Effluent and Waste Management in a Modern Refinery

Dr. Razam Abd Latip

12 June 2019
Table of Content
• Overview of Sime Darby
Plantation

• Overview of Sime Darby Oils

• Palm Oil Refining Process

• Sources and Type of Waste in Palm

Oil Refinery

• Wastewater Treatment Plant

• New Technology in Waste

Management
 3

More Than 100 Years of Presence

 4

Pioneering Plantation Growth

1890s 1960s
The group’s first 500
acres of rubber in Development of Oil
Malaya Palm

1980s – 2007
2000s Merger that Created
Strengthening the World’s Largest
downstream capacities Listed Oil Palm
Globally Plantation Company

In 2007, Guthrie, Golden Hope and Sime Darby was merged, to become the
Largest Listed Plantation Company in the World
 5

Pioneering Plantation Growth

January 2018 – Become Pure Play

Overview of Sime Darby Plantation Berhad
Sime Darby Plantation
Sustainable Journey
Sime Darby Plantation
Sustainable Journey
 Sime Darby Plantation
Sustainable Journey

Founding
member
RSPO

Pioneer -
Zero Burning

Launched
Responsible
Agriculture
Charter (RAC)

World largest
producer of
certified
sustainable
palm oil
Table of Content
• Overview of Sime Darby
Plantation

• Overview of Sime Darby Oils

• Palm Oil Refining Process

• Sources and Type of Waste in Palm

Oil Refinery

• Wastewater Treatment Plant

• New Technology in Waste

Management
Sime Darby Plantation
Downstream – Sime Darby Oils

Our Promise “Realising possibilities, together”

At Sime Darby Oils, we are committed to a partnership that is devoted to our customers’
success. We explore every possibility to ensure the right solutions for your business
needs, identifying new opportunities along the way. We are firmly focused on the future
– your future – and how we can work hand-in-hand to achieve the best possible results.
The Sime Darby Oils Brand Purpose

Upstream R&D Renewables

1. To avoid the confusion that Downstream is a

plantation business. Instead, we want to
distinguish ourselves as an oils and fats
processing, manufacturing and trading company.

2. A new corporate identity whereby at Sime

Darby Oils, we offer more than just palm oil.
We process sunflower oil, soybean oil, coconut
oil, and a premium manufacturer of
tocotrienols, animal feed and biodiesel.

3. An all-new brand creation and activation which can

help to transform our culture and cultivate the Six
Winning Mindset.
 12

Sime Darby Oils Composition

Sime Darby Oils

Malaysia Indonesia South Africa Thailand United Kingdom China Papua New Guinea Netherlands

Sime Darby Oils Sime Darby Oils Sime Darby Oils Sime Darby Oils
Sime Darby Oils Sime Darby Oils Sime Darby Oils Sime Darby Oils
Holding Co Rantau KCP Hong Kong Papua New
South Africa Singapore United Kingdom Netherlands
Malaysia Nominees Guinea

Sime Darby Oils Sime Darby Oils Sime Darby Oils Sime Darby Oils
Sime Darby Oils Sime Darby Oils Sime Darby Oils
Port Klang Morakot Holdings Liverpool Zwijndrecht
Pemantang KCP (HK) Kimbe Refinery
Refinery (Thailand) Refinery Refinery
Sime Darby Oils
PTGolden Hope Sime Darby Oils Rizhao Sime Darby Sime Darby Oils Sime Darby Oils
Kuala Langat
Nusantara Nonthaburi Oils & Fats Buka CCP Ingredients
Refinery
Sime Darby Oils Sime Darby Oils
PT SimeDarby Sime Darby Oils
Pasir Gudang Madang CCP
Oils Indonesia Morakot PCL
Refinery

Sime Darby Oils

Carey Island KCP

Sime Darby Oils

Bintulu Refinery

Sime Darby Oils

Biodiesel

Sime Darby Oils

Malaysia
Producing waste water
Sime Darby Oils
Asia

Sime Darby Oils - Hol ding Company

- Ma nufacturing Units
Professional
- Bus inessUnits
Sime Darby Oils
Nutrition
Table of Content
• Overview of Sime Darby
Plantation

• Overview of Sime Darby Oils

• Palm Oil Refining Process

• Sources and Type of Waste in Palm

Oil Refinery

• Wastewater Treatment Plant

• New Technology in Waste

Management
Compositions of Crude Palm Oil
• CPO is a complex mixture of chemicals.
• About 95% triglyceride and 5% of FFA and minor components.
• It can be divided into 5 groups.
• Triglyceride, Diglyceride , Monoglyceride
1. Oil • Phospholipids, Glycolipid and Lipoprotein
• Free fatty acids

2. Oxidized • Peroxides, Aldehydes, Ketones, Furfurals (from sugars)

Products

• Carotene
3. Non-oil (but oil • Tocopherols
soluble) • Squalene
• Sterols

• Metal particles
4. Impurities • Metal ions
• Metal complexes

• Water (moisture)
• Glycerol
5. Water Soluble • Chlorophyll pigments
• Phenols
• Sugars (soluble carbohydrates)
Why CPO need to be refined?
• To remove those components that have adverse
effect to overall oil quality and to ensure it is safe
for human consumption.
• Refining is also required to achieve
• Light color
• Bland taste
• Good oxidative stability
• Two type of refining
• Physical
• Chemical
Palm Oil Refining Process

Acid Oil

Acid Water
 Degumming and Bleaching

• Degumming is a process of adding H3PO4 into CPO.

• To coagulate the phospholipids and other organic waxes prior to bleaching.
• Bleaching process will allow the gums, some colour compounds & impurities to be trapped in
the bleaching earth.
• The reacted bleaching earth (spent earth) is discarded via Niagara Filter
 Deodorization

• Degummed and Bleached Palm Oil (BPO) is then channel to high temperature deodorizer.
• To remove FFA and remaining oxidation products.
• The refining by product is generally as termed as palm fatty acids distillate (PFAD)
 Palm Oil Refining Process

Acid Oil

Acid Water

• The main difference between chemical and physical refining lies in how the FFA are
removed.
• Chemical refining removes the FFA in the neutralizing process and soap stock is
produced.
• While physical refining removes the FFA in the deodorizing process.
 Soap Stock Splitting Process
• Soap stock consists of 70-95% water and 5-30% of fatty matter.
• To recover the fatty material (acid oil), the soap stock is acidulated with sulfuric acid to
liberate the fatty acids.
• Acidulation process - low pH of 2-3 to ensure that no soaps remain.
• The soap stock is break down into acid oil and acid water.
Table of Content
• Overview of Sime Darby
Plantation

• Overview of Sime Darby Oils

• Palm Oil Refining Process

• Sources and Type of Waste in Palm

Oil Refinery

• Wastewater Treatment Plant

• New Technology in Waste

Management
Type and Source of Waste from Refinery

• Spent Bleaching Earth

Solid • Waste Biological Activated Sludge
• Spent Catalyst – Hydrogenation &
Waste Chemical Interesterification

• Process wastewater
Waste • Rainwater runoff
• Noncontact cooling water Process wastewater
Water • Sanitary waste • Degumming
• Spent analytical chemical solution • Neutralization wash water
• Soap stock splitting effluent
• Deodorization process
• Steam condensate
Other waste
1. Gaseous - Boiler
2. Energy – Thermal and Electricity
Spent Bleaching Earth Disposal

INDUSTRY
Spent Bleaching Earth APPLICATIONS
Oil (“SBEO”) Biofuels

Spent Bleaching
Earth (“SBE”)

Pozzolan
INDUSTRY
APPLICATIONS
Building Materials,
Road Construction and
Infrastructure
Properties of Palm Oil Refinery Effluent (PORE)
Discharge Water Quality
Table of Content
• Overview of Sime Darby
Plantation

• Overview of Sime Darby Oils

• Palm Oil Refining Process

• Sources and Type of Waste in Palm

Oil Refinery

• Wastewater Treatment Plant

• New Technology in Waste

Management
 Wastewater Treatment Plant
Overall Process Flow

Coagulation
Fat Trap &
Flocculation
Wastewater Treatment Plant
Key Processes

1. Fat trap
2. Equalization Tank (EQ Tank)
3. Coagulation & Flocculation Tank
4. DAF Tank
5. Aeration Tank
6. Sludge
7. Discharge
 Wastewater Treatment Plant
Fat Trap
Fat Trap

• The main faction of Fat Trap is to eliminate oils and grease

Equalization
Tank (EQ • Treatment methods for oils and grease
Tank)
 Gravity method
 Flotation
Coagulation &
Flocculation  Chemical treatment
Tank
 Biological treatment
DAF Tank
 Membrane purification
• Fat trap is the most effective physical process

Aeration Tank

Sludge

Discharge
 Wastewater Treatment Plant
Fat Trap
Fat Trap
90% oil free waste
Optimum level at Oil float at top of water
Fat Trap the basin
Equalization
Tank (EQ
Tank)

Waste
Waste
Water
water inlet
Coagulation & outlet
Flocculation
Tank

DAF Tank

Aeration Tank
Baffle to prevent oil
drift towards outlet

Sludge Heavier solid sink

at bottom

When the wastewater goes inside a fat trap, its velocity decreases, which allows oil to
Discharge
float on the surface. Allows the movement of water below the fat and solid will be
settle down.
 Wastewater Treatment Plant
Fat Trap
Fat Trap
Process and quality control for fat trap operation
Equalization
Tank (EQ
Tank)
Good cleaning practice of fat
trap
Coagulation &
Flocculation
Tank

DAF Tank

Aeration Tank Level of oil and fat - to prevent

overflow of oil and fat

Sludge

Discharge
 Wastewater Treatment Plant
Fat Trap Equalization Tank
Air Supply Chemical Dosing.
Ex. Acid or Alkaline
Equalization Optimum level at
Tank (EQ EQ Tank
Tank)

Coagulation &
Flocculation
Discharge Pump
Tank

Waste
DAF Tank
water
inlet

Main line air

Aeration Tank supply

Main function of EQ tank:

Sludge 1. Act as buffer before enter the C&F

tank.
Air Disperser
2. To have consistent flow, pH of the
incoming effluent to the system
Discharge 3. Homogenization station before
treatment.
 Wastewater Treatment Plant
Fat Trap Equalization Tank

Process and quality control for EQ tank operation

Equalization
Tank (EQ
Tank)

Coagulation &
Flocculation
Tank

DAF Tank

Aeration Tank

Sludge
Flow rate of influent into the system
(consistent flow)

Discharge
pH of influent before enter the system
(6 – 9)
 Wastewater Treatment Plant
Coagulation and Flocculation
Fat Trap

• Coagulation and Flocculation is a chemical waste water treatment technique.

• This process enhance the removal of particles in waste water
Equalization
Tank (EQ
Tank)
• Most solids suspended in water posses a negative charge.
• They consequently repel each other.
Coagulation & • Coagulants destabilizes the particles’ charges.
Flocculation
Tank
• Coagulants are added to neutralize the negative charges.
• Once the charge is neutralized, the small-suspended particles are capable of
DAF Tank
sticking together.

Aeration Tank

Sludge

Discharge
 Wastewater Treatment Plant
Coagulation
Fat Trap

• The slightly larger particles formed through this process are called microflocs and
are still too small to be visible to the naked eye.
Equalization
Tank (EQ • Rapid-mix to properly disperse the coagulant and promote particle collisions is
Tank)
needed to achieve good coagulation and formation of the microflocs.

Coagulation &
• Mixing does not affect coagulation, but insufficient mixing will leave this step
Flocculation
Tank
incomplete.
• Proper contact time in the rapid-mix chamber is typically 1 to 3 minutes.
DAF Tank

Aeration Tank

Coagulation Chemical
Aluminium Sulphate (Al2(SO4)3)
Sludge
Ferric Sulphate (Fe2(SO4)3)

Discharge
 Wastewater Treatment Plant
Fat Trap Flocculation
 Flocculation is a gentle mixing stage,
Equalization increases the particle size from
Tank (EQ
Tank) submicroscopic microfloc to visible
suspended particles.
Coagulation &  The floc size continues to build through
Flocculation
Tank additional collisions and interaction with
inorganic polymers or with organic
DAF Tank polymers added.
 From Microflocs to Macroflocs.
 Design contact times for flocculation range
Aeration Tank
from 15 or 20 minutes to an hour or more.

Sludge

Discharge
 Wastewater Treatment Plant
Coagulation and Flocculation
Fat Trap

Process and quality control for Coagulation and Flocculation operation

Equalization 1. Coagulant and Flocculent

Tank (EQ
Tank) Dosing
2. Stirrer speed
Coagulation &
3. pH
Flocculation
Tank
Expected turbidity level after C&F
• < 10 NTU (Nephelometric
DAF Tank
Turbidity Unit)

Aeration Tank

Sludge

Discharge
Coagulation and Flocculation
Process Improvements : Bio-coagulant
Coagulation and Flocculation
Process Improvements : Bio-coagulant
INTRODUCTION OF TANNIN POLYMER

 We have evaluated polymer is a tannin based, derived from the

modification of the aqueous vegetal extract of the Acacia mearnsii De
Wild.

Reaction Mechanism

Coagulation – Surface Flocculation – Particle Bridging

Charge Neutralisation
INTRODUCTION OF TANNIN POLYMER

 Tanin trial result

Samples SS (mg/L) Turbidity (NTU) Hardness (mg/L) TDS (mg/L)

Initial 8 5 32 120
Control 19 5 46 120
1ppm 7 3 31 110
5ppm 3 1 31 110
10ppm 7 1 31 110
15ppm 2 1 32 115
30ppm 2 2 31 112
45ppm 7 4 29 114

Big floc was observed at

5ppm dosage
Coagulation and Flocculation
Process Improvements : Inline Turbidity Meter
 Wastewater Treatment Plant
Fat Trap Dissolved Air Flotation
 The main function of Dissolved air flotation (DAF) is clarifies wastewater
Equalization by removing suspended solids.
Tank (EQ
Tank)
 The removal is achieved by dissolving air in the wastewater under
pressure and then releasing the air at atmospheric pressure in a
Coagulation &
Flocculation flotation tank.
Tank

 The air causing the suspended matter to float to the surface of the
DAF Tank wastewater where it is then removed by a skimming device.

Aeration Tank

Sludge

Discharge
 Wastewater Treatment Plant
Fat Trap Dissolved Air Flotation
Sludge float by
aid of air
1 3
Equalization Water + sludge Water with no
Tank (EQ
Tank) enter DAF tank sludge to
Aeration Tank
Coagulation & 5
Flocculation
Tank

DAF Tank

Aeration Tank

Sludge 2 4
Air saturated
Sludge skimmed to sludge tank
water supply to
DAF tank
Discharge Main function is to reduce TSS and O&G
 Wastewater Treatment Plant
Fat Trap Dissolved Air Flotation
Process and Quality Control for DAF Operation
Equalization
Tank (EQ
Tank) Supply air pressure to DAF system Air : Water ratio (20 – 35%)
(40 – 80 psi) In Air Supply to DAF
Coagulation &
Flocculation
Tank

DAF Tank

Aeration Tank

Sludge
Expected water quality after DAF:

Discharge
Removal of TSS – 97%
Removal of O&G – up to 73%
 Wastewater Treatment Plant
Fat Trap
Activated Sludge Process

 The main function of aeration tank is to reduce COD in wastewater.

Equalization
Tank (EQ
Tank)
 When Activated Sludge is added, the organisms in this mixed liquor quickly
decompose the wastes in the wastewater.
Coagulation &  After a required period of aeration and agitation in the aeration tank, the mixed
Flocculation
Tank liquor flows to a separate tank called a clarifier where the activated sludge is
allowed to settle out and the remaining liquid is discharged as effluent.
DAF Tank
 The settled sludge is either disposed of as waste activated sludge or reused in
the aeration tank as return activated sludge.
 Some sludge must always be returned to the aeration tanks to maintain an
Aeration Tank
adequate population of organisms.

Sludge

Discharge
 Wastewater Treatment Plant
Fat Trap
Aeration Tank

Equalization
Tank (EQ
Tank)

Coagulation &
Flocculation
Tank

DAF Tank

Aeration Tank

Sludge

Discharge
Bacteria in activated sludge from a
wastewater treatment plant
 Wastewater Treatment Plant
Fat Trap
Aeration Tank
Process and Quality Control for Aeration Tank
Equalization
Tank (EQ
Tank)

Coagulation &
Flocculation
Tank

DAF Tank

Food / Microorganism ratio Mix Liquid Volatile Suspended Solid

(0.2 – 0.4) – proper performance (MLVSS) - 1000 – 2500 mg/L
Aeration Tank

Sludge

Discharge Contact time bacteria with food

(6 – 8 hours) Sludge age (3.5 – 10 days)
 Wastewater Treatment Plant
Fat Trap
Sludge

Equalization
Tank (EQ
Tank)

Coagulation &
Flocculation
Tank

DAF Tank

Aeration Tank

Sludge

Discharge
 Wastewater Treatment Plant
Fat Trap
Sludge

Equalization
Tank (EQ
Process and Quality control for filter press operation
Tank)

Supply pressure to filter (7 – 10 bars) Sludge cake dryness expected 50 – 70%

Coagulation &
Flocculation
moisture content
Tank

DAF Tank

Aeration Tank

Sludge

Discharge
 Wastewater Treatment Plant
Fat Trap
Discharge

Equalization
Tank (EQ
Tank)

Coagulation &
Flocculation
Tank

DAF Tank

Aeration Tank

Sludge

Discharge
Discharge Water Quality
 Refinery Waste
Gaseous Waste Management

Steam
Generation

Crude and
Refine Oil
Transport
Refinery Waste
Gaseous Waste Management
Refinery Waste
Gaseous Waste Management
Mostly the gaseous waste is from boiler
operation - incomplete combustion will
produce high % of CO2 in air

Maintain the efficiency of the boiler > 70%

Refinery Waste
Energy Waste Management
Major energy use in refinery consist of 2 types:
• Electrical energy
• Thermal energy

Electrical energy management:

• Using electrical motor / compressor / parts /
etc. with high star rating on energy efficiency

Thermal energy management:

• Boiler efficiency maintain at >70%
• Steam distribution system with less heat loss
• Condensate recovery system
Refinery Waste
Energy Waste Management
Refinery Waste
Energy Management Outline
Table of Content
• Overview of Sime Darby
Plantation

• Overview of Sime Darby Oils

• Palm Oil Refining Process

• Sources and Type of Waste in Palm

Oil Refinery

• Wastewater Treatment Plant

• New Technology in Waste

Management
New Technology in Waste Management
Solid Waste
Load Cell System

Mass balance system for bleaching earth (BE) dosing instead of density calculation.
The system is to have accurate dosing of BE into the system.
No excess BE dosing produce low waste of spent BE.
New Technology in Waste Management
Wastewater

Zero Liquid Discharge (ZLD) System

New Technology in Waste Management
Boiler Smart Monitoring System
New Technology in Waste Management
Energy
Energy smart monitoring system
New Technology in Waste Management
The Future
Good waste management for a better future
THANK YOU