Learning Experience 2.2
BP Refinery Kwinana – Cleaner Production Initiatives
ENVIRONMENTAL GOAL
BP Refinery Kwinana has undertaken many cleaner production and environmental
improvements in accordance with company policy and its commitment to continual
environmental improvement. It has been particularly active in minimising water use,
maximising energy efficiency and greenhouse gas abatement, protecting ground and
coastal waters, and reducing volatile organic compounds (VOC) and other air
emissions.
BP Refinery Kwinana was built in 1955 on the eastern shore of Cockburn Sound,
approximately 40 km south of Perth in the Kwinana Industrial Area. Neighbouring
industries include a variety of mineral and chemical processing companies.
Crude oil is delivered by ships or trucks to BP Refinery Kwinana, where it is refined into
a wide range of products for distribution throughout WA, Australia and the world.
These products include LPG, petrol and diesel for motor vehicles; aviation gasoline, jet
fuel and bitumen.
In accordance with BP's Health, Safety and Environmental Policy and its expectation of
no damage to the environment, the prevention of pollution arising from the refinery's
operations is of the highest priority. BP Refinery Kwinana is committed to continuous
improvement with regard to its environmental performance and the refinery has an
environmental management system certified to the International Standard ISO 14001.
Key environmental goals stated in BP Refinery Kwinana's Environmental Policy include:
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Protecting Cockburn Sound and water resources, including groundwater and
scheme water
Reducing greenhouse emissions
Reducing volatile organic compounds (VOC) emissions
Reducing other atmospheric emissions, including sulfur dioxide and nitrogen
oxides
Supplying clean fuels to help improve Perth's air quality, including supplying
only lead-free motor spirit.
Focus Area 1: WATER EFFICIENCY
BP Refinery Kwinana initiated a water reuse and minimisation programme in 1997 with
three main objectives: to minimise water use; to maximise water reuse in refinery
processes, either after or before treatment; and to substitute lower quality water in
place of potable water where practical.
The approach adopted involves four main steps, aimed to drive continuous
improvement:
Step 1:
Set targets for water use of the different water streams, for water recycling
and for the volume of water directed to the Waste Water Treatment Plant.
Step 2:
Monitor performance against targets, including periodically conducting a
detailed site water balance.
Step 3:
Report the performance against the targets set, and encourage
participation of the whole workforce in suggesting water minimization initiatives.
Step 4:
Implement water minimisation projects.
An innovative aspect of the programme was approaching water management with a
whole refinery perspective. All areas were targeted in order to save as much water as
possible. All employees were encouraged to discuss and put forward ideas on water
conservation, recycling or reuse. Quarterly meetings are held within the refinery to
discuss water minimisation and performance against the targets that have been set.
In 2008 the refinery commissioned its largest project for water minimisation, which
resulted in tertiary treated water from the Kwinana Water Recycling Plant (KWRP) being
substituted for all potable water use in the Refining process. This is a significant
investment which means that the only potable water used at the refinery is for typical
domestic purposes, such as drinking, toilet facilities and showers. This represents an
estimated reduction in potable water use of 1200 - 1500 klpd.
Previous initiatives have included:
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Recycling process water used in the Bypass Seal Pot of the Residue Cracker Unit’s
CO Burner. Operating conditions required 200-300 kL/day of water to prevent
high flue gas back pressure causing the Seal Pot to blow and consequently
shutting the CO burner down. Previously this overflow was directed to sewer. A
head tank and recycling system was installed, and pH and chloride testing was
carried out to enable the operation to be carried out under suitable conditions.
A refinery-wide steam trap programme aimed at reducing steam leakage and
improving condensate return.
Improved process water return where feasible eg. from cooling pumps.
Previously half of the total process water was not returned to the refinery.
Modifications to operating procedures for Fremantle, Kewdale and black oil
pipeline pumps to minimise process water use.
Maintenance on leaking 'fixed 'fire systems.
A project to recover lubes condensate losses.
Reuse of stripped sour water as wash water on the Crude Unit desalters. This
wash water is used to extract salts from crude oil to prevent corrosion and
minimise catalyst use.
Water consumption
The water reuse and minimisation programme resulted in a decrease in total water
usage from 7250 kL per day in 1996 to 4065 kL per day in 2007, and a decrease in
potable water usage from 6150 kL per day in 1996 to 2179 kL per day in 2007. The
programme also provided significant environmental benefits by reducing contaminant
loads (eg oil loading decreased from 17kg/day in 1996 to 2.8kg/day in 2007) in the
refinery's marine discharge, due to decreased flows and source control (1996 -5258
m³/day; 2007 - 2620m³/day) to the wastewater treatment plant.
The benefits from specific initiatives were:
Water minimisation initiative
Recycling: Residue Cracker Unit
Benefit
50-150kL/day and cost savings
Steam trap programme
Reduced leakage, improved condensate return
Black oil pipeline pumps
Total water savings 90kL/day
Fixed fire system leaks
Reduction of approximately 36kL/day
Reuse: Stripped Sour Water
Process/total usage reduced 500-900kL/day
Wastewater Treatment
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The wastewater treatment plant has been in operation since 1994. In the first
stage of the treatment process the free oil is separated from the wastewater and
sent back to the refinery for reprocessing. The separated wastewater is pumped
to an Equalisation Tank where it is held and pH adjusted to the required
conditions of the treatment plant.
The second stage involves the removal of small suspended oil particles in the
Dissolved Air Flotation Unit by binding the small particles into larger ones so
that they can float and be skimmed off. Up to this stage the treatment process is
covered to prevent Volatile Organic Compound (VOC) emissions.
The final stage involves the removal of dissolved contaminants and nutrients in
the Activated Sludge Units (ASUs), where biological breakdown occurs. The
wastewater then enters the clarifiers, where micro-organisms are settled before
returning to the ASUs. The wastewater is then directed to the polishing ponds,
which are another special feature of the treatment plant. Aerators aid the break
down of any remaining organic compounds.
Treated wastewater is discharged to Cockburn Sound under carefully controlled
conditions and to strict regulatory requirements. Average daily discharges would
place BP Refinery Kwinana as one of the best refineries in the world for
wastewater quality.
In 2009 the Refinery plans to commission a project which will divert all treated
process water from the current outfall into Cockburn Sound to the Sepia
Depression Ocean Outfall Line (SDOOL). The SDOOL line is directed further off
the coast where there is increased mixing and flushing.
Focus Area 2: ENERGY EFFICIENCY AND GREENHOUSE EMISSIONS
Following the signing of the Kyoto Protocol in 1997 by many industrialised nations,
climate change and reducing greenhouse emissions became a major issue for BP and
the world. BP set a target in 1997 to reduce its global greenhouse gas emissions by
10% from a 1990 baseline over the period to 2010, exceeding the reduction agreed in
1997 by the industrialised nations. BP reported in 2001 that the target had been
achieved, and set a new target to maintain net emissions at the 2001 levels until 2010,
while continuing business growth.
BP Refinery Kwinana is part of the BP Australia Greenhouse Challenge which focuses on
improvement in such areas as energy efficiency, process efficiency, enhancement of
carbon sinks and the effective use of resources. In addition, BP Refinery Kwinana has
implemented both onsite and offsite initiatives to reduce greenhouse emissions.
Offsite initiatives include tree plantations, which have been occurring since 1998,
delivering not only carbon sequestration but additional benefits, such as salinity
reduction, habitat conservation and socio-economic benefits to rural communities. BP
Refinery Kwinana's carbon sequestration project has achieved recognition through
being a finalist, runner up or winner of various environmental awards. Various onsite
initiatives to reduce greenhouse emissions have been implemented since 1996. A
number of these initiatives are summarised below:
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A 'no economic flaring' policy was introduced in 1997, with reductions in flaring
achieved by optimisation of plant throughputs and fuel gas usage, and increased
fuel gas sales.
A Cogeneration Plant was commissioned in 1996, in conjunction with Mission
Energy (now International Power), for the combined production of electricity and
steam. This plant provides 100% of the refinery's 40MW power needs, thereby
eliminating the need for electricity from the grid.
Commissioning of the Cogeneration Plant reduced fuel gas usage as the refinery
was able to shut down the onsite steam boilers.
A major study was completed in 1997 to identify areas for energy improvement
through to the year 2006.
A steam trap management program was initiated to minimise steam energy
losses.
Catalytic Reformer furnace air system modifications were carried out to improve
furnace efficiency.
Vacuum Distillation Unit modifications were carried out to increase efficiency
and reduce energy use and CO emissions per unit throughput. These included a
more efficient furnace and upgrades to the unit internals.
Crude Distillation Unit 1 furnace was upgraded in March 2000 to improve its
efficiency.
A comprehensive Energy Strategy was developed as part of a long term plan to
reduce energy consumption and greenhouse emissions.
Energy Benefits
Significant savings have been achieved, in addition to reduced greenhouse gas
emissions and associated cost savings.
The benefits from specific initiatives were:
Energy/greenhouse initiative
Benefit (annual CO2 reduction )
No economic flaring
16,600 tonnes
Steam boiler shutdown
73,000 tonnes
Steam trap programme
Significant energy savings
Catalytic Reformer furnace
Significant savings
Vacuum Distillation Unit
Significant savings
Crude Distillation Unit 1
8,000 tonnes
BP Refinery – Kwinana
Environmental
Management Area
Water Efficiency
Energy Efficiency and
Greenhouse Emissions
Environmental Management
BP’s Objectives
BP’s Action
BP’s Specific Initiatives
Benefits
Paragraph Framework
The main idea of the paragraph is …
Describe how BP Refinery in Kwinana manages one of the major environmental concerns
caused by its operations.
THINK
PLAN
Statement (Topic Sentence T.S.)
Explanation (Developing Sentence D.S.)
Examples (Supporting Sentence S.S.)
Conclusion (Concluding Sentence C.S.)
WRITE (Identify each type of sentence using T.S.[ST], D.S.[EXP], S.S.[EG], C.S.[CON]).
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EDIT
( ) Spelling
( ) Keywords
PRESENT
( ) Punctuation
( ) Grammar
( ) Sentences
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