) for removal of suspended oil particles. The next stage is the Activated Sludge Unit where organics removal and denitrification take place through the use of micro-organisms. The water then flows into the Clarifier to allow the micro-organisms to settle to the bottom. This settling process is not complete and a small number of microorganisms may remain suspended in the water and contribute to the TSS. If the quality of the feed to the Activated Sludge Unit (ASU) is not appropriate for the micro-organisms then
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they can become sick, and instead of settling out of the water in the clarifiers a larger number may remain suspended. 7.21.5 How is it managed? The Total Suspended Solid (TSS) concentration of the water discharged from BP Refinery (Kwinana) is managed in two ways; by controlling the discharges to the Waste Water Treatment Plant and controlling the treatment plant conditions. The pH and dissolved oxygen in the Activated Sludge Units of the Waste Water Treatment Plant are carefully controlled to maintain a healthy micro-organism population. The feed to the ASUs is also homogenized in the equalisation tank to try to avoid a shock of a sudden contaminant release. During process unit upsets there are many potential additional sources of discharge to the sewer, some of which may affect the performance of the ASUs and therefore cause elevated TSS concentrations. The Waste Water Treatment Plant has the capability to divert any discharges suspected of having high or unusual composition to a storage tank allowing it to slowly trickle through the treatment plant minimising the shock impact to the micro-organisms working in the ASUs. If the performance of the ASU is affected TSS in the treated process wastewater can be reduced by the addition of a flocculant to aid settling. 7.21.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation places a limit on the TSS of treated process wastewater discharged to Cockburn Sound at 40mg/L for a monthly average daily concentration, and a target of 25 mg/l based on a quarterly average. The Licence has slightly different limits and targets for treated process wastewater discharged to SDOOL, the following sections mainly discuss the performance against the Cockburn Sound limits and targets as these were applied from 2007 to 31st July 2009. 7.21.7 Performance From 2007 to 31st July 2009 all monthly average TSS concentrations were below the licence limit of 40 m/L (see Figure 72), and the licence target of 25m/L as a quarterly average.
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Monthly average TSS concentrations from BP Refinery (Kwinana) 2006 - 2009

45 40 35
TSS (mg/L)
30 25 20 15 10 5 0
20 06
20 07
20 08
Licence target
Licence limit
Figure 72: Monthly Average Daily Concentrations of Total Suspended Solid (TSS) in Process Wastewater from BP Refinery (Kwinana) Discharged to Cockburn Sound.
Note Figure 72 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The TSS concentrations from September 2009 to December 2009 were higher than historical summer levels as the Refinery adjusted to the new operating conditions. The TSS results from 1st August 2009 to the end of the year were within the Licence limit and target issued by the Department of Environment and Conservation for process wastewater discharged to SDOOL. 7.21.8 Comments on Performance Since 2002, the average emissions of Total Suspended Solids have remained relatively constant between approximately 10 mg/L to 15mg/L (Figure 73), as an annual average. The reduction in TSS over time is due to improved quality of influent water to the WWTP, less process upsets and better understanding and control of process conditions within the Activated Sludge Units.
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Annual Average TSS Concentrations in Wastewater from BP Refinery (Kwinana)

30.0 25.0
TSS (mg/L)
20.0 15.0 10.0 5.0 0.0

19 96 19 98 19 99 20 00 20 01 20 02 20 03 20 04 20 05 20 06 20 07 20 08 20 09
Figure 73: The Annual Average Concentration of Total Suspended Solids (TSS) in Process Wastewater from BP Refinery (Kwinana) Discharged to the Environment.
7.21.9 Future plans The Refinery will continue manage the concentration of Total Suspended Solids discharged through management of the quality of influent to the WWTP, improved WWTP reliability and enhanced control of process conditions within the Activated Sludge Units. 7.21.10 References Australian & New Zealand Environment & Conservation Council (ANZECC) (1992) Australian Water Quality Guidelines for Fresh and Marine Waters. Australian & New Zealand Environmental Conservation Council (ANZECC) (2000) Australian Water Quality Guidelines for Fresh and Marine Water Quality. National Water Quality Management Strategy Paper No. 4, Vol 1.
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7.22 Chemical oxygen demand (COD) / Biological oxygen demand (BOD) 7.22.1 What is it? Chemical Oxygen Demand (COD) is a measure of the amount of oxygen required to chemically oxidise all contaminants (ANZECC, 2000). COD does not differentiate between biologically available and inert organic matter. Biochemical (or biological) Oxygen Demand (BOD) is a measure of the amount of oxygen required by the biota to break down organic matter. It is measured by the decrease in oxygen content of water by the bacterial breakdown of organic matter (ANZECC, 2000). COD will typically be greater than BOD as the biota will not always be able to breakdown all the present organic materials. 7.22.2 Impacts The impact on humans of high COD or BOD in waterways is mainly related to the possibility of accelerated bacterial growth, and the aesthetic and potential associated heath issues. This may restrict the use (recreational or industrial) of the water system as the environment changes from aerobic to anoxic or even anaerobic. The environmental impact of high COD and BOD contaminated water is the consumption of the dissolved oxygen present in the water by bacteria. The reduced dissolved oxygen available for aquatic life can lead to a reduced abundance or even death of fish and benthic fauna. 7.22.3 Why do we emit it? Any chemical that can be biologically consumed will have an associated oxygen demand for that process to take place. In addition, if the contaminant can be biologically oxidized then the contaminant can also be chemically oxidised. There are a number of contaminants that are not readily consumed biologically and therefore these contribute to the COD. There are many potential sources of COD and BOD within the Refinery due to the oil feed stock (a naturally occurring organic material that can be both biologically and chemically oxidized) and the complex nature of processing crude oil to useful products, which utilizes a number of organic chemical compounds. 7.22.4 Sources There a number of sources within the Refinery that can produce high chemical oxygen demand and biological oxygen demand, including crude oil and its refined products, therefore waste water from the process will be a source of COD and BOD. Chemical compounds which contribute to COD and BOD which are used or produced as part of the refining process include phenols, acids and alkalis, sulphides, nitrogen compounds and a number of process by-products and waste products.
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7.22.5 How is it managed? COD and BOD concentration in the treated process wastewater are managed by controlling the influent ot the WWTP and optimising the treatment process. Education and communication within the Refinery is conducted to control and manage discharges to the oily water sewer that may contain high concentration of COD and BOD. Good communication allows the Waste Water Treatment Plant operators to reduce the impact of unexpected releases to the oily water sewer by diverting the inflow to the WWTP to storage tanks for treatemtn at a controlled rate. The Waste Water Treatment Plant can also be adjusted to maximize the removal of the COD and BOD via the treatment process. This can be done through regular monitoring of the performance of the Activated Sludge Units (ASU) and increasing the injection of air to optimise the treatmetn of contaminents that contribute to the residule COD/BOD. If the removal of COD and BOD is not considered adequate there is capacity to recycle the treated process wastewater through the treatment process again. 7.22.6 Context about limits and targets The licence issued to BP Refinery (Kwinana) by the Department of Environment and Conservation sets a limit on the COD content of process wastewater discharged at 100mg/L as a monthly average concentration, and 25mg/L monthly average concentration for BOD. The licence also sets a target for COD concentration to be less than 75mg/L as a quarterly average, and BOD concentration to less than 15mg/L as a monthly average. 7.22.7 Performance The COD and BOD concentrations from BP Refinery (Kwinana) from 2007 to 2009 were below the licence limits of 100mg/L and 25mg/L respectively as a monthly average (Figure 74).
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Average monthly concentrations of COD and BOD from BP Refinery (Kwinana) 2007 - 2009
100
80
60
40
20
0
20 08 20 07 20 09
BOD
COD
BOD licence limit
COD licence limit
Figure 74: Average Monthly Concentrations of Chemical Oxygen Demand and Biological Oxygen Demand from BP Refinery (Kwinana), 2007 to 2009.
# Note Where BOD monthly average concentrations are not represented in Figure 74 the results were below the Laboratory limit of reporting, that is <5mg/L.
Note Figure 74 does not contain the emission results from 1st August 2009 to 31st December 2009. The Refinery commenced discharging to SDOOL on the 1st August, and the compliance periods to the separate discharge locations are calculated separately as required by the Quality Assurance Procedure. The COD and BOD concentrations from September 2009 to December 2009 were slightly higher than historical summer levels as the Refinery adjusted to the new operating conditions. 7.22.8 Comments on Performance The COD concentrations from 2007 to 2009 were below the Licence limit of 100mg/L as a monthly average (Figure 74) and below the Licence target of 75mg/L as a quarterly average. The BOD concentrations from 2007 to 2009 were below the Licence limit of 25mg/L as a monthly average (Figure 74). BOD concentrations were predominantly below the Licence target of 15mg/L as a monthly average. The exception was in July 2008 where due to a WWTP process upset, the result was 17mg/L.
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Annual Average BOD Concentration from BP Refinery (Kwinana)

12
BOD (mg/L)
10 8 6 4 2 0
19 96 19 99 20 00 20 01 20 02 20 03 20 04 20 05 20 07 20 06 20 08 20 09
Figure 75: Annual Average Concentrations of BOD (mg/L) in Process Wastewater Discharged from BP Refinery (Kwinana).
Annual Average COD Concentration from BP Refinery (Kwinana)

70
COD (mg/L)
60 50 40 30
19 96
19 99
20 01
20 00
20 02
20 04
20 03
20 05
20 06
20 07
20 08
Figure 76: Annual Average Concentrations of COD (mg/L) in Process Wastewater Discharged from BP Refinery (Kwinana).
Figure 75 and Figure 76 outline the annual average performance from 1998 to 2009. 7.22.9 Future plans The Refinery will continue to manage the concentration of COD and BOD in process wastewater through management of the quality of influent to the WWTP, improved WWTP reliability and enhanced control of process conditions within the Activated Sludge Units.
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7.22.10 References Australian & New Zealand Environmental Conservation Council (ANZECC) (2000) Australian Water Quality Guidelines for Fresh and Marine Water Quality. National Water Quality Management Strategy Paper No. 4, Vol 1.
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7.23 Refinery Water Use 7.23.1 What is it? Water is extremely important in the refining process, used to either heat (as steam) or to cool, for maintenance and as a wash to remove impurities from product streams. Water use in this context includes potable (scheme) water, bore water, imported steam and more recently recycled water from the Kwinana Water Reclamation Plant (KWRP) used within the site of BP Refinery (Kwinana). Salt Cooling Water will not be discussed in this section. 7.23.2 Impacts Water use by the Refinery has two major impacts. The first is the use of a valuable resource in the context of a community that is often faced with water restrictions due to increasing demand on water supply. The second impact of water use by the Refinery is that a proportion of this water will need to be treated at the Waste Water Treatment Plant and then discharged. 7.23.3 Why do we use it? Heating and cooling is an essential part of the refining process, and both of these processes use water. Petrol for example, is heated and cooled again nine times before the final product is produced. It is also necessary to use water to remove impurities and perform maintenance activities as there is no appropriate substitute. 7.23.4 Sources The major sources of potable water use within the Refinery prior to 2008 were cooling towers, steam generation, and office use. Cooling towers work on the principle of counter current contact between water and air to cool the water. Fresh water is required to be continually added to cooling towers to replace water lost by evaporation and to replace blowdowns that prevent a build up of salts. Steam generation is done by using boilers, which are similar to a kettle, as water enters the boiler and is then heated to produce steam. Potable water use by offices are typical of household uses; kitchens, bathrooms and drinking water. In 2008 recycled water from KWRP was commissioned for use in the cooling tower and for steam generation under normal operating conditions. Process water at the Refinery is mostly composed of bore water extracted from within the Refinery, with potable water only added if necessary as makeup water. The sources of process use within the Refinery are within process units to wash catalysts, flush lines and hydroblast equipment among other activities. Process water is also used for pump cooling, pump water seals, process wash water and firewater for emergency purposes and for training exercises.
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7.23.5 How is it managed? In 1997 the Water Reuse and Minimisation Program was implemented at the Refinery with the objectives to reduce total water use (by minimizing use and increasing reuse), to significantly reduce potable water use and to achieve zero discharge of process wastewater to Cockburn Sound. A cross functional team was developed including members from all different areas/disciplines in the Refinery and clear targets were set for water reduction. Projects such as recycling water on the Residue Cracking Unit; change of the procedure to operate pumps and reuse of water from the Cooling Water Pump House were undertaken, and opportunities to use lower quality water (groundwater) in place of scheme water were found. This program was innovative and original as it approached water management with a whole refinery perspective as well as targeting specific areas. Management of water use is now included in the design of new refinery equipment; an example is the design of the new Hydrofiner Unit built in 2004. The new unit was designed so there was no net increase in water use by the Refinery. This design was achieved by recycling water within the new unit, and increasing the water recycle of other units. Water minimisation awareness is ongoing within the Refinery, and implementing simple actions on the ground such as fixing dripping taps/hoses and only running hoses when necessary can be effective in minimising water use. 7.23.6 Context about limits and targets BP Refinery (Kwinana) was the largest potable water consumer within the Perth Metropolitan area between 1989 and 1992, consuming approximately 6,100 7,900 kL of scheme water every day. The implementation of the Water Reuse and Minimisation Program had a significant effect, with the potable water use dropping to an average of 1,833 kL/day in 1999. Over the past decade the internal Refinery targets for potable water use and total water use have been set progressivly lower as water minimisation projects and management practices are implemented. In addition the Refinery began reporting its water use and targets to the Water Corporation in the form of a Water Efficiency Management Plan (WEMP). In 2009 the total water use Refinery internal target was <4500kL/day, and the potable water use target was <500kL/day.
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7.23.7 Performance The total Refinery water use and water use efficiency are presented in Figure 77. The Refinery has met its total water use internal target from 2007 - 2009, and overall use continues to reduce.
Average Daily Water Use at BP Refinery (Kwinana)

8000 7500 7000 0.40 6500 0.50
Water Use Efficiency (kL water/T throughput)
0.45
Water Use (kL/day)
6000 5500 5000 4500
0.35
0.30
0.25
0.20 4000 3500 3000 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 0.15
0.10
Water use
Water efficiency
Figure 77: Annual Average Daily Water Use at BP Refinery (Kwinana) and Water Use Efficiency (expressed as kL water use / tonne crude throughput).
7.23.8 Comments on Performance The reduction in total water use demonstrates there are still achievements being made in water reuse and minimisation. Water use efficiency improved slightly from 2007 to 2009 as water management practices are improved. In absolute terms total water use was the lowest ever recorded in 2009. 7.23.9 Future plans In 2008 the Refinery commenced taking recylced water from the Kwinana Water Reclamation Plant (KWRP). The plant takes secondary treated wastewater from the Woodman Point Wastewater Treatment Plant and using microfiltration and reverse osmosis produces high quality industrial grade water that is used by other industries in place of potable water. Currently KWRP water is used in the cooling tower and to generate steam replacing potable water use under normal operating conditions. In
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the future the Refinery plans to remove the last regular industrial uses of potable water and replace these with KWRP water. The Refinery will continue to monitor and report on water use performance through the Water Efficeny Management Plan.
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8 SOLID WASTE
The Refinery generates solid waste from crude processing and related activities. Solid wastes generated include: tank sludges, contaminated soils, spent catalysts and other spent chemicals, together with general and recyclable wastes. The amount of waste generated from BP Refinery Kwinana is dependent on unit operation, construction, demolition works and maintenance activities, and consequently varies from year to year. The systems and facilities in use at the Refinery for managing solid waste and the main waste types and their disposal routes are discussed. This section discusses the system and facilities in use at the Refinery for managing solid waste, it also descibes the main waste types and their disposal routes. Solid Wastes produced each year (2007 to 2009 inclusive) are broken down by waste category. 8.1 Background
A solid waste is defined as a solid or semi-solid (spadable) substance which is of no economic value to the generator. Wastes associated with the refining process cover a wide range of materials, however the quantity of waste produced is relativley small when compared with other major industries. On average it has been found that petroleum refineries produce around 0.13% waste from the raw product, compared to other industries such as mining, which produces on average >90% waste (CONCAWE, 1995). Solid waste is not classified as a Significant Environmental Aspect at BP Refinery (Kwinana), but has been included in this report to give a complete picture of the Refinery environmental activities. As it is not a Significant Environmental Aspect there are no specific targets around the amount of waste produced, however BP Refinery (Kwinana) waste management systems ensure wastes are handled and disposed of in a responsible manner, generation of wastes are minimized and recycling/reuse is maximized whenever possible. Waste management is an issue of concern to both industry, government and the wider community. Concerns over solid waste management are primarily associated with the loss of potentially valuable materials that could otherwise be recycled, the use of otherwise valuable land for landfill and the potential impacts of inadequate disposal techniques on human health and the environment. In Perth the majority of the potable water supply is derived from groundwater, therefore effective waste management is essential to protect the environment and health of the population. The Western Australian government has a set of guidelines and legislation in place regarding the proper handling and disposal of solid wastes. The current authoritative document on the classes and disposal of waste to Landfill in Western Australia, is the DEC 2009 amendment of the Landfill Waste Classification and Waste Definitions 1996. Other relevant waste handing and disposal documents include the:
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Environmental Protection (Controlled Waste) Regulations 2004 and Environmental Protection (Unauthorised Discharges) Regulations 2004. The construction of the Refinery in 1955 provided no facilities for the disposal and storage of waste. The Refinery was built in an era of limited knowledge and awareness of the composition of the waste produced from refining processes and the practice of onsite landfilling of waste was considered acceptable. Increasing awareness of the need for a treatment facility for solid waste led to the construction of the first Landfarm facility in 1988. This facility was designed to use the controlled application of oily waste to soil and use the dynamic physical, chemical and biological processes occurring in the soil to biologically degrade the waste.
Figure 78: Old Landfarm (left) and the Current Waste Management Area (right).
The Old Landfarm (Figure 78: Old Landfarm (left)), was in use until August 1991 when the facility was closed due to overloading with oily wastes. The current Waste Management Area (see Figure 78 Current Waste Management Area (right)), was commissioned in early 1993.
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8.2
Management Systems & Waste Facilities
The amount of solid waste produced at the Refinery can vary considerably from year to year, as it is dependent on the type of crudes processed, unit maintenance, project work, as well as stockpiling of bulk wastes. BP Refinery (Kwinana) has several systems in place to ensure wastes are handled and disposed of in a responsible manner, generation of wastes is minimized and recycling/reuse of wastes is maximized. 8.2.1 Responsibility BP Refinery (Kwinana), as part of the BP Group, has a policy to treat wastes in a cradle to grave manner. This ensures that generation, movement, treatment, storage and ultimate disposal of wastes is documented, controlled and meets all regulatory requirements. The Refinery has developed a Solid Waste Management Plan detailing the typical source, treatment and ultimate disposal route for all routine wastes produced by the refinery. The license issued to BP Refinery (Kwinana) by the DEC requires that oily sludges and hydrocarbon-contaminated soils be treated and disposed of according to the Quality Assurance Procedure (Waste Management Area Monitoring Procedure) and that an annual report regarding the management of the Landfarm is submitted to the DEC. 8.2.2 Solid Waste procedures BP Refinery (Kwinana) has developed procedures that relate to the management, handling and disposal of solid waste. The key management procedures are the Solid Waste Disposal Procedure and the Waste Permit Procedure. The Solid Waste Disposal Procedure covers the storage, treatment and disposal of hazardous wastes, process wastes, general wastes and recyclables. This procedure ensures all wastes generated are disposed of in accordance with the Environmental Protection (Controlled Waste) Regulations 2004 and BP internal policies. The Waste Permit Procedure ensures that all wastes generated are correctly managed and documented in a cradle to grave manner. Permits are required when a waste is to be relocated from the site of generation to either a storage location onsite or offsite and for the onsite or offsite disposal of the waste. An electronic waste permit system is maintained by the Environment and Dangerous Goods Department and hard-copy permits are issued to the solid waste carriers. 8.2.3 Permits Solid wastes generated at BP Refinery (Kwinana) are either disposed directly offsite, treated onsite and then disposed offsite or treated and disposed onsite. In addition to treating of solid wastes generated at the Refinery, BP Refinery (Kwinana) is also
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licenced to receive and treat specific wastes from external sources. The main categories of solid waste types found at the Refinery and their typical disposal location are shown in Table 10. The major wastes contributing to each category are discussed under their relevant sections below
Table 10: Solid Wastes at BP Refinery (Kwinana).
Wastes Treated Onsite and Disposed Onsite Centrifuged Oily Solids Oily Sludges BPRK Contaminated Soil Bio Solids External Wastes Remediated Onsite and Disposed Offsite External OilContaminated Soils Wastes Disposed Offsite
Catalysts (eg. RCU catalyst) Industrial Wastes (eg. Concrete) Process Wastes (eg. Filter clay) General Wastes inc. Recyclables (eg. food scraps, paper) Miscellaneous Wastes
8.2.4 Management Facilities for Solid Wastes In 1992 the Waste Management Area was constructed specifically for the handling, storage and treatment of solid wastes awaiting disposal. The area was designed so that wastes could be managed without contaminating the soil and groundwater. The Waste Management Area contains the Refinery landfarm facility, commissioned in 1993, for the bio-remediation of oily sludges and oil contaminated soils. The Waste Management Area consists of four 90m x 90m landfarm cells, a number of concrete pads and covered sheds. The landfarm cells were designed to allow the bioremediation of hydrocarbon-contaminated sludges and soils. The cells are fertilised, irrigated and tilled (by rotary hoe or scarifier) to accelerate the remediation process. Process solid wastes, such as filter clays, charcoals and catalysts that require pre-treatment or weathering to reduce the hydrocarbon concentration are handled on the concrete slabs and in the sheds. One shed is dedicated to drum handling, while another has a small concrete wall that allows specific handling of sludges. The sheds and one concrete weathering slab are connected to the Refinery oily water sewer system. The Hazardous Waste Storage Shed has a segregated sump that is emptied by vacuum truck and collected wastewater is disposed of at an appropriate liquid waste facility.Figure 79 is a detailed plan of the Waste Management Area (WMA).
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Figure 79: Plan of the Waste Management Area (WMA).
The Landfarm facility allows managed waste treatment and disposal of oily waste. Oily waste (mainly from the WWTP) is spread evenly over the landfarm surface using a manure spreader and then rotary hoed into the surface soil layer (Zone of Incorporation) to a maximum depth of 15-20 cm (see Figure 80). Weekly rotary hoeing of the soil is carried out to increase aeration and maximise degradation of the oil by aerobic microorganisms that are naturally present in the soil. Biological processes break down hydrocarbons into carbon dioxide, water and soil humus. Inorganic fractions present in the soil become physically and chemically bound to soil particles which limit the potential for contaminant migration.
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...
Figure 80: (a) The Use of the Rotary Hoe to Incorporate Oily Solids into the Landfarm for Bio-remediation (left); (b) and Spreading Oily Solids onto the Landfarm.
The Machinery Shed is used as an equipment store for the Waste Management Area. The Oily Sludge Drying Shed and the Solid Waste Shed are both undercover, they have concrete bunded areas connected to the sewer for the storage and treatment of low level contaminated waste. The Drum Storage Shed is a designated compliant area for drums of waste prior to disposal. The Hazardous Waste Shed is located in a separate area with a secure (independent) drainage system for the storage of hazardous waste prior to disposal. The Weathering Slab is constructed of concrete and underlain with an impervious, chemically resistant, HDPE liner. The slab is bunded on four sides with a leachate collection drain which flows to the Refinery oily water sewer system. The slab is used for the short term storage, handling and weathering of wastes. The CaF Pits are used to store and primary dewatering of the calcium fluoride (CaF), a byproduct produced from the treatment of effluent streams from the Alkylation Unit. Calcium chloride is reacted with flouride to precipate solid calcium flouride. The CaF Slabs are used for secondary dewatering of the material prior to disposal. The Refinery has three Biopile cells (Figure 81: Biopile Cells at BP Refinery (Kwinana)), for the remediation of hydrocarbon contaminated soil. The biopiles, like the Landfarm cells, use naturally occurring micro-organisms to degrade hydrocarbons into products such as water and carbon dioxide. Biopiles optimise the conditions required for this degradation by managing the availability of water, oxygen and nutrients.
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Figure 81: Biopile Cells at BP Refinery (Kwinana).
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8.3
Current Wastes Produced & Disposal Routes
8.3.1 Solid Waste Treated and Disposed Onsite 8.3.1.1 Oily wastes The types of oily waste produced at the Refinery include: centrifuged oily solids and oily sludges. Oily sludges can be produced anywhere in the Refinery where solids, water and oil come together such as in tanks, sumps and process vessels. Where ever possible, oily sludges are blended with crude oil and reprocessed through the Refinery. Oily sludges that are not suitable for direct processing are typically processed through a centrifuge which separates materials of different density within the sludge. There are three outputs produced: solids, recovered oil and water. The solids are transferred to the landfarm where they are treated by biodegradation. The recovered oil is then clean enough to re-process and the water enters the Waste Water Treatment Plant where it is treated with the Refinery process wastewater. 8.3.1.2 Miscellaneous and Non-oily waste The only non-oily waste routinely generated onsite and disposed of onsite is Waste Activated Sludge. The Refinery operates two Activated Sludge Units (ASU) to biologically remove dissolved phase hydrocarbons, nutrients and other contaminants from the process wastewater stream. In order to maintain an active population of biomass in the ASU, it is necessary to waste a quantity of surplus biomass solids on a regular basis. The waste activated sludge is thickened prior to treatment in an aerobic digester to reduce the amount of biosolids requiring disposal. The digested biosolids are dewatered using a filter belt press prior to onsite bio-degradation at the old Landfarm. Miscellaneous wastes are primarily made up of refinery contaminated soils and clean fill. The amount of these wastes varies depending on the construction and maintenance work conducted onsite in any given year. Contaminated Soil is produced as the result of the removal of soil from historically contaminated sites or spills. The Refinery can remediate most of this soil onsite and the rest is sent to licenced landfill facilities. Where ever possible the remediated soil is reused onsite. Clean fill is produced as the result of the removal of soil from uncontaminated areas of the Refinery. Where possible the soil is reused onsite.
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8.3.2 Solid Wastes Disposed Offsite 8.3.2.1 Catalyst Catalysts are required in some of the process units of the Refinery to aid the chemical reactions necessary in the refining process. A catalyst by definition is not consumed by the reaction, however over time it can be fouled by impurities reducing its effectivness and therefore needing to be replaced periodically. The largest source of catalyst waste is from the Residue Cracking Unit, which uses a zeolite catalyst consisting of fine grained alumina-silica powder which is impregnated with rare earths. The catalyst in this unit is continuously circulated between the riser where the reaction takes place and the regenerators which burns off the coke, in order for the catalyst to be reused. To maintain the catalyst activity it is necessary to remove some used catalyst and add some fresh catalyst on a daily basis. The Residue Cracking Unit also produces catalyst fines, which are small particles of the catalyst, produced by the high temperature and air velocity inside the unit. Catalyst fines are too small to be returned to the process, so they must also be removed. The used catalyst and the catalyst fines are recycled by another industry. The second largest producer of catalyst waste is the Catalytic Polymerisation Unit. This catalyst is composed of silica and silicon phosphate impregnated with phosphoric acid, extruded into pellets. Small impurities in the reaction cause gums to form and the catalyst bed becomes blocked, therefore needing replacement. Due to the high content of phosphorous, this catalyst is useful as a soil amendment and is recycled by another industry. The remaining units that produce catalyst waste do so more infrequently, ranging from two years to six years between catalyst changes. Some catalyst (e.g. Reformer and Isomerisation catalysts) are sold back to the manufacturer for precious metal recovery while others (e.g. Hydrotreater catalyst) are sent to metal reclaimers to recover the metals in the catalyst for alternative uses. 8.3.2.2 Industrial waste Industrial Waste is predominately made up of construction rubble, used abrasive blasting garnet, refractory brick and scrap wood. Volumes of Industrial Waste produced by the Refinery vary greatly depending on building and construction projects and maintenance activities such as unit turn arounds. Generally these materials can either be recycled or landfilled at appropriately licenced facilities without requiring treatment. 8.3.2.3 Process waste Process Waste is a broad range of wastes that are generated as a result of the refining process and vary greatly due to the wide range of different units and
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chemical processes. The major wastes making up this category include: filters, alumina driers, calcium fluoride, charcoal and material generated from large scale maintenance such as process unit turnarounds. The volume of process wastes produced at BP Refinery (Kwinana) is typically around 500 tonnes per year. Process wastes are disposed offsite at appropriately licenced facilities. 8.3.2.4 General waste General Waste includes general rubbish and recyclables that are primarily generated from the Refinery offices, stores area and crib areas. General waste may contain small amounts of larger items such as scrap wood, ropes, buckets and discarded metal strapping. General wastes are disposed of to approprialy licenced land fill facilities. Recyables are processed through a materials resource recovery facility, where all recyclables are segregated for final reuse in various industries. To encourage source separation of recyclables from general waste, performance against an internal target is monitored and reported to site. 8.3.2.5 Wastes from external sources remediated onsite The facilities at BP Refinery (Kwinana) make it suitable to accept some wastes from external sources to allow for their appropriate treatment and disposal. These wastes are mostly hydrocarbon contaminated soils. The Refinery is a licensed third party solid waste disposal facility for oily wastes. By accepting these wastes from other BP facilities such as fuel terminals and retail sites the wastes can be handled, stored and treated at the Refinery to minimise any unnecessary environmental impact. In the period of 2007 to 2009 around 1900 tonnes of soil was accepted for remediation from three BP retail sites. Around 4800 tonnes of treated soil were sent offsite for either disposal or reuse.
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8.4
Performance
The table below (Table 11) details the amount of solid waste produced each year for the period 2007 2009 by waste category. The amount of waste produced in any one year is highly variable and dependent on factors such as Refinery throughput, process unit upsets, maintenance activities, and construction and demolition activities. Waste production as a percentage of the Refinery throughput compares well against the CONCAWE benchmark of 0.13%. For every tonne of feed processed by the Refinery less than 2kg of solid waste is produced. In 2007 the Refinery commenced recycling some of its industrial wastes that had historically been landfilled. This equates to around 15% recycling of material from this category. In the Catalyst Waste category the Refinery typically recycles around 95% of the waste by mass. In 2009 this was reduced to around 13% due to the recycler for the Residue Cracking Unit Catalyst being unavailable to receive the waste. The Refinery will focus on new opportunities to re-establish the reuse of this waste in 2010.
Table 11: Waste Produced by BP Refinery (Kwinana) by Category (tonnes/year).
Category Oily Wastes Catalysts Industrial Wastes Process Wastes General Waste Miscellaneous Waste 2007 354 3526 1896 2008 456 3899 1859 2009 392 2898 1288
285 485 2530
366 580 2976
154 343 1764
Calculated as per the Solid Waste Index Quality
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8.5
Future Plans
The Refinery will continue to focus on cleaner and more efficient production to minimise the amount of solid waste that is produced. The Refinery will also continue to seek reuse and recycling options for wastes that can be utilised by other industrial processes.
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9 SOIL AND GROUNDWATER

9.1 Historical Background
Past operational practices have resulted in the loss of oil to ground at many locations across the Refinery. These losses were the result of operational practices including venting, draining, spills and leaks. An example of this is the original Refinery design which lacked a tank farm drainage system. As a result, water draining from tanks was directed onto the ground. Inevitably some entrained oil was carried over from the tank water draining and oil was drained into the ground. The Refinery oily water sewer system also failed at several locations over time and this was a source of hydrocarbons to ground in process areas. The result of these losses has been an accumulation of oil in soil and groundwater beneath the Refinery. Further to this, all solid wastes generated by the Refinery (except municipal type general rubbish) were disposed of onsite until the late 1980s. These waste disposal practices have lead to some localised contamination of the soil and groundwater with hydrocarbons and heavy metals. Contamination first became evident at the Refinery in the 1960s when hydrocarbon expressed itself near ground surface. Analysis of aerial photographs over the history of operation at the Refinery shows evidence of surface hydrocarbon staining due to oil spills. Figure 82: Evidence of Subsurface Hydrocarbon Staining.
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Figure 82: Evidence of Subsurface Hydrocarbon Staining.
The loss of oil to ground and subsequent accumulation of separate-phase and dissolved-phase hydrocarbons beneath the Refinery has resulted in the formation of subsurface hydrocarbon plumes. During 1974 and 1975 Layton Groundwater Consultants were engaged to determine the extent of the hydrocarbon contamination and, in particular, to identify areas where recoverable quantities existed. A total of 244 shallow auger borings were drilled throughout the Refinery. As a consequence many bores and wells were installed with the purpose of recovering hydrocarbons. Most had only limited success and no longer exist. One exception was an electric powered dual phase recovery system installed in the 400 series tank farm in 1979. Intense monitoring began in the early 1980s, and the effort to recover oil escalated later in the decade as the size and distribution of the contamination was further documented. From 1993 attention was given to the transport of dissolved phase hydrocarbon and other pollutants (such as heavy metals) into Cockburn Sound. This transport was occurring via the Safety Bay Sand, Tamala Limestone and Rockingham Sand aquifers. Monitoring wells, which were screened at the top and bottom of these aquifers, were installed at the coast, eastern Refinery boundary and various mid Refinery locations. These have been sampled annually and monitored closely since their installation.
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9.2
Setting
9.2.1 Geology The Refinery is situated on an area composed generally of Safety Bay Sands and Tamala Limestone, overlying the older Leederville Formation. The Formation provides a low permeability basement with a distinctive dark colour, with the groundwater confined in the sandstone beds. Deep drilling at the Refinery has revealed a prominent section of coarse quartz sand approximately 5-7m thick located at 23 to 25m below the surface, between the Leederville Formation and the Tamala Limestone. This sand has been assigned to the Rockingham Sand that underlies the Tamala Limestone in the Rockingham area. The Tamala Limestone is mainly comprised of coarse to medium grained sand of calcareous skeletal fragments and variable amounts of quartz. It is typically white, grey or tan in colour depending on weathering or alteration, and is 7 to 11m thick, located approximately 15 to 24m below the surface. A single outcrop of Tamala Limestone exists on the western side of the Refinery at the shoreline. The outcrop is highly porous and some groundwater seeps have been found in this area. This outcrop significantly affects the local hydrology of the area. A dark clay layer, rich in intact shells, is consistently found at the base of the Safety Bay Sands. This layer can be up to 2m thick and is informally referred to as Basal Clay, due to its position above the Tamala Limestone. The dark colouration of this layer is attributed to the presence of organic matter. East of the Refinery the Basal Clay layer hydraulically isolates the Safety Bay Sand and Tamala Limestone aquifers so that the latter is confined. While generally present within the Refinery there are places, particularly close to the shoreline, where the Basal Clay thins out or is absent. The Safety Bay Sand overlies the Tamala Limestone, with a thickness of 14 to 16m at the Refinery. This system is a succession of marine, littoral, coastal plain and dunal sands comprising of skeletal fragments, quartz and minor feldspars, a similar composition to the Tamala Limestone. The deposition of the Safety Bay Sands was strongly influenced by the Tamala Limestone outcrop, with thicker deposits above the flat Tamala Limestone surface, and the Sands thinning and pinching out over the limestone outcrop. Consequently, the geology of the Refinery has good load bearing characteristics but high porosity, resulting in rapid downward migration of any hydrocarbon leakage that comes in contact with the surface of the site.
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9.2.2 Hydrology The watertable (the level at which all soil spaces below are saturated with water) is approximately two to five metres below the surface of the Refinery. Each of the soil types beneath the Refinery has different sized spaces (pores). These pores dictate how water can move and where it is stored. The differences in composition of the soil types means that water stored in the pores of one soil interacts in different ways with water in other soil types. This is how the aquifers, water stored in different soils, are distinguished. Understanding how aquifers behave and interact is extremely important for managing the groundwater beneath the Refinery. Variation in the watertable height within the Safety Bay Sand aquifer is strongly seasonal due to the affects of local recharge. The Tamala Limestone aquifer is not as affected by local recharge, however changes in sea level do cause a variation as the aquifer is open to the ocean. Head pressure differences between the Safety Bay Sand and Tamala Limestone aquifers are normally observed. East of the Refinery boundary head differences have been reportedly up to 0.5m. This creates leakage from the Safety Bay Sand Aquifer into the Tamala Limestone, especially where the aquitard is absent. The Safety Bay Sand is generally higher in head due to surface recharge in this relatively low conductivity formation (Layton, 1979). Although flow between the two aquifers generally experiences a downward gradient, in areas where tidal stresses are important, the hydrostatic head difference between the aquifers may reverse. Tamala Limestone is more permeable than the Safety Bay Sands, therefore the velocity of water movement in the Tamala Limestone aquifer is typically much higher than in the Safety Bay Sands. The overall water table slopes gently across the Refinery site towards the coast, typical of coastal locations, with the groundwater generally flowing in a northwesterly direction. The overall water table gradient across the Refinery site is about 0.001m/m distance, with local variations of up to 0.0005m/m.
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9.3
Subsurface hydrocarbon
9.3.1 What is it and what affects it? The original 1950s design of the Refinery, environmental expectations of the day and various spills and leaks have left the Refinery with a sub-surface hydrocarbon plume. The point sources of this plume were addressed through the installation of a tank water draining system, the use of electronic monitoring systems to detect leaks, lining the sewer to prevent leaks and bunding chemical storage areas. Furthermore, the Refinery has had a recovery program to extract the underground hydrocarbon since 1979. Hydrocarbon in the sub-surface exists in a number of phases (gas, dissolved phase and liquid). The hydrocarbon may change state and become a soil gas that exists in the spaces between the soil particles. These vapours can migrate through soils and may pose a risk if allowed to accumulate in buildings. When hydrocarbon is in contact with the groundwater it may produce dissolved constituents, resulting in a contaminated groundwater plume. This is of concern as it makes the contamination more mobile and can prevent the groundwater from being used as a water resource. The hydrocarbon may also remain in its original liquid form. As a liquid it can also exist in different ways within the soil. These are controlled by capillary pressures associated with the respective fluid characteristics and soil pore sizes. The liquid may be absorbed onto soil particles or form isolated discontinuous droplets, referred to as residual hydrocarbon which cannot move or flow. The hydrocarbon that remains in a liquid state can be at positive fluid pressure and continuous, referred to as the free product, or non-aqueous phase liquid (NAPL). This is generally mobile and available for recovery (see Figure 83: Photograph of NAPL (degraded diesel) Recovered from a Groundwater Well (Courtesy of CSIRO). NAPL does not exist as a discrete thickness in the soil, instead the NAPL is distributed in a saturation profile defined by a range of properties, therefore thickness is a conceptual term only. It is important to note that not all free product is mobile, and with fluid pressure changes, hydrocarbon that was continuous and mobile can become discontinuous and therefore residual. The presence of free product is of concern as it has the potential to migrate and contaminate other soil or water resources (e.g. Cockburn Sound). The free-flowing subsurface hydrocarbons, commonly referred to as Light NonAqueous Phase Liquids (LNAPL) are those that float on top of the groundwater table. LNAPL thickness in bores located across the Refinery is monitored on a monthly bases to determine any spreading or increase of the plume. Additionally weekly leak detection monitoring is carried out, focussing around the Tank Farm areas, to detect any hydrocarbon leaks from the tanks.
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Figure 83: Photograph of NAPL (degraded diesel) Recovered from a Groundwater Well (Courtesy of CSIRO).
9.3.2 Licence conditions and reporting guidelines The licence issued to the Refinery by the Department of Environment and Conservation (DEC) requires the continuous recovery and monitoring of the accumulated free product under the site. The results of recovery and monitoring must be submitted to DEC every year. Australia has National water quality guidelines that have been published through Australian and New Zealand Environment and Conservation Council (ANZECC) (2000) and can be used to assess water quality. Of more relevance to the Refinery is the Environmental Quality Criteria Reference Document for Cockburn Sound, released by the WA EPA. This document identifies recommended concentration limits for discharges into Cockburn Sound. These guideline values are used by the Refinery to interpret the groundwater quality. Where values are not available through the Reference Document for Cockburn Sound, guidelines are taken from other sources such as the ANZECC guidelines (2000). To allow for attenuation mechanisms such as mixing and dispersion in the nearshore coastal zone, the protection guideline values are multiplied by 10x to create a trigger guideline that is used to highlight discharge zones of concern. 9.3.3 Dissolved Phase Contamination A series of monitoring wells (referred to as the 900 series monitoring wells) were installed in 1993. The design and placement of the bores where aimed at ensuring the greatest probability of intercepting any migrating dissolved pollutants. The bores are screened to intercept the top and bottom 2-3 m of each aquifer. They are located
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along the Refinery coast to detect any contaminants discharging to Cockburn Sound, within the Refinery and along the southern and eastern boundary to detect dissolved contaminants entering the Refinery site from external sources (see Figure 84: BP Refinery (Kwinana) 900 Series Monitoring Bores for bore locations).
2000
946 - 949
931 - 934
BERM
1800
954 - 955 945 972 971 965 - 968
1600
944
1400
942 - 943 950 - 953

EAST FLARE
940 939 938 936937 921 - 924 929 928 930 927 969 - 970
Easting (mE)
1200
WEST FLARE
Pond 5 - 6
1000
POLISHING POND
925 926 960 - 963

FIRE TRAINING
POLISHING POND
901 - 902
HYDROBLAST AREA
800
903 - 907
919 - 920 917 - 918 912 - 916
600
25
50
75
100 125 150
908 - 909
SOUND
910 - 911
SCALE
(m)
400
COCKBURN
6200
6000
5800
5600
5400
5200
5000
4800
4600
4400
4200
4000
3800
Northing (mN)
Figure 84: BP Refinery (Kwinana) 900 Series Monitoring Bores.
The 900 series monitoring bores have been sampled annually since 1993. All wells are tested for major components, heavy metals, nutrients and organic contaminants typical of oil refineries (total petroleum hydrocarbons, polycyclic and mono-aromatic hydrocarbons). These results are compared with the Environmental Quality Criteria (EQC) Reference Document for Cockburn Sound. These guidelines are most relevant to the Refinery as they have been specifically developed for the waters of Cockburn Sound. Rockingham Sand Aquifer The Rockingham Sands aquifer has some parameters that have exceeded the protection criteria in some previous monitoring rounds. These were: copper (below criteria limit since 2008), lead (below since 1996),
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3600
zinc (below since 2002) and ammonia (below since 1997).
Manganese has been consistently present in the two bores since 1993. This result suggests manganese may be naturally occurring or introduced into the groundwater upstream of the Refinery, as there is no known point source of manganese at the Refinery. Tamala Limestone Aquifer The Tamala Limestone aquifer has previously recorded copper, lead and zinc at concentrations that exceed the guidelines. The concentration of these contaminants has been decreasing since 1995 and the recent results are predominantly within the guidelines. Exceptions to this were: zinc which was elevated in 2008 at one coastal location (but not in 2009) and in the middle of the Refinery in 2009 (potentially a sampling method issue), arsenic has been above guideline during 2007 2009 at locations along the southern and western boundary and at two coastal locations, arsenic was also above the guidelines during 2007 at one eastern monitoring well, believed to be from another offsite plume migrating onto the Refinery site, arsenic was also detected at middle of the Refinery during 2007 and 2009, levels were only slightly above guidelines. This well had previously recorded levels below detection since 2001, ammonia flowing onto the site from the south currently exceeds the guidelines and benzene and ethylbenzene has also been above the guideline values during 2007 2009 at the approximate mid-point of the Refinery. This has been decreasing since 2006 to below guideline in 2008 and 2009 (for benzene) and since 2007 to below guideline for ethylbenzene.
The south and west boundary locations result from known contaminant plumes moving onto site.
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Safety Bay Sand Aquifer As the Safety Bay Sand aquifer is the water table aquifer it is most susceptible to contamination by above ground activities. Due to the sensivity of this area all wells are monitoring and analysed for a broad range of contaminants. Of the analytes tested the following exceptions were found to above the guidelines: copper at one coastal location and two landfarm well locations, lead at one coastal location in 2009, molybdenum at one location in the landfarm area, zinc at three coastal locations and the middle of the Refinery in 2009, (thought to be due to the previous sampling method), ammonia as NH3-N at the two southern monitoring wells, benzene on the eastern boundary and in the middle of the Refinery in 2007, ethyl benzene in 2007 and 2008 on the eastern boundary and arsenic at the southern edge of the Refinery can be attributed to a plume moving onto the Refinery from offsite.
Monitoring has also shown an increase in chlorophenols on the eastern boundary of the Refinery; this can be attributed to an offsite plume that is migrating towards the ocean. The halogenated phenol CIK plume originated from the now defunct Chemical Industries of Kwinana facility near the corner of Rockingham and Mason Roads. The groundwater flow direction in the Safety Bay Sand aquifer is from the southeast. The source of arsenic is likely to be the defunct Kwinana Nitrogen Company (KNC). Arsenic formed part of the Vetrocoke solution, which was used in the manufacture of ammonia at KNC, which was formally owned by BP, sold in 1987. There may have been instances of releases and spills, which although cleaned up to the standards of the day, could potentially be the source of the arsenic presently discharging from beneath the Refinery. Site investigations carried out to locate the arsenic source on the property adjacent to the Refinery clearly showed a plume of dissolved arsenic and ammonia discharging onto the Refinery. A remediation program to remove the arsenic (and ammonia) from the soil and groundwater is occurring at this adjacent site. Nitrogen loads to Cockburn Sound are an increasingly important issue with the Department of Environment and Conservation and the community as it promotes algal growth. Wells located on the southern and south eastern boundary intercept a
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nitrogen plume migrating through the Refinery from the south west corner from an external source, these have had higher levels of nitrogen detected above the guidelines. There are also two wells on the coast with high levels, these are currently under investigation to determine the source of the increased concentration. Due to a number of wells within the landfarm area also being high in nitrogen, a current review of fertilising practices is underway. The levels of TPH (Total Petroleum Hydrocarbon) that discharge into Cockburn Sound have been showing a continual decline with a decrease in total TPH at all coastal wells. In 2009 no coastal wells had total TPH values above the level of detection. This has been a trend over the past few years and is likely to be attributed to the (see Section 9.3.4) dune air sparge curtain and natural attenuation. Dissolved phase hydrocarbon contamination transport to Cockburn Sound is significantly inhibited by the process of natural attenuation. Natural attenuation refers to the observed reduction in contaminant concentrations as contaminants migrate from the source. In 2008 Methyl tert-butyl ether (MTBE) was detected at a coastal monitoring well. In 2009 all wells on site were tested in an attempt to determine its extent. MTBE was found to be present in a number of southern, south eastern boundary wells and southern coastal wells. It was predominantly in the deep Tamala wells along the southern and eastern boundary (suggesting an offsite source). MTBE was also detected in a Tamala well in the middle of the Refinery. In the Safety Bay Sands wells along the south and southern coastal boundary (suggesting a more localised source). The source of this contaminant will be further investigated in 2010. Where monitoring by the Refinery has detected plumes migrating offsite, control measures have been put into place to intercept and treat the hydrocarbons prior to them leaving the site. The Refinery installed two air sparge systems for the purpose of remediating contaminated groundwater that is moving offsite. This has been carried out at two locations onsite, at the south-eastern site boundary, as well as at the dunes directly opposite the series 100 tank farm. Details pertaining to the air sparge systems are included in Section 9.3.4. Two coastal dissolved phase hydrocarbon plumes are known to be moving offsite in the direction of the Cockburn Sound. One plume is located to the west of the WWTP and another is migrating offsite from near the southern end of the 100 Series Tanks (see Section 9.4.2). A biosparging trial has being conducted at the 100 series tank plume. Five air injection wells and a network of monitoring wells were installed on both the up- and down-gradient sides of the zone of influence in late 2008. The trial was run during 2009 and the success of this trial is still being investigated. If successful, a full scale development of the biosparging line will be undertaken in 2010. Further investigations are proposed for the plume west of the WWTP area before a remediation strategy can be considered.
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9.3.4 Air Sparge Systems The Refinery operates two air sparge lines to remediate hydrocarbon impacted groundwater that has the potential to migrate offsite. Air sparging is a remediation technology that involves the injection of air into the subsurface to breakdown contaminants dissolved in the groundwater and trapped within soil pores in the saturated and capillary zones. The dominant mechanisms of air sparging are volatilisation and biodegradation. Injected air volatilises hydrocarbons from the liquid phase to the air phase which are then biodegraded in the vadose zone. In addition, the delivery of oxygen from the injected air into the liquid phase stimulates aerobic biodegradation of contaminants. The two air sparge lines in operation on the Refinery are called the PICL Sparge Line and the Dune Sparge Line. The location of the PICL and Dune Sparge Lines is shown on Figure 85. The PICL Sparge Line was commissioned in 1999 and the Dune Sparge Line was commissioned in 2004.
Figure 85: Location of the PICL and Dune Sparge Lines.
Monitoring programs have been established for both sparge lines to assess the performance of the systems and determine what affect the systems have on dissolved phase contamination in the underlying groundwater. The monitoring of dissolved phase hydrocarbon concentrations on both the up- and down-gradient sides of the sparge lines continues to confirm that both sparge systems are effective at reducing hydrocarbon concentrations in groundwater
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underlying the sparge sites. Monitoring results to date indicate the sparge systems are most effective at reducing hydrocarbon concentrations in the top and middle zones of the aquifer and have only limited effectiveness at reducing hydrocarbon concentrations at the base of the aquifer (near to the injection zone). While various operating cycles have been tested to improve the system effectiveness at remediating the deeper aquifer through diffusion processes, monitoring results to date identify a limitation in the remediation of groundwater at depth by air injection. The reduction in lateral dispersion of air at the base of the aquifer results in a noncontinuous curtain of air at the base of the aquifer allowing impacted groundwater to flow through the sparge lines at depth. The monitoring of soil gas vapours near the vicinity of both sparge lines continues to not detect VOCs (C5 to C15 carbon range) above the laboratory limit of reporting. These results demonstrate that any TPH vapours generated by the operation of the sparge lines are attenuated in the vadose zone before reaching the ground surface. 9.3.5 Liquid Phase Contamination As liquid phase hydrocarbon is present in different phases within the soil rather than a distinct layer of constant concentration, it is extremely difficult to accurately describe the variable free product available for recovery, and mathematical descriptions are complex. A number of methods have been trailed on the Refinery to estimate total and recoverable hydrocarbon volumes, including the apparent thickness method, CONCAWE Method, Bail-down Method, McWhorter Method and the Intact Core Method. A comparison of all methods has allowed the Refinery to establish the Intact Core Method as the most suitable method of estimating the size of the hydrocarbon contamination at this site. The Intact Core Method detects absorbed and entrapped hydrocarbon (residual hydrocarbon) in addition to the mobile hydrocarbon that is free to migrate to the monitoring wells. Three (3) intact core surveys have been conducted on the Refinery. The first core study was conducted in 1992 and found the total subsurface hydrocarbon mass to be 45,000 tonnes. The second core study was conducted in 2002 and found the total subsurface hydrocarbon mass to be 35,500 tonnes. The third core study was conducted in 2006/07 and found the total subsurface hydrocarbon mass to be 33,000 tonnes. The difference between the values in 1992 and 2002 were thought to be due to the effectiveness of the LNAPL recovery program, the location of the wells chosen for the coring studies and the subtleties of electronic contouring packages. It was reported that the reduction in mass from 2002 to 2006/7 was consistent with the mass of oil recovered and known new sources of LNAPL identified during this period. The first core study estimated the mass of free product to be 16,000 21,000 tonnes. In 2002 this mass was estimated to be 15,000 16,000 tonnes and in 2006/7 the estimated recoverable mass was 13,000 14,000
tonnes. This is expressed as a range because the calculation has a degree of subjectivity due to the difficulty of estimating the concentration at which hydrocarbon becomes mobile. The extent of the LNAPL plume underneath the Refinery is shown in Figure 86. Error! Reference source not found.
Figure 86: Extent of LNAPL Plume.
The amount of free hydrocarbon provides an estimate of the theoretical limit of possible hydrocarbon recovery from the subsurface. The difference between this figure and the total hydrocarbon estimates the residual component of the hydrocarbon. This residual is at less than atmospheric pressures in the soil and will not enter recovery wells. The Intact Coring Method does have limitations as there is limited resolution (100mm core sections) and assumptions are required to convert total hydrocarbon to mobile free product. 9.3.6 Recent sources of subsurface hydrocarbons There have been no major releases of hydrocarbon to the subsurface, such as leaks from tanks, in the period 2007 to 2009. 9.3.7 Storage Improvement Plan In the previous PER (2002 2006) three major tank leaks were described a gas oil leak of 230kL from tank 114 in 2003, 2 800kL of isomerate from tank 611 in 2004 and diesel from tank 311 in 2005 (50 70kL). As described in the previous report a number of product recovery options were successfully employed to remediate these areas.
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During this time a new licence condition was added to the Refinery licence. This condition centred around improvements to the storage facilities on site. It resulted in a detailed audit of the entire Refinery and a subsequent plan for improvements. As part of the external agreement to this plan the Refinery was also required to perform a risk assessment for large storage (greater than 50kL). From the site wide assessment of storage a 5 year improvement plan was developed the Storage Improvement Plan (SIP). This plan was implemented in 2005 with the initial completion date set at 2010. A requirement for half yearly summary reports (for work completed and work planned for the next half year) was also stipulated. Due to the complexity of some projects the initial completion date is currently being renegotiated. Numerous projects have been completed over the past 5 years, greatly reducing the risk of material losses across the Refinery. Examples of two of these projects are outlined below. Dye Facility Upgrade The dye storage facility was initially designed (see Figure 87) to accept delivery of Intermediate Bulk Container (IBC), for filling via gravitational feed from the roof. The design included rails on the storage shed which were used for the temporary location of the transportable vessels whilst the decant process into the permanently installed tanks took place. Prior to decanting, the connections from the old to new IBC needed to be changed over. This frequently resulted in spills on either the shed roof or the hardstand in front of the shed. The main improvement provided by this project was the relocation of the decant operation to ground level and within the bunded area of the dye shed. This involved the removal of a dye tank and associated pipework that was no longer in use. In the space created, an IBC unloading platform was built and three transfer pumps installed to move the dye to the permanent tanks. The IBC is now delivered to site with the appropriate dry break coupling fitted to the IBC, minimizing the spills risk when changing over connections. Once in the unloading platform the IBC is connected to the correct permanent tank via a dedicated pump and flexible hose and the contents immediately transferred (see Figure 88: The Dye Facility After Being Upgraded.
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Figure 87: The Dye Facility Prior to Being Upgraded.
Figure 88: The Dye Facility After Being Upgraded.
Total Corrosion Control Yard The storage facility for paints at the Total Corrosion Control (TCC) yard previously involved a sea container and or pallets (see Figure 89). This was replaced with a purpose built portable dangerous goods storage container, suitable for the storage of Dangerous Good Class Three (see Figure 90).
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Figure 89: Total Corrosion Control Yard Prior to Upgrade.
Figure 90: Total Corrosion Control Yard After Being Upgraded.
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9.4
Recent Investigations
9.4.1 PB8 Following the release of isomerate from Tank 611 in 2004 (see Section 9.3.7), BTEX (benzene, toluene, ethylbenzene and xylene) concentrations were detected in groundwater samples collected from the vininity of production bore PB8. The location of PB8 is shown on Figure 91. PB8 supplies process water for the Refinery and has been in use since 1999.
Refinery Tank Farm Historical landfarm area
Existing landfarm area PB8
Historical catalyst disposal
BP/ CSBP Fenceline
Figure 91: Location of PB8.
Although initially thought to be associated with the release of isomerate from Tank 611, isomerate is a gasoline blendstock that does not contain BTEX compounds. Investigations commenced in late 2004 to determine the source and extent of the BTEX contamination. Investigations conducted in 2004 and 2005 defined the lateral extents of the dissolved phase hydrocarbon plume and investigations conducted in 2006 identified dissolved phase hydrocarbons in groundwater crossing the southern Refinery boundary with CSBP in the vicinity of PB8. Although wells installed in the top and bottom of the superficial aquifer (Safety Bay Sands) failed to delineate the down-gradient extent of the plume, relatively low concentrations of TPH/BTEX identified in groundwater samples from these wells suggest the plume is not likely to extend an appreciable distance beyond the limits of the monitoring network. Subsequent investigations have identified two potential source areas impacting on groundwater quality in the area of PB8. The first appears to be the Refinery tankfarm
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where separate phase hydrocarbons are periodically identified in monitoring wells. This plume is characterised by relatively high benzene and/or ethylbenzene concentrations. The extent of the plume impact on groundwater quality beyond the Refinery boundary is not known as it mixes with impacted groundwater from the second identified source area. Contours of benzene concentrations in groundwater from the top of the Safety Bay Sands aquifer indicate the impact of this source on water quality beyond the site boundary may be limited (see Figure 92: Benzene Concentration Contours for PB8 Investigation.
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Figure 92: Benzene Concentration Contours for PB8 Investigation.
The second identified potential source zone is in soil located to the east of PB8. This source contains relatively high concentrations of xylene consistent with the dissolved phase plume crossing the site boundary down gradient. This plume is impacting on groundwater quality through the entire Safety Bay Sands aquifer profile in the order of 250m in a south westerly direction from the site boundary. Additional investigations will be conducted in 2011 to further delineate and identify the second identified source zone in soil located to the east of PB8. If, as expected, the secondary source zone is a plug of contaminated soil, it will most likely be excavated and remediated at the Refinery. Considering the nature of the dissolved phase contamination (BTEX), the most effective means of groundwater remediation is likely to be air sparging. The technology has been proven to be effective on site and is likely to be the preferred strategy. 9.4.2 Southern Dune Dissolved Phase Plume The Southern Dune Dissolved Phase Plume is located on the western side of Tanks T117/T119 (see Figure 93).
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T118
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Figure 93: Location of the Southern Dune Dissolved Phase Plume.
Groundwater samples collected from the area detected dissolved phase hydrocarbons in the C15 C28 range. The hydrocarbons are identified as polar compounds, which are a combination of source material (diesel fuel) and degradation by-products. The polar compounds are oxygenated petroleum hydrocarbons, which are highly soluble (in relation to non-polar hydrocarbon compounds) in groundwater and highly resistant to biodegradation. Analysis of the groundwater samples also identified low levels of saturate and aromatic compounds. Samples collected from some of the wells were analysed for groundwater chemistry to assess the degree of natural attenuation that was occurring in the area. Results indicated a reduction of sulphate in the shallow aquifer, indicating that sulphate reduction of hydrocarbons was taking place in the aquifer. It is not know if natural attenuation processes have completely degraded the polar compounds or if they were not present in the original source material. Subsequent investigations conducted in the area identified trends in methane, TPH and sulphate concentrations, suggesting that the levels of TPH in groundwater were being reduced by natural attenuation processes (sorption, dispersion, dilution and/or sulphate reduction and methanogenesis). Decreasing trends in TPH concentrations in groundwater samples collected from down-gradient wells suggests that attenuation is effective, though the distance between the source and Cockburn Sound is insufficient for complete attenuation.
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An investigation into the change in concentration of total aromatic, saturate and polar compounds along a east/west transect in the area of the Southern Dune Dissolved Phase Plume identified changes in relative percentage composition of the different compounds, whereby over a distance of less than 50m the concentration of the polar compounds decreased from 13,300g/L to about 700g/L. There was however no clear trend in the behaviour of the saturate and aromatic compounds, with the concentrations varying along the transect. Near the discharge boundary (on the beach) the petroleum hydrocarbons consist almost solely of the polar hydrocarbons indicating attenuation processes in the aquifer are more effective in reducing concentrations of or act preferentially on aromatic and saturate fractions. The Refinery has commenced a biosparging trial at the Southern Dune Dissolved Phase Plume site and the trial will be completed in 2011. If successful, full scale development of the biosparging line will be undertaken in 2012/2013.
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9.5
LNAPL Recovery Methods
The Refinery has a two-fold approach to the liquid phase hydrocarbon contamination beneath the site. The first aim is to prevent any further major additions to the contamination through undetected leaks. To meet this aim a weekly monitoring program is in place to measure the level of hydrocarbon in over 100 bores across the Refinery site. The second aim is to recover the liquid hydrocarbon. Over the past few decades efforts have been made to recover the mobile hydrocarbons from the subsurface. There are currently four types of recovery systems in use on the Refinery: Passive recovery trenches, Single phase recovery wells, Dual phase (water phase and oil phase) recovery wells; and Vacuum enhanced recovery system.
9.5.1 Passive recovery trenches Passive recovery trenches (see Figure 94) are gravel filled trenches that extend past the zone of hydrocarbon contamination, so the hydrocarbon collects in the trench and can then be rapidly removed by vacuum tankers. Recovery trenches are useful as they do not require electricity or compressed air services to the area, and provide a barrier to migration if regularly emptied. There are 35 recovery trenches on the Refinery, mainly situated in the Tankfarm (see Figure 95).
Recovery Wells
Natural Soil LNAPL in Soil A ir/oil interface Water Table
Trapped LNAPL
Gravel filled trench
Figure 94: Schematic of Passive Recovery Trench Design.
Oil/water interface
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Figure 95: Location of Passive Trenches at BP Refinery (Kwinana).
9.5.2 Single phase recovery wells Single phase recovery wells are at a similar depth to recovery trenches and are regularly pumped as hydrocarbon passively accumulates in them. Selective Oil Skimmers are used to control this process as they float at the oil-water interface and separate the oil by the use of a selective membrane, automatically adjusting to water table movements. There are currently ninety skimmers in use, however previously the available locations were limited by the requirement for pressurised air in the process. Figure 96: Schematic and Photographs of Single Phase Skimmers.6 shows a schematic of a single phase recovery system and photographs of the above ground components. Currently the Refinery has six solar unit pumps (see Figure 97), which can be easily transported around the site and allow recovery at any location, each capable of running four skimmers at a time.
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Figure 96: Schematic and Photographs of Single Phase Skimmers.
The Refinery has six solar powered recovery units which are used to recover LNAPL in areas of the Refinery where there is no access to plant utilities (electricity and compressed air). Three (3) of the hydrocarbon recovery units are shown in Figure 97.
Figure 97: Solar Powered Air Compressor Units used for Product Recovery.
The recovery units use two solar panels to generate electricity, which powers a small air compressor that is used to supply air to operate four product recovery pumps and associated skimmers. The recovery units are trailer mounted, which allows easy placement in areas where free product is most recoverable. LNAPL recovered by the units is pumped to surface storage tanks which are emptied weekly by a vacuum tanker. The pumps do not operate continually as the rate of hydrocarbon flow into the well is lower than the pumping rate. An air logic control system is used to set the discharge and recharge pumping intervals. Pump on (LNAPL discharge) and off (LNAPL recharge) times are set according to the rate of LNAPL inflow to the well.
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9.5.3 Duel phase recovery wells Dual phase recovery wells involve using one well to pump out groundwater to create a cone of depression in the water table. This encourages the accumulation of hydrocarbons, which can then be recovered through the second well using skimmers in the same way as the single phase recovery system. Figure 98 shows a schematic of a dual phase recovery system and a photograph of the above ground components. All oil recovery prior to 1986 was achieved with one dual phase recovery well, which was then decommissioned due to design problems. The Refinery has six dual phase recovery systems, with three currently in operation. The other three systems were decommissioned as they were no longer able to produce an acceptable rate of recovery in their field of influence. These systems are scheduled for recommissioning in 2011.
Figure 98: Schematic and Photographs of Dual Phase Recovery Systems.
9.5.4 Vacuum Enhanced Recovery (VER) Vacuum Enhanced Recovery (VER) is designed to artificially increase the local hydraulic gradient to draw the LNAPL into the recovery well by applying suction pressure to the recovery well. Figure 99 shows photographs of the above ground components of a VER system.
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Figure 99: Photographs of VER System and Generator.
9.6
Subsurface product recovery
Subsurface product recovery records commenced at the Refinery in 1985. Since the commencement of recovery records, a total of 27,114 tonnes have been recovered and reprocessed (up to the end of 2009). Annual recovery and the cumulative total are presented in Figure 100: Historical Sub-surface Product Recovery.
4,000 Annual Recovery 3,500 Annual Recovery (tonnes) 3,000 2,500 2,000 1,500 1,000 500 0 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 Cumulative Recovery (tonnes) Cumulative Recovery 24,500 21,000 17,500 14,000 10,500 7,000 3,500 0 28,000
Year
Figure 100: Historical Sub-surface Product Recovery.
Product recovery rates from 2007 2009 were lower than historic values. Despite all of the recovery methods in operation throughout most of this period, reduced oil recovery rates over these years is most likely the result of extremes in water table elevations (some of the highest (winter and summer levels) recorded on the Refinery). These extremes in water table elevation result in an overall reduction in the amount of LNAPL available to mobilise and accumulate on the water table during the drier summer months when LNAPL thicknesses are typically at their greatest. In
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addition, assuming there are no additional product losses to the sub-surface, product recovery rates typically decrease over time as LNAPL volumes become less available and more difficult to recover.
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9.7
Treatment of Contaminated Soil
Contaminated soil generated by development, maintenance and remediation activities requires treatment and disposal. The present options for the treatment of contaminated soil involve the removal of the soil to be treated (ex-situ). Present treatment options in use on the Refinery are landfarming and biopiles. Landfarming is a commonly used technique for waste treatment involving the controlled application of oily waste to soil. The conditions of the landfarm are managed using irrigation, aeration and fertiliser application to create the optimum level of degradation by naturally occurring micro-organisms. This biological process breaks down any hydrocarbons to carbon dioxide, water and soil humus. Biopiles are used when an adequate batch of contaminated soil is generated. This system operates using the same principles as landfarms, in which bacteria and other soil organisms in the soil are used to degrade the hydrocarbon contaminants. The Refinery has 3 biopile cells where soil is piled 1.5 metres high on a permanent sand pad. An aeration system located within the sand pad creates a vacuum on the pile to optimise the aeration of the contaminated soil whilst water and nutrients are supplied through a reticulation system. Air permeable covers are placed over each pile to control rainwater erosion and evaporation. The advantages of using biopiles to remediate contaminated soil are the relatively short treatment time and smaller area required for the treatment facility.
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9.8
Historical contaminated sites
Historical operational and waste disposal practices at the Refinery have resulted in a number of small isolated areas that are contaminated with specific substances. Referred to as the Historical Contaminated Sites, they are generally located away from the main process and tank farm areas of the Refinery and typically contain contaminants related to metals and oil. These historical operational and waste disposal practices are now considered inappropriate and are no longer conducted. Assessments conducted on the Refinery have identified 26 sites which had the potential to be impacted as a result of historical operational and waste disposal practices. The Refinery keeps a register of all known contaminated sites and progressive clean-up of the sites has been occurring since 1990. Table 12 Identifies the status of the Refinery Historical Contaminated Sites and Figure 101 shows the location of the sites.
Table 12: Status of the Refinery Historical Contaminated Sites.
Site Name Old Landfarm Cells Description The Old Landfarm Cells are located east of the 600 series tanks. They consist of three cells (Cells 1, 2 & 3) measuring 670m long x 20m wide x 1.5m deep and were used primarily for the biodegradation of oily sludge from cleaning of crude and residue storage tanks and the API separator. Other solid wastes such as filter clay, spent catalysts and activated carbon were also disposed in the landfarm cells. Plastic packing which was used at the Kwinana Nitrogen Company (KNC) and known to be contaminated with arsenic was disposed of in a 670m long x 4m wide trench located in the centre of Cell 3 in the Old Landfarm Cells when KNC was sold. This plastic packing (approximately 200m3) was washed to remove the arsenic prior to disposal. Trace levels, calculated at less than 10mg/kg were present on this packing after washing. Sludges and scale removed in tank cleaning operations which contain organic lead (tetra ethyl lead) in high concentrations, are oxidised within cement cells through exposure to air and sunlight in order to reduce organic lead levels below 10mg/kg. Occasionally, the compound drainage sump and the compound itself overflowed, allowing soluble metals and hydrocarbons to be spilt onto the soil around the perimeter. Use of the compound was discontinued in 1989. The KNC Catalyst Storage Area consists of a concrete slab measuring 30m x 16m located near the boundary of CSBP, which has been used in the past to store spent catalyst from the KNC plant. Potential metal contamination was identified around the perimeter and/or underneath the slab. When land to the north-east of the Refinery was sold to PICL (Petrochemical Industries Corporation Limited), rubble from this site was transferred to the existing Refinery site to create a bund (700m long x 30m wide x Status (Dec 09) Cells 1 and 3 of the Old Landfarm Cells were remediated in 1998/1999 and were closed. Cell 1 however is still being used for the disposal of biosolids.
Arsenic Contaminated Packaging Landfill
The Arsenic Contaminated Packaging Landfill was remediated and closed in 1998/1999 as part of the Cell 3 landfarm closure.
East Gate Leaded Sludge Compound
The East Gate Leaded Sludge Compound was remediated in 1998 and closed.
KNC Catalyst Storage Area
The KNC Catalyst Storage Area was remediated in 2005 and closed.
TiWest Bund and Leaded Residue Landfill
The TiWest Bund and Leaded Residue Landfill was remediated in 2005 and closed.
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Site Name
Description 5m high) along the TiWest boundary. The soil covering this pile of rubble was contaminated with heavy metals and hydrocarbons. Under the rubble bund located at the TiWest boundary, sludge and scale from the east gate leaded compound was buried in a trench approximately 100m long x 30m wide. Spent catalyst from KNC has been stored along the PICL boundary since the 1970s. The area of the catalyst dump was approximately 600m long x 10m wide. Calcium Fluoride (CaF2) is generated on the Refinery from the neutralisation of hydrofluoric acid (HF) which is used as a catalyst in the Alkylation Unit. A caustic stream neutralises the HF during the normal operation of the unit. When this stream drops below a pH of 10, it is drained into the precipitation basin. Calcium chloride is then added to precipitate insoluble calcium fluoride. Calcium hydroxide is also a by-product of this process due to the high pH of the caustic stream and therefore the high availability of hydroxide ions. These precipitates (CaF2 and Ca(OH)2) were removed for disposal at the CaF2 pits. These pits covered an area 160m long x 10m wide and were approximately 2.5m deep. A proportion of the PICL Property was contaminated due to migration of separate phase hydrocarbon from the subsurface LNAPL plume originating from the tank farm.
Status (Dec 09)
PICL Piles
The PICL Piles were remediated and closed. The Calcium Fluoride Pits were remediated and closed.
Calcium Fluoride Pits
PICL Property
The PICL Property was remediated in 1999 and an air sparge system continues to operate in the area to remediate and prevent the migration of dissolved phase hydrocarbons onto the PICL Property. An ESA of the Arsenic Shed site was completed in 2000 and confirmed that the site was not contaminated and did not require remediation.
Arsenic Shed
Located at the southern end of the Refinery near the small boat harbour, the Arsenic Shed was formally used for storing drums of spent arsenic trioxide, before being taken off-site for disposal. Arsenic trioxide had been used in a liquid and solid form at KNCs Vetrocoke unit. It was not clear from historical records whether there had been any spillage of arsenic in or near the shed. The Hydroblast Slab was originally constructed as a work area during the construction of the tank farm in the mid 1950s. It was subsequent modified for use as a hydroblast facility and used again in 1990. Half of the slab had containment facilities to catch contaminated run off, and the other half, used as a standing area for drums or skips of waste, did not have any containment facilities. The surface soil was contaminated with hydrocarbons and heavy metals. The RCU Laydown Area was located to the east of the lubes intertankage and was formally used for the laydown of materials associated with the Refinery.
Hydroblast Slab
The Hydroblast Slab site was remediated in 2003 and closed.
RCU Laydown Area
An ESA of the RCU Laydown Area was completed in 2005/2006, as part of Cliffhead Facility build and confirmed that the area was not contaminated and did not require remediation. The Workshop Hydroblast Slab site was remediated in 2003 and closed.
Workshop Hydroblast Slab
The Workshop Hydroblast Slab had been used for many years for a range of hydrojetting and other maintenance and cleaning activities that led to contamination of the
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Site Name
Description underlying and surrounding soil with hydrocarbons and heavy metals. The Cogen Site was located north-east of the intertankage area and was assessed to be contaminated with hydrocarbons. The area of impact was approximately 29m by 19m, to a depth of approximately 3.2m. The Biosolids and CPU Catalyst Storage Site was located on the eastern side of the Refinery, south of the spent catalyst polymerisation site. The site was formally used as a dewatering area for biosolids collected from the salt cooling water circular separators. The Co/Mo and Ni/Mo Storage Site was located in the south-east corner of the Refinery and covered an area of approximately 5,000 m2. The site was formally used as a disposal site for spent Cat Poly Unit catalyst (phosphoric acid impregnated onto diatomaceous earth) and as a storage area for spent Ni/Mo and Co/Mo catalyst that is used to desulphurise products. Disposal of the Cat Poly Catalyst in the area resulted in leaching of phosphoric acid to the groundwater and spillage from the Ni/Mo and Co/Mo catalyst storage resulted in contamination of the surface soil with nickel, cobalt and molybdenum. The HF and TEL Weathering Yard was established in 1989 following closure of the East Gate Lead Compound. The weathering yard was located east of landfarm Cell 3 (Old Landfarm Cells) and was formally used to weather leaded sludge and scale; and lead contaminated equipment. Lead contamination of surface soils resulted from accidental spillage. Adjacent to the lead (TEL) weathering yard, a facility was constructed to weather HF acid contaminated equipment. Occasionally equipment was not entirely decontaminated of hydrocarbons before being sent to the weathering yard. Surface soil contamination with hydrocarbons resulted from accidental leaks. The Refinery has 41 sub-stations containing single or multiple banks of transformers. As the vintage of these extend before the 1980s when PCBs were banned, there was potential for soil surrounding the transformers to be impacted with PCBs The Old Fire Training Ground was located north of the Environmental Warehouse and south-east of the eastern flare. Due to previous fire fighting training activities at the site, petroleum products (mainly naphtha and in some cases diesel) were used as fuel for training. Contamination of soil and groundwater may have occurred when props were doused in petroleum products. Excess fuels may have drained and spilt from the props contaminating soil. The Fire Training Ground Sump was located in the southeast area of the Fire Training Ground. The sump was pit used to collect excess liquid runoff from the Fire Training Ground. It was identified that the liquid might contain petroleum based products such as oily waste and naphtha. The Old Flare Site was located approximately 130m north
Status (Dec 09)
Cogen Site
The Cogen Site was remediated in 1995 and closed. A drawdown system was installed down-gradient to prevent recontamination. The Biosolids and CPU Catalyst Storage Site was remediated in 2003 and closed.
Biosolids and CPU Catalyst Storage Site
Co/Mo and Ni/Mo Storage Site
The Co/Mo and Ni/Mo Storage Site was remediated in 2003 and closed.
HF and TEL Weathering Yard
The HF and TEL Weathering Yard was remediated in 2003 and closed.
Transformer Sites
ESAs of the transformer sites were conducted in 2005 and confirmed that the sites were not contaminated and did not require remediation. An ESA of the Old Fire Training Ground was conducted in 2004/2005 and confirmed that the area was not contaminated and did not require remediation.
Old Fire Training Ground
Fire Training Ground Sump
An ESA of the Fire Training Ground Sump was conducted in 2003 and confirmed that groundwater in the vicinity of the sump was not contaminated and did not require remediation. An ESA of the Old Flare Site
Old Flare Site
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Site Name
Description east of the Waste Water Treatment Plant (WWTP). The flare was used as a pressure relief system in case of process upsets and was decommissioned in the mid 1980s, replaced with a larger flare. Contamination to the surrounding area with hydrocarbons was possible as a result of seal pot overflows. The Old Scrap Metal Yard was located east of the Environmental Warehouse and was formally used to store valves and pipes from routine maintenance activities, and large vessels from the demolition of redundant units. The Old Drum Yard was located east of the Environmental Warehouse and was formally used to store scrap material and drums of chemicals and residue material from the Process Units prior to being collected for offsite disposal. Anecdotal information suggests loss of containment occurred through leaks and spills. The RCU Catalyst Storage Areas are located south of the 400, 500 and 600 series tanks, whereby the areas were historically used for the disposal of spent catalyst material from the refining process. The spent catalyst material contains high metal concentrations, which have the potential to leach into the underlying soil and groundwater. The Old Sand Blast Yard was located east of the Environmental Warehouse and was formally used to sandblast layers of scum, scale and paint from equipment by the abrasive force of the garnet particles. Anecdotal information suggests the residual material was bagged and taken away for disposal. Catalyst material has been observed on the surface of the yard. BTEX (benzene, toluene, ethylbenzene and xylene) concentrations have been detected in groundwater samples collected from the vicinity of production bore PB8.
Status (Dec 09) was conducted in 2005/2006 and the site was remediated in May 2007 during development of the WWTP holding ponds (Duck Ponds). An ESA of the Old Scrap Metal Yard was conducted in 2005/2006 and remediation of the yard was conducted in 2008. An ESA of the Old Drum Yard was conducted in 2005/2006 and remediation of the yard was conducted in 2008.
Old Scrap Metal Yard
Old Drum Yard
RCU Catalyst Storage Areas
ESAs of the areas were conducted in 1992 and 2003. Spent catalyst material has been progressively removed from the areas and disposed of offsite since 2004 and is ongoing. An ESA of the Old Sand Blast Yard was conducted in 2005/2006, 2007 and 2008. Additional assessment and remediation of the yard was conducted in 2009. ESAs and investigations to determine the source and extent of the benzene in the area surrounding PB8 have been conducted in 2004, 2005 and 2008. Investigations of the area are ongoing. An ESA of the site is proposed for 2011.
Old Sand Blast Yard
PB8
Area South of Fire Training Ground
Anecdotal information suggests the area south of the Fire Training Ground was used to bury drums of liquid and other waste material containing petroleum based products such as oily waste and naphtha.
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Figure 101: Location of BP Refinery (Kwinana) Contaminated Sites
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9.9
Future Plans
Additional investigations will be conducted in 2011 to further delineate and identify the second identified source zone in soil located to the east of PB8. If, as expected, the secondary source zone is a plug of contaminated soil, it will most likely be excavated and remediated at the Refinery. Considering the nature of the dissolved phase contamination (BTEX), the most effective means of groundwater remediation is likely to be air sparging. The technology has been proven to be effective on site and is likely to be the preferred strategy. An environmental assessment of the area south of the Fire Training Ground is proposed for 2011. Old Landfarm Cells Two and Three have been intensively planted with trees to evaluate the effectiveness of phytoremediation and Cell One is still an active disposal site for biosolids. Investigation results and remediation activities as required will be reported over the next reporting period (2010 2012).
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10 BIODIVERSITY
Biodiversity is the variety of all life forms: the different plants, animals and microorganisms, their genes and the ecosystems of which they are part (Department of Environment and Heritage, 2003). Australia is one of the most biologically diverse countries in the world, with a large portion of its species found nowhere else in the world (Department of Environment and Heritage, 2003). Almost half of Australias 25,000 known plant species grow in the west, and 8,000 of these grow in the state south-west (Laurie, 2000). BP Refinery (Kwinana) was built in the 1950s, on the edge of the natural harbour of Cockburn Sound. The area was predominately what is now known as the Quindalup vegetation complex, which includes herblands, sedgelands and Acacia shrubland (D.A. Lord & Associates, 2001). The site was cleared for the construction of the Refinery, and the later industrial development of the coastline north, south and east of the Refinery has resulted in little remnant vegetation remaining in the immediate vicinity. The nearest State Park/Recreation Area (Leda Reserve) is approximately 2.5 kilometres away to the southeast (Smith, 2000). BP Refinery (Kwinana) has two patches of native Quindalup vegetation on site. These are located on the western boundary in the dunes. This area has been impacted by the Refinery as it has been fragmented from other remaining vegetation by roads and access ways; however the area has been protected from destruction by public access (Smith, 2000). Based on existing records there are very few terrestrial fauna species of special conservation significance likely to occur in the Cockburn Sound area. The Southern Brown Bandicoot (Isoodon obesulus fusciventer), the Peregrine Falcon (Falco peregrinus) and Carpet Python (Morethia spilota imbricata) were reported as the only species of special conservation significance likely to occur in the area by the Cockburn Sound Pressure State Response report (D.A. Lord & Associates, 2001). A study of the Kwinana site in 2000 concluded the opportunities to make a positive contribution to biodiversity protection appear to be limited on the Kwinana Refinery site (Smith 2000, p3). BP Refinery (Kwinana) is making a positive contribution to both biodiversity and conservation offsite in Western Australia southwest through a reforestation project (Smith, 2000). In 1998 BP Refinery (Kwinana) commenced a project to establish tree plantations on working farms in the southwest region. These trees provide a sink for carbon dioxide, offsetting some of the emissions unavoidably produced by the refining process.
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The southwest region is currently under threat from dryland salinisation. This results from the extensive clearing of native vegetation for agriculture, and the consequent rise in the water table. This rising water mobilises naturally occurring salts in the soils, rendering the affected areas virtually useless. Salinity itself is a threat to biodiversity in the southwest, as the natural ecosystem is replaced by the few salt tolerant species. Planting trees (maritime pine) in specific recharge areas can reduce the amount of water reaching the water table and therefore contribute to reducing the amount of land affected by salinity. The project also directly contributes to preserving the biodiversity of the region by either planting 10% of each plantation as native species or providing a fencing subsidy to fence off native remnant vegetation. Since the project began over 2,600 hectares of trees have been planted, and the project has been judged to have the potential to significantly positively impact both, biological and conservation in south western Western Australia (Smith 2000, p17). The Refinery salt cooling water discharges to Cockburn Sound. This is a semienclosed marine embayment which provides the only protected water within 200 km of Perth. Cockburn sound is a multiple use waterway and its uses include: as a recreational area for sailing and fishing, a major port, for commercial fishery, a source of industrial water supply, a receiving environment for industrial process, cooling water and liquid wastes and for habitat protection. There are currently no marine conservation areas gazetted within Cockburn Sound.
Under normal circumstances disposal of treated wastewater occurs through the Sepia Depression Ocean Outlet Landline (SDOOL). The SDOOL is a pipeline that ends 4km offshore at the Sepia Depression. This location has a higher rate of dilution than within Cockburn Sound and is also subject to a monitoring and maintenance programs to ensure sustainability. A number of industries share the SDOOL pipeline and extensive environmental conditions are a requirement of its use. 10.1.1 References D.A. Lord & Associates (2001) Cockburn Sound Pressure-State-Response (Draft). Report number 01/187/1. Department of Environment and Heritage (2003) Australian Biodiversity [online]. Australian Government, Available from www.deh.gov.au/biodiversity/ [Accessed on 18/12/03). Laurie, V (2000) Salt n science [article] The Weekend Australian, April 15-16 2000.
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11 VERIFICATION STATEMENT

Kwinana Refinery 2007 2009

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BP Refinery (Kwinana) Mason Road, Kwinana, WA 6167

Public Environmental Report Jan 2007 Dec 2009

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BIODIVERSITY ...............................................................................................247 VERIFICATION STATEMENT ........................................................................249

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Figure 1: Location of BP Refinery (Kwinana) in relation to Australia.

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Figure 2: Location of BP Refinery (Kwinana) within the Kwinana Industrial Area.

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Environmental Management System

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Figure 3: Location plan of BP Refinery (Kwinana).

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Crude processing at BP Kwinana Refinery

BP Kwinana Refinery Flow Diagram

Kero/Jet Diesel Diesel

Sulphur Recovery Units

Refinery Fuel Gas Sulphur Gasoline Gasoline

Residue Cracker PPU2

Vacuum Distillation Unit

Alkylation Cat Poly

Fuel Oil Bitumen Oxidiser Bitumen

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Figure 6: The Catalytic Reformer (CR3) at BP Refinery (Kwinana).

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Figure 7: The Bitumen Unit at BP Refinery (Kwinana).

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Figure 8: The East flare at BP Refinery (Kwinana).

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Figure 9: The Waste Management Area at BP Refinery (Kwinana).

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Figure 10: Salt Cooling Water Circulars

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3 ENVIRONMENTAL MANAGEMENT SYSTEM

3. OBJECTIVES AND TARGETS

4. ENVIRONMENTAL MANAGEMENT PROGRAMME

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Des Gillen March 2010 Business Unit Leader

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Legal and other requirements

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Environmental Management Program

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5 SIGNIFICANT ENVIRONMENTAL ASPECTS