Idrabel Italia S.r.l.Environmental Technologies for Refineries

Prof. Dr. Ibrahim Banat, BSc PhD CBiol FIBiol Professor of Biotechnology, University of Ulster, UK.

Dr. Ivo Rancich, Idrabel Italia, Genoa, Italy.

No man Entry Tank Cleaning’ and ‘VOC Control’ Using

Biotechnological Interventions

Topics of presentationTopics of presentation• A flexible biotechnological "no man entry" tank

cleaning technology. • Adaptation of "no man entry" systems for desludging

damaged tanks. • Application of biotechnological VOC emission tank

control system and its advantages. • Case histories of achievements for the "no man entry"

BioRecOilTM technology & VOC control.

Sludge accumulationSludge accumulation

Sludge accumulates in storage tanks due to slow sedimentation of high gravity petroleum products. Leading to:

• Loss of operational capacity

• Loss of working time• Acceleration of corrosion

in the storage tanks.

Biological based technologyBiological based technology

Idrabel developed a biotechnological automated system that allows recovering ≥

95% of the

hydrocarbons present in the sludge & minimizing waste to be treated or ‘safely’ disposed of.

BioRecOilBioRecOil™™ ProcessProcess

Patent n. EPPatent n. EP1427547 e E0662041427547 e E066204

Biosurfactants

Access Access throughthrough manholesmanholes

Rotating modules are installed on the manholes opening using the Cold tap technique.

No welding and heating.

Pumps access

The modules are connected to large pumps installed in the basin

of the tank

to allow circulation.

Sludge mappingSludge mappingIdrabel also developed a sludge mapping modelling

system, using thermographic measurements to determine sludge volume & distribution in tanks

Oil

Sludge

Water

3 D mapping data modelling3 D mapping data modelling

Mapping output

Topographical Profile

BioRecOilBioRecOilTM TM ProcessProcess

Oil

Sludge, sand and gravel)

Manhole

• Fluxing oil (crude or gasoil), water & biosurfactant

are added• Circulation complete & separation of phases achieved• Recovery processes to be followed

AfterBefore

Oil

circulation circu

lation

VOC Control SystemVOC Control System

• Idrabel also developed a VOC control system• The System uses biotechnological and chemical products

(LECS)

• A spray atomization system

is installed around the tank with lines provided with nozzles, and adjustable sprinklers sprays using a

limited

quantity of fire-water

containing the product.

VolumeDiameter ProductSludge vol. Composition

90,000 m3

76 m – floating roofCrude oil (quantity approx. 30,000 m3)3,000 m3

~ 95 % hydrocarbons

Main problems related to the tank

the floating roof is damaged, sunk & unusable the roof legs cannot be repositioned the gasket seals compromised in part exposed vapour-space exist between roof and oil the pontoons of the roof were flooded with crude the crude has an high H2 S content important leakages present at the tank bottom water was introduced to avoid crude oil loss

““No man entryNo man entry”” case history 1case history 1

Damaged Roof top

““No man entryNo man entry”” case history 1case history 1

Objectives

Recover all oil in the tank (pumpable, not pumpable and sludge).

Safe demolition of the roof.

Minimize sludge volume

Process description

BioRecOilBioRecOil™™ ProcessProcess stared installing 3 telescopic modules through manholes.

crude oil contained in the tank was used as fluxing oil.

2 circulation phases were carried out.

Mobilisation

Operational steps

Collection and interpretation of thermometric data using the SW Sludge Viewer.

Increasing safety and elimination of explosion risk through installation and use of a VOC nebulizing

system on top of the roof

Gas monitoring detection systems (internal and external)

Process description

Installation of BioRecOil equipment for sludge fluidizing

Extraction of oil/water and Oil Recovery

2nd fluidizing phase and water washing drainage &

discharge using hot water and oil/water/sludge

Continue Process description

Degassing and monitoring

Blanketing and foam spraying in the cold cutting areas for opening the tank shell

Washing and progressive blanketing of pontoons

from the external part

Cold holes cutting of pontoons to measure internal explosion values and HP washing using specific product to eliminate explosion risk

Progressive cutting of the roof with shears while localized spraying of LECS product under continuous monitoring

Distribution of a foam layer on the bottom of the tank to increase safety

All demolition devices were equipped with an LEL detector connected to a control station

Continue Process description

Achievements

1. Recovery phase took 35 days

from mobilization to start of demolition.

2. The entire work including complete demolition lasted 15 weeks

3. Amount Crude oil recovered was 30,000

m3

4. Crude oil recovery from sludge was 2,850

m3

5. Final residue (waste was 150

m3) to be disposed of

6. No “near accident”

detected during overall activity

BIORECOIL EFFECT ON TANK BOTTOM (ONLY FEW CENTIMETERS OF RESIDUAL SLUDGE REMAIN)

Other cleaned tanks

Case History 2

VolumeDiameter Product

65,000 m3

61m –

floating roofCrude Oil

Sludge amount

9700 m3

: quantified by thermographic imaging and manual depth measurements

Main problems related to the tank

high sludge quantity prevented proper use of the tank (handling & unloading activities)

the tank remained in service because it was equipped with a floating

suction facility

the roof runs the risk of sinking in the sludge

risk of sending sludge to the pipeline during transfer activities

loss of tank capacity (20,000 m3)

Tank and sludge level

Sludge profiling

Thermographic imagingTank farm areal view

Process and Achievements

Process descriptionIn service cleaning

3 telescopic modules were installed on the tank shell through existing manholes

crude oil in the tank was used as fluxing oil

biosurfactants were loaded into the tank and

circulation was carried out

Work duration

The work lasted 30 days

including mobilization and demobilization

During the BioRecOil®

Process the tank was kept in service all the time

Achieved results

Tank remained out of operation only for 130h

during the circulation phase

Hydrocarbons recovery (8000 m3) ≈

90% of

bottom sludge reduction

Tank capacity almost totally recovered (sludge reduced to less than 20cm

height)

Case History 3 VOC

Problem detected

VOC emissions in an oil storage farm connected to the largest Western European inland oil field caused bad odors release

Sources of emissions were two tanks with floating roof (containing high sulfur compound) and a nearby water treatment basin

Problems with the local community.

Causes

VOC emissions during loading and unloading turbulence in tanks.

Temperature increasing vapors release

Wind acting as an extraction factor

Possible intervention options

A- Reduction and uptake of bad smell emissions:

Site covering,

Entrapping emissions and directing to an external treatment system for strip washing,

Use of absorbing Columns.

B- Use of biotechnological substances capable of reduction of bad odor emissions:

Installation of VOC Control

System on top of the

tank controlling VOC emissions through nozzles nebulizing LECS product over emission points

ESTIMATED INVESTMENT COSTS

OPTION ACost (€) excluding VAT

Coverage of each

floating roof tank 458,000.00Coverage of water treatment basin 26,500.00Collection & reduction VOC emissions System 461,800.00

OPTION BVOC Control System for each

tank 10,000.00

LECS product for each tank 8,000.00 €/monthVOC Control System for water treatment basin 8,000.00LECS product 5,000.00 €/month

VOC control system on roof top

LEL total reduction on the floating roof

VOC control system

Operational VOC control system on floating tank roof

Wireless monitoring system and Station with supplies

Box with 4 dosage system & 1 tank

213

3 3

PCPORTABLE MULTIGASDETECTOR

MODEM EXSTENDING DETECTION RANGE

VOC Sensors and detectors

Sensor probe connected to the multigas portable detector

Portable multigas detector on shell of tank roof

Detect VOC, Gas, LEL

CONCLUSIONS

Option AAlthough

Radical technology that almost eliminates the source of odor emissions

Technology accredited by years of experience

Yet

Involves a long period of down-time to cover areas and installation of an emissions collection system and to

provide a treatment system for collected emissions

It involves ambitious programme from a technical and economical point of view

CONCLUSIONS

Option B in comparison

Minimal construction and installation impact.

Investment needs are kept at minimum.

Has a high efficiency in totally reducing VOC emissions.

For further information

The endThe end

IDRABEL Italia S.r.l.Tel. 010/9131029 Fax. 010/9131022

e-mail : idrabel@idrabel.itWeb sit : www.idrabel.it