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					ANNUAL PERFORMANCE
        2007

    Engen Refinery
    465 Tara Road
       Durban
The Engen Refinery Team
•   Willem Oosthuizen     -   General Manager
•   Lynne Hanekom         -   HSE Manager
•   Pravin Motilal        -   Engineering Manager
•   Sandra Redelinghuys   -   Environmental Manager
•   Pam Cele              -   Health Services Manager
•   Velephi Manzini       -   Environmental Advisor
•   Namo Thambiran        -   Environmental Engineer
•   Anthony Stoffels      -   Incident Investigator
•   Herb Payne            -   Communications Specialist
•   Thabisile Gumede      -   Communications Coordinator
•   Lulama Nanto          -   HSE Administrator
Agenda
    • Overview
    • Background
    • Sustainable business & general
    • Annual performance review
         • SO2
         • VOC
         • PM10
         • NOx
         • Flares
         • Noise
         • Waste
         • MHI
         • Pipeline integrity
    • Complaints
    • Incidents
    • Conclusion
2007 Overview

• Permitting process is working
• Regular interface meetings with authorities keep the
  focus
• Environmental Management Plan (EMP) enables priority
  areas to be set and managed
• Significant improvements in SO2 ambient levels
• Continuous Improvement results from the permit process
Background

•   1st recipient in South Africa of 5 year Scheduled Trade Permit.

•   1st recipient in South Africa of both 5 year permits - Scheduled Trade
    Permit and Trade Effluent Permit.

•   Level playing fields
     •   Same permit requirements with respect to Industry competitors


•   Reasonableness
     •   Realistic time frames for implementation of permit requirements.


•   Engen encourages working together of the 3 tiers of government in
    terms of reporting requirements

•   Streamlining of permit requirements by 3 tiers of government
Background contd… - Reduction Initiatives

• Environmental Management Plan (EMP) developed in
  November 2006 and agreed to by eThekwini Health , now
  reviewed annually

• EMP based on prioritised risks associated with each
  issue of concern including SO2, VOC’s, PM10, NOx,
  Flares, Smell, Noise, and Pipeline Integrity

• The EMP ensures that resources are focused on the
  priority issues.
Sustainable Business & General

• Focused Continuous Improvement
  – EMP
• Environmental Management System ISO 14001
  – SAFOR ( Lube oil Refinery ) attained certification in 2006
  – Refinery and Island View now also ISO14001 certified
  – New electronic Corrective Action Management System implemented
  – New Document Management System implemented to ensure better
    control of documents
Sustainable Business & General contd…

• Monitoring Programme in place as per permit and
  followed
• Successful Turnaround executed in June 2007
• Occupational Health and Safety Programme in place
   – Occupational Noise, Lighting, Benzene, MMT, H2S, SO2, MEK and Furfural

• Community Participation and Social Investment
   – CLF, Junior Achievement Programme, Saturday School, Computer Centres,
     Community Computer Training, Entrepreneurial Programme, Childhood
     Development, Environmental Awareness Campaign, Waste Management
     Workshop, Safe drums support, Mayor’s Excellence Awards, Wentworth
     Hospital Vegetable Garden, Community NGO Workshop and Community
     Policing Forum Support
Ambient SO2 Air Quality
                                 ces   Engen Related                      Yearly Limit                  2007 Cumulative
                                        250
                                                               222
   N ber of 10 m ute S 2 exceeden




                                        200
                      O




                                        150
                                               119112        105
                                                        94
                in




                                        100


                                         50
                                                                                               35
                                                                     11
    um




                                                                             4   4                  2         1        11
                                          0
                                               CYCYCYCYCYCY                 J- F- M- A- M- J- J- A- S- O- N- D-
                                               02 03 04 05 06 07            07 07 07 07 07 07 07 07 07 07 07 07


                                          Averaging          Guidelines       No. of permissible          Engen 2007
                                          Period             Value            exceedences per
                                                                              annum

                                          10 minutes           191 ppb                   35                   11
                                              24 hour          48 ppb                    Nil                   0
                                              Annual           19 ppb                    Nil                   0
Average Monthly SO2 Emissions in Tonnes /day

                           SO2 emissions                      Permit limit
               80

               70   72

               60

               50          50
    Tons/day




               40                 40

               30
                                         25     25
               20                                      22      22     20       20          19
               10
                    46.4


                           38.0


                                  32.0


                                         16.6


                                                12.9


                                                       13.9


                                                               16.5


                                                                      12.6


                                                                             12.8


                                                                                    11.3
                0
                    CY     CY     CY     CY     CY     CY      CY     CY     CY     CY
                    98     99     00     01     02     03      04     05     06     07
SO2 progress in summary

•   Understand our SO2 situation so much better
     – Follows Studies by Jacobs Comprimo, Exxon Mobil and Sulfur
       Experts
     – Control System improvements
     – Plant stability and reliability focus
     – Operating changes - catalysts and procedure improvements
     – Plant modifications including post clean fuels design modifications
     – Costs of modifications to date ±R200 million
     – Future focus
        • Fuel gas scrubbing
        • Stability of operation
        • Understanding the weather impact
VOC Ambient Monitoring Programme

• Continued with fence line monitoring programme
• Sampling points on the boundaries of the refinery
• Run by an independent Approved Inspection Authority
• Monitors fugitive emissions of Benzene, Toluene, Xylene and
  Ethyl Benzene on a two weekly basis.
• Results low
• VOC reduction remains a focus area – several projects in this
  area
• VOC reduction as measured by Ilitha indicates that there was a
  67% reduction in overall VOC emissions between 1999 and
  2005
Passive Sampling Locations




                               Main Gate   Admin Gate
     Southern Works


                                                        Rec Club
                  Badulla




                      Mosque
VOC Monitoring Programme - Benzene

                                Benzene - EC limit 10 μg/m3
                     CY 03              CY 04          CY 05          CY 06
                     CY 07              W HO Limit     EC Limit
   Benzene 12 mth ave,



                         20.0

                         15.0
         μg/m 3




                         10.0

                          5.0

                          0.0
                                Admin   Main Mosque Scrap Badulla South
                                        Gate         Yard Fence Works


 Average Benzene annual concentration of 3.99 μg/m3, which is
 39.9% of the stricter EC limit.
VOC Monitoring Programme – Ethyl benzene

                                       Ethyl Benzene - WHO limit 2200 μg/m3
                                       CY03     CY04     CY05         CY06        CY07
 3
  Eth Benzene 12 mth ave, μg/m




                                 10
                                  9
                                  8
                                  7
                                  6
                                  5
                                  4
                                  3
                                  2
                                  1
                                  0
                                      Admin   Main   Mosque   Scrap     Badulla    South
                                              Gate            Yard      Fence      Works

 Average Ethyl Benzene annual concentration of 4.4 μg/m3,
 which is 0.2% of the WHO limit.
VOC Monitoring Programme - Xylene

                                          Xylene - WHO limit 870 μg/m3
                                      CY 03   CY 04    CY 05   CY 06   CY 07     W HO Limit
    3
    Xylene 12 mth ave, μg/m



                              1000
                               800
                               600

                               400
                               200
                                 0
                                     Admin    Main    Mosque   Scrap   Badulla   South
                                              Gate             Yard    Fence     Works


 Average Xylene annual concentration of 19.6 μg/m3, which is
 2.3% of the WHO limit.
VOC Monitoring Programme - Toluene

                                                 Toluene - WHO limit 260 μg/m3
                                        CY 0 3      CY 04     CY 05     CY 0 6     CY 07       W HO Limit
       3



                                  300
       Toluene 12 mth ave, μg/m



                                  250

                                  200
                                  150
                                  100

                                   50
                                    0
                                          Admin        Main    Mosque      Scrap     Badulla      South
                                                       Gate                Yard      Fence        Works


 Average Toluene annual concentration of 24.7 μg/m3, which is
 9.5% of the WHO limit.
VOC Reduction Programme

Reduction initiatives include:
• Reduction in emissions from tanks (secondary seals and
vapour sleeves), sampling points (convert to closed loop
sampling), and pumps (double seals).
• Vapour recovery unit at effluent treatment plant
• Planned vapour recovery for benzene loading
• Leak Detection and Repair programme in place for
fugitive emission reduction
PM10 Emissions

                                Ave Daily PM10 emissions                                 Permit Limit (1 Ton/day)
                  1.2

                  1.0

                  0.8
       Tons/day




                  0.6

                  0.4

                  0.2

                  0.0
                                CY 07



                                               F-07
                                        J-07




                                                             A-07



                                                                           J-07

                                                                                  J-07

                                                                                           A-07

                                                                                                  S-07

                                                                                                         O-07

                                                                                                                N-07

                                                                                                                       D-07
                                                      M-07



                                                                    M-07
                        CY 06




•   2007 PM10 daily average – 0.68 tons/day
•   2007 Annual emissions – 249 tons/day
PM10
• Success at last
• Installed Particulate Separation System in 2005 (R50M)
  which did not work
• Commissioned alternative solution – 4th stage separator –
  evaluation in progress – results to date very encouraging
NOx Emissions

                                   Ave D aily N Ox emissions                          Permit limit (8 tons/day)
                     9.0


                     8.0


                     7.0
          Tons/day




                                                                                 l


                     6.0


                     5.0


                     4.0
                                    CY 07

                                            J-07

                                                   F-07

                                                          M-07




                                                                        M-07

                                                                               J-07

                                                                                      J-07

                                                                                             A-07

                                                                                                    S-07

                                                                                                           O-07

                                                                                                                  N-07

                                                                                                                         D-07
                                                                 A-07
                           CY 06




•   2007 NOX daily average – 5.7 tons/day
•   2007 Annual emissions – 2089 tons/day
NOx Reduction

•   Engen is a small source as confirmed by recent studies
•   Vehicles make a significant impact
•   Permit requires a reduction from 8t/d to 6t/d
•   Installation of stages fuel burners in Safor boiler –
    commissioned and now been evaluated
Complaints and Reportable Flaring

                Total Complaints              Reportable Flare
         80
         70
         60
         50
Number




                    42
         40
                         30
         30
         20    18
                                      7                            6
         10                   1   2       2   6
                                                       2   1   2       1
          0
              CY- CY- CY- J - F - M - A - M - J - J - A - S - O- N- D-
              05 06 07 07 07 07 07 07 07 07 07 07 07 07 07


         Flaring Plan submitted to EH for June Turnaround
Flares

• Flares BAT compliant
• Several past projects including
   – Rerouted the Knockout pots away from the flare.
   – Flare video monitoring upgrade
• Participated in the DEAT flaring project
• Due to permit requirements we report against tighter
  standards than others
Noise

• Peaks in noise levels are investigated – focus on
  preventing upsets
• Steam system management and steam leaks – task
  teams
• Background noise screening survey done during 2007
  June TA by independent consultant
• Study indicate high levels of background noise from
  vehicles and planes when refinery is down
• Study to be repeated by another consultant at next
  suitable full refinery shutdown
Waste Management
• Proactive process to ensure compliance with proposed
  NEMA: Waste Management Act
   – Consultant employed to develop and implement an Integrated Waste
     Management Plan as may be required by new Act


• Waste service provider audits
   – 11 audits were conducted off site
   – Compliance with transport requirements for hazardous substances


• Contracts
   – Consolidation of waste service providers
   – Terms under review to ensure cradle-to-grave compliance with legal
     requirements
   – Extend contracts to recycling service providers to ensure continued
     drive towards reuse and recycling
Waste Management contd…
• Training
   – Members of ESD trained to audit drum recyclers, landfills and recyclers


• Waste Classification
   – New reclassification cycle commenced


• New Appointment 2007
   – Strategic waste scientist - to close looped systems eg. recycling of
     catalysts back to suppliers where possible
MHI

• Study conducted by ERM to the Seveso II standards
  (beyond local standards)
• Submitted as required to the relevant authorities
Pipeline Integrity

• Engen Pipelines have been well managed over the years
• Integrity programme in place to ensure they stay in good
  condition
   – Some modifications to enable good information gathering on pipeline
     condition
   – Hydrostatic testing
   – Remote monitoring of protection systems
• Part of ROW committee
Total Annual Complaints

                 Flare           Noise          Smell          Fallout         Smoke
           225
           200
                       24
           175
           150
                       55
  Number




                  84        35
           125
           100         43
                  23        54
           75
           50               25
                  72   72
           25
                            33
            0                     1
                                  2
                 CY CY CY J-          F-   M-   A-   M-   J-   J-   A-   S-   O-   N-   D-
                 05 06 07 07          07   07   07   07   07   07   07   07   07   07   07
Complaints cont…
 •   Odours
     –   Cooling Water System
     –   ETP
     –   Methyl Mercaptan System
     –   Kill the Stink Programme

 •   Noise
     – Safety valves lifting
     – Steam Leaks
     – Safor

 •   Fallout & Smoke
     – CO Boiler Incident
     – X104 Fire Incident
     – Insurance
Incidents 2007

• Alkylation Unit Fire
• Fluidised Catalytic Cracker Unit Fallout
• X104 Tank Fire
• Vacuum Unit Bottoms Fire
In conclusion

•   Good success story – especially on SO2
•   VOC results remain low but will still be a focus area for us in coming
    years
•   PM10 success (at last)

• CLF is a good base for relationship building and to discuss priority
  areas
• EMP gets results
• Regular meetings with eThekwini Health has resulted in good
  outcomes
• Good community and Authority support during our incidents
• We look forward to continually improving our impact
Thank you

				
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