WASTE WATER

TREATMENT PLANT

BPCL KR , Ambalamugal

BY
TEAM INNOVATORS

INTRODUCTION
Cochin Refineries Limited was incorporated in the
joint sector as a Public Limited Company in
September 1963.
The Refinery was commissioned in 1966 with a
crude processing capacity of 2.5 Million Metric Tons
per Annum (MMTPA).
The name of the Company:

Kochi Refineries Limited (KRL) in May 2000.

Pursuant to Order dated 18th August 2006 issued by
Ministry of Company Affairs the refinery has been
amalgamated with Bharat Petroleum Corporation to
form BPCL Kochi Refinery.

 Presently its having a crude oil refining capacity of

9.5 Million Metric Tonnes per Annum (MMTPA).
The product portfolio of the 190,000 barrels per day
refinery today includes petrochemical feedstocks and
specialty products in addition to its range of quality
fuels.

 Environmental care and protection.

Anti-pollution measures
BPCL-KR is an ISO 14001 company
KRs Environment Management Systems conform to
international standards.
Kochi Refinery is the first organization in Kerala to receive the
ISO 14001 certification.

The design of the effluent water treatment system

The water discharged from the treatment unit is well within the
quality levels prescribed by the State Pollution Control Board and
the national standards.

Kochi Refinery is the first industrial unit in Kerala

permitted by the State Pollution Control Board, to
discharge treated water into inland rivers.

PETROLEUM PRODUCTS
Liquefied Petroleum Gas (LPG) and Superior
Kerosene Oil (SKO) for households and industrial
uses
Motor Spirit (MS/ Petrol) and Hi-speed Diesel
(HSD) for automobiles
Naphtha, the major raw material for fertilizer
and petrochemical industries
Furnace Oil (FO), Light Diesel Oil (LDO) and
Low Sulphur Heavy Stock (LSHS) as fuel for
industries
Aviation Turbine Fuel (ATF) for aircrafts

SPECIALTY PRODUCTS
Benzene for manufacture of caprolactum,
phenol, insecticides and other chemicals
Special Boiling Point Spirit (SBPS) used as
solvent in tyre industry
Toluene for manufacture of solvents and
insecticides, pharmaceuticals and paint
Mineral Turpentine Oil (MTO) for use in textile
and paint industry

Sulphur for use in fertilizer, sugar, chemicals

and tyre industry
Poly Isobutene (PIB) for manufacture of
lubricants and cable jelly

EXCLUSIVE PRODUCTS
Natural Rubber Modified Bitumen or
Rubberised Bitumen: Natural Rubber Modified
Bitumen (NRMB) is one of Kochi Refinerys
premium products that revolutionized road
development. NRMB has been on a fast track
since its introduction in 1999.
Bitumen, which is derived from petroleum, is a
critical component in road building. Polymer
added to Bitumen enhances both quality and
longevity of roads. Kochi Refinery in association
with leading research institutes made an in-depth
study on feasibility of using natural rubber
available in abundance in Kerala, to develop the
premium product, NRMB.

BITUMEN EMULSION
This eco-friendly product was launched by the refinery in June
2005. Bitumen in different grades is used for road maintenance and
construction. Bitumen requires heating for the temporary
reduction of viscosity.
Bitumen Emulsion, which is a ready to use product, there is no need
for the preliminary heating. Reduced road maintenance cost,
energy savers, economical, longer service life for roads and
reduced atmospheric pollution during road laying/
maintenance are some of the advantages of Bitumen Emulsion.
The following grades of Bitumen Emulsion are produced in Kochi
Refinery meeting IS 8887:2004 specifications:

Bitumen
Bitumen
Bitumen
Bitumen
Bitumen

Emulsion
Emulsion
Emulsion
Emulsion
Emulsion

Rapid Setting-1 (BERS-1)

Rapid Setting-2 (BERS-2)
MediumSetting-1 (BEMS-1)
Slow Setting-1 (BESS-1)
Slow Setting-2 (BESS-2)

BPCL-KR
solution to dispose of
waste plastics

Solution for the disposal of waste plastics without

causing any disturbance to the eco-system.
up to 3 % of waste plastics could be added to the
bitumen and beyond this level, the waste plastics
tend to separate
on re-heating the waste plastic bitumen blends
prior to laying solu:- onsite mixing of waste plastics along with
the aggregates prior to laying of bitumen
It is possible to incorporate clean shredded waste
plastic in the bitumen while road paving. The
Karnataka PWD has laid about 40 km of waste plastic
modified bitumen in and around Bangalore

HAZARDOUS EFFECT OF OIL

SPILS ON ENVIRONMENT

Oil Extraction
0.75-1.8 billion gallons of crude oil wasted
annually
Occupational hazards
Chronic diseases cadmium , arsenic , cyanide
Offshore rigs contaminate sediments , fish
and fish consumers
Spills, explosions and fires have mu;ti[;e
effects on environment
Marine life
Drilling harms sensitive eco systems

Oil transport
Spills and leaks from transport of
petroleum
Many leaks occur in developing
nations
Marine mammals are affected by the
oiling of their fur and skin

Oil Refining
chemical, thermal, and noise
pollution.
affects the health and safety of
refinery workers
health hazards for human
communities
Regulations on labor, safety,
emission standards and
environmental protection are often
inadequate

Gasoline
Its additives cause acute and chronic
toxicity
Victims are: employees, people living
near refinerys, gas station workers
Lead poisoning in developing nations

Combustion: Air
Pollution
Gas flaring at the point of extraction
The additives and products of oil
combustion, VOCs, NOxs, SOxs, CO,
CO2, PM-10s, PM-2.5s and Pb
Chemical and particulate air pollution
are related to heart and lung disease
NOxs and VOCs combine to form ground
level ozone
formation of photochemical smog

Combustion: Acid Rain

Acids formed from oxides of nitrogen (NOxs) and
sulfur (SOxs) acidify all forms of precipitation
The anticipated recovery of acidified soils
Calcium and magnesium deficiencies in soils
harm plants and animals.
Acidification leaches lead, copper and aluminum
into drinking water.
NOxs from oil combustion) cause eutrophication
of lakes, estuaries and marine coasts lrsfd to
biological red zones.

Combustion: Climate
Change
altered the levels of atmospheric
greenhouse gases
Land surfaces and the deep ocean are
warming
Droughts are becoming more severe
and persistent
Melting of permafrost threatens the
integrity of northern latitude pipelines

BPCL - Initiative

Carbon disclosure project

Corporate sustainability report
Adopted norms of GRI
Systems to arrest/ monitor
emission
Bio-remediation of sludge
CDM opportunities

Continuation

Benzene vapour recovery system

Rain water harvesting
Waste water recycling and reuse
Biogas plant from canteen waste
Solar heating, wind mill, solar cell
power for lighting
bio- disel and hydrogen fuel cell plant

Energy Consumption
The two major indices of energy
consumption for a petroleum refinery are: Plant fuel and loss (% of crude oil processed)
specific energy consumption (MBTU/Bbl/NRGF).
The company have been
able to reduce their energy consumption by
adopting energy efficient practices and
implementing innovative process schemes for
improving the energy efficiency of process units.

Energy Consumption

Plant Fuel & Loss

Energy Cost as % of
Manufacturing Cost

Specific Thermal Energy

Consumption

Specific Electrical Energy

Consumption

Key points to be noted

As seen from the graphics above, last three years have
witnessed tremendous improvement in their energy
efficiency.
Apart from creating records in crude processing and
production of various fuels, a number of energy
conservation activities were taken up resulting in annual
fuel savings of more than 27,000 Metric Tonnes.
Reduction in green house gas emissions close to
1,00,000 tonnes were also achieved as a result of
these efforts.
Such impressive improvement in energy efficiency was
made possible by the synergistic
efforts of our Energy Group, Process Engineering, Other
technical groups and operations groups

OBJECTIVE
Is to analyse the waste water treatment
mechanisms in BPCL KR
Analyse optimum utilisation of resources
To analyse whether BPCL KR has
undertaken the responsibility of
managing the waste and does not bring
harm to the environment

 Oily water is harmful to plant and

animal life and therefore it is very
important that all traces of oily
contaminants are removed before
the effluent is routed to the paddy
fields. The system also provides for
proper treatment of sanitary sewage
from the installation and the Housing
Colony.

TREATMENT SECTIONS
The system consists of five sections:1.
2.
3.
4.

The API Seperator

The Equalization Pond
Flocculation/Floatation Unit
Biological Treatment Unit
There are also two sludge ponds, No.1
and No.2

SURGE
POND

API
API
OIL
SUMP

SEPERATOR
SEPERATOR
FLASH
MIXER

SLUDGE
POND

FLOCCULATOR/FLOT
ATION
PH
ADJUSTMENT

TRICKLING
FILTER

POND
POND

FIRE
FIRE

HAY FILTER

FINAL
CLARIFI
ER

AERATOR

RECIRCULATION
SUMP

SOURCES OF OILY WATER

Primary process area

Truck loading gantry
Wagon loading gantry
Pump houses

WASTE WATER
TREATMENT PLANT NO-1

API SEPERATOR
Two compartments-east bay and west bay
Uses specific gravity difference between
oil and water
Oil skimmer handle takes off oil at top
layer to sump
Flight scraper removes oil of the
skimmer(inlet to outlet valve)
Prevent water from entering sump(over
skimmer movement)

 Oil pumped from sump to slop(crude

tank)
Strainers prevent solid substance
entry into API and out from API
Water moves to equalisation pond

EQUALISATION POND
Two inlet valves lead to primary basin
Skims off over carried oil from previous
stage
Two compartments(removes most of
effluents) lead to final compartment
Has inlet fro storm water from dyke and
process area(pen stock valve open)
When storm water has less oil -penstock
closed-so water moves directly to fire water
pond

 Primary basin having oil-carried to API

Skimmed and moved to sump
Sludge dumped in asphalt quarry
Final compartment has 3 valves-top,
middle, bottom
Top valve->flocculation or floatation unit
Control level using valve in this outlet
If heavy rain ->open bottom valve to
maintain level
water directly to fire pond from bottom
valve

FLOCCULATION/FLOTATION UNIT
3 Sections- fast mix, flocculation and
flotation chamber
Sources of entry- equalization pond,
(boiler blow down, cooling water
blow down-add caustic lime for later
stages)
Fast mix chamber-mix using electric
motor driven mixer->add lime to
increase Ph->help flocs formation

 Flocculation chamber->has slow mixer

with wooden paddles->help flocs to
grow in size(increase surface area)
->collect oil traces ->Skim flocs and oil
floating matter using side pump
Flotation chamber->through perforation
between both chamber walls->skim top
layer to sump using flight scrapers
Sump->sludge pond->using bucket
pump
Oil free water moves to biological
treatment unit

BIOLOGICAL TREATMENT UNIT

Two compartments- aeration basin,
clarifier
Aeration basin-large concrete tanks
wit 3 Yeo cone aerators
Sources-Flotation unit, sanitary
sewage from buildings and cafeteria
and housing colony
Mixture is drawn through draft tube
of cones and thrown out by spinning
action of blades

 Sludge mixture->consist of living and

dead microorganism->promote
bacteria growth->helps to purify
sewage
So water when contact with sludge
assimilate absorb and multiply
organic matter
Oxygen is collected for the aerobic
bacteria(using Yeo cone aerators)
Indicated by brown flocculation
sludge on mixer in the aeration pond
Water overflows to the clarifier

CLARIFIER
Sludge settles with organic matter leaving
behind pure water
Method->mixture enters through circumference
of tank->inlet hole in circular baffle->around
and in to the overflow weir at the centre of tank
Overflow weir velocity ->in order to settle solid
and give way to pure water->fire water pond
Settled sludge->bottom sump->using motor
driven scraper->send to aeration basin

 Sludge at periphery to sump->using

scraper
Recycling and removal of large
amount of accumulated sludge to
sludge pond->done by pump at
clarifier side

WASTE WATER
TREATMENT PLANT NO-2

FEATURES
Better designed due to nature of
effluent
Done for secondary processing
facilities
Same principle as plant no:1
IMPURITIES
Oil
Organic compounds (phenol,
mercaptans)
Inorganic compounds (cyanides,

SYSTEM
Sources: merox wash from merox unit
effluent stream of SPF unit
Two large 3000KL Capacity surge ponds
->collect water for treatment
Surge pond 1: collect contaminated rain
water and floor washings->from 360 RCC
pipe
RCC tank 2:collect spent caustic drained
from LPG and naphtha caustic wash in
primary unit

 RCC tank 2 content is added to

effluent at a rate of 1KL/day
After flow equalization the matter is
taken to API seperator
De oiled storm water->hay filter
chamber if no oil content .Else to
API seperator
Gooseneck outlets->prevent water
spill during heavy rain from surge
pond to fie water pond

API separator
Two compartments divided using cylindrical
concrete blocks: pre-separator channel and
main separator channel
Pipe with cup type valves->draw sludge
from floor to sludge lagoons
Both section has slotted skimmer
Main section has flight scrapper->free oil to
sump
Tank 1 can use either one of compartments

 Oil free water->flash mixer->agitator for

chemical treatment
To precipitate sulphides and cyanides>ferrous sulphate and chlorine solution is
added
Ferrous sulphate 10%->to make chlorinated
copper as solution
liquid chlorine(.14 to .16)->to destroy
sulphides and cyanides in flash mixer
Correct Ph to 9 by adding basic alkali using
Ph indicator, recorder and controlled
system(if acid-10% sulphuric acid,basecaustic soda)

 Chemical treated mixture

->clariflocculator->Ph adjustment
tank
Under sludge of clariflocculator
->chemical sludge
Rake mechanism thickens sludge>sludge lagoon
Oil of skimmer->scum trough
arrangement->slop oil sump

Ph adjustment tank
Range to be 6.8-7.5
To nurture and sustain microorganism used to degrade organics
Adjust Ph using acid/alkali using
automatic ph controller and
recorder(caustic soda used)
Ph adjustment tank->biological
treatment unit

BIOLOGICAL TREATMENT UNIT

2 Stages
Trickling filter: mix stream of
water with recycling sump that
contains bacteria
Di ammonium sulphate and
urea(80% siluted to 10%) is
added
Mixture->crushed
granite(increased surface area to
stabilize waste)
Semi stabilized waste->for
recirculation cum effluent
transfer path-> as it has bacteria

 Sanitary waste and treated effluent

also enter sump for re-circulation
Aeration tank(with 2 surface
agitators)
->provide max O2
dissolution and keeps biomass
developed in unit suspension
Aeration tank and trickling filter
avoided when water does not require
treatment

 Stabilised waste of aeration pond>final clarifier by gravity

Flocs settle-> collect using rake arm>remove through gate valve
Overflow of final clarifier ->hay filter

HAY FILTER
Consist of hay basket filled with hay
effluent from final clarifier and rain
water surge pond
Remove last free oil
water->fire pond

SLUDGE
Final clarifier sludge->
biosludge sump->aeration
pond/ sludge drying beds(based
on concentration)(use pumps)
SLUDGE DRYING BEDS: shallow
gravel beds encase the pipes
underneath
Biosludge water-> percolates
sand-> open drains-> recycled
to bio treatment plant
Slurry remaining on sand is
dried for disposal

NOTE
Got in concentrated forms
Diluted to required strength on a day
to day basis based on requirement

SPECIAL
THANKS TO

BALAKRISHNAN
mployee of BPCL KR,
OM Dept.)

P VELAYUDHAN
etired BPCL KR Employee, S&OM Dept.)

THANK YOU