2011 Sines Data Book - Galp Energia

Sines Refinery 

2011 DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT

Sines Refi nery 

2011 DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT 

www.galpenergia.com

SINES REFINERY 

2011 DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT 

01 • 

02 • 

2.1 

2.2 

2.3 

03 • 

3.1 

3.2 

3.3 

04 • 

4.1 

4.2 

4.3 

05 • 

5.1 

5.2 

5.3 

5.4 

06 • 

6.1 

6.2 

6.3 

07 • 

08 • 

09 • 

MESSAGE FROM THE REFINERY MANAGEMENT 

FRAMEWORK 

HEALTH, SAFETY AND ENVIRONMENTAL POLICY 

INTRODUCING THE REFINERY 

DESCRIPTION OF ACTIVITY 

ACTIVITIES, ACTIONS AND PROJECTS 

GOALS AND TARGETS 

COSTS AND INVESTMENTS 

HEALTH, SAFETY AND ENVIRONMENT TRAINING 

ACTIVITY INDICATORS 

LEVEL OF ACTIVITY 

PRODUCTION 

CONSIGNMENTS 

ENVIRONMENTAL PERFORMANCE 

RESOURCE CONSUMPTION 

ATMOSPHERIC EMISSIONS 

WASTEWATER 

WASTE 

SAFETY AND HEALTH PERFORMANCE 

PREVENTION 

ACCIDENTS 

OCCUPATIONAL MEDICINE 

COMMUNITY RELATIONSHIPS – GISA PROJECT 

GLOSSARY 

STATEMENT OF CONFORMITY 

6 

8 9 

9 

10 

12 

13 

13 

14 

16 

17 

17 

17 

19 

20 

21 

24 

26 

27 

28 

29 

30 

31 

34 

39

The Sines refinery Data Book outlines the 

refinery’s performance in Health, Safety and 

Environment in a factual and direct manner, 

discussing and analysing various typical activity 

indicators as well as matters of interest to the 

public, stakeholders and public entities.

01 MESSAGE MENSAGEM FROM DA THE DIRECÇÃO REFINERY DA MANAGEMENT REFINARIA 

01 

02 03 04 05 06 07 08 09 

01 . MESSAGE FROM THE REFINERY 

MANAGEMENT 

6 SINES REFINERY / 2011 DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT

MESSAGE FROM THE REFINERY MANAGEMENT 02 03 04 05 06 07 08 09 

Message from the refi nery management 

In 2010 the Sines refi nery achieved its OHSAS 18001:2007 

Safety and NP EN ISO 14001:2004 Environment Management 

System Certifi cation. 

2011 has been dedicated to strengthen the Management 

System according to those Standards. The Management 

System is not a goal in itself, but the matrix where these 

matters are to be addressed and is intended to support an 

harmonious evolution towards a future mandatorily based on 

an unquestionable sustainability. 

In 2011, despite an unfortunate incident with lost workdays 

injury, we were able to achieve a remarkable Lost Workday 

Injury Frequency of 0.2, which means a world class 

performance. 

REGARDING THE ENVIRONMENT, WE TOOK SOME 

STEPS TOWARDS THE FUTURE, STRENGTHENING 

OUR PERFORMANCE AS IT CAN BE SEEN ON THE 

DECREASING TRENDS OF THE AIR EMISSIONS. 

Nevertheless, on liquid effl uents we had not an equivalent 

performance. 

We are still in the beginning of a long path that we started 

some years ago towards EXCELLENCE. 

Sines refi nery management 

Cordeiro Catarino, Sines refi nery director 

SINES REFINERY / 2011 DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT 

7 

01

02 01 

ENQUADRAMENTO 

FRAMEWORK 

02 

03 04 05 06 07 08 09 

02 . FRAMEWORK 

2.1 

2.2 

2.3 

HEALTH, SAFETY AND ENVIRONMENTAL POLICY 

INTRODUCING THE REFINERY 

DESCRIPTION OF ACTIVITY 


01 

FRAMEWORK 03 04 05 06 07 08 09 

2.1 Health, Safety and Environmental Policy 

Galp Energia acknowledges that the protection of the 

Environment, Safety and Health of its employees, customers 

and community in general, are essential values for the 

Organization sustainability and is, therefore, aware of its 

responsibility in managing the impact of its activities, products 

and services within the society of which it takes part. 

Thus, establishes a commitment to integrate Health, Safety 

and the Environment (HSE) into the Company’s strategy and 

activities, as well as into the continuous improvement of 

its performance, making these it’s Management pillars and 

thereby contributing to achieving a sustainable development 

and corporate excellence. 

Galp Energia is committed to: 

• establish Health, Safety and Environmental Protection as 

fundamental values of the Company; 

• acknowledge that managing Health, Safety and the 

Environment is a direct leadership responsibility and risk 

prevention is a shared responsibility within the Organization; 

• promote training for all employees in these subjects, 

involving partners and other interested parties, committing 

them to Health, Safety and the Environmental matters in 

order to act proactively both within and outside the working 

environment; 

• apply the best management practices and technical solutions 

available, over and above legal compliance, in continuous 

prevention strategies by identifying, controlling and 

2.2 Introducing the refi nery 

Operator details 

Sines refi nery is an asset of Petrogal, S.A. a company in the 

Galp Energia Group. The following table shows its relevant details: 

Sines refi nery 

Refi naria de Sines, Petrogal, S. A. 

Daldas do Meio, 7520-952 Sines 

Telephone: + 351 269 630 800 

Fax: + 351 269 630 880 

CAE: 19201 - Manufacture of refi ned Petroleum Products 

Date of Incorporation: March 26 th 1976 

Headquarters: Rua Tomás da Fonseca - Torre C 1600-209 Lisboa 

Telephone: + 351 217 242 500 - Fax: + 351 217 240 573 

Equity: € 516,750,000 

Tax Registration Number: 500 697 370 

Registration Number at the Lisbon CRC: 523 

monitoring risks to ensure Health, Safety and Environmental 

protection; 

• create conditions that allow the Organization as a whole to 

be permanently prepared to respond to emergencies; 

• ensure the sustainability of projects, ventures and products 

throughout their life cycle, through the use of technology, 

facilities, resources and best practices to prevent or minimize 

adverse consequences; 

• establish challenging targets and goals, measuring and 

evaluating the results obtained and taking the necessary 

action to pursue them; 

• ensure effi cient use of energy and resources and the 

incorporation of safe and innovative technologies when 

managing its activities, minimizing the impact, so as to 

guarantee the Company’s sustainability and Environmental 

protection; 

• make this Policy known and available, in a responsible and 

transparent way, to all interested parties, communicating 

regularly the Company’s Health, Safety and Environmental 

performance. 

Galp Energia, therefore, assumes its role as a socially 

and environmentally responsible Company, operated by 

a motivated, competent and innovative team of people, 

committed to protect the Environment, Health and Safety of its 

employees, customers, partners and the community, actively 

contributing to the wellbeing of the Society. 

Sines refi nery 


9 

02

02 01 

FRAMEWORK 03 04 05 06 07 08 09 

10 

Historical overview 

Year Event 

1978 Startup of Sines refi nery activity. 

1993/1994 

Process reconfi guration at the refi nery through the introduction of cracking and gasoline Complexes, consisting of vacuum distillation, catalytic cracking, 

alkylation, visbreaker and sulphur recovery units. 

1997 

Start-up of Diesel fuel desulphurisation, acid water stripper and amine treatment. Construction of the pipeline for CLC (Companhia Logística de 

Combustíveis, located in Aveiras). 

1999 Installing the Vapour Recovery Unit (VRU) at the tanker fi lling station. 

2000/2002 

Construction begins on the Splitter and cracking gasoline hydro treatment, hydrogen production and purifi cation units, and modifi cation of the Diesel oil 

Desulphurization Units (increase in capacity/severity). 

2003/2004 

Changes to the Desulphurization Unit for vacuum gas (FCC unit load) to sulphur in the produced streams (namely gasoline, diesel and fuel oil); start-up 

of boiler 4. 

2005 

Revamping the vacuum gas Hydrobon, HV; revamping the effl uent pre-treatment system. Issue of the Greenhouse Gas Emissions Document number 

196.01. 

2006 Revamping the Bitumen Storage Site. 

2007 Issue of Environmental License number 48/2007; revamping the Waste Treatment Park (temporary storage of the installation’s solid waste). 

2008 

Start of operations for the Electrostatic Precipitator. General maintenance shutdown at the refi nery. Environmental impact assessment for the refi nery 

Reconfi guration Plan – Project classifi ed as PIN+. Issue of a new LA No. 210/2008. Beginning of the construction of the new units. 

Start of operations for Cogeneration Unit; Sines refi nery qualifi es in safety and the environment according to ISO14001 and OHSAS 18001; End of 

2009 

phase 1 of the Project to to redirect purges in a closed system at Plant 1; Upgrade of the Atmospheric Emission Control System – SIAC; Installing of 

process environmental analysers at the Atmospheric Distillation Units and FCC. 

2010 

Incorporation of new additive in the FCC Unit to reduce gaseous emissions of NO . Certifi cation renewal of the Sines refi nery HSE management system, 

x 

according to ISO: 14001 and OHSAS: 18001. An historical maximum of 2 million working hours without accidents with lost days has been achieved. 

2011 

Refi nery technical sutdown to link the new operational units, recording 500,000 hours worked with no lost work day injuries. 

Renovation of the Safety and Environment System, according to ISO: 14001 and OHSAS: 18001 Standards. 

Licences 

Sines refi nery, is a facility under the Integrated Pollution 

Prevention and Control (IPPC) Directive and holds an 

Environmental Permit Licence - LA nº. 210/2008. This 

document sumarizes all the environmental legal requirements 

that the installation is required, including the compliance 

requirements of the operation of the new units of the Sines 

refi nery Conversion Project. 

2.3 Description of Activity 

Capacity 

Sines refi nery has an installed refi ning capacity of 10 million 

tonnes of crude oil per year, producing a diversifi ed range of 

refi ned commercial products, namely: 

• LIQUEFIED PETROLEUM GAS: 4.1% 

• GASOLINES: 32.6% 

• JET/OIL: 9.7% 

• DIESELS: 36.0% 

• FUELS: 16.8% 

• SULPHUR: 0.3% 

• BITUMEN: 0.5% 


Being also covered by the European Union Emissions Trading 

System, the Sines refi nery, has a permit to emit Greenhouse 

Gases Emissions (Título de Emissão de Gases com Efeito de 

Estufa), TEGEE number 196.02.II, that awards 2,137,550 CO 2 

Emission Allowances. 

The Cogeneration Plant is included, in TEGEE and in LA, as part 

of Sines refi nery. 

The refi nery’s storage capacity is approximately 3 million 

tonnes, with 1.5 million allocated to crude oil and the 

remaining capacity to intermediate and fi nal products. 

Description of the main raw materials 

Sines refi nery processes two types of crude: SOUR and SWEET, 

the names deriving from their sulphur content. 

The following table shows the proportions of each crude type, 

as well as its main features.

01 

FRAMEWORK 03 04 05 06 07 08 09 

Type of line Indicator 2007 2008 2009 2010 2011 

Proportion of use (%) 68% 70% 69% 73% 65% 

SWEET 

Load density (º API) 34.75 36.01 34.90 36.88 36.25 

Sulphur (% m/m) 0.34 0.30 0.27 0.29 0.28 

Proportion of use (%) 32% 30% 31% 27% 35% 

SOUR 

Load density (º API) 32.19 33.33 36.61 37.18 37.39 

Sulphur (% m/m) 1.96 1.90 1.19 1.26 1.25 

The selection of the crude types depends on various 

commercial, technical and environmental factors, such as: 

quality, market availability, international market value, refi nery 

production plans, and storage capacity. 

Description of process 

Currently the refi nery has 27 processing units, including 

the Atmospheric and Vacuum Distillation, where the initial 

separation of fractions of gases, naphtha, kerosene, Diesel fuel, 

fuel oil, vacuum gasoil and vacuum residue, contained in the 

crude oil, and the treatment units to decrease sulphur content. 

In the remaining units (molecular conversion) to produce 

lighter and cleaner products: vacuum gasoil Catalytic Cracking 

Units (FCC), vacuum residue Thermal Cracking (Visbreaker) 

and naphtha Hydrocracking (Isomax). In Catalytic Reforming 

Process scheme 

Crude 

Oil 

Fuel gas 

Atmosferic 

destilation 

Atmospheric 

residue 

Liquified petroleum gas 

Vacuum 

destillation 

(2 plants) 

Atmospheric 

residue 

SPLITTER 

Light 

naphta 

Medium 

naphta 

Kerosenes 

Atmospheric gas oil 

Heavy Diesel oil 

H2 

Vacuum gas oil 

Vacuum residue 

Desactivation / 

isomerisation 

HV 

H2 

Visbreaking 

LPG 

Isomax 

H2 

Platforming 

FCC 

(Fluid 

Catalytic 

Cracker) 

Vacuum 

destillation 

Molecular Conversion Units (Platforming), the octane index 

of gasoline is improved, with hydrogen by-production; in 

alkylation, an aromatics and olefi n free gasoline is produced 

from gas streams, and, in steam reforming hydrogen is 

produced from natural gas. 

Sines refi nery carries out the following activities under the 

Integrated Pollution Protection and Control Regime (IPPC): 

IPPC IDENTIFIER Description 

1.1 Combustion facilities with combustion heat output 

over 50MW 

1.2 Oil and gas refi neries 

LCO 

Slurry 

LCO 

FRC 

Hidrogen 

production 

and 

purification 

H2 

HD 

HG 

FCC Petrol 

H2 

Propylene 

H2 

FRC Butylenes 

Asphalt 

Oxydation 

SPLITTER 

Alkylation 

HT 

Fuel gas 

Propane 

Butane 

Propylene 

Isopentane 

Isomax petrol 

Chemical naphta 

Hydrogene 

Platformed petrol 

Kerosenes/jet fuels 

Atmospheric gas oils 

Desulphurised 

Diesel oil 

Alkyladted derivatives 

FCC light petrol 

FCC desulphurised 

kerosene 

Light cycle oil 

Fuel oil 

Atmospheric residue 

Bitumens 


11 

02

03 01 02 

ACTIVITIES, ENQUADRAMENTO 

ACTIONS AND PROJECTS 

03 

04 05 06 07 08 09 

12 

03 . ACTIVITIES, ACTIONS AND PROJECTS 

3.1 

3.2 

3.3 

GOALS AND TARGETS 

COSTS AND INVESTMENTS 

HEALTH, SAFETY AND ENVIRONMENT TRAINING 

REFINARIA DE SINES / DATA BOOK DE SEGURANÇA, SAÚDE E AMBIENTE 2011

01 

02 

3.1 Goals and targets 

ACTIVITIES, ACTIONS AND PROJECTS 04 05 06 07 08 09 

According to its vision and values, Galp Energia establishes 

performance goals for Environment, Quality and Safety on all 

the different levels of the organization. 

These goals are defi ned in several fi elds, to comply with the 

management requirements and standards assumed by the 

Organization, including those set in the Environmental, Quality 

and Safety Management Systems implemented in accordance 

with internal and external Reference Standards. 

Issue 

Water consumption 

Wastewater production 

Marks achieved in certain goals are refl ected in the 

performance evaluation of our employees, thus leading to a 

global and cross-cut commitment of the entire organization. 

The continuous improvement processes leads to goals 

appropriate to the nature of the activities and the relevance 

of their impact on HSE performance. The Sines refi nery 

framework of goals and targets is an example of this 

commitment. 

2011 Goal/ 

Target 

Do not exceed the 20 percentile of the refinery´s BREF 

[0.10-4.50] m 3 water/tonnes of crude oil treated – 0.98 m 3 water/tonnes of crude oil treated 

Do not exceed the 20 percentile of the refinery´s BREF 

[010-5.50] m 3 wastewater/ tonnes of crude oil treated – 

1.08 m 3 wastewater/tonnes of crude oil treated 


Value 

NO x emissions Do not exceed the ELV’s of the Main Stack – 400 mg/Nm 3 212 

SO 2 emissions Do not exceed the ELV’s of the Main Stack – 3,000 mg/Nm 3 2,485 

Total particulate matter emissions Do not exceed the ELV’s of the Main Stack – 150 mg/Nm 3 52 

CO 2 emissions Do not exceed 2,181,798 t CO 2 

0.64 

0.36 

1,769,213 

Sulphur content in the RFO Do not exceed 2% 1.57 

Preventive Observations for Environment 

and Safety 

Accomplish 1,500 hours of OPAS 1,390 

Drills Accomplish 8 drills 7 

Lost work day injury frequency (number 

of lost work day injuries per million hours 

worked) 

3.2 Costs and investments 

The following chart shows the main environmental costs and 

investments. 

Costs and investments concerning the protection of enviroment (€M) 

Less than 0.34 (2010 value) 0.24 

2007 

1.43 1.29 0.58 4.68 

2008 

1.78 1.25 0.21 11.47 2.19 

2009 

2.63 

1.41 1.49 6.75 0.25 

2010 

3.20 

0.79 0.56 7.74 0.32 


5.50 1.53 0.28 4.56 0.13 

Water protection Waste management Soil and groundwater protection Air and climate quality 

Environment protection and management 

Level 

of fulfi lment 

REFINARIA DE SINES / DATA BOOK DE SEGURANÇA, SAÚDE E AMBIENTE 2011 

13 

03

03 01 02 


14 

The amounts reported annually as environment investments 

refl ect the projects cycle. Its evolution, therefore, must 

be seen in an integrated, cumulative way, representing 

successive stages in the consolidation of the investment 

plans. From this perspective, annual fl uctuations do not refl ect 

different levels of commitment in the pursuit of improved 

environmental performance. 

The safety investments amounted a total €5.19 million in 

2011. 

From the amounts shown in the chart above, the following 

chart splits operational costs from investments. 

Relationship between costs and envionmental 

investments (€M) 

2007 

5.36 2.62 

2008 

13.56 3.34 

2009 

8.28 4.30 

2010 

7.83 4.81 


4.19 7.82 

Investments Costs 

The Galp Energia training policy seeks to ensure employees 

personal and professional development, aiming to contribute 

to Group’s culture consolidation, promoting the development 

of strategic skills regarding value creation and supporting the 

individual development plans. 

Health, Safety and Environment issues are absolutely strategic, 

especially in an industrial activity as the refi ning, and over the 

past few years the cultural development of the organization 

has made clear its commitment to training and qualifi cation as 

essential tools to ensure the activity sustainability at all levels. 

Training plays a key role and is therefore taken very seriously 

by the refi nery, its employees and contractors. 

The following charts show, for the period between 2008 and 

2011 the number of training hours; the number of trainees 

and the number of training HSE sessions attended to by Sines 

refi nery employees: 


Examining the nature of the investments in terms of 

environmental management and protection, it can be 

seen the considerable effort that refi nery makes integrating 

technologies to prevent and reduce the generated pollution, 

avoiding, whenever possible the investment in end-of-line 

measures aimed to reduce the impact of the produced pollution. 

It should be noted that the adoption of end-of-line technologies 

often renders technical and structural constraints making the 

implementation of pollution-prevention technologies unviable. 

Overview of environmental investments in 2011 (€M) 

38% 

Integrated 

equipment and 

technology 

3.3 Health, Safety and Environment training 

Number of hours of training in HSE 

2008 

2009 

2010 


2,768 

4,266 

Number of training sessions in HSE 

2008 

2009 

2010 


38 

91 

98 

5,266 

Number of trainees in training sessions in HSE 

2008 

2009 

2010 


363 

528 

658 

62% 

End-of-line 

equipment 

7,495 

183 

1,062

01 

02 


The following charts show the same indicators for the training 

provided by the refi nery: 

Number of trainees in training provided in HSE 

2008 

2009 

2010 


3,084 

5,000 

Number of hours of training provided in HSE 

2008 

2009 

2010 


13,688 

14,338 

17,539 

Number of training sessions provided in HSE 

2008 

2009 

2010 


187 

217 

244 

319 

5,855 

6,079 

22,560 


15 

03

04 01 02 03 

INDICADORES ACTIVITY INDICATORS DE ATIVIDADE 

04 

05 06 07 08 09 

04 . ACTIVITY INDICATORS 

4.1 

4.2 

4.3 

LEVEL OF ACTIVITY 

PRODUCTION 

CONSIGNMENTS 


01 

02 

4.1 Level of activity 

03 

The following chart shows the load and the crude oil processed 

in the refi nery. The load processed includes, not only crude, 

but also the remaining raw materials and components, that is: 

load of the cracking unit, heavy aromatics, atmospheric residue, 

fuel gas, natural gas, MTBE (Methyl ter-butyl ether), biodiesel, 

Diesel fuel and fuel. 

4.2 Production 

The following chart shows Sines refi nery production, excluding 

breaks and consumptions, as well as the sulphur production 

Production volume (10 3 ton) 

4.3 Consignments 

Bellow we can see the shipments by consignment: 

ACTIVITY INDICATORS 05 06 07 08 09 

Level of activity (10 6 ton) 

2007 

2008 

2009 

2010 


Load processed Crude oil processed 

8.0 

8.1 

7.2 

8.3 

8.0 

9.1 

9.2 

that is considerably lower than the remaining products. 

2007 

2008 

176 2,143 

3,407 640 2,871 373 

111 2,008 3,056 623 2,342 309 

2009 

138 1,600 2,639 675 2,181 237 

2010 

101 1,842 3,109 844 2,652 328 


34 1,646 2,602 633 2,186 265 

Bitumens Fuels Diesel oils Jet/Kerosene Gasolines Gases 

Product shipments per mean of consignments (10 3 ton) 

2007 

824 3,674 

299 557 4,622 

2008 

770 

3,425 302 532 3,848 

2009 

673 

2,964 102 606 3,789 

2010 

655 

3,020 109 718 4,583 


529 2,755 109 702 3,674 

Tank cars Pipeline Tank wagon Bunkers Ship 

10.5 


6.9 

9.4 

17 

04

04 01 02 03 

ACTIVITY INDICATORS 05 06 07 08 09 

18 

As far as the shipped products quantities are concerned, 

pipeline and ship consignments stand out, due to the capacity 

Number of consignments per means of consignment 

2007 

2008 

2009 

2010 


29,036 

32,421 


34,488 642 

34,539 

Tank cars Pipeline Tank wagon Bunkers Ship 

22,005 450 4,737 571 293 

The 2011 decrease is due to the shutdown to tie-in the new 

operational units. 

of these means. The following chart shows the number of 

consignment operations to deliver the products: 

448 4,410 432 293 

561 7,016 518 327 

539 4,759 518 382 

7,896 511 351

01 

02 

03 

04 

ENVIRONMENTAL DESEMPENHO EM PERFORMANCE AMBIENTE 

05 

06 07 08 09 

05 . ENVIRONMENTAL PERFORMANCE 

5.1 

5.2 

5.3 

5.4 

RESOURCE CONSUMPTION 

ATMOSPHERIC EMISSIONS 

WASTEWATER 

WASTE 


19 

05

05 01 02 03 04 

ENVIRONMENTAL PERFORMANCE 06 07 08 09 

20 

5.1 Resource consumption 

Due to its signifi cant use and environmental relevance, this 

chapter contains information and indicators on water, energy 

and raw materials consumption. 


The Sines refi nery captures raw water from the Municipal 

Water and Sanitation Services (Águas de Santo André - AdSA), 

from the Morgavel Dam. In addition captures water from 4 

underground boreholes. 

The following chart shows the total water consumption, as well 

as recycled water and water used by source. 

Water consumption and recycled water (10 6 m 3 ) 

2007 

2008 

2009 

2010 


0.23 

0.05 

0.30 

0.35 

Water consumption Recycled water 

The decrease of the recycled water is due to the cleansing 

of the Fresh Water Tank. Afterwards, it was realized that this 

water contained too many suspended solids which caused the 

obstruction of the fi re extinction equipment’s. Therefore, and 

for Safety reasons, the refi nery stopped the use of this water 

on the fi re equipment’s and, at the moment, is studying a 

solution to improve that water quality. 

The chart below shows the relation between the use of ground 

water and local supply network. 

Water consumption by source 

91% 

AdSA 

4.77 


5.03 

5.14 

9% 

Boreholes 

5.46 

5.32 

According to the monthly progress reports, it appears that the 

levels of use of the groundwater are stable and compatible 

with the uses of the aquifer, so it is possible to keep the 

operating regimes established for each of the capture holes. 

The following chart shows water consumption per level of 

activity in 2011. 

Water consumption per level of activity (m 3 /ton) 

2007 

2008 

0.520 

0.546 

2009 0.590 

2010 0.563 

2011 0.646 

The increase on the water consumption is due to the refi nery 

shutdown for the tie-in of new operational units. 

Energy consumption 

Regarding the energy, the following indicators are considered: 

consumption of residual fuel oil (known as RFO), fuel gas, 

natural gas, and electricity consumption. 

The following charts show consumption of these fuels at the 

refi nery. Note that in recent years, there has been a reduction 

in RFO consumption, and consequently, a need to increase the 

consumption of fuel gas and natural gas, as a result of changes 

in the Utilities Central and the beginning of operation of the 

Cogeneration Plant. 

RFO consumption (10 3 ton) 

2007 

2008 

2009 161 

2010 137 

2011 95 

252 

302

01 

02 

03 

Fuel gas consumption (10 3 ton) 

2007 

2008 

2009 202 

2010 213 


Regarding electricity, the refi nery sells or acquires it from the 

network, depending on whether it has a surplus or shortfall. 

The following chart shows the electricity produced, consumed 

and sold. 

5.2 Atmospheric emissions 

This chapter focuses on atmospheric emission of relevant 

pollutants in terms of the environmental air quality. 

Sulphur oxides 

The following chart shows the total sulphur oxides emissions 

based on the equivalent sulphur dioxide. 

04 

Natural gas - fuel consumption (10 3 ton) 

2007 

2008 

2009 

2010 


7.5 

17.8 

6.1 

89.3 

Cogeneration LCP’s Process 

Electricity energy (GWh) 

2007 

2008 

2009 

2010 


35 

12 

34 

16 

74 

67 

110 

230 

Electricity energy production 

Electricity energy sales 

304 

338 

313 

384 

615 

198 


10.7 5.5 

198.6 

Electricity energy aquisition 

178.0 9.5 5.7 

669 

238 

890 

2.5 4.6 

Electricity energy sales, presented in the previous chart, 

include both the energy sold to Redes Energéticas Nacionais 

(REN) and the energy transferred to other Galp Energia Group 

consumers (Sigás, CLC and LPG Storage Plant). 2010 sustains 

the trend started on the previous year, with the startup of the 

Cogeneration Plant, that sells the whole production directly 

to the power network. The refi nery buys it back according to 

its needs. In 2011 we can watch a similar trend, with a slight 

decrease explained by the above mentioned shutdown. 

Raw materials consumption 

In addition to crude, which consumption was shown 

previously, Sines refi nery consumes natural gas as a raw 

material in the Hydrogen Production Unit. This unit produces 

the hydrogen necessary for desulphurising Diesel and 

gasoline’s fuels, in order to obtain low sulphur-content fuels, 

resulting in lower sulphur oxide emissions in the transports 

sector. This decrease is also due to the earlier mentioned 

stoppage. 

Natural gas consumption – feedstock to hydrogen 

production unit (10 3 ton) 

2007 

2008 

37.04 

35.84 

2009 35.65 

2010 49.35 


SO2 emissions (10 3 ton) 

2007 

3.58 5.65 

2008 

3.46 4.62 

2009 

3.03 2.30 

2010 

3.22 0.90 


2.21 0.78 

Process LCP’s 


21 

05

05 01 02 03 04 


22 

The following chart normalizes absolute emissions based on 

the level of activity: 

SO 2 emissons per level of activity (kg/ton) 

2007 

2008 

2009 0.658 

2010 0.436 


Percentage of sulphur in RFO (%) 

2007 

2008 


0.881 

0.877 

The reduced SO 2 emissions per level of activity shows the 

impact of the refi nery investments and efforts – reducing 

the sulphur content of the RFO and the increase of the 

consumption of gaseous fuels. 

Sulphur is a natural component of crude and during the 

refi ning process it is only possible to recover part of this 

element, the remaining is inevitably emitted into the 

atmosphere or retained in the refi ned products. 

The sulphur content in the RFO, shown in the next chart, 

affects SO 2 emissions: 

The following chart makes clear the performance of the Claus 

Units. It shows the elemental sulphur recovered, reducing 

the atmospheric emissions and the level of sulphur in the 

products. 

1.5 

2009 1.7 

2010 1.5 

1.6 


Recovered sulphur 

2007 

2008 

18 

2009 

18 

2010 


Recovered sulphur (103 2.25 

1.92 

2.19 

2.43 

2.07 

ton) 

Sulphur recovered per level of activity (kg/ton) 

19 

24 

3.0 

Nitrogen oxides 

The following chart shows absolute nitrogen oxide emissions 

of the refi nery. 

NO x emissions (10 3 ton) 

2007 

1.74 2.04 

2008 

1.43 1.88 

2009 

0.74 1.84 0.62 

2010 

0.40 2.05 1.38 


0.35 1.61 1.25 

LCP’s Process Cogeneration 

The following chart shows NO x emissions per level of activity: 

NO x emissions per level of activity (kg/ton) 

2007 

0.360 

2008 

0.359 

2009 0.396 

2010 0.405 


Despite the strong focus of the refi nery on BAT (Best 

Available Technology) and in the consumption of cleaner 

fuels (Natural Gas), the Cogeneration has no signifi cant 

impact on reducing NO x emissions, because the majority 

of the production of this compound is due to the presence 

of nitrogen in the air and to the formation of thermal NO x . 

As matter of fact, the Cogeneration is highly effi cient and 

is equipped with low NO x burners (also a BAT) in order to 

minimize emissions of this pollutant. 

The absolute increase in NO x is inevitable and is also induced 

by the Cogeneration high capacity, that provides vapour to 

the refi nery and produces electricity that is transferred to 

the electric network. In relative terms, it should be noted 

that the normalization of the total NO x emissions is based on 

the refi nery activity level, that is the indicator for the main 

installation activity as a whole, but it may not be the best 

indicator of the activity level of the Cogeneration Plant. 

Total particulate matter 

The following chart shows the values of total particulate 

matter emissions for the studied period:

01 

02 

03 

Particulate matter emissions (ton) 

The following chart shows the specifi c emissions of particulate 

matter at Sines refi nery: 

The quality of fuels burned and particularly the preference 

for cleaner fuels, such as the implementation of others BAT, 

have been determining factors in reducing the atmospheric 

emissions. 

Carbon dioxide 

The following chart identifi es CO 2 emissions deriving from the 

Sines refi nery activity and illustrates the compliance with the 

emission ceiling (EU-ETS - PNALE). 

The decrease of the CO 2 emissions in 2011 is due not only to 

the operational shutdown but also to some improvements 

performed on the pre-heating of the Atmospheric Distillation, 

which means a reduction of the fuel consumption in the ovens 

that heats the load. 

04 

2007 

447 368 

2008 

314 333 

2009 

107 290 39 

2010 

11 

336 86 


8 240 78 


Particulate emissions per level of activity (kg/ton) 

2007 

2008 

2009 0.055 

2010 0.046 


CO 2 emissions under PNALE (10 6 ton) 

2007 

0.713 1.382 

2008 

0.602 1.226 

2009 

0.314 1.167 0.247 

2010 

0.163 

1.339 0.549 


0.153 1.118 0.498 


License emission 


0.070 

2.138 

2.182 

2.314 

2.379 

2.307 

0.078 

Continuous monitoring 

At Sines refi nery SO 2 , NO x and particulate matter are 

continuously monitored in certain stationary sources, following 

the stipulated by the facility’s environmental permit. 

The following charts show the results, for these pollutants, on 

the control of the Main Chimney, which is the source with 

more weight in the facility, since it receives the smoke from 

most of the processing units and from the Utilities Plant. 

There aren’t values in February for none of the presented 

pollutants since this was the month of the operational 

shutdown. 

Continuous monitoring of SO 2 in the main stack 

(mg/Nm 3 ) 

4,000 

3,000 

2,000 

1,000 

0 

jan. feb. mar. apr. may. jun. jul. aug. sep. oct. nov. dec. 

Limit Concentration 

Continuous monitoring of NO x in the main stack 

(mg/Nm 3 ) 

800 

600 

400 

200 

0 



As far as the particulate matter are concerned there are 

no values for March as well, which can be explained by an 

equipment failure. 


23 

05

05 01 02 03 04 


24 

Continuous monitoring of particulate matter in the main 

stack (mg/Nm 3 ) 

200 

150 

100 

50 

0 



5.3 Wastewater 

Wastewater production 

Sines refi nery discharges its wastewater, after the pre-treatment, 

into the Moinhos Ribeira of Wastewater Treatment Plant 

(WWTP) network, managed by the company Águas de Santo 

André (AdSA). 

The following chart presents the wastewater production: 

Wastemater produced (10 3 m 3 ) 

2007 

2008 

2009 

2010 


1,730 194 

1,745 156 

Industrial effluent Saline effluent 

2,885 165 

2,817 

2,597 253 

Wastewater produced per level of activity (m 3 /ton) 

2007 

0.18 

2008 

0.21 

2009 0.38 

2010 0.32 


The increase observed in the wastewater production is mainly 

due to the operational shutdown and to the intervention 

performed in the effl uents pre-treatment system, during 

September and October, aiming to make the system able to 

receive the wastewater produced in the new operational units. 


208 

The slight noncompliance regarding the SO 2 emissions in April 

was caused by problems on the control system of one of the 

sulphur recovery units. When the anomaly was detected, the 

situation was corrected and the SO 2 value reestablished. The 

offi cial authorities were promptly noticed. 

Wastewater quality 

As mentioned above, Sines refi nery discharges its wastewater 

for the Moinhos Ribeira WWTP network. The costs assumed 

by the refi nery depend on the quality of the wastewater 

discharged, more specifi cally on the concentration of several 

pollutants. 

The charts below show the concentration of the monitored 

pollutants, also showing concentration values above which the 

discharge into the WWTP is disadvantageous. In these cases, 

the refi nery incurs in a price increase due to the addition of the 

billed class to the wastewater. 

Sines refi nery is engaged in reducing its wastewater production 

and minimising its pollution load. Nevertheless, it is the 

Moinhos Ribeira WWTP network that assumes the responsibility 

on discharging the wastewater into the water environment 

complying with the applicable legislation, ensuring adequate 

levels of protection for aquatic life and water resources. For its 

share of responsibility, Sines refi nery pays the component of 

rejection of effl uents of a tax for the use of the water resources, 

that is charged by the Moinhos Ribeira WWTP. 

This is so important that, in order to minimize the impacts of 

the shutdown of the pre-treatment system, the refi nery and 

AdSA installed an alternative scheme. This scheme, made by 

fl otation and provisional oxidation systems, was set both in the 

refi nery and in the Moinhos Ribeira WWTP, that costed Galp 

Energia over €M2. 

The following chart shows the pH of wastewater discharged in 

WWTP:

01 

02 

03 

pH of wastewater into the Moinhos Ribeira WWTP 

2007 

2008 

04 

7.28 

2009 7.74 

2010 7.80 


Discharge prohibited 

7.71 

The following chart presents the concentration of oil and fats in 

the wastewater: 

Oils and greases in the wastewater into the Moinhos 

Ribeira WWTP (mg/l) 

2007 

2008 

29.12 

2009 29.10 

2010 48.10 



50.31 

10 


100 

We can conclude that there was an increase on the oil and fat 

concentration regarding the previous years, which was due to 

two factors: the operational shutdown and the fact that there 

has been a considerable acidity in the crude loaded, which 

caused the diminishing of the pre-treatment effi ciency. 

The following chart presents information regarding Chemical 

Oxygen Demand (COD), a measure of the organic matter in the 

wastewater: 

COD of wastewater into the Ribeira de Moinhos WWTP (mg/l) 

2007 

2008 

377 

443 

2009 433 

2010 624 



2,000 

Also for this parameter it can be seen a slight increase in 2011, 

and the reason is the same as previously explained, since both 

COD and Oils and Fats are a measure of the organic matter in 

the wastewater. 

As far as sulphides are concerned, the following chart is 

presented: 

Sulphide in the wastewater into the Moinhos Ribeira 

WWTP (mg/l) 

2007 

2008 

2009 1.34 

2010 0.20 


3.09 

5.35 


Finally, we present the evolution of the phenols concentration 

in the wastewater: 

Phenols in the wastewater into the Moinhos Ribeira 

WWTP (mg/l) 

2007 

2008 

1.68 

2.97 

2009 2.12 

2010 6.10 



The increase of the phenols concentration was mainly due to 

the stop and start-up of several of the treatment equipment’s 

during the treatment system revamping period, which caused 

some instability in its performance. 


20 

40 

25 

05

05 01 02 03 04 


26 

5.4 Waste 

The information presented in this chapter refers to waste. 

These indicators are typical environmental performance 

indicators of a plant, due to its relation to the effi cient use of 

raw materials and resources. 

Waste production 

Not only is the absolute quantity of waste produced important, 

but also its type. The following chart distinguishes hazardous 

and non-hazardous waste produced at Sines refi nery for the 

past years: 

Industrial waste produced (10 3 ton) 

- regular production regime 

2008 

2009 

2010 


0.8 

1.6 

2.1 

2.0 

2.3 

Hazardous industrial waste Non-hazardous industrial waste 

As noticeable, there has been since 2010 a better waste 

segregation, allowing the reduction of the percentage of 

hazardous waste, and the increase of the percentage of 

non-hazardous waste. This is not only related to the awareness 

campaigns that involved all the employees (internal and 

external), but also with the reinforcement of the number of the 

waste containers, and its correct identifi cation, which was done 

in all the operational areas. 

The improvement in 2011 is clear as the efforts to reduce the 

hazardous waste production continued. For instance, the Sines 

refi nery reduced the sludge produced by reducing its water 

quantity before sending the waste to its fi nal destiny. 

The following chart presents the results of the waste produced 

in the specifi c external services (including the waste produced 

in the construction of the Conversion Project of Sines refi nery. 


5.1 

4.9 

6.7 

Industrial waste produced (103 ton) - specific external services 

2008 0.6 

3.5 

2009 1.4 

3.1 

2010 0.1 

4.8 


7.5 


The next chart shows the standardising of the absolute waste 

production based on the level of activity: 

Industrial waste produced per level of activity (kg/ton) 

2008 

2009 

2010 


0.1 

0.2 

0.2 

0.3 

0.3 


The following chart shows the trend of the solid urban waste 

production: 

0.5 

Solid urban waste production (ton) 

2008 66 

2009 82 

2010 94 


The increase of solid urban waste production, in the past three 

years, is related to the increase of number of the meals served 

in the refi nery canteen, due to the presence of construction 

staff in the Conversion Project of Sines refi nery. 

0.8 

0.9

01 

02 

03 

04 

05 

06 . SAFETY AND HEALTH 

PERFORMANCE 

6.1 

6.2 

6.3 

PREVENTION 

ACCIDENTS 

OCCUPATIONAL MEDICINE 

SAFETY AND HEALTH PERFORMANCE 

06 

07 08 09 


27 

06

06 01 02 03 04 05 

SAFETY AND HEALTH PERFORMANCE 07 08 09 

28 

6.1 Prevention 

New risk management approach 

Risk management, particularly as far as serious industrial 

accidents prevention is concerned, are a fulltime job in Sines 

refi nery. 

The risk analysis has been carried out considering different 

purposes, from legal requirements to new investments (such as 

revamping and modifi cations), or even maintenance activities. 

Being a site where the Seveso Directive is applicable, several 

specifi c risk analysis were needed, according to more or less 

complex methodologies and considering criteria established at 

an administration level. One can tell that these criteria as well 

as the adopted methodologies have been evolving over time, 

in order to respond prevously, to the concern regarding the 

most severe consequences of catastrophic scenarios and, more 

recently, in the prevention of the most likely to occur serious 

industrial accidents. 

On the other hand, aiming to sustain maintenance and 

reliability functional criteria, the refi nery developed a risk 

management system called RBI (Risk Base Inspection) which 

intends to predict the risk caused by static equipment failure, 

considering its probability and severity, according to operational 

characteristics of each situation. 

The fi rst goal was to make compatible and coherent the two 

above mentioned approaches. That lead to the development of 

a project, involving the operational departments, that intended 

to identify the “potential” accident situations and to model 

their consequences, not only in less likely to occur catastrophic 

scenarios but also others of inferior severity that are more 

prone to occur. 

The refi nery has about 400 scenarios, modeled in its specifi c 

risk software that considers these criteria. This situation is 

rather relevant as the Seveso Safety Report considers only 

about 100 scenarios. 

On a second phase, considering an internal Standard Procedure, 

a data base and a tool have been developed in order to 

acknowledge the risk analysis in every part of the site. This 

information is to stand for the preliminary risk assessment 

to the several purposes (Seveso safety reports, change 

management, safeguards defi nition, SIL basis, etc). 

Risk management is a dynamic process, not only regarding the 

assessment itself but also regarding the adopted methodology. 

Supporting this approach is the way we face risk and its 

management, having accessible, coherent, updatable data 

from which every “operator” identifi es the conditions and risks 

regarding its industrial units. 


Drill exercises 

In a facility as the Sines refi nery it’s essential to ensure a 

permanent capacity and competence to deal with emergency 

situations. Carrying out drills aims to prepare effective and 

appropriate responses to emergency scenarios of several 

scales. 

In 2011 there was a decrease in the number of drills performed 

due to the operational shutdown. Nevertheless, seven drills 

were carried out which allowed the identifi cation, not only of 

good practice but also of the limitations and the improving 

opportunities on the several scenarios considered in the 

Internal Emergency Plan (PEI), as follows: 

• diesel oil pipe rupture followed by fi re; 

• fi ssure in the 10’’ pipe near the welding in Sigás, with 

propane loss; 

• methanol spill in Warehouse 3, causing fi re; 

• CPX (Command Post Exercice) in the Crisis Management 

Room; 

• fi re in the administrative building due to a short-circuit; 

• CPX on a district level based on serious accident scenarios of 

two Seveso facilities; 

• Partial rupture on a pipe joint leading to a H 2 S leakage. 

Drills (No.) 

2008 

4 

2009 11 

2010 11 


OPAS - Preventive Safety and 

Environmental Observations 

The Preventive Safety and Environmental Observations (known 

as OPAS) Programme aims to raise awareness and motivate 

for positive HSE behaviour and attitudes, and is a positive 

approach technique. The method is based on the observation 

of the employees and contractors while they are working. The 

benefi ts of this programme are:

01 

• focus on HSE; 

02 

03 

• identify and correct non-conformities; 

6.2 Accidents 

Personal accidents - own staff (No.) 

2008 

2009 

2010 

04 

• avoid/prevent incidents and accidents; 

• communicate and clarify standards expected of HSE; 

• assess the level of understanding and application of HSE Standards; 

• assess the level of effectiveness of the HSE management, 

identify their strengths and improvement opportunities; 

The refi nery has been continuously monitoring its performance, 

with the goal of Zero Accidents, including personal, environmental 

and material damaging accidents, and operational or road 

accidents, whether among its own staff or among contractors. 

The following chart shows the number of personal accidents by type. 


5 

7 1 2 

6 1 2 

3 

19 4 1 

First Aid Medical treatment cases Lost workday injuries 

There has been an increase on the number of personal accidents 

regarding own staff. This results from the operational shutdown 

that means a higher risk level not only considering the type of 

work being held (for instance, tasks performed above the ground 

level, in the interior of equipment, mechanical load elevation), but 

also regarding the number of workers in the fi eld. 

Aiming continuous improvement and increasingly stricter and 

rigorous demands in reporting the occurrences, the following 

chart shows not only the number of personal accidents 

among our own staff but also the personal accidents involving 

contractors in 2011. 

05 


• reinforce positive attitudes and behaviour in HSE; 

• motivate people; 

• identify where and how people take risks; 

• promote top management interaction with the fi eld activities. 

At Sines refi nery, during 2011, 1,390 hours of OPAS were 

conducted by qualifi ed Galp Energia employees, adequately 

trained that have established monthly goals. 

All these accidents were reported, classifi ed, recorded and 

investigated according to a Galp procedure. As a result of the 

investigation, reports are made and corrective measures are 

proposed, which the refi nery implement, in the shortest time 

possible, to ensure risk minimization and to prevent those 

accidents recurrence, or a similar occurrence of the same nature as 

an attempt to control or eliminate the identifi ed causes. 

Personal accidents (No.) 

Galp Energia 

19 4 1 

Galp Energia 

+ service 

providers 35 11 1 

First Aid Medical treatment cases Lost workday injuries 

It’s noticeable that there hasn’t been any fatality and that 

we assist to a decrease of the accidents which led to medical 

treatment. Nevertheless, we regret a lost workday injury in 

2011. 

The following chart shows the evolution of the Injury Frequency 

(number of accidents per million hours worked), including own 

staff and contractors, displaying the continued effort to line up 

with the international best practices in performance indicators 

communication. 


29 

06

06 01 02 03 04 05 


30 

Lost workday injuries (No.) and injury frequency own 

frequency (own staff and contractors) 

2009 

2010 


1 

1 

Lost workday injuries Injury frequency 

4 1.90 

A decreasing trend can be perceived in the Injury Frequency 

since 2009 in Sines refi nery, achieving in 2011 a value of 

0.24. It’s important to mention that this value is much lower 

than the reference from our sector in Europe – Concawe that 

reported, in 2010, an Injury Frequency of 1.9 (including both 

own staff and contractors). 

Regarding the personal, material and environmental 

occurrences and near accidents, the following chart is 

presented, in forms of a pyramid where the base represents 

the less severe class (1) and the top the more severe class (4). 

0.34 

0.24 

2011 total accidents (personal, property damaging, 

environment and near accidents (No.) 

0 - Class 4 1 - Class 3 

14 - Class 2 


47 - Class 1 

6.3 Occupational medicine 

The occupational medicine, a preventive medicine fi eld, has 

two main goals which are the professional diseases and the 

labor accidents prevention. 

In order to achieve these goals, the activities of these 

professionals are divided between offi ce work (examinations 

in their various types) and fi eldwork (observation and study of 

the workplace). 

This team has the collaboration of the top management (in 

examinations calling, securing presence on required occasional 

medical examinations, etc.), of the area of occupational 

health and safety in the study of the workplaces (prevention 

occupational disease and accident), and of the human 

resources. 

Analyzing the total accidents by type, we can conclude that 

the personal accidents are still the majority (48%). It is 

relevant to mention that there is a high percentage of near 

miss occurrences which represent 39% and are seen as 

an opportunity to better perform by introducing corrective 

measures on a continuous improving level. 

The majority of the environmental and property damaging 

occurrences were class 1. 

Distribution of occurrences 

39% 

Near miss 

6% 

Environmental 

Medical examination undertaken (No.) 

2008 

2009 

2010 


271 266 16 

48% 

Personal 

400 32 

242 413 23 

Admission exams Regular exams On-request exams 

7% 

Property damaging 

With this continuous improving approach in Sines refi nery we 

aim to achieve a sustained prevention culture, based upon 

a HSE management of high performance, which allow us to 

reduce/eliminate the risk and to accomplish excellence levels. 

In 2011 no professional disease has been registered. 

270 389 44 

252

01 

02 

03 

04 

05 

06 

COMMUNITY RELATIONSHIPS – GISA PROJECT 

07 

08 09 

07 . COMMUNITY RELATIONSHIPS 

– GISA PROJECT 


31 

07

07 01 02 03 04 05 06 COMMUNITY RELATIONSHIPS – GISA PROJECT 08 09 

32 

The fi rst stage of the GISA Project – HSE integrated 

management, led by the CCDR – Alentejo - which has been 

developed by Instituto Superior Técnico (IST) and Instituto 

Superior de Ciências do Trabalho e da Empresa (ISCTE), ended 

in late 2011. This Project, sponsered by local Companies 

including the Sines refi nery and Local City Halls lasted for 4 

years and its main goal was the creation of evaluation and 

monitoring methodologies of Air and Health and in order to 

ensure an integrated management and provide the Alentejo 

Coast with the instruments for its implementation through the 

development of a single platform: http://www.gisaproject. 

org. The study covered the whole Alentejo Coast, integrating 

the following counties: Alcácer do Sal, Grândola, Santiago do 

Cacém, Sines and Odemira. The covered area is about 526,000 

hectares corresponding to approximately 100,000 inhabitants 

(according to the 2001 Census). 

This project was aimed to implement a space-time integrated 

data system regarding air quality. To achieve this, other specifi c 

goals were established, as follows: 

(i) optimization of a monitoring and biomonitoring net which 

allows the evaluation in space and time of the main air 

pollutants; 

(ii) development of a data system regarding the development 

of data bases in terms of spot air pollutants sources and air 

quality; 

(iii) development of an alert system considering the air quality, 

intended to predict critical situations regarding local 

impacts of the air quality in public health; 

(iv) implementation of a public health indicators evaluation 

methodology; 

(v) risk assessment of air quality impacts on public health 

followed by the integration of all the tasks in a data 

system. 

To accomplish all the above mentioned objectives, many 

actions were performed over these last 4 years: 

(i) gathering of all the information regarding air pollution 

sources and their emissions; 

(ii) implementation of an air quality monitoring network, 

including stationary and mobile stations and the 

development of regular campaigns of diffuser tubes; 


iii) use of lichen as bioindicators to evaluate the air quality on 

health; 

iv) establishment of a data system regarding the air quality 

management in the covered area, considering the pollutant 

sources and the air quality monitoring net; 

v) development of an alert system considering the air quality 

intended to predict critical situations regarding local 

impacts on public health caused by air pollution; 

vi) data gathering from health centers and evaluation of the 

health and psicosocial indicators in order to implement an 

epidemic monitoring system; 

vii) modeling indexes of environmental impact and health data 

(morbidity) in order to get risk maps and space-time 

patterns for all the region; 

viii) integration of all kind of data and models in a structure of 

data system; 

ix) design of a website with the purpose of informing the 

population about environmental matters at the local level. 

These instruments will allow the regional authorities to 

monitor, evaluate the alert situations and the environmental 

management regarding public health. The last actions are 

related to the spread of the project results, involving all 

participants. 

So far the main conclusions from this stage of the project 

have been presented last December and proved that the 

investments made by the major companies of the industrial 

complex site in Sines with the aim of reducing the air 

emissions have brought very positive results, with a substantial 

decrease on the particulate matter, SO 2 and NO X emissions 

between 2002 and 2009. The biggest success has been with 

the SO 2 emissions that registered a signifi cant reduction both in 

the monitoring stations and in the biomonitors.

01 

02 

03 

This project, pioneer at a national level, tried to cross the 

regional health data with the information related to the air 

quality, aiming to fi nd a relationship between the industrial 

presence in the region and the highest or lowest incidence 

of certain diseases affecting the local populations. Several 

methods were used in order to measure the air quality, being 

the most innovative the use of lichens. 

Massic flow SO2 emitted by Petrogal, EDP e Repsol 

(ton/h) 

2006 

2007 

2008 

2009 

0 20,000 40,000 60,000 80,000 100,000 

04 

05 

06 

COMMUNITY RELATIONSHIPS – GISA PROJECT 08 09 


33 

07

08 GLOSSARY 

08 

09 

01 

02 

03 

08 . GLOSSARY 

34 SINES REFINERY / 2011 DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT 

04 

05 

06 

07

01 

02 

03 

04 

05 

Term Defi nition Unity 

Accidents in itinerae Represent accidents occurring on the route normally taken by the worker, whichever direction he or she is 

heading in, between the workplace or training location linked to said worker’s professional activity and his or 

her main or secondary residence, the place he or she normally has meals or the premises where he or she 

normally receives wages, resulting in death or bodily harm. Considers only the own staff. 

Admission examinations Refers to the mandatory medical examinations occurring when a worker is hired, aiming to verify the 

employee’s physical and mental ability to carry out the duties for which he or she was hired. 

API density Unit of density according to the indicator of the American Institute of Petroleum (°API = (141.5/ specifi c weight 

at 60° F) - 131.5). 

Biochemical oxygen 

demand 5 (BOD 5 ) 

06 

Corresponds to the oxygen consumed in the degradation of organic material at a mean temperature of 20ºC over 5 

days in the waste effl uents, in accordance with the laboratory analyses conducted in the refi nery laboratory. 

CO 2 emissions under PNALE Represents total carbon dioxide emissions accounted for in accordance with the EV- ELV - provisions of Refi ner´s 

Greenhouse Gas Emission permit. 


of NO x 


of particulate matter 


of SO 2 

Under existing requirements, the refi nery is committed to carry out continuous monitoring in some of the 

sources of atmospheric emissions. The values of continuous monitoring are obtained by analyzers et the stack, 

and this indicator represents the result of continuous monitoring of the main stack. 


sources of atmospheric emissions. The values of continuous monitoring are obtained by analyzers of the 

chimney, and this indicator represents the result of continuous monitoring of the main chimney. 


sources of atmospheric emissions. The values of continuous monitoring are obtained by analyzers at the stack, 

and this indicator represents the result of continuous monitoring of the main stack. 

Costs Total operating expenditure for operations related to each of the environmental categories (protection of water 

resources; waste management; soil and groundwater protection; air and climate protection). Classifi cation is 

made in accordance with the defi nitions of the National Statistical Institute . 

Electricity energy acquisition Represents the electricity energy purchased from EDP, to supply production needs. GWh 

Electricity energy sales Represents the electricity energy that was sold to EDP, and also includes the electricity energy that was 

transferred to other consumers: Sigas, CLC and LPG Gasworks. 

Electricity production Represents electricity production measured on the boiler counters. GWh 

End-of-line equipment Facilities, equipment and identifi able machinery parts, as well as construction, that operate at the end of the 

production process, aimed at treating, preventing or measuring pollution. 

Environmental accidents Refers to the total number of accidents causing damage to the refi nery’s surroundings, including air, water, soil, 

natural resources, fl ora, fauna, people and their interrelations. 

First aid Refers to the total number of work accidents (excluding accidents on the way to or from work), requiring the 

worker to be attended, but not by a doctor. 

Fuel gas consumption Fuel gas consumption, for burning in Large Combustion Plants and process furnaces. Consumption by Flares is 

also associated with the process. 

Hazardous industrial waste 

produced 

Represents the quantity of industrial waste that does represent a hazard to health and the environment, 

according to the applicable legislation and the European Waste List. Includes recovered and non-recovered 

waste. 

07 

GLOSSARY 09 

Number of accidents 

Number of 

examinations 

º API 

mg/l 


ton 

mg/Nm 3 

mg/Nm 3 

mg/Nm 3 

€ 

GWh 

Number of 

examinations 



ton 

ton 

35 

08

08 01 02 03 04 05 06 07 

GLOSSARY 09 

36 


Industrial waste (hazardous 

and nonhazardous) 

produced per level of 

activity 

Injury rate (total and lost 

workday injuries) 

Means the ratio between the quantity of industrial waste (hazardous or non-hazardous) and the load 

processed. 

Means the ratio between the number of accidents (total and with working day losses, respectively) and the 

million hours worked. The hours worked relate to the sum of actual annual hours worked by each employee. 

This includes Commercial Park hours. 

Integrated technologies Equipment and/or facilities or parts of equipment and/or facilities, that have been modifi ed to reduce 

pollution, integrated into the production process. Includes studies involving integrated analysis of solutions to 

improve environmental performance. 

Investments Total of the amounts of investment in the various environmental categories (Protection of water resource; 

Waste management; Soil and groundwater protection; Air and climate protection) and Safety, Health and 

Hygiene at Work. The classifi cation is made according to the provisions supplied by the National 

Statistical Institute. 


kg/t 


per million hours 

worked 

LCP’s Large Combustion Plant used in energy production, with thermal power greater than 50 MWt. Multiple of € 

Load processed The load processed is a measure of the refi nery’s production intensity and Level of Activity, and is provided by 

the quantity, in mass, of raw materials that are processed. This value is obtained via mass calculations, taking 

into account the transfers between Sines and Porto refi neries and the stock inventory. 

Lost workday injuries Refers to the total number of work accidents (does not include accidents in itinerae), in which there were days 

or shifts in which the worker did not perform his or her duties, due to any inability to carry out his or her work. 

Material damaging accidents Refers to the total number of accidents causing damage to material goods, namely, assets, equipment, product, 

productivity, stoppage of production, fi nes for non-compliance with legislation or expenses of another nature, 

related to the accident or the person involved in the accident. 

Medical treatment cases Refers to the total number of work accidents (excluding accidents on the way to or from work), requiring the 

worker to be attended by a doctor. 

Natural gas consumption Natural gas Consumption associated with hydrogen production. ton 

Natural gas-fuel consumption Consumption of natural gas as fuel, in cogeneration, in the process and in LCP’s. ton 

Non-hazardous industrial 

waste produced 

Represents the quantity of industrial waste that does not represent a hazard to health and the environment, 

according to the applicable legislation and the European Waste List. 

NO emissions Represents nitrogen oxide emissions (nitrogen monoxide and nitrogen dioxide), deriving from combustion of 

x 

RFO, Fuel gas and Natual gas, in boilers, Cogeneration and process furnaces. 

NO = NO + NO + NO + NO x x RFO x FG x GN LCP x Cogeneration 

NO (t) = Consumption (t) x F x PCI (TJ/t) x 10 x RFO RFO emission FG FG -3 

NO (t) = Consumption (t) x F x PCI (TJ/t) x 10 x FG FG emission FG FG -3 

NO (t) = (Consumption (t) x PCI (TJ/t) + Consumption (t) x PCI (TJ/j)) x F x 10 x Cogeneration GN GN FG FG emission Cogeneration -3 

NO x GN LCP according to “Air Pollutant Emission estimation methods for EPER and PRTR reporting by refi neries, 

Concawe, report number 3/07R: 

NO = NO + NO x GN x thermal x fuel 

NO (kg) = 10 x thermal -3 x Consumption (t) x 11,1 x PCI (MJ/t) x F x F x F x F x F GN Base H2 Control Pre heat H2O x FLoad x FBurn The emission factors in the table below (the sum of thermal powers of the sources of the process is greater 

than 50 MWt) apply to Estimation formulas for emissions of NO x RFO, FG and fuel used in Cogeneration: 

Combustion units Type of fuel Emission factor 

With thermal power > 50MWt 

Natural gas or fuel-gas used in Cogeneration* 140 

RFO 190 

Fuel Gas 140 

* For Cogeneration, the emission factor was assumed as appears in the Environmental Impact Assessment for 

the Facility. 

This methodology don’t considered emissions from the FCC. 

€ 

multiple of ton 




ton 

multiple of ton

01 

02 

03 

04 

05 


NO x emissions 

per level of activity 

Number of hours of training 

in HSE 

Number of hours of training 

provided in HSE 

Number of trainees 

in training programmes 

in HSE. 

Number of trainees in 

training programmes 

provided in HSE 

Number of training 

programmes in HSE 

Number of training 

programmes provided 

in HSE 

06 

Means the ratio between NO x emissions, counted according to the contents of “NO x Emissions” and the load 

processed. Excludes the Cogeneration (counted separately, taking into account the electricity produced). 

Represents the total number of hours’ training regarding matters of Health, Safety and the Environment 

attended by own staff in internal and external training activities, such as: courses, seminars and other activities. 

Represents the total number of hours’ training provided by the Safety and Environment departments to own 

staff and service providers regarding matters of Health, Safety and the Environment. 

Represents the total number of Galp Energia trainees that attended the internal and external training activities 

regarding matters of Health, Safety and the Environment. 

Represents the total number of trainees (own staff and service providers), who attended training activities 

regarding matters of Health, Safety and the Environment provided by the Safety and Environment departments. 

Represents the total number of different internal and external training activities regarding matters of Health, 

Safety and the Environment attended by staff, such as courses, seminars and other activities 

Represents the total number of training sessions regarding matters of Health, Safety and the Environment 

provided by the Environment and Safety Department to staff and service providers. 

Occupational diseases Refers to as illnesses caused by the activity performed by the worker or included on the list of occupational 

illnesses (Dec-Reg 12/80 and Decree-Law No. 248/99). 

Oils and fats in the effl uent 

discharged into the WWTP 

Means the concentration of oils and fats in effl uent discharged into the Wastewater Treatment Plant, through 

laboratory analyses undertaken. 

On-request examinations Refers to the number of examinations undertaken for specifi c reasons, or on a doctor’s orders/ initiative, or at 

the worker’s request, in cases where regular examinations had previously occurred. Only Petrogal workers are 

considered. 

Particulate matter emissions Represents particulate matter emissions (unburnt fuel, soot and incondensable matter in suspension in gas 

fl ows), deriving from RFO and Fuel gas combustion, in boilers, cogeneration and in process furnaces. 

The following formulas, derived from different from different refi nery sources, apply to combustion emissions: 

Particles = Particles + Particles + Particles RFO FG GN 

Particles (t) = RFO Emissions FactorRFO x ConsumptionRFO (t) 

Specifi c Mass (g/cm RFO 3 ) x 1000 

Particles (t) = FG Emissions FactorFG x ConsumptionFG (t) 

Specifi c Mass (g/cm FG 3 ) x 1000 

Particles (t) = FG Emissions FactorGN x ConsumptionGN (t) 

Specifi c Mass (g/cm FG 3 ) x 1000 

The emission of particulate matter in Flares is accounted for and the same formulas apply as for combustion. 

Type of fuel / Source 

Emission 

Factor (kg/m3 ) 

RFO 2.3 

Fuel gas 0.34 

Natural gas (Cogeneration) 0.34 

Natural gas (LPC’s) 0.12 

The emission of particulate matter in Flares is accounted for and the same formulas apply as for combustion. 

Since 2008, the electrostatic precipitator effi ciency factor has been applied in Boiler (η ESP 90%): 

Particles Boiler 4 = (Particles FG + Particles RFO ) x η ESP 

07 

GLOSSARY 09 

kg/t 

Number of hours 

Number of hours 



Number of activities 

Number of activities 

Number of cases 

mg/Nm 3 

Number of 

examinations 

ton 


37 

08

08 01 02 03 04 05 06 07 

GLOSSARY 09 

38 


Particulate matter 

emissions per level 

of activity 

Means the ratio between the particulate matter emissions, accounted for according to the contents of 

“Particulate matter emissions” and the load processed. 

Personal accidents Refers to the total number of accidents suffered by employees excluding in itinerate. Includes accidents 

involving fi rst aid, cases of medical treatment and accidents leading to working day losses. 

pH in effl uent 

discharged in to WWTP 

Phenols in industrial 

effl uent discharged 

Refers to the potential hydrogen in the effl uents discharged from the refi nery WWTP, through laboratory 

analyses conducted. 

Means the concentration of Phenols in effl uent discharged into Wastewater Treatment Plant, via laboratory 

analyses undertaken. 

Process Process includes the plant activities involving fuel consumption. Flares are included under this heading. ton 

Processed crude Represents the quantity of crude oil processed in the refi nery, supplying the units. ton 


kg/t 


Sorensen Scale 

Production Represents the quantity of each type of product produced in the refi nery. Multiple of ton/product 

Recovered sulphur Represents in terms of mass the sulphur recovered in sulphur recovery units. This value is determined based 

on the refi nery mass balances, according to the load of H2S in the units and its purifi cation effi ciency. The 

effi ciency of the unit is determined empirically on the basis of monthly iterations (there is a counter with a 

systematic error of approximately 30%), adjusting the values for the mass balance monthly. 

Recovered sulphur per load 

processed 

This is provided by the ratio between recovered sulphur, accounted for as described in the contents of 

“Recovered sulphur”, and the load processed. 

Recycled water Represents the water that is treated and consumed in the production process. m 3 

Regular examinations Refers to the number of examinations undertaken with an internally predetermined regularity (annually). Only 

Petrogal workers are considered. 

RFO consumption Consumption of residual fuel oils (fuel-oil for internal consumption), for burning in LCP´s and process furnaces. ton 

SO 2 emissions This indicator represents sulphur dioxide emissions deriving from RFO combustion boilers and in process 

furnaces. This emissions are calculated on the basis of the following formula: 

SO 2 emissions per level of 

activity 

Sulphides in industrial 

effl uent discharged into the 

WWTP 

SO 2 = SO 2 RFO (t) = Consumption RFO (t) x % S RFO x 0,02 

% S RFO represents the sulphur content of RFO (See “Sulphur content in RFO”). Neither SO 2 , Fuel gas or Natural 

gas emissions were considered, since these typically have sulphur contents very close to zero. In this indicator, 

FCC and Claus Unit emissions are not considered. 

Means the ratio between SO 2 emissions, accounted for according to the contents of “SO 2 Emissions” and the 

load processed. 

Means the sulphides concentration in effl uent discharged into the Wastewater Treatment Plant, via laboratory 

analyses undertaken. 

Sulphur content in the RFO Means the percentage value of sulphur content in RFO. This value is determined in the laboratory, through 

weekly analyses on compound samples, the annual value constituting a weighted average of the mean 

monthly values. 

Waste produced considered 

solid urban waste 

Wastewater 

produced 

Wastewater produced per 

level of activity 

Means the quantity of domestic or similar waste produced, due to its nature or composition. ton 

Includes the volume of wastewater produced, covering both industrial effl uent and saline effl uent. Saline 

effl uent is the result of purges in the cooling towers and demineralisation of raw water. 

Means the ratio between liquid effl uents produced, accounted for according to the contents of “Liquid effl uents 

produced” and the load processed. 

Water consumption Represents water consumption for factory processes, and includes water brought up from the boreholes and 

purchased water. 


per level of activity 

This indicator is provided by the ratio between raw water consumed and the load processed in the refi nery. It 

represents the specifi c consumption of water. 

mg/l 

ton 

kg/t 

Number of 

examinations 

ton 

ton 

mg/l 

% 

m 3 

m 3 /t 

multiple of m 3 

m 3 /t

01 

02 

03 

04 

05 

06 

07 

08 


09 

09 . STATEMENT OF CONFORMITY 


39 

09

09 01 

02 03 04 05 06 07 08 


40 

SINES REFINERY / 2011 DATA BOOK ON HEALTH, SAFETY AND ENVIRONMENT

01 

02 

03 

04 

05 

06 

07 

08 



41 

09

Galp Energia, SGPS, S. A. 

Public Company 

Investor Relations and Corporate 

Communication Division 

Rua Tomás da Fonseca, Torre C 

1600-209 Lisboa 

Tel.: +351 217 240 866 

Fax: +351 217 242 965 

e-mail: investor.relations@galpenergia.com 

www.galpenergia.com

2011 Sines Data Book - Galp Energia

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