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Total Water & Waste Water Management at Reliance Jamnagar Refinery
Ajay Popat, Chief Executive Officer, Ion Exchange Waterleau Ltd., Mumbai. Reliance Industries Limited has enhanced the capacity of the Jamnagar Refinery to 1,20,0000 barrels per stream per day (1200K BPSD) with the Jamnagar Export Refinery Project (JERP) commissioned in December 2008, in Gujarat. Speaking volumes for customer confidence in Ion Exchange reliability and capability to execute the water management for this prestigious project, the contract for water treatment plant (13 x 388 m3/h demineralisation plant and 3 x 388 m3/h condensate polishing unit) was awarded to Ion Exchange India, and that for the effluent treatment plant to Ion Exchange Waterleau.

The waste water treatment is carried out in a dedicated state-of-art completely automated & PLC operated effluent treatment plant (ETP) supplied by Ion Exchange Waterleau. The effluent treatment area is designed to contain and treat all internal process/utility waste water and storm/ firewater, with the objective of zero discharge from the new refinery complex. The treated water is recycled back to the high total dissolved solids treatment train or guard tanks, as required.

Effluents are segregated into four identical wastewater streams designed for a treatment capacity of 500 m3/ h each and maximisation of reuse. The low total dissolved solids (LTDS) stream, a mixture of process/oily waters which include non- phenolic waste waters, is treated to an effluent quality adequate for reuse for cooling water make up, fire water make up and irrigation water for development and maintenance of the local green belt. The high total dissolved solids (HTDS) stream is a mixture of process/oily wastewaters that have been in contact with process streams, such as in the crude unit desalters, and have absorbed or dissolved mineral ions such as sodium chloride. This stream also contains (treated neutralised) process solvents such as spent caustics, and phenolic waste water. This water is treated to an effluent quality adequate for re-use as partial make up in a sea water cooling tower. The oily water sewer (OWS) stream is a mixture of process/oil waters which includes oily condensates from various refinery units, sanitary sewage (after primary treatment), drainage from tanks, contaminated storm water etc. The treated OWS effluent is used for horticulture.

The scope of treatment also includes three by-product streams generated during the treatment of refinery waste water - skimmed or slop oils; oily sludge and biological sludge. Skimmed oil is chemical and heat treated, with recovered oils transferred back to the refinery for reprocessing. Oily sludge is thickened and then transferred back to the delayed coker unit for reprocessing. Biological sludge is thickened, stabilised, dewatered and disposed off to landfill.

The treatment scheme also includes an automatic belt filter press for dewatering biological sludge, two chemical houses; three analyzer houses and twenty samplers skids for automatic sampling and analysis of critical effluent parameters on a continuous basis. Our scope includes supply of specialty INDION polymers and effluent treatment chemicals along with its maintenance by a team of trained and competent process engineers.

The effluent treatment plant is treating 100 percent effluent generated by the refinery since its commissioning in December 2008 and consistently producing treated effluent (pH 6-8.5, Sulphide < 0.5 ppm, COD < 50 ppm, Oil & Grease < 5 ppm, Phenol < 0.35 ppm) meeting guarantee parameters for re-use for various applications mentioned earlier.