Genesis Water Technologies, Inc.

GWT BIO PS10 Series Case Study- Petrochemical Sludge Reduction


Courtesy of Genesis Water Technologies, Inc.

GWT BIOSeries Natural Microbiological Product

Petroleum Refinery Field Case Study

This field case study describes how our GWT BIO PS10 series natural microbiological product provides an alternate solution for disposal of hazardous organic compounds and offers a long term, cost-effective solution to the toughest waste water treatment problems in the petroleum industry. GWT BIO™ series products were developed for biological degradation of various hydrocarbons in waste water, surface water, soil and ground water. BIO series products are composed of specifically selected blends of naturally occurring strains of freeze dried bacteria with exceptionally high disintegration capabilities.

A petroleum refinery was classified as a hazardous waste generator under the Resource Conservation and Recovery Act (RCRA) and as part of this classification, they are required to have a waste minimization program in place. This refinery has a waste water treatment plant with a 320,000 GPD design capacity The waste water generated in the plant flows through the following treatment processes, a Primary clarifier, a Dissolved Air Flotation (DAF) unit, an Activated Sludge unit and a Secondary clarifier. A portion of the sludge from the Activated Sludge system is returned to an aerobic digestor and the remaining sludge is recycled back to maintain the necessary F/M ratio.

$105,000 saved by reducing disposal of Non-Hazardous Sludge

The aerobic digestor has a 265,000 gallon capacity. Solids from the aerobic digestor are considered non-hazardous waste and after dewatering they are disposed of in a landfill. Prior to use of GWT BIO series product, the Refinery dewatered and shipped approximately 105 tons of solids from the digestor at a cost of about $114,000. The first dosage of the GWT BIO™ PS10 was initiated into the digestor in order to reduce the amount of sludge handling. The GWT BIO™ PS10 products have specifically blended strains of bacteria that are highly effective in degrading oils and petroleum hydrocarbons, which might have escaped through the treatment units.

After the depletion of these oil/hydrocarbon compounds, cell biomass itself becomes a food source. The dewatering characteristics of the sludge is improved. The application of the BIO ™ product resulted in a significant reduction in solids content within the digestor system and the Refinery has not hauled away any additional sludge since.

$200,000 saved by reducing Listed Hazardous Sludge

The DAF unit is designed to remove oil, grease and solids from the waste water influent before the effluent water is sent to the aeration tank. The solids removed from the DAF are considered as a “listed hazardous waste’ for the petroleum refinery. In order to comply with the “90 Days” rule the Refinery was required to dewater and transport this hazardous waste for disposal through incineration or fuels blending. This rule also determines the frequency of the dewatering cycle and becomes an important cost factor. Approximately 125 tons of DAF solids were disposed in the prior to this field case study costing more than $305,000. Due to the great results obtained in sludge reduction in the digestor process, the Refinery decided to pilot study the possibility of treating there hazardous waste (up to 10% oil and grease) using the BIO series product. A section of the aeration basin was selected for this study. Within two weeks of the initial treatment the sludge batch was completed and met the requirements for a normal landfill. This Refinery has not sent any DAF waste out for disposal since this initial pilot-scale study and has saved more than $205,000 since it conducted the successful pilot study.

Using the GWT BIO™ product has also provided a reduction in the overall ammonium-N content and helped this particular refinery to meet the local discharge limit requirements.


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