Route to Clear Water

15.06.2013

Early in July this year Antipinsky Oil Refinery plans to complete the construction of up-to-date treatment facilities. What is meant here is the application of the most advanced methods to treatment of industrial and rainfall as well as domestic sewage waters at the refinery

Antipinsky Oil Refinery CJSC is one of the major oil refining enterprises in the Urals Federal District which is operating in the area of industrial and environmental security, labor protection. The refinery strives to comply with international quality standards and fulfils the provisions of the laws of the Russian Federation, as well as its own regulatory documents and standards which provide for preventing emergencies, accidents, and incidents at hazardous industrial facilities.
Of late against the background of growing oil production and refining volumes the issues of environmental protection and industrial security are of top priority for both, governmental structures and oil refining companies. Acute necessity for introducing no other than comprehensive measures at modern refineries aimed at minimizing the harmful effect on the environment due to industrial exploitation of oil refining facilities is noticed.
In this connection in the course of construction and technical modernization of Antipinsky Oil Refinery special attention is paid to selection of up-to-date technological equipment with the application of high environmental standards which fact will make it possible to attain objectives set in the area of industrial and ecological security.
To reduce environmental pressure a number of technological solutions were taken into account at the design stage of the refinery making it possible to minimize impact on the ambience, including water consumption which entails wastewater discharge, pollutant emissions into the atmosphere, prevent oil and oil-product spillage in the soil, surface and underground waters.
Such solutions include as follows:
- the use of burner units in process furnaces which comply with the most stringent environmental requirements;
- the application of a sealed system within the entire process flow;
- the control, computerization, and telemetry of technological processes to prevent accidents, as well as to minimize pollutant emissions to the atmosphere by strict adherence to established technological parameters;
- the provision of a leak-proof filling of light oil products with gas removal to tanks via gas equalizing lines;
- the use of air-cooling systems for process flows;
- the use of water removal systems which prevent wastewater discharge to surface waters;
- the construction of construct concrete platforms for processing equipment and oil loading racks with guard rails and ladders. The implementation of these solutions minimizes environmental damage.
Today Antipinsky Oil Refinery CJSC is busy with the design and construction of the third workflow phase of the refinery which after commissioning of new units will make it possible to provide the region vehicles on the ambience in the south of the Tyumen Region .
Since water is needed for refining oil and oil products at new units the construction of the third workflow phase began with the building of water intake, water conditioning, and treatment structures. High-technology equipment of Russian and well-known foreign companies will be applied at the new facility of the refinery.

The equipment in question will make it possible to:
- prevent any changes of the Tura River bottom and any limitations of water traffic when using water intake structures;
- provide the refinery with water of required quality complying with regulations imposed on equipment installed in the basic and auxiliary technological units;
- reduce the area of construction four times as compared with traditional treatment technology at primary and secondary sludge basins (biological wastewater treatment technology);
- minimize operational costs (low power consumption equipment, use of advanced chemical agents, etc.);
- reduce the impact of harmful factors (such as noise, vibration, emissions, and discharges, etc.) on the environment and employees. Treatment facilities occupy the area of 10.73 hectares. Wastewater treatment process consists of five stages. At the first stage water passes through the preliminary treatment block. In this block the process of sedimentation takes place and scrapper mechanisms are continuously removing trapped impurities (produced by Zickert Swedish company). To remove any large impurities a mechanical rake grid is provided in front of the settler (EKO-Umvelt CJSC is the supplier). The second stage (the physical-chemical wastewater treatment block) provides for thin-layer sedimentation in fine purification separators (produced by “Komsomolets” Tambov Plant OJSC) and reactant impeller floatation (produced by American company Separation Specialists).
Biological treatment is conducted at the third stage (biological treatment block) in aeration tanks-displacers with nitrification and de-nitrification zones with subsequent filtration in membrane bioreactors (supplier of equipment and technology for membrane bioreactors is Hungarian company GE Water and Process Technologies).
The advanced treatment and disinfection block is provided at the fourth stage. Advanced treatment is carried out using FSU sorption carbon filters (produced by TEKO-FILTR Production Enterprise LLC), treated wastewaters are disinfected at the UV disinfection station (produced by LIT Research and Production Association).
At the fifth stage trapped impurities enter the dehydration block for oil products, residues, and excess active sludge, accumulate in residue-homogenization apparatuses, mix for the purpose of averaging as per quantity and quality, and then become subject to a three-stage separation at a horizontal centrifuge (produced by German company Andritz Separation AG). After centrifuging dehydrated oil products are directed for reuse.
Dehydrated residues are directed to the bio-destruction site and processed with biological preparations which oxidize residuary hydrocarbons. After the bio-oxidation process the dehydrated residue transfers to the IVth class of hazardous waste and can be used in industrial areas for filling trenches and pits.
The above technological solution will ensure the required extent of wastewater treatment, reduction of pollutant emissions into the atmosphere, protection of soil and underground waters against oil effluents. Up-to-date methods applied to the treatment of industrial and rainfall as well as domestic sewage waters will enable the refinery to reuse up to 60% of treated wastewaters for technical purposes of the enterprise, to make the remaining 40% of water meet hygienic requirements applied to surface water protection and channel it to the Tura River.
Wastewater quality control will be exercised at all stages of wastewater treatment using modern equipment of the accredited ecological and analytical laboratory of Antipinsky Oil Refinery CJSC.

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