Refinery Plant Research Articles

Comparison of the Ability of Woody Plants of Different Species to Accumulate Heavy Metals in Urban Environment

Soil and aerotechnogenic migration of metals into woody plants (birch (Betula pendula) and balsam poplar (Populus balsamifera)) from technogenic zones of Tyumen was studied. Soil and tree leaves were sampled in the conditionally background area, near the airport, railway station and bus station, as well as in the area of enterprises: engine-building, oil refinery, battery and metallurgical plants. The content of acidsoluble form of metals in soils and leaves was determined by atomic emission spectroscopy. It was revealed that the accumulation of metals in soils from the anthropogenic zones of Tyumen compared to the control decreased in the series Pb>Cd>Cr>Cr>Ni>Zn>Cu>Fe>Co>Mn and reached 20 times. The accumulation of metals by birch leaves was found to decrease in the series Pb>Cr>Fe>Co>Cu>Cu>Ni>Zn>Mn>Cd, and by poplar leaves – Cr>Fe>Pb>Zn>Cd>Cu>Co>Mn>Ni. The accumulation and migration of metals in soils and trees from the urban environment were analyzed, which allowed us to identify Cd, Pb and Cr as metals with the “highest ecological risk”.

An investigation into the performance and perikinetics of Brassica nigra meal in the treatment of real vegetable oil refinery condensate effluent.

In this study, the treatment of vegetable oil refinery plant condensate effluent (VORCE) having high total suspended solids (TSS) and chemical oxygen demand (COD) generated from acid oil unit was focused. The utilization of waste Brassica nigra meal (BNM) as protein flocculant in treating VORCE was explored. The B. nigra meal flocculant (BNMF) exhibited a crystalline nature, with the presence of amino and carboxyl functional groups, rendering it highly efficient (89.69% efficiency) in floc formation. Zeta potential and particle size (-5.6mV and 240.68 nm, respectively) indicate BNMF's effectiveness in initiating floc formation. The interactive effects of pH, dosage, settling time on COD, and TSS removal were investigated using the Box-Behnken design. At an optimal pH of 6.9 and BNMF dosage of 0.77 g/L, a maximum removal of 85.38% COD and 72.56% TSS was obtained. The perikinetic theory for the coagulation-flocculation followed a second-order rate reaction with high Kc (0.0001 L/mg min), low settling time (37.04 min), and high collision efficiency (2.703 × 1017), indicating the model's significance in achieving maximum COD and TSS removal. These findings highlight the potential use of BNMF in the treatment of VORCE, leading to circular economy by valorizing waste from mustard oil extraction and zero discharge. PRACTITIONER POINTS: Valorization of waste Brassica nigra meal (BNM) as a potent protein flocculant Optimization for vegetable oil refinery condensate effluent (VORCE) treatment was done. Interactive effects of the process parameters were analyzed using Design expert. Perikinetic theory for VORCE treatment follows second-order reaction rate with high Kc.

Industrial circular water use practices through the application of a conceptual water efficiency framework in the process industry

Increased industrial water demand and resource depletion require the incorporation of sustainable and efficient water and wastewater management solutions in the industrial sector. Conventional and advanced treatment technologies, closed-water loops at different levels from an industrial process to collaborative networks among industries within the same or another sector and digital tools and services facilitate the materialization of circular water use practices. To this end, the scope of this paper is the application of the Conceptual Water Efficiency Framework (CWEF), which has been developed within the AquaSPICE project aspiring to enhance water circularity within industries in a holistic way. Four water-intensive process industries (two chemical industries, one oil refinery plant and one meat production plant) are examined, revealing its adaptability, versatility and flexibility according to the requirements of each use case. It is evident that the synergy of process, circular and digital innovations can promote sustainability, contribute to water conservation in the industry, elaborating a compact approach to be replicated from other industries.

Assessment of water quality in the Great Zab River (Erbil city, Iraq) exposed to wastewater from different industries using the WQI and GIS-based Python script approaches

ABSTRACT This study was conducted to assess the water quality of the Great Zab River (GZR) under potential pollutant pressure from some industries. The Water Quality Index (WQI) was used to evaluate the results of the water quality monitoring study. WQI and Geographical Information System (GIS)-based Python scripts were used to evaluate the results. Results indicate varying water qualities, ranging from moderate to poor, with fluctuations attributed to pollution from industrial plants mixing with river water. The WQI rating of the GZR before industrial discharges was 57.48, and in the lower part, after discharges, the WQI rating was 56.00, indicating marginal water quality. In contrast, the areas near the Cola Factory, where the river confluence occurs, have WQI values of 43.32 and 44.97, representing unacceptable, poor water quality. The study highlights that the refinery, Cola factory, and power plant locations significantly impact the river's water quality. These findings underscore the urgent need to adopt ecological practices, establish environmental regulations, and implement sustainable technologies to preserve the river's natural state. Concise measures aimed at eliminating pollutant sources and enhancing environmental awareness within communities are essential for the conservation of the GZR and the the protection of its surrounding ecosystems. surrounding ecosystems.

Assessment of sewage sludge as a component for the tire char co-gasification process

The work aimed to assess various sewage sludge (from coking, refinery, and fat-processing plants) as components for tire char co-gasification. The sewage sludge were analysed (basic characteristics, thermal stability, ash characteristics). Then, CO2 gasification and co-gasification measurements of individual materials and their blends (ratio: 70:30, 40:60) were made using the TGA, based on which the process and synergy effect were assessed. Moreover, a detailed analysis of char gasification formed during the pyrolysis was performed (reactivity assessment, kinetic parameters determined using the n-order Coats and Redfern model, and correlation between the individual elements in materials and their reactivity). Co-gasification measurements proved that the addition and increasing sewage sludge share in blends enhanced the process (TG curves were shifted towards lower temperatures, reactivity indicators, and final conversion degrees were improved compared to tire char). The greatest impact on the pyrolysis stage had the sludge from the refinery, while on the gasification stage sewage sludge from coking and fat-processing plants (where the synergy was observed). Moreover, the addition of sewage sludge to tire char reduces the activation energy and, in most cases, the pre-exponential factor. Finally, the correlation between reactivity and the Na, Mg, and P amount in the samples has been proved.

Industrial Wastewater Efficiency Assessment of Al-Dora Refinery Plant in Baghdad by Decreasing BOD5 and COD Concentrations

In petroleum refineries, cooling towers, steam engines, and vacuum distillation all require a large volume of water. Before being dumped into the water bodies, it is then transported to an industrial water treatment facility. One of the study's objectives is to verify how well different processing units in the industrial wastewater treatment plant at the cycle refinery remove concentrations of chemical and biological oxygen demand (COD) and BOD. Five samples of industrial wastewater were collected before and after each treatment unit and one sample of wastewater was drained as a final product to the Tigris River. Over the summer, the BOD5 values after each processing unit were 180.8, 175.2, 111, 43, and 37 ppm. Winter readings were 106.8, 99.6, 81.2, 33.8, and 31 ppm, with summer and winter complete elimination rates of 79% and 71%, respectively. The reason for higher BOD5 concentrations in summer than in winter is due to higher temperatures that lead to evaporation and increased concentrations of BOD5 and COD pollutants. While COD concentrations were during the summer after each processing unit 399.6, 383.2, 187.2, 72.8, and 55.4 ppm, in winter they were 324.4, 310.2, 115, 46, and 42.6 ppm with a total removal rate of 86% in summer and 87% in winter. It was found that the refinery's water-drained treatment method, which includes a high proportion of BOD5 and COD concentrations in the main treatment plant, is effective. The water that flowed from the treatment plant into the river was within the national standard of the river water.

Project Financing Strategy in the Oil and Gas Downstream Industry (Case Study: The Integrated Oil Refinery and Petrochemical Plant Project at PT ABC)

Project Financing Strategy in the Oil and Gas Downstream Industry (Case Study: The Integrated Oil Refinery and Petrochemical Plant Project at PT ABC)

Current frameworks for environmental and health assessment of hydrocarbon streams and products are flexible and ready for alternative non crude oil-based feeds.

Hazard and risk assessment of complex petroleum-derived substances has been in a state of continuous improvement since the 1970s, with the development of approaches that continue to be applied and refined. Alternative feeds are defined here as those coming into a refinery or chemical plant that are not hydrocarbons from oil and gas extraction such as biologically derived oils, pyrolysis oil from biomass or other, and recycled materials. These feeds are increasingly being used for production of liquid hydrocarbon streams, and hence, there is a need to assess these alternatives, subsequent manufacturing and refining processes and end products for potential risk to humans and the environment. Here we propose a tiered, problem formulation-driven framework for assessing the safety of hydrocarbon streams and products derived from alternative feedstocks in use. The scope of this work is only focused on petrochemical safety assessment, though the principles may be applicable to other chemistries. The framework integrates combinations of analytical chemistry, in silico and in vitro tools, and targeted testing together with conservative assumptions/approaches to leverage existing health, environmental, and exposure data, where applicable. The framework enables the identification of scenarios where de novo hazard and/or exposure assessments may be needed and incorporates tiered approaches to do so. It can be applied to enable decisions efficiently and transparently and can encompass a wide range of compositional space in both feedstocks and finished products, with the objective of ensuring safety in manufacturing and use.

Structural and Functional Characteristics of the Oral Cavity Organs and Tissues in Workers of the Petrochemical Industry of the Republic of Uzbekistan.

Purpose: The aim of the study was to determine the dental status, level, and structure of dental diseases, as well as to identify some clinical and functional deviations in the organs and tissues of the oral cavity among workers in certain industrial enterprises. Methodology: A comprehensive dental examination was conducted on 1600 individuals, including 420 from the Fergana Oil Refinery Plant (FNPP - main group (MG)-1), 425 from the Almalyk Mining and Metallurgical Plant (AGMK - MG-2), and 605 from the Navoi Chemical Plant (NavCP - MG-3), as well as 150 patients as a control group (CG) who visited a dental clinic. Tooth sensitivity (TS), pain and discriminatory sensitivity (PS and DS) of the oral mucosa, taste perception threshold, and functional mobility of the taste receptors on the tongue, enamel resistance to caries, microhardness (MH) of enamel and dentin, and the condition of periodontal tissues and pH of mixed saliva were determined. The data obtained were processed using statistical methods. Findings: It was determined that the levels and relative weights of the main dental diseases among workers in the studied industries remain quite high; carious and non-carious lesions of the tooth hard tissues, deformation and defects of teeth and dental rows (18.5%), periodontal tissue diseases (74.7%), diseases of the oral mucosa - 38.7%; the need for prosthetics (58.4%) and other pathologies. Additionally, almost all clinical and functional indicators and local non-specific reactivity of the tissues of the oral cavity in workers were disrupted. Unique Contribution to Theory, Policy and Practice: The presence of the main dental diseases among those surveyed from the studied groups is quite high, with noted reductions in the excitability threshold of teeth, around tooth tissues and the oral mucosa, disruption of PS and DS of the oral mucosa, as well as deterioration of the condition of tooth hard tissues. Based on the obtained results, the authors suggest continuing in-depth scientific research with the aim of developing effective methods for the diagnosis and prevention of dental diseases among workers in these industries.

Removal of COD from petroleum refinery wastewater by adsorption using activated carbon derived from avocado plant

In the present work, removing of COD from wastewater generated via Al-Diwanya petroleum refinery plant located in Iraq by adsorption with activated carbon (AC) derived from avocado seeds was successfully performed via a two-step approach. In the first step, AC was prepared from avocado seeds via impregnating with H3PO4 at 400 °C where effects of H3PO4 concentration and calcination time on the specific surface area of AC were studied. Additionally, properties of the prepared AC were examined by XRD, SEM, and FTIR to knowledge the features of the internal structure of AC. Results showed that the prepared AC has mesopores structure with pore diameters in the range between 30.07 and 50.8 µm. Increasing the weight percent of H3PO4 led to an increase in the specific surface area of AC to reach a maximum value beyond which a decrease in the specific surface area was happened with further increasing in H3PO4 percent. Increasing the time resulted in an increase in the AC specific surface area to reach a maximum value beyond which a decrease in specific surface area was happened. The best value of AC specific surface area was 436.6 m2/g which obtained at 70 %H3PO4 and 4 h. At the second step, the performance of the prepared AC in removing of COD by adsorption process was evaluated via studying the effects of three operating parameters, namely adsorbent dosage (1–5 g/L), pH (3–9), and shaking speed (100–400 rpm) on the removal of COD(RE%) using a response surface methodology (RSM). Increasing AC dosage led to an increase in RE% while increasing each of pH and shaking speed resulted in lowering RE%. The optimum conditions for higher RE% were AC dosage of 5 g/L, pH of 3, and shaking speed of 100 rpm in which a removal efficiency of 94.54 % was obtained. The degradation of COD with time was found to obey a second order kinetic confirming the chemisorption is the rate limiting step in the adsorption process.

Designing a Reliability Maintenance Plan for Refinery Plants: A Case Study of a Nigerian-Based Refinery and its Power Systems

This study developed a comprehensive and effective reliability maintenance plan for refinery plants. Using a Refinery based in Nigeria as a case study, the research identified key factors affecting the reliability of refinery operations and proposed strategic maintenance measures to enhance operational efficiency and safety. The study utilized reliability centered maintenance (RCM) and failure modes and effect analysis (FMEA). From the evaluation, breaking down the components of the power system in the plant and addressing them individually exposes more vividly the errors in that system. Each failure mode was analyzed in terms of possible consequences on operation, function, or system status. The subject of risk assessment was presented and utilized to develop an approach for implementing the RCM in refinery power systems Finally, a proposed action plan was introduced to reduce the RPN number, thereby increasing the overall reliability and efficiency of the system component. It was observed that by reducing the RPN of each component, the overall efficiency of that component increases saving the company huge maintenance cost.

Two-stage chance-constrained programming based on Gaussian mixture model and piecewise linear decision rule for refinery optimization

The two-stage chance-constrained program (CCP) is studied for a refinery optimization problem. In stage-I, the refinery decision-makers determine the type and quantity of crude oil procurement under operational uncertainties to maximize the expected profit under all possibilities. In stage-II, process unit flowrates are adjusted based on the realized uncertainties and available crude oil, while introducing probabilistic constraints to manage the off-spec risk. To solve such a two-stage optimization problem, we propose a novel approach using Gaussian mixture model (GMM) to characterize uncertainties, and piecewise linear decision rule for stage-II operations. Comparing to the conventional scenario-based mixed-integer linear program (MILP), our new approach offers three advantages. First, it leverages a well-developed global optimization scheme for joint CCP to avoid scenario generation and potential bias. Second, the data-driven GMM enables CCP to handle uncertainties with general distributions. Third, the stage-II variables are parameterized via Gaussian component induced piecewise linear decision rule to strike an excellent trade-off between optimality and computational time. A simplified refinery plant, consisting of distillation, cracker, reformer, isomerization, and desulfurization units, is used as a test bed to demonstrate the superiority of the proposed optimization method in solution time, probabilistic feasibility, and optimality over the large-scale scenario-based MILP.

Removal of chemicals from effluent using photobioreactor technology to improve environmental and health impacts

Abstract The treatment of industrial waste water using cyanobacteria in photobioreactor for the removal of sulphide, COD and phenol. The microorganisms were collected from the effluent treatment plant of a petroleum refinery and a biofilm was developed in nutrient medium. The reactor was fed with cyanobacteria. After biofilm formation and acclimatization, the same procedure was followed for 16 days in a rectangular tray type photo bioreactor for the treatment of industrial waste water. From continuous mode of operation, it was found that the phototrophic microorganisms can degrade the pollutants present in industrial waste water. The removal efficiency of hardness 75 %, sulphide 95.8 %, COD 98.7 %, phenol 99.9 % and nitrate 83.7 % was studied. The present works shows that it is feasible to use cyanobacteria in a photo bioreactor for the treatment of industrial waste water.

Association Between Multiple Heavy Metal Exposures and Cholesterol Levels in Residents Living Near a Smelter Plant in Korea.

Considering the interactions between heavy metals, a comprehensive evaluation of the effects of exposure to various types of co-interacting heavy metals on health is required. This study assessed the association between dyslipidemia markers and blood mercury, lead, cadmium, iron, zinc, and nickel levels in residents of an abandoned refinery plant. A total of 972 individuals (exposed group: 567, control group: 405) living near the Janghang refinery plant in the Republic of Korea were included. Blood mercury, lead, cadmium, iron, zinc, nickel, cholesterol, and triglyceride levels were measured. The combined effect of the six heavy metals on dyslipidemia markers was evaluated using a Bayesian kernel machine regression (BKMR) model and compared with the results of a linear regression analysis. The BKMR model results were compared using a stratified analysis of the exposed and control groups. In the BKMR model, the combined effect of the six heavy metals was significantly associated with total cholesterol (TC) levels both below the 45th percentile and above the 55th percentile in the total population. The combined effect range between the 25th and 75th percentiles of the six metals on TC levels was larger in the exposed group than that in the total population. In the control group, the combined effects of the changes in concentration of the six heavy metals on the TC concentration were not statistically significant. These results suggest that the cholesterol levels of residents around the Janghang refinery plant may be elevated owing to exposure to multiple heavy metals.

Production of Fuel Oil from Blends of Refinery Products for Powering Heat Exchanger

Fuel oil, also known as furnace oil is a fraction of crude oil obtained when distillation processing is carried out in the refinery. Due to the high viscous of the heavy fuel oil, that makes it difficult to be pump throughout the pipework of the power plant, it is necessary to produce a fuel oil that will meet up the required standard. The aim of this study was to produce fuel oil from the blend of refinery intermediate product which meet certain European fuel specifications outlined in the EN 590:2009 standard alongside NMDPRA Standards. The blending stocks obtained from the Warri Refinery and Petrochemical Company (WRPC) were first filtered to remove some particulate impurities before they were analyzed to determine their properties after which, they were introduced into a mixed-tank that has an agitator connected and the blending was done using the blending ratio obtained from literature. The fuel oil produced was eventually analyzed for properties such as: Specific Gravity, API Gravity, Density, Viscosity, Kinematic Viscosity, Moisture Content, Flash Point, Cloud Point, Pour Point and Sulphur content. The sample with a composition of 33.3% of Decant oil (DCO), 33.3% Heavy gas oil (HGO), 33.3% light cycle oil (LCO) produced fuel oil of specific gravity 0.916, API Gravity 22.95, Density 0.896, Viscosity 40, Kinematic viscosity 4.7, pour point -6.5 and flash point 109, The analysis of the fuel oil meet the standard for blended fuel oil, according to the ISO 8217:2017 Standard. The results confirmed that blending of decant oil with conventional petroleum diesel (heavy and light gas oil) has a highly significant effect on the properties of the resulting fuel blend. The results show that by increasing the heavy gas oil content of the blend, the flash point of the blend increases; while increasing the decant oil content of the blend results in a decrease in Cloud point. The results of the analysis of the produced fuel oil confirms that its properties fall within the acceptable range for Fuel Oil and can be used as fuel for fired heaters and furnaces of the refinery and other process plants.

Land Conversion for Oil Refinery Plant Area in Jenu District, Tuban Regency, East Java, Indonesia

This article examines the construction of the Tuban-based oil refinery plant that processes crude oil into petroleum products as raw materials for fuel oil and the petrochemical industry. In 2015, the plan was to build an oil refinery in Tuban Regency, specifically in Jenu District. The land in Jenu District was chosen because it requires approximately 840 hectares of land. The construction of an oil refinery in Tuban is one of the list of national strategic projects. The regulations are contained in Presidential Regulation Number 3 of 2016 concerning the Acceleration of Implementation of National Strategic Projects. In 2016 the Minister of Energy and Mineral Resources gave the mandate to manage this project to Pertamina. The need for a large area of land prompted Pertamina to submit an application to the Ministry of Environment and Forestry for obtaining 328 hectares of state lands. The area is strategic because it is close to the existing fuel installation supporting facilities. The conversion of land for the construction and development of an oil refinery in Jenu District, Tuban Regency, caused environmental damage and gave rise to social problems.

Two-stage conversion of CO2 to methanol and dimethyl ether using CuO–ZnO–Al2O3/protonated Y-type zeolite catalysts

The CuO-ZnO-Al2O3/protonated Y-type zeolite (CZA/HYZ) catalysts were prepared via co-precipitation method and employed in a two-stage CO2 conversion process using a dual fixed–bed column at different temperatures and 50 bar. Catalytic components of CZA/HYZ were copper species that have been identified with XPS. Remarkably, the fine structures of CZA/HYZ catalysts metal atoms were confirmed with XANES and EXAFS spectra. Molecular configurations of catalytic species in CZA/HYZ catalyst simulated from the XANES/EXAFS spectra-analyzed fine structural parameters were schematically displayed. The optimal catalytic performances of CZA/HYZ (CH3OH conversion=78.0%, CH3OCH3/HCOOH selectivity=91.7%/8.3%, CH3OCH3/HCOOH yield=71.5%/6.5%) were achieved at 250 ºC. The Arrhenius equation and a pseudo-first-order/second-order model were used to evaluate the activation energies and rate constants of CH3OH and CH3OCH3 formations at various catalytic temperatures. The low activation energies (2.720 and 1.160 kJ mol−1) and Gibbs energies (3.26 and −40.00 kJ mol−1) of CH3OH and CH3OCH3 formations at 250 ºC, demonstrated that their spontaneities were remarkably improved via CZA/HYZ, respectively. The total income from a 10–ton per day (10–TPD) for a petrochemical refinery plant waste gas utility process was USD $43,557d−1, as well a payback of 3.23 years, based on cost evaluation. The proposed process provides a continuous two-step process for manufacturing high–value-added chemicals using industrial CO2 emitted and syngas.

Optimum Design of Naphtha Recycle Isomerization Unit with Modification by Adding De-Isopentanizer

Environmental standards have recently imposed very rigorous limitations on the amounts of benzene, aromatics, and olefins, which can be found in finished gasoline. Reduction of these components could negatively affect the octane number of gasoline, so the isomerization process is gaining importance in the present refining context as an excellent safe alternative to increase the octane number of gasoline. The main aim of the naphtha isomerization unit is to modify the molecular structure of light naphtha to transform it into a more valuable gasoline blend stock, and simultaneously the benzene content is reduced by saturation of the benzene fraction. In this work, Aspen HYSYS version 12.1 is used to simulate the hydrogen once-through isomerization unit of an Egyptian refinery plant, located in Alexandria, in order to determine the properties, composition, and octane number of the isomerate product. Many potential changes are investigated in order to find the best design that efficiently raises octane number with the least amount of expense. Firstly, the plant is modified by adding one fractionator either before or after the reactor, then by adding two fractionators before and after the reactor; then the configuration which gives the highest product octane number with the highest Return on Investment (ROI) is chosen as the recommended optimum configuration. The results show that using two fractionators before and after the reactor is the best configuration. Optimization of this best configuration resulted in an increase in octane number by 7% and a decrease in the total cost by 13%.

Energy, exergy, economic, and environmental analysis of natural gas sweetening process using lean vapor compression: a comparison study

Abstract Gas sweetening with an aqueous solution of diethanolamine is a crucial and common process in natural gas processing. However, the process, particularly in the solvent regeneration section, consumes a substantial amount of energy, significantly escalating the cost of gas. This paper presents a simulation and optimization of an existing natural gas refinery plant using a lean vapor compression method. The simulation results indicate that the current process requires 2.73 GJ/tacid gas for solvent regeneration, with exergy destruction of 14,120.59 kW in the solvent regeneration section. The total annualized cost for the current process is 11.68 M$. A modified scheme is proposed to address the issue of high energy consumption and the associated costs. The proposed scheme demonstrates significant improvements in the aforementioned parameters. Specifically, energy for solvent regeneration, exergy destruction in the solvent regeneration section, total annualized cost, and cost of gas are reduced by 16.12 %, 25.04 %, 20.97 %, and 20 % compared to the current process, respectively. These improvements enhance the thermoeconomic indexes, making the proposed scheme a viable and cost-effective alternative to the current process.

Predicting the performance of an industrial furnace using Gaussian process and linear regression: A comparison

Maintenance is a crucial aspect of the process industry affecting economic and efficiency losses. Among different approaches, predictive maintenance allows for anticipating failure, thus reducing downtime. This work explores a data-driven approach to predictive maintenance by comparing the performance of two different statistical models in extrapolating the future performance of an industrial furnace. The models of interest are a polynomial regression model and a Gaussian process regression model, compared using rolling cross-validation. Moreover, three different machine learning techniques were compared during the training phase: cross-validation, ensemble method and train/test split. The models were trained on real-time series data collected from the distributed control system of a refinery plant. The best performance was obtained with the Gaussian process regression model trained with a train/test split approach. The resulting model can satisfactorily extrapolate the performance of a process furnace over a relatively short-term period.