data and computational requirements for meaningful ana- lytics can overwhelm traditional analysis methods. • Next‑generation industrial AI is now extracting that value . Data-driven AI platforms can ingest years of time‑series data, automatically identifying subtle, non‑ linear relationships between operating strategy and asset degradation. Think of it as a centralised model that con- tinuously learns: “When I push coker yields by 3% at these cut points, heater coking accelerates; when I back off here, I can safely defer decoking by two weeks.” For organisa- tions pursuing full automation, degradation models like this are embedded inside closed‑loop AI controllers, while lighter‑touch deployments use the same model to surface actionable insights to both operations and reliability teams. This unified approach ultimately maximises uptime and capital efficiency across the refinery. Q With water supply and quality causing more concerns than crude supply in refinery and petrochemical opera ‑ tions, what can be done to maintain the quality of recy‑ cled treatment water? A Mark Schmalfeld, Global Marketing Manager, Refining Catalyst, BASF, mark.schmalfeld@basf.com Maintaining the quality of recycled treatment water in refin - ery and petrochemical operations is crucial for ensuring sustainable and efficient processes. As water supply and quality become more pressing concerns vs crude supply, implementing effective water management strategies is essential. One primary method of maintaining high-quality recycled water is through advanced filtration systems. Technologies such as membrane bioreactors (MBRs) and reverse osmo- sis (RO) are highly effective in removing contaminants and improving water quality. These systems can filter out fine particles, microorganisms, and dissolved substances, ensuring that the recycled water meets stringent quality standards. Regular monitoring and testing of water quality param- eters are also vital. Continuous assessment of factors like pH, turbidity, and contaminant levels allows for early detection of issues and ensures compliance with regulatory standards. By maintaining a rigorous monitoring schedule, refineries can promptly address any deviations in water quality. Chemical treatment processes play a significant role in enhancing water quality. Techniques such as coagulation, flocculation, and disinfection help neutralise contami - nants and adjust water chemistry. These treatments can effectively remove suspended solids, organic matter, and pathogens, making the water safe for reuse in various operations. Biological treatment methods, including activated sludge processes and biofilm reactors, are also essential for main - taining water quality. These processes utilise microorgan- isms to degrade organic pollutants, resulting in cleaner water. Biological treatments are particularly effective in breaking down complex organic compounds that are dif - ficult to remove through physical or chemical means.
Optimised water management practices are crucial for improving the quality of recycled water. Implementing best practices such as reducing water usage, recycling wastewater, and optimising the treatment process can significantly enhance water quality. By mini - mising water consumption and maximising reuse, refiner - ies can reduce their environmental footprint and improve operational efficiency. Investing in modern infrastructure and technologies is another key strategy. Upgrading water treatment systems to incorporate the latest advancements can enhance their efficiency and effectiveness. Modern infrastructure can better manage the complexi - ties of water treatment, ensuring consistent and high- quality output. By focusing on these strategies, refiner - ies and petrochemical plants can maintain high-quality recycled treatment water, ensuring operational efficiency and environmental compliance. Addressing water quality concerns not only supports sustainable operations but also contributes to the overall resilience and competitiveness of the industry. A Doug White, Principal Consultant, Emerson, doug. white@emerson.com Traditionally, efficient water use in refineries and chemical plants has been a very low priority. However, this is chang- ing as freshwater availability becomes more limited and effluent standards are tightened. There are many ways that plants can reduce their freshwater usage. Steam produc- tion is a major source of water requirements, but the steam condensate recovery is sometimes ignored. A well-run plant should be recovering in excess of 70% of the condensate produced, but many plants are running at 30% recovery or lower. Worse, many plants lack the measurements and systems to even be able to accurately calculate their recovery. Malfunctioning steam traps are an easy target with non-intrusive measurements available to identify which traps are not working. Cooling towers are another major user of fresh water, which can be easily instrumented and controlled to reduce usage. For refiner - ies, desalters are a major user of fresh water and a major source of wastewater. It is easy for desalter water usage to creep up with dirtier and heavier crude processing and not be reduced when switching to lighter crudes, Real-time monitoring and dis- play of important key performance indicators (KPIs) for the desalter and their crude-dependent targets can assist the operators in maintaining effective desalter operation. There are many other process modifications and changes that can be made to reduce water usage. However, the underlying requirement is an overall real-time water and steam bal- ance that monitors daily usage and helps identify problem areas. With regard to wastewater treatment, a number of new technologies, such as reverse osmosis and ultrafiltration, have been proven to be effective in tertiary treatment of wastewater. These technologies allow planned reuse of treated wastewater, which significantly reduces fresh water requirements.
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PTQ Q3 2025
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