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Sulfolane-Techassist-Appx-F.Pdf APPENDIX F Supporting Documentation for Case Studies and Remediation - Page Intentionally Left Blank - AIM15.qxd 11/12/2003 4:24 PM Page 12 Managing Hydroblast Water During Turnarounds By Hiram Perez A case study turnaround at a refinery or Case Study Before the Turnaround: chemical plant is typically a This case study examines ways Planning is Key major event involving that one refinery essentially elimi- As with most turnaround activi- numerous plant and contractor nated their disposal costs of ties, success is directly linked to personnel, all performing a vari- hydroblast water during a recent the amount of planning that is ety of activities under strict budg- major turnaround by proactively performed. In many cases, envi- ets and timelines. These activities managing and track- usually include the disassembly, ing waste generation, cleaning, refurbishing, and storage, and disposi- tion. reassembly of all feed lines, stor- age tanks, process towers, and The Setting: associated equipment. One tech- North to Alaska nique that is commonly used to Williams Alaska clean surfaces of residual prod- Petroleum, Inc. owns ucts such as scale, sludge, and and operates the polymer buildup is hydroblast- largest petroleum ing. refinery in Alaska with Hydroblasting crude oil processing Hydroblasting uses specialized capability of 220,000 equipment to clean surfaces by barrels per day. "blasting" them with water at an Located outside of elevated pressure of around Fairbanks in North 10,000 PSI. Compared to other Pole, Alaska, the refin- cleaning techniques, hydroblast- ery produces about ing is relatively quick and cost- 75,000 barrels per day effective. However, a typical of various petroleum products ronmental and waste issues are hydroblaster uses anywhere from including gasoline, naphtha, jet seen as something to be dealt with after the turnaround, not some- 30 to 60 gallons of water per each fuel, heating fuel, diesel fuel, and thing to be planned for before the minute of use. Assuming it takes asphalt. During May 11-27th of turnaround. Fortunately, this was one 10-hour shift to clean a typical this year, the refinery shut down not the case here. Technicians distillation tower, that's up to production to begin a $6 million from CAM Environmental 36,000 gallons of contaminated scheduled turnaround of one of Services arrived the week before wastewater that now has to be its main crude units. Turnaround dealt with. With water disposal work actually began in order to specialist AltairStrickland West costs ranging anywhere from familiarize themselves with the Inc. was brought in to provide $0.50 per gallon for non-haz- plant and to evaluate and finalize overall project management as ardous contaminants to over $2.50 the waste management plans that well as to coordinate the many per gallon for hazardous contami- would guide the tracking, testing, nants, you'd be looking at dispos- contractors that would be storage, and final disposition of al costs of anywhere from $18,000 required. Along with other spe- all waste streams generated dur- to over $90,000 for this one piece cialized contractors, CAM ing the turnaround. Particular of equipment alone. Provision for Environmental Services was emphasis was placed on strategies this is frequently overlooked in brought in to play a small but to minimize the total volume of the turnaround budget. important role in this major event. hydroblast water as well as ways 12 American Industrial Magazine AIM15.qxd 11/12/2003 4:26 PM Page 13 of keeping contaminant levels (primarily Have a plan before you need one. Sulfolane) low enough so it could be Know how you will handle waste treated by the plant's own bioponds 1streams before they are generated. instead of having to be shipped for out- Otherwise, you are always in reaction side disposal. mode trying to catch up. Involve an During the Turnaround: environmental firm during the planning Directing the Flow stage of any turnaround. CAM Technicians worked 12-hour shifts Segregation of waste keeps small during the turnaround functioning as problems from grow ing into big ones. waste stream staging officers directing It only takes a small amount of haz- the flow of hydroblast water and other 2 ardous waste accidentally mixed in with waste products to appropriate tanks or a large tank of water to make it all haz- containers. Each tank or container was ardous. Track the source of all waste manifested for tracking purposes, ana- streams and keep them separated by lyzed to determine contaminant levels, hazard type. and then segregated to avoid cross-con- tamination. As the analytical results Analyze your options. Perform an were received, it was then possible to analysis of each storage tank so you determine which tanks or containers know the contaminant level of each. could be combined before being dis- 3 You can then decide whether to recycle, charged to the plant's bioponds for rou- combine, dilute, or dispose. tine treatment as the turnaround pro- gressed. Process as you go. Have a system After the Turnaround : in place for processing waste as it is Conclusions and Lessons 4being generated instead of waiting until you have a huge quantity to try to Learned get rid of all at once. Waste management During a similar turnaround in 2002, the is part of the turnaround process, not waste management plan in place under- something separate from it. estimated the impact of Sulfolane-con- taminated wastewater on the overall Augment key support functions. management of turnaround wastewater, Turnaround operations can put a and the burden of heavy burden on environmental managing turn- 5 staffing levels appropriate for routine around-related envi- operations. Augmenting the regular ronmental issues environmental staff with additional severely taxed the qualified environmental professionals environmental staff. provides additional support to manage As a result, a large large, non-routine projects. quantity of hydrob- last water was gen- erated that had to be stored in rail cars until it could be processed. In bout the Author contrast, during Hiram Perez is President of CAM the 2003 turn- Environmental Services, a Houston around, all of the based company with offices in hydroblast water was han- Beaumont, Dallas, and Baton Rouge dled in-house providing a wide range of Industrial with no need Hygiene, Program Safety, and for outside disposal. Environmental services. Also, since the water was treated For more information, please visit as the turnaround progressed, there www.cam-enviro.com. was no need for any type of long- term storage. Lessons learned from this experience are included in the following list. American Industrial Magazine 13 SULFOLANE IMPACTED SOIL AND GROUNDWATER TREATABILITY STUDY Vladimir Agatonovic, P. Geol., CCEP. – Senior Hydrogeologist, EBA Engineering Consultants Ltd. Elena Vaisman, P. Chem., M.Sc. Senior Research Chemist, Tomographic Imaging and Porous Media Laboratory, Faculty of Engineering/Science, University of Calgary ABSTRACT During the long-term groundwater quality monitoring, elevated concentrations of dissolved organic carbon (DOC) were reported at two of the gas processing plants located in Alberta. The concentrations of petroleum hydrocarbons (PHC) were several orders of magnitude less than the DOC concentrations, or were not detected. Glycols and amines were included in the analytical schedule to observe if the analytical results of any of these could be correlated to the DOC concentrations detected. They returned non-detectable concentrations. A plant site historical product inventory was conducted to determine if the presence of any other products at the site could cause elevated DOC concentrations. The result of the review detected that, in 1992, existing amine process replaced the Sulfinol® process. The Sulfinol® gas sweetening method involves a combination of chemical and physical processes. It also utilizes diisopropanolamine (DIPA) as a chemical solvent. DIPA interacts with sour gas via its central nitrogen atom. In 2000, sulfolane analyses were added to the existing groundwater quality analytical schedule to address the results of the historical plant operations. More than a half of the groundwater monitoring wells reported concentrations of sulfolane above the background concentrations. There were no guidelines for the maximum allowable concentrations (MAC) of sulfolane in soil and groundwater at that time. In 2004, EBA, conducted several laboratory treatments trials for the remediation of the soils and groundwater impacted by sulfolane in preparation for the site remediation. In 2005, Canadian Council of ministers of Environment (CCME), and Alberta Environment (AENV) adopted the Canadian Association of Petroleum Producers (CAPP) guidelines. The soil treatability study investigated potential for bio-cell or bioreactor option. The bio- treatability trial conducted at the Hydroqual Laboratories showed that significant decrease in the sulfolane concentrations in soil occurred after 78 days of treatment. The groundwater treatability trials were conducted at TIPML and the Ecoterra Solutions Inc. facilities. The TIPML conducted three trial utilizing mineralization, UV treatment and combination of both of the methods. The combination of mineralization and UV irradiation achieved 95% sulfolane removal ratio. Ecoterra conducted an aeration trial utilizing micro bubbles technology (GLR) in conjunction with slurry mixing and nutrient amendments and achieved 73% of sulfolane removal ratio. INTRODUCTION In the last 20 years, soil and groundwater
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