Treatment and disposal of refinery sludges: Indian scenario

Crude oil is a major source of energy and feedstock for petrochemicals. Oily sludge, bio-sludge and chemical sludge are the major sludges generated from the processes and effluent treatment plants of the refineries engaged in crude oil refining operations. Refineries in India generate about 28,220 tons of sludge per annum. Various types of pollutants like phenols, heavy metals, etc. are present in the sludges and they are treated as hazardous waste. Oily sludge, which is generated in much higher amount compared to other sludges, contains phenol (90-100 mg/kg), nickel (17-25 mg/kg), chromium (27-80 mg/kg), zinc (780 mg/kg), manganese (19-24 mg/kg), cadmium (0.8-2 mg/kg), copper (32-120 mg/kg) and lead (0.001-0.12 mg/kg). Uncontrolled disposal practices of sludges in India cause degradation of environmental and depreciation of aesthetic quality. Environmental impact due to improper sludge management has also been identified. Salient features of various treatment and disposal practices have been discussed. Findings of a case study undertaken by the authors for Numaligarh Refinery in India have been presented. Various system alternatives have been identified for waste management in Numaligarh Refinery. A ranking exercise has been carried out to evaluate the alternatives and select the appropriate one. A detailed design of the selected waste management system has been presented.