Automated process for treatment of refinery wastewater

An automated process for treating refinery wastewater, the process capable of surpassing, or withstanding shock loads, the process comprising:

• (i) treating the refinery wastewater in an aeration tank having a mixed liquor suspended solids (MLSS) in a range of 800-1200 ppm, wherein the aeration tank is provided with a first set of sensors comprising a pH sensor, a TDS/conductivity sensor, a dissolved oxygen (DO) sensor, a total organic carbon (TOC) sensor, a cell count or an MLSS sensor, a sludge volume index (SVI) sensor, a specific oxygen uptake rate (SOUR) sensor, an electrochemical sensor, a nitrogen and phosphorus sensor, an ammonia sensor, a temperature sensor, and a level sensor, wherein the electrochemical sensor is configured to monitor a cell voltage and an anode potential of an electrochemical cell, wherein the aeration tank is connected to a hybrid packed bed reactor, and wherein the hybrid packed bed reactor has a plurality of chambers;
• (ii) monitoring and identifying shock loads and toxic ingressions in the aeration tank continuously;
• (iii) dosing an active culture of microbes from a microbial dosing system connected to an on-site customized microbe generation system to obtain treated water, and sludge;
• (iv) polishing the treated wastewater;
• and
• (v) recycling 1-8% of the sludge produced in the hybrid packed bed reactor to the aeration tank;
• wherein the process parameters are controlled through a distributed control system (DCS) based integrated system, and
• wherein an increase in the cell voltage and the anode potential beyond a threshold value, as identified by the electrochemical sensor, is responded by immediate dispensing/dosing of the active culture of microbes by the microbial dosing system to increase the MLSS in each of the plurality of chambers of the hybrid packed bed reactor to 1200 mg/l-1800 mg/l, and by increasing air purging to maintain the dissolved oxygen (DO) to a level of 4-8 ppm, and wherein a decrease in the cell voltage and the anode potential beyond the threshold value, as identified by the electrochemical sensor, is responded by immediate dispensing/dosing of H2O2 from a feed tank and by immediate dosing of the active culture of microbes by the microbial dosing system to oxidize sulfides and ammonia produced during treating the refinery waste water.