Optimization of Water Optimization of Water

Usage At Petroleum
Refineries Refineries
Water/Energy Sustainability Forum
Ground Water Protection Council
Salt Lake City, Utah
S t b 15 2009 September 15, 2009
Agenda Agenda
Overviewwater usage in petroleum Overview water usage in petroleum
refineries.
Discuss drivers for water conservation Discuss drivers for water conservation.
Review opportunities to reduce water
ti consumption:
Matching supply quality to the demand need.
Utilization of municipal wastewater.
Zero discharge concepts.
Water Use in Petroleum
Refineries
Adding heat to the processes (steam) Adding heat to the processes (steam).
Removing heat from the process (cooling
water) water).
Removing salt and impurities from crude.
Protecting equipment from corrosion.
Generation of hydrogen (used to remove y g (
sulfur from motor fuels).
Equipment cleaning and maintenance Equipment cleaning and maintenance.
Water Usage in the Petroleum
Refining Industry Refining Industry
70
40
50
60
20
30
0
10
1 2 3 4 5 6 7 8 9 10 11 12 13
Best in Class
(10-20 gal/bbl)
Worst in Class
(50-60 gal/bbl)
Water usage varies greatly from facility to facility.
Gallons/bbl Doesnt Tell the Story Gallons/bbl Doesn t Tell the Story
Raw water quality varies:
Target ion concentrations Target ion concentrations.
Hardness.
Refinery configuration Refinery configuration
Water usage very linked to energy efficiency
of the facility. of the facility.
Crude slate
Poor quality price advantagedcrude oil Poor quality price advantaged crude oil
requires more water.
Some refineries have much greater challenges than others in their Some refineries have much greater challenges than others in their
efforts to control water usage.
Primary Uses Primary Uses
Utility Water Potable Water
5% <1%
Steam
42%
Cooling Water
53%
The Water Used Is: The Water Used Is:
Contained in
Sludges
5%
Consumed
5%
Vented as
Steam
5%
Evaporated equates to
energy lost
Evaporated
38%
11%
Discharged
41%
Cost Drivers Cost Drivers
9
7
8
4
5
6
$
/
1
0
0
0

G
a
l
.
2
3
$
$
$
0
1
S.W. LA Industrial
W t
Typical Industrial
W ll W t
Midwest Public
W t
EBMUD Los Angeles Area
( t)
Los Angeles Area
( j t d) Water Well Water Water (current) (projected)
Other Drivers Other Drivers
Some refineries have had to cut rates due Some refineries have had to cut rates due
to limited water supply.
Direct costs of water may be low Direct costs of water may be low.
Cost of lost production is very high.
Water Conservation
O i i Opportunities
Matching Water Quality with Process Matching Water Quality with Process
Requirements.
Treated Municipal Wastewater Reuse Treated Municipal Wastewater Reuse
Projects.
Z Di h C t Zero Discharge Concepts.
Match Water Quality with
P R i Process Requirements
Many facilities utilize water frommore than Many facilities utilize water from more than
one source.
All facilities generate reusable wastewater All facilities generate reusable wastewater
streams.
B tt lit t h ld b Better quality water sources should be
supplied to processes that can benefit
f th from them.
Cooling Tower Example Cooling Tower Example
Cooling Towers Cooling Towers
Evaporation
Raw Water
Process
Heat
Exchangers
T
Blowdown to Remove Calcium,
Magnesium, Silica, etc.
Considerations Considerations
Cooling towers must be blown down to prevent
bl i f i h i h h problem ions from concentrating to the point that they
form scale when heated in process exchangers.
Depending on water quality, cooling tower blowdown
ranges from 10 to 30% of the raw water make up rate.
Water sources with lower problem ion concentrations
result in reduced blowdown rates, resulting in water g
savings.
Water with higher problem ion concentrations can still
be used in processes where the water will not be p
heated .
Alternate Sources of Cooling
Tower Make-up
Reverse osmosis unit reject (fromboiler Reverse osmosis unit reject (from boiler
water treatment).
Cold steamcondensate Cold steam condensate.
Excess boiler feedwater.
Alternate water supplies.
Cooling Tower Example Cooling Tower Example
2500
Savings--638
1500
2000
M
Y-4801
Y-6
Y-5
gpm
500
1000
G
P
M
Y-4
Y-3
Y-2
Y-1
0
Current Make-up Rate Sabine River Water as Make-up
Water Source #2 Water Source #1
By switching to a readily available water source with lower silica
concentrations (5 ppm vs. 50 ppm), water demand was reduced by over
600 600 gpm.
Reuse of Treated Municipal
Effl Effluent
In some areas, municipal effluent is being p g
provided to industry as a substitute for
fresh water.
Californias East Bay Municipal Utility
District has successfully implemented one District has successfully implemented one
project, and is planning others.
Los Angeles and Anglian Water (U K ) are Los Angeles and Anglian Water (U.K.) are
also planning projects.
Typical Reuse Process Typical Reuse Process
Public System Industry
Publically Owned
Hi h Q lit
S
Wastewater
Treatment
System
Reverse Osmosis
System
High Quality
Water Supply
Z
e
o
l
i
t
e
S
o
f
t
e
n
i
n
g
Reject to Disposal or
Discharge
Benefits Benefits
Proven technologies Proven technologies.
Recovers up to 70% of municipal
wastewater wastewater.
Provides a very high quality water
l t l supplysupports low usage.
Concerns Concerns
So far economically feasible only with So far, economically feasible only with
subsidies (California and the U.K.).
Produces waste streamwith high Produces waste stream with high
dissolved solidsdisposal issues.
Zero Discharge Concepts g p
The zero discharge concept has been
around for many years around for many years.
Serious planning to achieve zero
di h i j t t ti t t k discharge is just now starting to take
place.
Existing infrastructure, coupled with new
technologies can bring facilities close to
the zero discharge goal.
Zero Discharge Challenges Zero Discharge Challenges
Salts and impurities must be removed Salts and impurities must be removed
from the system.
Make up is still required to replace large Make up is still required to replace large
evaporation rates.
Zero Discharge Process Zero Discharge Process
Evaporation
Summary Summary
Petroleum refining is a water intensive
industry.
Increasing water costs, availability, and g , y,
conservation initiatives are driving the
need to re-evaluate usage and supply g ppy
alternatives.
Improved water use strategies, old Improved water use strategies, old
technologies, and newer technologies are
providing opportunities. providing opportunities.