Effective treatment of petroleum oil-contaminated wastewater using activated sludge modified with magnetite/silicon nanocomposite

The study aimed to optimize the treatment of oil refinery-contaminated wastewater through modification of the well-established activated sludge process with new nanocomposite (NC) materials to produce high-quality treated effluents for potential reuse. Refinery wastewater samples were collected from one of the major oil refineries, Alexandria, Egypt, where the operation, performance, and efficiency of the current activated sludge (AS) unit were evaluated for 6 consecutive months. Two AS bench scale PVC basins were constructed. Magnetite nanoparticles (Fe3O4 NPs) and magnetite silica (Fe3O4/silica) nanocomposite (NC) were prepared and characterized. Bioremediation trials were carried out in a sequential batch mode using Fe3O4/silica NC-modified AS and control (unmodified AS). The proposed treatment produced high-quality effluents in a very short time (2 h) despite the very high initial pollutant concentration accompanied with a reduction in the produced sludge. The highest removal of TSS, TDS, BOD, COD, and OG from raw industrial wastewater recorded 78.33, 3.6, 87.65, 85.17, and 92.92% compared to 55.3, 12.6, 50.0, 40.22, and 56.84%, respectively, achieved by the unmodified AS unit. The results confirmed that integration of the AS treatment with nanomaterial composite is highly effective, promising, and economic for the treatment of highly toxic and complicated industrial wastewater such as petroleum refinery effluents.

A novel physical-biochemical treatment of refinery wastewater

As of 2022, China has achieved a crude oil processing capacity of 918 million tons, leading to a notable escalation in the production of refinery wastewater. The composition of refinery wastewater is intricate and diverse, posing a substantial challenge to its treatment. In order to facilitate appropriate discharge or reuse, an exhaustive separation process is imperative for refinery wastewater. Conventional pre-treatment processes typically employ inclined plate separators and dissolved air flotation (DAF) for the removal of oil and suspended solids (SS), while sequencing batch reactor (SBR), oxidation ditch, or biological aerated filter (BAF) are employed for the biological treatment process. However, these approaches encounter challenges such as a large spatial footprint, suboptimal treatment efficiency, and high energy consumption. In response to these challenges, this study introduces a novel integrated apparatus consisting of a high-efficiency oil remover (HEOR), coalescence oil remover (COR), and an airlift-enhanced loop bioreactor (AELR). A pilot-scale test was conducted to evaluate the performance of this integrated system in practical field applications. The pilot-scale tests reveal that, without the addition of chemical agents, the petroleum removal efficiency of "HEOR + COR" system was 1.2 times that of DAF. Compared with the SBR system, AELR's volume loading was increased by 1.56 times. The effluent quality achieved in the pilot-scale tests attained parity with that the original process. The "HEOR + COR + AELR" system exhibited energy and carbon emissions reduction of 28% and 30% compared to the "DAF + SBR" system, respectively. Therefore, the operating costs was reduced by approximate 1 Chinese Yuan (CNY) per ton of treated water. This technological advancement serves as a valuable reference for the implementation of low-carbon treatment of refinery wastewater.

Unravelling the relation between processed crude oils and the composition of spent caustic effluents as well as the respective economic impact

Spent caustic discharges are responsible for increasing oil and grease (O&G) matter in refineries wastewater, leading to increasing treatment costs due to low water quality and environmental constraints associated with high O&G concentration discharges. As a way to settle and optimize treatment technologies for such complex effluents, more insight regarding the effluents impact and deeper characterization is necessary. The present study intends to assess the possibility of a relationship between the processed crude oils with the polar O&G concentration in naphthenic spent caustic as well as in the final wastewater; Sines refinery was considered as case-study. Also, in order to get insights about the nature of the polar O&G compounds, their structures and their prevalence in the effluent treatment system was carried out through detailed analytical characterization studies. Proton nuclear magnetic resonance (¹H NMR), Fourier transform infrared spectroscopy (FT-IR) and gas chromatography-mass spectrometry (GC-MS) were chosen. It was found that, for the Sines refinery, spent caustic discharges may increase the refinery effluent management cost up to 3 €/ton of processed crude oil, every time a high kerosene cut acid crude oil is processed. It was also found that the typical spent caustic O&G effluents are composed by organic contaminants with low molecular weight (MW), with aromatic and polar arrangements, like phenolic groups and naphthenic acids. This outcome is crucial for subsequently establishing the best technologies able to deal with such complex effluents.

Isolated heterotrophic nitrifying and aerobic denitrifying bacterium for treating actual refinery wastewater with low C/N ratio

Heterotrophic nitrifying and aerobic denitrifying bacteria that have been widely isolated from complicated activated sludge microflorae demonstrate dominant advantages in simultaneous removal of ammonium and nitrogen oxides under aerobic conditions. However, owing to the need of organic carbon to support bacterial growth, nitrogen removal of actual industrial wastewater with low carbon-to-nitrogen (C/N) ratio remains a challenge. Here, Pseudomonas mendocina Y7 was identified and presented to effectively remove nitrogen of actual refinery wastewater with low C/N ratio. The isolated bacterium showed high removal efficiency of NH₄⁺-N, NO₂^--N, and NO₃^--N up to about 90% in single (100 mg/L) or mixed (200 mg/L) nitrogen source media at low C/N ratio of 6 when it was cultivated for 12 or 21 h. According to PCR amplification, the heterotrophic nitrification and aerobic denitrification capability of strain Y7 was attributed to the functional genes of amoA, hao, napA, and nirS. In activated sludge process for treating actual refinery wastewater with low C/N ratio, compared to abundant accumulation of NO₂^--N and NO₃^--N only using the activated sludge, strain Y7 significantly improved the removal efficiency of NH₄⁺‒N and total nitrogen (with influent concentrations of about 40 and 55 mg/L) from about 47% and 22% to about 85% and 73%, respectively, without the accumulation of nitrogen oxides. Microbial community structure analysis revealed that strain Y7 could coexist well with other microorganisms in the activated sludge and maintain highly efficient and steady nitrogen removal in continuous treatment system. This discovery provides a promising treatment approach toward actual nitrogen-rich industrial wastewater.

A comprehensive review on the applications of functionalized chitosan in petroleum industry

The biomaterials have gained the attention for utilization as sustainable alternatives for petroleum-derived products due to the rapid depletion of petroleum resources and environmental issues. Chitosan is an economical, renewable and abundant polysaccharide having unique molecular characteristics. Chitosan is derived by deacetylation of chitin, a natural polysaccharide existing in insects' exoskeleton, outer shells of crustaceans, and some fungi cell walls. Chitosan is widely used in numerous domains like agriculture, food, water treatment, medicine, cosmetics, fisheries, packaging, and chemical industry. This review aims to account for all the efforts made towards chitosan and its derivatives for utilization in the petroleum industry and related processes including exploration, extraction, refining, transporting oil spillages, and wastewater treatment. This review includes a compilation of various chemical modifications of chitosan to enhance the petroleum field's performance and applicability.

A corrosion evaluation of mild carbon steel in reclaimed refinery stripped sour water

Reclaiming water for cooling systems in oil refineries has been strongly encouraged over the past years for decreasing the large consumption of fresh water, thus contributing to the efficient use of this valuable resource. In a recent study [Journal of Environmental Management 261 (2020) 110229], some of the authors studied the retention of phenols in refinery wastewater through reverse osmosis (RO) and found rejections of up to 98% of phenols and 99% of both chemical oxygen demand (COD) and total organic carbon (TOC). The permeates complied with the quality standards for make-up water in cooling processes. A missing aspect, important for the water to be used in the oil and gas industry, was the level of corrosivity of the new permeates. In this work the corrosion of mild carbon steel in the permeates and in the original cooling tower make-up water was studied by electrochemical techniques. The corrosion rate of steel in the permeates in aerated conditions was lower (between 0.053 ± 0.006 and 0.123 ± 0.011 mm year^-1) than in the make-up water (0.167 ± 0.030 mm year^-1), confirming their suitability for replacing make-up water in the cooling towers. The low corrosion of carbon steel was attributed to the low conductivity and absence of oxidizing species in the fluids, compared to fresh water.

Reuse and recycle solutions in refineries by ozone-based advanced oxidation processes: A statistical approach

Fresh water sources are under pressure globally by the increasing population and consequently increasing production, which increases the water demand day by day. Thus, decreasing the industrial fresh water demand and wastewater production became crucial both for the water availability in the future and for its impact to the environment. This study examined the ozone-based treatments as the possible solution to a refinery to treat the effluent already treated by the traditional techniques to reach the final requirements for reuse and recycle purposes. The screening tests performed by fractional factorial design revealed that the significant parameters for the treatment were ozone feed ratio, H₂O₂ amount and processing time while pH was found insignificant for this case. Based on the box-Behnken response surface methodology for effluent collected after biological treatment, the significant parameters were optimized as the ozone ratio of 0.9 g/h, H₂O₂ amount of 47 mg/L and 60 min duration. However, in case of increasing the H₂O₂ amount to 80 mg/L the duration can be minimized to 37.5 min decreasing the energy and reagent consumption costs by a 37%, reaching a final total organic carbon (TOC) under 4 mg/L, that is the target for reuse possibilities.

Reverse osmosis performance on stripped phenolic sour water treatment - A study on the effect of oil and grease and osmotic pressure

Technologies for water recycling within oil refineries have been gaining interest at an extensive rate due to the large volume of wastewater generated, high dependency of water and the progressive scarcity of this valuable resource. Phenols are part of a specific class of organic pollutants that have been contributing to a low-quality effluent in oil refineries due to their hazardous nature and strict environmental legislation associated. The reuse of stripped sour water within refineries is often blocked due to its rich phenolic content. This study evaluates the retention of phenols in refinery wastewater through reverse osmosis (RO) at its major source of emission, for water reclamation. The RO membrane selected exhibited rejections of up to 98% of phenols and 99% of both chemical oxygen demand (COD) and total organic carbon (TOC). Permeate quality remained intact despite flux decline caused by phenolic and hydrocarbon adsorption when the oil content, in the feed, reached 771 ppm. The effluent's low conductivity due to lack of salts led to minor osmotic pressure differences (less than 2.5 bar at a volume concentration factor of 3), therefore, showing appealing performances of reverse osmosis filtration. Characterization of all permeates obtained from cross-flow filtration experiments showed COD levels in line with water reuse quality standards for make-up water in cooling processes.

Oily wastewater treatment by a continuous flow microbial fuel cell and packages of cells with serial and parallel flow connections

This study reports the results of the application of microbial fuel cells (MFC) in refinery wastewater (RW) treatment. In this research, the effect of hydraulic retention time (HRT), and scale-up on the performance of a novel expandable modular design of single-chamber MFC (SCMFC) has been investigated. In the first part of the paper, the effect of HRT on chemical oxygen demand (COD) removal and electricity generation was examined. The generated steady open-circuit voltage (OCV) was 785 mV at HRT 90 h, and the provided maximum power density (PD) was 113 mW/m² at HRT 15 h. At HRT of 45 h, COD removal increased up to 87% via an increase in the HRT. In the second part, the scale-up of SCMFC was investigated by serial (SFC) or parallel (PFC) connecting the outlets and inlets of fluid flows. The average produced OCV was 760 mV in PFC mode, and average produced PD in PFC and SFC modes were 97 and 75.6 mW/m², respectively. COD removal in SFC and PFC modes were reported to be 89 and 42%, respectively. Compared to PFC mode, SFC mode was more efficient in terms of COD removal and coulombic efficiency. However, it produced lower PD compared to PFC mode. It is possible to control the quality and capacity of wastewater treatment by using combining the SFC and PFC mode connections in packages of MFCs.

Bioremoval of priority polycyclic aromatic hydrocarbons by a microbial community with high sorption ability

The treatment of large volumes of wastewater during oil refining is presently a challenge. Bioremediation has been considered an eco-friendly approach for the removal of polycyclic aromatic hydrocarbons (PAHs), which are one of the most hazardous groups of organic micropollutants. However, it is crucial to identify native PAH-removing microorganisms for the development of an effective bioremediation process. This study reports the high potential of an anaerobic microbial consortium enriched from a petrochemical refinery wastewater to remove two priority PAHs-acenaphthene and phenanthrene. Seventy-seven percent of acenaphthene was removed within 17 h, whereas phenanthrene was no longer detected after 15 h. Bioremoval rates were extremely high (0.086 and 0.156 h^-1 for acenaphthene and phenanthrene, respectively). The characterization of the microbial communities by next-generation sequencing and fluorescence in situ hybridization showed that the PAH-removing consortium was mainly composed by bacteria affiliated to Diaphorobacter and Paracoccus genera, independently of the PAH tested. Moreover, besides biodegradation, biosorption was a relevant mechanism involved in the removal of both PAHs, which is an important finding since biosorption is less expensive than biodegradation and can be carried out with dead biomass. Although biodegradation is the most commonly reported biological mechanism for PAH removal, this study demonstrated that biosorption by this microbial community may be extremely efficient for their removal. Given the outstanding ability of this microbial consortium to quickly remove the compounds addressed, it could be further applied for the bioremediation of PAHs in refinery wastewaters and other contaminated environments.

Oil refinery hazardous effluents minimization by membrane filtration: An on-site pilot plant study

Experiments for treating two different types of hazardous oil refinery effluents were performed in order to avoid/minimize their adverse impacts on the environment. First, refinery wastewater was subjected to ultrafiltration using a ceramic membrane, treatment, which did not provide an adequate reduction of the polar oil and grease content below the maximal contaminant level allowed. Therefore the option of reducing the polar oil and grease contamination at its main emission source point in the refinery - the spent caustic originating from the refinery kerosene caustic washing unit - using an alkaline-resistant nanofiltration polymeric membrane treatment was tested. It was found that at a constant operating pressure and temperature, 99.9% of the oil and grease and 97.7% of the COD content were rejected at this emission point. Moreover, no noticeable membrane fouling or permeate flux decrease were registered until a spent caustic volume concentration factor of 3. These results allow for a reuse of the purified permeate in the refinery operations, instead of a fresh caustic solution, which besides the improved safety and environmentally related benefits, can result in significant savings of 1.5 M€ per year at the current prices for the biggest Portuguese oil refinery. The capital investment needed for nanofiltration treatment of the spent caustic is estimated to be less than 10% of that associated with the conventional wet air oxidation treatment of the spent caustic that is greater than 9 M€. The payback period was estimated to be 1.1 years. The operating costs for the two treatment options are similar, but the reuse of the nanofiltration spent caustic concentrate for refinery pH control applications can further reduce the operating expenditures. Overall, the pilot plant results obtained and the process economics evaluation data indicate a safer, environmentally friendly and highly competitive solution offered by the proposed nanofiltration treatment, thus representing a promising alternative to the use of conventional spent caustic treatment units.

Genotoxicity of refinery waste assessed by some DNA damage tests

Refinery waste effluent is well known to contain polycyclic aromatic hydrocarbons, phenols and heavy metals as potentially genotoxic substances. The aim of the present study was to assess the genotoxic potential of Mathura refinery wastewater (MRWW) by various in vitro tests including the single cell gel electrophoresis, plasmid nicking assay and S1 nuclease assay. Treatment of human lymphocytes to different MRWW concentrations (0.15×, 0.3×, 0.5× and 0.78×) caused the formation of comets of which the mean tail lengths increased proportionately and differed significantly from those of unexposed controls. The toxic effect of MRWW on DNA was also studied by plasmid nicking assay and S1 nuclease assay. Strand breaks formation in the MRWW treated pBR322 plasmid confirmed its genotoxic effect. Moreover, a dose dependent increase in cleavage of calf thymus DNA in S1 nuclease assay was also suggestive of the DNA damaging potential of MRWW. A higher level of ROS generation in the test water sample was recorded which might be contributing to its genotoxicity. Interaction between the constituents of MRWW and calf thymus DNA was also ascertained by UV-visible spectroscopy.

Treating refinery wastewaters in microbial fuel cells using separator electrode assembly or spaced electrode configurations

The effectiveness of refinery wastewater (RW) treatment using air-cathode, microbial fuel cells (MFCs) was examined relative to previous tests based on completely anaerobic microbial electrolysis cells (MECs). MFCs were configured with separator electrode assembly (SEA) or spaced electrode (SPA) configurations to measure power production and relative impacts of oxygen crossover on organics removal. The SEA configuration produced a higher maximum power density (280±6 mW/m(2); 16.3±0.4 W/m(3)) than the SPA arrangement (255±2 mW/m(2)) due to lower internal resistance. Power production in both configurations was lower than that obtained with the domestic wastewater (positive control) due to less favorable (more positive) anode potentials, indicating poorer biodegradability of the RW. MFCs with RW achieved up to 84% total COD removal, 73% soluble COD removal and 92% HBOD removal. These removals were higher than those previously obtained in mini-MEC tests, as oxygen crossover from the cathode enhanced degradation in MFCs compared to MECs.