During the construction of new and modernization of existing facilities of the Michurinsky Oil Refinery, special attention is paid to minimizing the impact of the production process of the enterprise on the environment - these issues are a constant component of the plant's economic management system.
Michurinsky Oil Refinery is one of the largest water consumers in the city of Tambov. In this regard, the enterprise is constantly improving production technology, introducing wastewater treatment methods, monitoring the volume of water consumption and water disposal, as well as the quality of discharged wastewater.
Among the projects aimed at minimizing environmental risks are the existing treatment facilities of the plant. They make it possible to improve the quality of industrial wastewater treatment at an enterprise.
WATER INTAKE AND WATER TREATMENT
The need to provide the existing projected installations of the plant with its own technical and softened water led to the construction of a river water intake and the organization of water treatment.
The water intake is located on the right bank of the Tura River.
These structures provide the supply of service water and softened water to the plant. Process water goes through three stages of purification (filtering channel water intake, settling tank with a coalescer and clarifying filters).
Softened water is obtained from part of the process water (two stages of ion exchange filters). Water intake capacity - 300 m 3 / h, softened water production capacity - 120 m 3 / h.
filtering channel water intake;
1st lift pumping station;
a sump combined with a coalescer;
industrial filter building;
clean water reservoirs;
block of pumping stations;
containers of chemically purified water;
pumping station for chemically treated water.
The uniqueness of the structures is in ensuring the supply of water of constant quality (practically free of suspended solids and iron and manganese ions), regardless of the quality of water in the Tura River.
During the design and construction of the water intake, modern solutions were used: under-channel water intake without elevated structures, equipped with submersible axial-flow pumps; the use of diving operations without draining trenches and pits during the construction process.
At the beginning of 2014, Michurinsky Oil Refinery commissioned five-stage treatment facilities and water treatment facilities , unique for Tambov enterprises , occupying 10.7 hectares.
The facilities of the treatment facilities provide for the reception and treatment of all industrial, rainfall and domestic wastewater generated at the facilities of the Michurinsky Oil Refinery.
Wastewater entering the treatment plant undergoes a full treatment cycle before being discharged into the Turu River: preliminary treatment (sand traps with precipitators), physical and chemical treatment (separators, impeller flotation devices), biological treatment with membrane bioreactors, additional treatment (sorption filters and ultraviolet disinfection ).
Sludge, sludge, excess activated sludge and captured oil products formed in the process are processed in the dewatering unit using three-phase centrifuges from Andritz Separation AG.
Wastewater is pre-treated in grit traps and precipitators. The pre-treatment unit is designed to protect the main structures from debris, volley and emergency discharges of pollutants, and to regulate the uneven flow of initial wastewater.
The peak performance of the block is no more than 2670 m 3 / h.
Physical and chemical cleaning unit
The block includes a separation unit and a flotation unit.
The separation unit consists of two separators. The principle of operation of the separators allows you to simultaneously separate suspended matter and oil products from the effluent. Due to the tangential water input, oil products are collected in the center at the top of the separator, and suspended solids - in the lower conical part of the separator. The separated oil products and suspended solids are pumped by pumps for further dehydration to the sludge and oil products dewatering unit.
The reagent impeller flotation unit consists of two Separation Specialists units. Separation principle: air bubbles adhere to particles that are poorly wetted by water (oil products and suspended solids) and lift them to the surface. The sludge collector rotated by an electric motor displaces the flotation sludge (foam) into the so-called sludge pocket, from which it is directed to the foam settler unit, followed by the direction of the settled sediment and the captured oil product to the dewatering unit. The capacity of the block is 400 m 3 / h.
Biological treatment unit
This unit is designed for wastewater treatment using unique technologies from GE Water & Process Technologies. This technology uses membrane bioreactors, which make it possible to repeatedly intensify processes, exclude secondary sedimentation tanks from the scheme, remove suspended solids by almost 100%, BOD by 99%, and reduce the occupied area by 4 times compared to conventional sludge sedimentation tanks.
Up to 60% of treated wastewater is returned to the production to feed water circulation system that provides significant ecological and economic effect of reducing consumption of natural resources, namely the fresh water from river tours to the needs Antipinsky refinery in the amount of not less than 1.7 million m 3 / year. The rest goes to the deep post-treatment unit.
Excess sludge is sent to the unit for collecting and dewatering the captured oil product, sludge and excess activated sludge. The capacity of the block is 400 m 3 / h.
Deep post-treatment and disinfection unit
Treated waste water, which is not used to make up the water circulation systems, is sent to the block for deep post-treatment and disinfection of waste water.
After passing through sorption carbon filters and ultraviolet disinfection installations, the quality of such water meets all the requirements for the quality of waste water discharged into fishery reservoirs. Purified wastewater after additional treatment is discharged into the Tura River. The unit capacity is up to 400 m 3 / h.
Dehydration unit for captured oil products, watered sludge and excess activated sludge
The unit receives the captured watered oil products and sediment from the preliminary treatment unit, from the separation unit, foam from the flotation unit, active excess sludge from the biological treatment unit.
The watered sludge, watered oil product, excess activated sludge are sent for further processing in tanks for accumulation and homogenization of the watered oil product.
The tanks are vertical steel tanks equipped with a mixing device. They are designed to accumulate the required volume of raw materials for feeding to centrifuges and averaging the supplied raw materials by quality.
A pipe-in-pipe heat exchanger is required to heat the raw material (heated raw material is better separated) before the centrifuge.
Two three-phase centrifuges from Andritz Separation AG are designed to separate watered oil products into three phases:
oil product phase;
aqueous phase (centrate);
solid phase (cake).
The oil product phase is sent to the tank of the dehydrated oil product, followed by pumping out and transportation by special vehicles for further processing to the production workshops of the enterprise.
The aqueous phase is directed to the pre-treatment unit.
The solid phase (cake) is sent to the biodegradation site.
After the end of the technological process of biodegradation, the resulting waste has a 4 hazard class and can be used in an industrial area for backfilling of trenches and pits.
UNIQUENESS OF TREATMENT FACILITIES
The treatment facilities ensure the quality of discharge into the Tura River, which fully meets the requirements of water bodies for fishery purposes. Almost all the quality indicators of treated wastewater are better than those of the source water in Tours.
All wastes undergo the necessary processing (dehydration, purification, biodegradation), which allows them to be reused: the captured oil products - as hydrocarbon raw materials, and the waste obtained in the biodegradation process - as soil for backfilling during construction work.
Treatment facilities occupy a record small area (about 6 hectares). The placement of such treatment facilities in such cramped conditions became possible thanks to the use of modern equipment and technologies for water purification and treatment of sewage sludge.
In particular, for example, the device of a biological treatment unit using GE technology with a membrane bioreactor (MBR) made it possible to completely abandon massive secondary sedimentation tanks for capturing activated sludge after aeration tanks - accordingly, the area decreased by 3-4 times.
The use of separators made it possible to reduce by 2-3 times the area of the facilities of the physical and chemical treatment unit by ensuring the separation of oil products and suspended solids during the movement of wastewater in a vertical spiral direction, and not in a horizontal direction, as is usually implemented in oil traps at treatment facilities in Russia.
The use of centrifuges from Andritz Separation AG made it possible to abandon the traditional massive complex of dewatering facilities, while the technologies used improve the quality of the dewatered oil product and cake for their subsequent processing or disposal.
The equipment of treatment facilities, water intake and water treatment allows:
exclude changes in the bottom of the Tura River and not restrict the movement of water transport during the operation of water intake facilities;
provide the plant with water of the required quality required for the equipment of the main and auxiliary technological units;
minimize operating costs (low energy consumption of equipment, use of the latest chemical reagents, etc.)
to reduce the impact of harmful factors on the environment and service personnel (noise, vibration, emissions and discharges).
Composition of structures:
control room of treatment facilities;
transformer substation 10 / 0.4 kV with switchgears - 0.4 kV.
The operation of the water intake, water treatment and treatment facilities is controlled from a unified automatic control system for technological processes located in the control room of the treatment facilities.
It is worth emphasizing that at the new facility of the plant only high-tech equipment is used by the most advanced Russian companies OJSC "Tambov plant" Komsomolets ", NPO" LIT ", CJSC" EKO-Umvelt ", LLC" Industrial enterprise "TEKO-FILTER", as well as foreign firms: Zickert (Sweden), Separation Specialists (USA), GE Water & Process Technologies (Hungary), Andritz Separation AG (Germany) and others known all over the world.
Implementing this project, in 2014 Michurinsky Oil Refinery won the First National Prize in the field of the water management complex "Water of Russia" in the nomination "The best project aimed at reducing pollution of water bodies".
Wastewater quality control is carried out at all stages of treatment using modern equipment of the eco-analytical plant laboratory of Michurinsky Oil Refinery LLC.
The Ecoanalytical Laboratory (EAL) was established on May 1, 2013 and became part of the central plant laboratory as a result of the reorganization of the chemical analytical laboratory of Michurinsky Oil Refinery LLC. The area of activity of EAL currently includes:
analysis of natural (ground and surface) water (within the framework of production control in order to ensure environmental protection);
analysis of drinking water (within the framework of production control in order to ensure compliance with the sanitary and hygienic standards of consumed water);
analysis of all types of industrial waters for the purpose of operational control and regulation of technological processes, as well as to ensure the safe operation of equipment;
analysis of waste water and treated effluents (including using biological research methods) at all stages of treatment;
analysis of the gas-air environment of the enterprise in order to ensure safe working conditions and industrial safety requirements;
hydrobiological analysis of activated sludge in order to control the quality of treatment and operation of the biological unit of treatment facilities.
biotesting is carried out to determine the toxicity of natural water, waste water and treated effluents. Test objects are Ceriodaphnia and Paramecium caudatum
The laboratory is equipped with up-to-date analytical equipment capable of solving practically all tasks necessary for an enterprise in the field of water analysis, allowing the determination of the measured components in a wide range of concentrations.
The laboratory staff is staffed with highly professional personnel - 97% of EAL employees have diplomas of higher specialized vocational education, all employees undergo internal training when introducing new types of work, improve their qualifications in leading training centers in Russia.
The team of the Ecoanalytical Laboratory is constantly improving: mastering modern methods of analysis, introducing new measurement techniques in order to meet the continuously expanding needs of the Company.
Competence in the field of activities of the central plant laboratory, which is in the field of state regulation, is confirmed by an accreditation certificate in accordance with the current legislation of the Russian Federation.
Solving production problems, the management of the plant creates conditions for an open demonstration of the company's environmental responsibility. So, in July 2014, the Michurinsky Oil Refinery launched an Environmental Public Reception, where you can get information about the environmental situation around the enterprise at any time.
The staff of the central plant laboratory is 116 people.
In 2015, more than 120 thousand analyzes were carried out.
As part of the analytical control of the quality of wastewater and treated chemically treated, industrial water for the needs of the enterprise, about 600 analyzes are performed weekly for various indicators.