Improving the Reliability of Equipment and Facilities for the Rail Tank Wagon Receiving Process Through Modifications to the SUSI (Support System Direct Dry Coupler) to Achieve Low-Emission Operations and Resource Efficiency

Abstract

This study evaluates the effectiveness of the Support System Direct Dry Coupler (SUSI) as a modification of the Direct Dry Coupler (DDC) system in improving Rail Tank Wagon (RTW) receiving process reliability while reducing environmental impact through pollution prevention and eco-innovation approaches. A before-and-after comparative study design was employed, comparing operational conditions prior to and following SUSI implementation at PT Pertamina Patra Niaga Fuel Terminal Tegal. Parameters analyzed included connect/disconnect process time, discharge loss, VOC emission reduction using the IOGP Tier-1 method, A332-1 hazardous waste generation reduction, housekeeping water-use efficiency, and wastewater quality based on pH, oil and grease, and Total Organic Carbon (TOC) levels. Results demonstrate that SUSI implementation reduced connect/disconnect time from 45–90 minutes to 5–10 minutes while eliminating fuel spillage potential at 78 connection points, yielding a total spill reduction of 142,350 L/year. VOC emission reduction potential reached 6.77 × 10⁻⁵ tons of VOC/year based on the IOGP Tier-1 method. Reduced hydrocarbon influx into drainage systems decreased A332-1 oil sludge formation potential, improved wastewater quality with TOC concentration <3 mg/L, and reduced water demand for RTW area housekeeping from 25 kL/year to 5 kL/year, achieving an 80% water-use savings rate. Beyond improvements in operational reliability and occupational safety, this study demonstrates that spill-prevention-based connection system modifications provide simultaneous environmental benefits through air emission reduction, hazardous waste reduction, water-use efficiency, and reduced water pollution load.