The Equipment is based on proven and available recovery and separation methods in the likes of Coalescers and Gravity Separators combined with technologies to speed up the process. The technologies is available for use are of non-chemical origin additives to improve and accelerate sludge wetting and fluidization with efficient separation of solids and water that facilitate the further processing of crude. The complete systems performs pit sludge cleaning designed with the goal of 98% hydrocarbons recovery.
It has two stages:
Stage 1 – Sludge Recovery (Pit or Tank)
Stage 2 – Sludge Processing/Hydrocarbon Recovery
Modular 3000HDT Up to 15 gal/min (3.4 m3/hr)
Integrated Diesel Power Unit or Power Line Input
Sludge Collection: This stage requires special tool to collect the sludge from pit or spill. Depend on size of the pit or spill, different tools and collection system can be used. It can be done in 3 or less stages depend on depth and conditions of the pit or spill.
Tools for the collection of oil sludge:
SLUDGE EXTRACTION / PROCESSING
Oil sludge comes indifferent forms and content. However, it can be split in three levels:
Oil – always on top;
Liquid mix of heavier and dissolved in Water light solid hydrocarbons;
Solids at the bottom is a mix of heavy hydrocarbon solids, clay, sand, etc.
The levels size and conditions of the Sludge are varying:
For Example, in a Pit:
Level 1 - Oil extracted by floating skimmer and can be taken directly to the Primary Separation Tank;
Level 2 - Liquid mix can be pumped by special pump with protection from large size impurities; then to Primary Separation Tank;
Level 3 – Bottom Solids and Surface Spills, Preferred rate of Solids at 30%-70% water
Oil (Hydrocarbons), Water and Solids Separation (OWS)
Sludge delivered to Agitator tank, where Bio-flocculant, to promote solids separation, is added, and then the mix is pumped to the Primary Separation Tank.
Primary Separation Tank has coalescing type separation complex designed in compliance with API separation requirements. It separates:
Oil and moved to the Oil Purification Unit using GreenZyme Detergent Separator;
Water to move to the Secondary Separation;
Solids at the bottom to move to the Solids Processing Unit, which can have just a clarifier to remove solids only or combination of optional Digester Unit to process hydrocarbons below 1% and affluent clarifier.
Some heavy hydrocarbons and light solids still left in the Water. The Secondary Process Unit is gravity separation API type tank for final separation of Water and Solids. The main task
of this unit further purify water from hydrocarbons and solids.
Digester Option: Turn this unit in bio-digester with installation of baffles and ultrasonic unit for sludge activation in front of t . Special mix of biological BioRem-L to process the TPH with production of biogas and potential fertilizer. Mainly, this technology is used in our standard Digester Unit.
Oil or Product Polishing/Purification.
To reach required purity, the optional Purification Unit is used, where using GreenZyme Separator dissolved in water helps to separate emulsions using dynamic force and collect it on top of a gravity separation tank, Recovering pure hydrocarbons, like Marine Diesel or Fuel Oil.
Optional - Biological Solids Processing (Digester).
For larger processing capacity, we offer additional bio-digester with solids clarifier to comply with environmental regulations, which require the solids to have Total Hydrocarbon Content (TPH) below 2% (in China) or even 1% (in Malaysia and others). It is designed as a Pro-Active Baffled Type Digester using a proprietary biological mix . Additionally processed solids separated in a clarifier/dryer to reach solids dryness below 20%.
Water Collection, Re-circulation and Purification.
The separated water collected in the Process Water Tank (not shown) for preparation for re circulation.
Some extra water has to be discharged. The purity of discharged water has to be in compliance with the regulations, and therefore has to be purified in the optional water treatment unit.
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