Reference Document on Best Available Techniques for Mineral

4,24
MB Oil and Gas Refineries

518
stron

1099
ID JRC-IPTS Instituto de Prospectiva Tecnológica (IPTS)

2003
rok

EXECUTIVE SUMMARY I

PREFACE IX

SCOPE XXV

1 GENERAL INFORMATION 1

1.1 The purpose of refineries .1

1.2 Refinery sector in the EU 1

1.3 European refineries.6

1.3.1 Technical characteristics of European refineries 9

1.3.2 Employment in the European refinery sector .13

1.4 Main environmental issues in the refining sector 14

1.4.1 Emissions to the atmosphere.15

1.4.2 Emissions to water16

1.4.3 Waste generation 17

1.4.4 Soil and groundwater contamination 18

1.4.5 Other environmental issues.19

2 APPLIED PROCESSES AND TECHNIQUES 21

2.1 General overview of the refinery processes.21

2.2 Alkylation .25

2.3 Base oil production27

2.4 Bitumen production .29

2.5 Catalytic cracking 31

2.6 Catalytic reforming33

2.7 Coking processes .35

2.8 Cooling systems38

2.9 Desalting.40

2.10 Energy system.41

2.11 Etherification .48

2.12 Gas separation processes .51

2.13 Hydrogen consuming processes.53

2.14 Hydrogen production .60

2.15 Integrated refinery management 63

2.16 Isomerisation .66

2.17 Natural gas plants 68

2.18 Polymerisation70

2.19 Primary distillation units71

2.20 Product treatments .74

2.21 Storage and handling of refinery materials76

2.22 Visbreaking.78

2.23 Techniques for the abatement of emissions .80

3 CURRENT EMISSION AND CONSUMPTION LEVELS 81

3.1 Current emission and consumption levels in refineries as a whole81

3.1.1 Present consumption levels in refineries.83

3.1.2 Emissions to air.84

3.1.3 Emissions to water92

3.1.4 Waste generation 94

3.2 Alkylation .96

3.3 Base oil production98

3.4 Bitumen production .100

3.5 Catalytic cracking 101

3.6 Catalytic reforming106

3.7 Coking processes .108

3.8 Cooling systems.110

3.9 Desalting.112

3.10 Energy system.114

3.10.1 Energy management .114

3.10.2 Energy capacity and consumptions.115

3.10.3 Emissions . 117

3.11 Etherification 122

3.12 Gas separation processes. 123

3.13 Hydrogenconsuming processes 124

3.14 Hydrogen production. 127

3.15 Integrated refinery management 130

3.16 Isomerisation 134

3.17 Natural gas plants 136

3.18 Polymerisation 138

3.19 Primary distillation units . 139

3.20 Product treatments. 141

3.21 Storage and handling of refinery materials . 143

3.22 Visbreaking . 146

3.23 Emissions from waste gas treatment techniques . 148

3.24 Emissions from waste water treatment techniques 150

3.25 Waste generation. 152

3.26 Monitoring 154

4 TECHNIQUES TO CONSIDER IN THE DETERMINATION OF BAT 159

4.1 General overview of activities considered in this chapter . 160

4.2 Alkylation. 162

4.2.1 Hydrofluoric acid alkylation process 162

4.2.2 Sulphuric acid alkylation process. 163

4.2.3 Upgrade feedstock by selective hydrogenation or isomerisation . 165

4.3 Base oil production . 166

4.3.1 Multipleeffect extraction process 166

4.3.2 Types of solvent used in the aromatic extraction unit 167

4.3.3 Solvent recovery from dewaxing units. 168

4.3.4 Wax reprocessing unit 169

4.3.5 Lube oil cleanup 170

4.3.6 Storage of base oil intermediates and products 170

4.3.7 Storage and benchmarking of solvents. 171

4.3.8 Sulphur treatment from hydrogenation units 171

4.3.9 Stripping of waste water from aromatic extraction 172

4.3.10 Hot oil system. 172

4.4 Bitumen production. 174

4.4.1 Storage of bitumen products. 174

4.4.2 Techniques to control emissions to the air . 174

4.4.3 Techniques to control emissions to the waste water. 177

4.4.4 Techniques for prevention of generation of waste . 177

4.4.5 Hot oil system. 178

4.5 Catalytic cracking 179

4.5.1 Full combustion mode in regenerator. 179

4.5.2 Residue catalytic cracking (RCC) 180

4.5.3 Partial combustion mode in the regenerator . 181

4.5.4 Hydrotreatment of feed to the catcraker . 182

4.5.5 Waste heat boiler and expander applied to flue gas from the FCC regenerator . 184

4.5.6 Catalyst selection 185

4.5.7 Waste water management within FCCU 185

4.5.8 Nitrogen oxides abatement techniques. 186

4.5.9 Particulate abatement techniques . 189

4.5.10 Sulphur oxides abatement techniques 193

4.5.11 Combined abatement techniques 198

4.5.12 Waste management techniques. 198

4.6 Catalytic reforming . 200

4.6.1 Continuous catalytic reformer 200

4.6.2 Semiregenerative reformer . 200

4.6.3 Type of catalyst promoter. 201

4.6.4 Cleaning of the regeneration flue gas. 202

4.6.5 Electrostatic precipitator in the regeneration flue gas 202

4.6.6 Dioxins formation in catalytic reforming units 203

4.7 Coking processes. 204

4.7.1 Delayed coking. 204

4.7.2 Fluid coking205

4.7.3 Calcination process.205

4.7.4 Flexicoking .206

4.7.5 Use of oily sludges and/or waste as coker feedstock 207

4.7.6 Cleaning of the coking gas208

4.7.7 Water use in the cooling/cutting process 209

4.7.8 Handling and storage of the coke210

4.7.9 Techniques to reduce air emissions 211

4.7.10 Techniques to prevent emissions to water 212

4.7.11 Techniques to reduce soil contamination213

4.8 Cooling systems.214

4.8.1 Segregation of cooling and process waters .214

4.8.2 Air cooling.214

4.8.3 Prevention of oil leakages into cooling water .215

4.9 Desalting.216

4.9.1 Good desalting practices.216

4.9.2 Enhance the oil/water separation before discharge to the waste water treatment plant 216

4.9.3 Enhance the solid/wateroil separation .217

4.9.4 Reuse of water for the desalter 218

4.9.5 Stripping of the desalter brine.219

4.10 Energy system.220

4.10.1 Energy management .221

4.10.2 Refinery fuels: types and cleaning225

4.10.3 Energy production techniques.229

4.10.4 Nitrogen oxide control and abatement techniques 236

4.10.5 Particulate abatement techniques249

4.10.6 Sulphur oxides abatement techniques.251

4.11 Etherification .254