Re-engineering materials management: a case study on an Indian refinery

Materials management function is always a major concern to the management of any industrial organisation as high inventory and an inefficient procurement process affect the profitability to a great extent. Problems multiply due to a very current business environment in India. Hence, existing materials planning and procurement processes and inventory management systems require a re-look with respect to a changing business environment. This study shows a radical improvement in materials management function of an Indian petroleum refinery through business process re-engineering (BPR) by analysing current processes, identifying key issues, deriving paradigm shifts and developing re-engineered processes through customer value analysis. BPR has been carried out on existing processes of “materials planning and procurement” and “warehousing and surplus disposal”. The re-engineered processes for materials management function trigger a few improvement projects that were identified by the group of executives who took part in the re-engineering exercise. Those projects were implemented in an integrated framework with the application of the state of art information technology tools.

Treatment of phenanthrene and benzene using microbial fuel cells operated continuously for possible in situ and ex situ applications

Bioelectrochemical systems could have potential for bioremediation of contaminants either in situ or ex situ. The treatment of a mixture of phenanthrene and benzene using two different tubular microbial fuel cells (MFCs) designed for either in situ and ex situ applications in aqueous systems was investigated over long operational periods (up to 155 days). For in situ deployments, simultaneous removal of the petroleum hydrocarbons (>90% in term of degradation efficiency) and bromate, used as catholyte, (up to 79%) with concomitant biogenic electricity generation (peak power density up to 6.75 mWm−2) were obtained at a hydraulic retention time (HRT) of 10 days. The tubular MFC could be operated successfully at copiotrophic (100 ppm phenanthrene, 2000 ppm benzene at HRT 30 days) and oligotrophic (phenanthrene and benzene, 50 ppb each, HRT 10 days) substrate conditions suggesting its effectiveness and robustness at extreme substrate concentrations in anoxic environments. In the MFC designed for ex situ deployments, optimum MFC performance was obtained at HRT of 30 h giving COD removal and maximum power output of approximately 77% and 6.75 mWm−2 respectively. The MFC exhibited the ability to resist organic shock loadings and could maintain stable MFC performance. Results of this study suggest the potential use of MFC technology for possible in situ/ex situ hydrocarbon-contaminated groundwater treatment or refinery effluents clean-up, even at extreme contaminant level conditions.

Análise da Eficiência de Nitrificação em Reatores Biológicos de Leito Móvel (MBBR) em escala de bancada utilizando efluente de Refinaria de Petróleo.

As atividades industriais petroquímicas, incluindo as refinarias de petróleo, são grandes consumidoras de água e, consequentemente, grandes geradoras de efluentes industriais contendo uma infinidade de contaminantes. No caso das refinarias de petróleo brasileiras, o nitrogênio amoniacal tem se tornado um componente crítico a ser tratado, o que tem sido feito através de processos de tratamento biológicos que utilizam a nitrificação como base. Neste trabalho, foi avaliada a operação de um reator de leito móvel (MBBR), em escala de bancada, utilizando suportes de polietileno com área específica de 820 m2.m-3, para tratar um efluente proveniente de uma refinaria brasileira com alta concentração de nitrogênio amoniacal. O efluente bruto apresentou demanda química de oxigênio entre 100 e 300 mg.L-1, teores de nitrogênio amoniacal entre 60 e 90 mg.L-1 e condutividade elétrica entre 1 e 2 mS.cm-1. Mesmo com variações da qualidade da alimentação da planta ao longo do estudo, como o aumento das concentrações de contaminantes, incluindo inibidores da nitrificação típicos dos efluentes de refinaria, a planta atendeu à Resolução CONAMA 430/2011 (BRASIL, 2011), que limita a concentração de descarte em 20 mg.L-1 para o contaminante nitrogênio amoniacal, em 93% das medições. Para o caso de uma fictícia legislação mais restritiva, que exigisse limite de 5 mg.L-1 desse contaminante, houve sucesso no tratamento em 83% do tempo, com eficiência média de nitrificação de 93,1%, evidenciando que há uma possibilidade real de utilização do processo MBBR em refinarias brasileiras.

As dimensões estratégia e sócio-comunicacional da rede de terceirização: impactos e perspectivas na visão gerencial, sindical e dos trabalhadores terceirizados na Petrobrás

O objetivo do trabalho foi estudar as implicações/impactos (sociais, gerenciais e políticos) do processo de terceirização - viabilizado por um novo tipo de competição capitalista por intermédio de redes inter-empresas - em um segmento da indústria do petróleo. Dessa forma, desenvolveu-se uma pesquisa empírica tendo como material de investigação o setor de manutenção industrial de uma refinaria de petróleo do Rio de Janeiro, durante o período de 1999 a 2001. As diferentes ópticas dos sujeitos sociais envolvidos foram consideradas nesta investigação, quais sejam: gerencial, sindical e dos próprios trabalhadores terceirizados. Os resultados do estudo demonstraram que a terceirização em curso no setor pesquisado tem implicado em movimentos simultâneos de destruição/reconstrução de relações produtivas tradicionais, combinando modernização e organização da produção em rede com práticas tayloristas/fordistas. Novas e antigas formas de (des)sociabilização e precarização podem ser evidenciadas através de discrepantes condições salariais e de trabalho e na criação de duas categorias de trabalhadores: os petroleiros e os terceirizados. A partir desse estudo a ambigüidade e fragilidade dessa "rede" de terceirização ficaram bem nítidas, pois a concentração de poder e recursos em pontos específicos e o prevalecente aspecto instrumental e economicista em detrimento do dialógico remetem a um distanciamento do próprio princípio de interdependência, inerente a noção de rede. A forma como a terceirização está sendo implementada nessa indústria aproxima-se mais à um padrão predatório que à um padrão flexível e interdependente como características inerentes a concepção gerencial de rede. Além disso, os mecanismos de inclusão/exclusão social e econômica entre efetivos e terceirizados, indicando cidadanias diferenciadas no âmbito da empresa, evidenciam a coexistência de velhas e novas formas de exploração sob o paradigma da rede.

Estudo da influência de compostos recalcitrantes na remoção de matéria orgânica biodegradável no tratamento de efluente de refinarias de petróleo

Petroleum Refinery wastewaters (PRW) have hart-to-degrade compounds, such as: phenols, ammonia, cyanides, sulfides, oils and greases and the mono and polynuclear aromatic hydrocarbons: benzene, toluene and xylene (BTX), acenaphthene, nitrobenzene and naphtalene. It is known that the microrganisms activity can be reduced in the presence of certain substances, adversely affecting the biological process of wastewater treatment. This research was instigated due the small number of studies regarding to this specific topic in the avaiable literature. This body of work ims to evaluate the effect of toxic substances on the biodegradability of the organic material found in PRW. Glucose was chosen as the model substrate due to its biodegradable nature. This study was divided into three parts: i) a survey of recalcitants compounds and the removal of phenol by using both biological and photochemical-biological processes; ii) biomass aclimation and iii) evaluation of the inhibitory effect certain compounds have on glucose biodegradation. The phenol degradation experiments were carried out in an activity sludge system and in a photochemical reactor. The results showed the photochemical-biological process to be more effective on phenol degradation, suggesting the superioruty of a combined photochemical-biological treatment when compared with a simple biological process for phenol removal from industry wastewaters. For the acclimation step, was used an activated sludge from industrial wastewaters. A rapid biomass aclimation to a synthetic solution composed of the main inhibitory compouns fpund in a PRW was obtained using the following operation condition: (pH = 7,0; DO ≥ 2,0 mg/L; RS = 20 days e qH = 31,2 and 20,4 hours), The last part was consisted of using respirometry evaluation toxicity effects of selected compounds over oxygen uptake rate to adaptated and non adaptated biomass in the presence of inhibitory compounds. The adaptated sludge showed greater degration capacity, with lower sensibility to toxic effects. The respirometry has proved to be very practical, as the techiniques used were simple and rapid, such as: Chemical Oxygen Demand (COD), Dissolved Oxygen (DO), and Volatile Suspended Solids (VSS). Using the latter it is possible to perform sludge selection to beggingthe process; thus allowing its use for aerobic treatment system`s behacior prediction

Obtenção de novos derivados de ß-naftol e cardanol hidrogenado e avaliação dos seus efeitos antioxidativos em gasolina automotiva

The chemical nature of the hidrocarbons found in gasoline directly affects the formation of oxidation complexes known as gums. Such complexes are slightly soluble in gasoline and their formation is delayed with the use of inhibitors, known as antioxidants. In this study, a synthetic compound (βnaphtol) and a natural subproduct (hydrogenated cardanol, derived from cashewnut shell liquid CNSL) have been used in order to generate novel antioxidant substances. These compounds were submitted to chemical reactions including alkylation, nitration and reduction, with the purpose of forming the following derivatives: 6(Nethyl,Nethylamino)βnaphtol (AO1); 6(Nethyl,Ndiethylamino)βnaphtol (AO2); aminoβnaphtol (AO3); 2(Nethyl,Nethylamino)pentadecylphenol (AOC1), 2(Nethyl,Ndiethylamino)pentadecylphenol (AOC2) and aminopentadecylphenol (AOC3). The derivatives were subjected to accelerated oxidative stability assays (Potential Gum and Induction Period) and to storage assays (Washed Gum and ASTM Color) during six months, with naphtha provided by the petroleum refinery RPBC (Refinaria Presidente Bernardes de Cubatão, in Brazil). The results for the derivatives were compared to those for commercial additives [DBPC (2,6ditbutyl4methylpcresol) and PDA (N,N disecbutylpphenylenediamine)], which were also added to the naphtha produced at RPBC at the moment of sampling. From all tested antioxidants, the novel antioxidant AOC1 (derived from hydrogenated cardanol) yielded a better global performance. During the period of time in which the naphtha was stored, an examination of this material was carried out in parallel, using the mass spectrometry technique. This study allowed to monitor the formation of a triolefinic compound, as well as the observation of subsequent formation and rupture of the olefinic constituents. As an eventual result from these experimental investigations, a reaction route leading to gum formation has been suggested

Clastogenicity of landfarming soil treated with sugar cane vinasse

The addition of nutrients and/or soil bulking agents is used in bioremediation to increase microbial activity in contaminated soils. For this purpose, some studies have assessed the effectiveness of vinasse in the bioremediation of soils contaminated with petroleum waste. The present study was aimed at investigating the clastogenic/aneugenic potential of landfarming soil from a petroleum refinery before and after addition of sugar cane vinasse using the Allium cepa bioassay. Our results show that the addition of sugar cane vinasse to landfarming soil potentiates the clastogenic effects of the latter probably due the release of metals that were previously adsorbed into the organic matter. These metals may have interacted synergistically with petroleum hydrocarbons present in the landfarming soil treated with sugar cane vinasse. We recommend further tests to monitor the effects of sugar cane vinasse on soils contaminated with organic wastes. © 2012 Springer Science+Business Media B.V.

Avaliação do potencial genotóxico e mutagênico do Rio Paraíba do Sul, numa área sob influência de uma refinaria de petróleo, utilizando Oreochromis niloticus (Perciformes, cichlidae) como organismo-teste

Pós-graduação em Ciências Biológicas (Biologia Celular e Molecular) - IBRC

Avaliação da gestão de áreas contaminadas de uma unidade industrial, localizada no município de Cubatão, São Paulo

Pós-graduação em Geociências e Meio Ambiente - IGCE

Análise multivariada no monitoramento do processo de produção de óleo diesel numa refinaria de petróleo

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Análise da toxicidade e da mutagenicidade de um solo de landfarming, proveniente de um refinaria de petróleo, antes e depois de processos que visam estimular a biodegradação de hidrocarbonetos

Pós-graduação em Ciências Biológicas (Biologia Celular e Molecular) - IBRC

Evaluation of the Atibaia River water quality using Lecane bulla as a test organism

In view of the diversity of environments found in the Brazilian territory, it is understandable that the use of native species can provide more relevant information for ecotoxicological studies. The purpose of this work was to evaluate the quality of water samples from the Atibaia River in an area that is under the influence of petroleum refinery using a native test-organism and submitting the data to PCA statistical analysis. Therefore, acute toxicity assays with Lecane bulla (Rotifera) were performed in four locations of the river, as well as physical-chemical analyses. Sampling was drawn in the dry and rainy seasons. The bioassays were static and lasted 48 hours; dead organisms were quantified at the end of the tests. Toxicological differences among the samples/per location and control were compared by means of the Analysis of Variance. Physical-chemical and mortality variables were simultaneously analyzed by multivariate analysis of the principal components and the Pearson correlation coefficient. Water samples from the exit of the refinery stabilization pond (location S.1) were toxic to L. bulla in both seasons, with significant differences in relation to the control and between the seasons. The statistical treatment of data showed that mortality was strong and positively correlated with total hardness, chlorides and EC, which together with pH presented higher values in location S.1, in the dry and in the rainy seasons. Due to its sensibility to the quality of the Atibaia river water samples, the potential use of L. bulla for ecotoxicological studies as an alternative test organism could be demonstrated.

PROTECTION FOR THE "TURNAROUND WORKER"

This document characterizes the types and magnitude of exposures to toxic substances faced by various turnaround workers in the petroleum industry. The safety and health professional is acquainted with the basic petroleum refinery, refinery equipment and causes for scheduled or emergency turnarounds. Common work procedures during the turnaround are discussed with emphasis on performing the job safely and without adverse consequence to worker health. A listing of commonly encountered substances with a corresponding summary of recognized exposure limits, recommended personal protection, hygiene measures and hazard information is provided to equip the safety and health professional with a ready checklist for worker protection.^ The use of this document was tested and found to improve the average prescription of work procedures and equipment from 38% appropriate (prior to receipt of information) to 84% appropriate (post receipt of information). All participants statistically improved their ability to protect the health and safety of the turnaround worker. ^

Integrated approach to materials management:a case study

The materials management function is always a major concern to management of any industrial organization, since high inventory and an inefficient procurement process significantly affect profitability. Problems multiply due to the current dynamic business environment in many countries. Hence, existing materials planning and procurement process and inventory management systems require a review. This article shows a radical improvement in the materials management function for an Indian petroleum refinery through business process re-engineering (BPR) by analyzing the current process, identifying key issues, deriving paradigm shifts and developing re-engineered processes through customer value analysis. BPR has been carried out on the existing processes of "material planning and procurement" and "warehousing and surplus disposal.

Petroleum contamination impact on macrobenthic communities under the influence of an oil refinery: Integrating chemical and biological multivariate data

Petroleum contamination impact on macrobenthic communities in the northeast portion of Todos os Santos Bay was assessed combining in multivariate analyses, chemical parameters such as aliphatic and polycyclic aromatic hydrocarbon indices and concentration ratios with benthic ecological parameters. Sediment samples were taken in August 2000 with a 0.05 m(2) van Veen grab at 28 sampling locations. The predominance of n-alkanes with more than 24 carbons, together with CPI values close to one, and the fact that most of the stations showed UCM/resolved aliphatic hydrocarbons ratios (UCM:R) higher than two, indicated a high degree of anthropogenic contribution, the presence of terrestrial plant detritus, petroleum products and evidence of chronic oil pollution. The indices used to determine the origin of PAH indicated the occurrence of a petrogenic contribution. A pyrolytic contribution constituted mainly by fossil fuel combustion derived PAH was also observed. The results of the stepwise multiple regression analysis performed with chemical data and benthic ecological descriptors demonstrated that not only total PAH concentrations but also specific concentration ratios or indices such as >= C24:< C24, An/178 and Fl/Fl + Py, are determining the structure of benthic communities within the study area. According to the BIO-ENV results petroleum related variables seemed to have a main influence on macrofauna community structure. The PCA ordination performed with the chemical data resulted in the formation of three groups of stations. The decrease in macrofauna density, number of species and diversity from groups III to I seemed to be related to the occurrence of high aliphatic hydrocarbon and PAH concentrations associated with fine sediments. Our results showed that macrobenthic communities in the northeast portion of Todos os Santos Bay are subjected to the impact of chronic oil pollution as was reflected by the reduction in the number of species and diversity. These results emphasise the importance to combine in multivariate approaches not only total hydrocarbon concentrations but also indices, isomer pair ratios and specific compound concentrations with biological data to improve the assessment of anthropogenic impact on marine ecosystems. (c) 2008 Elsevier Ltd. All rights reserved.