Cost analysis study through optimization of a sludge drying plant for a petroleum refinery

Abstract

A Sludge Drying Plant (SDP) produces bio-sludge cakes as end products. In most cases, it is the final processingfacility of Effluent Treatment System (ETS) before it is sent out for final disposal, either through landfill or handing it overto a third party body with some economic impacts. Efficiency of the SDP determines the economic impact should this bio-sludge is handed over to a third party body for disposal. The resultant of the dry solid produced from the SDP can alsotremendously affect the overall process costs. In an ideal state, the dry solid produces contain 0% water content; however,in an actual plant 0% water content can never be achieved. On disposal, Kualiti Alam, a body appointed for disposalpurposes, will charge the dried cake sludge based on the weight, regardless water or dry solids. Therefore it is only sensibleto export the dried cake at maximum dryness. Suitable sludge management which includes preventive maintenance andoperating costs can reduce the overall process costs. This paper focuses on how cost and sludge management correlates andimprovement is practically seen on an actual implementation of this optimization. Factors that contributes to the overallSDP performance for parameter optimization for the SDP is identified through actual process data a capture from a lifeSDP plant and analysis as well as identification of the subsystems within the SDP itself.