PTQ Q2 2025 Issue

Increasing refinery recycled water quality and usage

A refinery ensured a reliable source of recycled water for cooling make-up water by applying a biofilm detection and control programme to its wastewater treatment plant

Christina Möring, Johan Hutsebaut and Caroline Bird Solenis

W ater scarcity is one of the most pressing global challenges of the 21st century, presenting wide-ranging ramifications for water-intensive industries. The refining and chemical processing industries, cornerstones of global manufacturing and energy produc- tion, are among the industries most affected by limited access to fresh water. As the climate continues to change and water resources become increasingly stressed, these industries must grapple with the potential for operational disruptions, increased costs, and stricter environmental regulations. Water plays an indispensable role in both refining and chemical processing, where it is used for cooling, generat- ing steam, and transporting materials (such as oil, chemi- cals, and waste) and acts as a solvent in various chemical reactions. Refinery processing, for example, requires large volumes of water for desalinisation, distillation, and hydro - processing. Similarly, chemical processing relies on water to maintain optimal temperatures in reactors, treat waste products, and ensure equipment integrity. Therefore, water shortages or poor water quality can significantly decrease production capabilities and lead to increased operating costs. As water scarcity intensifies, competition increases not only within these industries but also between other water-intensive industries, such as power production and mineral processing. In regions where water is already scarce, this competition can strain relationships between industries and local communities, potentially leading to social and political tensions. Recycling and reuse technologies To mitigate these rivalries, many companies within the refining and chemical processing industries are increas - ingly turning to innovative solutions to reduce their fresh - water usage and improve their water management. One of the most promising strategies is the adoption of water recycling and reuse technologies. By treating and reusing wastewater within their refineries and chemical processing plants, engineers can significantly reduce the consumption of freshwater and minimise the discharge of wastewater. Chemistry, equipment, and processes, used judiciously, help refineries and chemical processing plants reduce

freshwater intake and enhance water recycling efforts. The application of innovative chemical treatments can opti - mise water reuse, enabling water to be reused repeatedly by removing impurities and contaminants and preventing scaling, corrosion, and biofouling throughout cooling tow- ers and boilers. Anti-scaling agents, for example, allow refineries and chemical processing plants to use more recy - cled or lower-quality water, thereby reducing the need for pristine freshwater supplies. Corrosion inhibitors protect equipment and piping, ensur - ing the longevity of water reuse systems and reducing the need for frequent replacement or maintenance. By incor - porating advanced equipment such as real-time monitoring systems, refinery and chemical processing plant engineers can continuously assess water quality and adjust chemi - cal dosages and filtration processes for optimal efficiency. Corrosion inhibitors protect equipment and piping, ensuring the longevity of water reuse systems and reducing the need for frequent replacement or maintenance Technologies such as membrane filtration and reverse osmosis and processes such as advanced oxidation allow companies to purify wastewater and reuse it in cooling sys- tems, boilers, and other stages of production. The following case history explores how a European refinery uses chem - istry and equipment in tandem to ensure a reliable source of recycled water. European refinery case history The operators of a large petroleum refinery in a drought- stricken area in Europe wanted to implement circular water usage solutions (collecting, recovering, and recycling water resources within the system). However, they were strug - gling to improve and maintain the quality of their cooling make-up water. This refinery’s engineers intended to use grey water as

PTQ Q2 2025