oil sludge treatment
TRANSCRIPT
Tap a new oil well
FLOTTWEG DECANTERS and TRICANTERS®
for oil sludge treatment
2
Treatment of oily waste water
The processing of crude oil in
refineries and petrochemical
plants creates oil emulsive
waste water. Processing this
waste water means separating
it into its main components
of oil, water, and solids. The
objective is to recover as much
oil as possible and to dispose
of the other components in an
efficient way.
The first step is static separa-
tion in API* separators. The oil
concentrates on the surface
whereas the solids sink to the
bottom as sludge. Between
these two components a water
phase is built up which then
goes to the waste water treat-
ment facility. The floating layer
of the surface and the sludge
coming from the underflow of
separation efficiency using the
FLOTTWEG TRICANTER®.
Heating treatment reduces the
viscosity of the oil; additionally
it is possible to add surfactants
in order to improve the separa-
tion. Fine solids particles can
be separated more efficiently
by adding polymer flocculation
aids or precipitation agents.
The water coming from the
API separator goes first to a
flotation plant where the solids
are separated. The separated
used in municipal and indus-
trial sewage plants for this
purpose.
*API = American Petroleum
Institute
aeration tank
FLOTTWEGHTS-DECANTER®
FLOTTWEGTRICANTER®
floatinglayer
water
flotation
oil solids
water
oilywastewater
pH
APIseparator
acid / lye
oilsludge
effluentsolids
sludge
effluent
pre-treatment
sewage sludge
Oil and sewage sludge treatment with FLOTTWEG CENTRIFUGES
solids can then be further pro-
cessed together with the oil
sludge. The real waste water
treatment is done in a mechan-
ical-biological sewage plant.
Waste water treatment gener-
ates sewage sludge which
should be as dry as possible in
order to reduce the costs of
transport, disposal, or incine-
ration. The FLOTTWEG HTS
DECANTER® is specially
designed for the high-dewater-
ing of sewage sludge and is
the API separator are consoli-
dated and further processed
as oil sludge. The FLOTTWEG
TRICANTER® is especially
designed for the continuous
separation of three-phase
mixtures and is able to sepa-
rate the three components oil,
water, and solids in a single
step. The manner of oil sludge
pre-treatment is crucial for
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• The recovered oil can be
reused as valuable oil.
• 90 % reduction in volume
dramatically reduces trans-
portation and disposal costs.
• Significant reduction of all
costs for waste treatment as
only 10% of the original
quantity has to be handled.
Benefits of oil and sewage sludge treatment using the FLOTTWEGDECANTER and TRICANTER®
Oil sludge treatment: Composition before and after separation(data based on 100 kg oil sludge)
oil sludgebeforeseparation
24,2
71,1
4,7
2,1
0,4
69,4
0,7
0,10,2
21,4
1,54,2
100
solids water oil
solidsafterseparation
waterafterseparation
oilafterseparation
Cost-efficiency
• Significant reduction of
hydrocarbon emissions into
the environment.
• Approximately 80 to 90 % of
the oil is recovered. The oil
can be recycled in the
refinery or processed and
utilized for lubrication
purposes.
• The solids waste separated
by the FLOTTWEG
DECANTER equates to only
10 % of the original volume.
The solids can be delivered to
an incinerator or disposed of.
• Automatic and continuous
operation even at varying
compositions of the sludge.
100
® = registered trademark in various countries
• Low personnel costs due to
continuous and automatic
operation.
• Low specific energy
demand.
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oil lagoon
steam
waste oilpump
waste oil collecting tanks
water andflocculant
automaticpreparationof chemicals
directsteam
injection
prefilter
circulationpump30-100 m /h
overflow
dilution waterflocculantpump
feedpump
heatex-chan-ger
heatex-chan-ger
steam
steam
variableimpellersystem
variablebowldrive
variablescrolldrive
pump
waste-watercollecting tank
water phaseto biologicaltreatment plant
solidsdiverter
solidstransport
clean oilcollecting tank
pump1234599999
clean oilcounter
oil torefinery
50-500 m
50-500 m
controlpanel
FLOTTWEGTRICANTER
®
3
3
3
System for processing oil sludge from lagoons and sedimentation ponds
Oil recovery from lagoons and sedimentation ponds
In the past, it was common to
dump oily residuals from
refineries, petrochemical
plants, and other industries
into large sedimentation
ponds. Even today, huge
lagoons and ponds can be
found in many places around
the world where these residuals
have been settling for decades.
FLOTTWEG can provide
equipment or complete
systems to effectively process
the residues and recover
valuable oil.
Part of the FLOTTWEG oil
recovery system is an oil-
suction unit that enables the
extraction of oil sludge from a
defined depth below the
pond’s surface. The suction
pump is mounted on a pontoon
that floats on the surface of the
pond or lagoon. If the suctioned
portion contains high contents
of paraffins and asphaltum, the
oil sludge is fluidized in the
suction pipe using steam
operated heater coils. The
extracted oil sludge is then
processed like slop oil. The
slop oil is heated, surfactant
and flocculant are added, and
finally, oil, water, and solids are
separated via a FLOTTWEG
TRICANTER®.
Cost-efficiency
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Benefits of oil recovery fromsedimentation ponds using the FLOTTWEG TRICANTER®
• Approximately 90% of the
existing oil is recovered.
• The residue volume is
reduced to only 10 to 20%
of the original sludge quantity.
The solids phase from the
FLOTTWEG TRICANTER® is
either incinerated or dispo-
sed of.
• Automatic and continuous
operation even at varying
compositions of the
TRICANTER® feed.
• Elimination of environmental
and human health hazards
generated by the oil sedi-
mentation ponds.
• The recovered oil can be
reused as crude oil.
• Reduced costs for
- transportation
- disposal and
- incineration
because only 10 to 20% of the
original volume remains for
waste disposal.
Treating oil sludge from lagoons and sedimentation ponds: Compositionbefore and after separation (data based on 100 kg oil sludge)
feedbeforeseparation
solids water oil
solidsafterseparation
waterafterseparation
oilafterseparation
35,0
53,0
12,0
100
2,9
0,2
46,5
0,5
0,20,3
31,6
6,2
11,6
100
® = registered trademark in various countries
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3
3
3
hydraulicpump
dieselengine
20“ - container
flotating roof tank
solidtransfer pump
agitator with hydraulic drive
hydraulicdrive
hydraulicdrive
solids
FLOTTWEGDECANTER
80 m /h
5-32 m /h
preheating (optional)
5 mcentrate
container
hydraulicoil tank
diesel-oiltank
variablebowldrive
variablescrolldrive
Tank cleaning
Oil recovery from residualsduring tank cleaning
Crude oil is stored in tanks
ranging in size from 5,000 cubic
meters (1.3 mil gallons) to
130,000 cubic meters (34 mil
gallons). Over time, a wax-like
layer consisting of heavy
hydrocarbons and inorganic
impurities such as sand, rust,
and heavy metals, builds up on
the bottom of the tanks,
thereby reducing the utilizable
tank volume. Prior to safety
inspections, and maintenance
and repair jobs, the tank has to
be completely emptied and
cleaned.
Tanks are cleaned with crude
oil, diesel oil, and water. Depend-
ing on the size of the tank, up
to 1,000 metric tons of residuals
remain for disposal or incinera-
tion after cleaning. These resi-
duals can be processed using
a FLOTTWEG TRICANTER® to
recover the major part of the
oil, to deliver a water stream
that can be fed to a sewage
treatment plant, and to reduce
the volume of the solids phase.
Finally only 10% of the original
quantity remains for incineration.
Cost-efficiency
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Crude oil storage tanks
Benefits of using the FLOTTWEG TRICANTER® for processingoil sludge from tank cleaning
• 90 to 95% of the oil con-
tained in the residuals layer
is recovered.
• The amount of solids sepa-
rated by the FLOTTWEG
TRICANTER® is only 10% of
the original sludge volume.
• The solids phase is suitable
for disposal, it can be trans-
ported or incinerated without
high risk to the environment.
• Automatic and continuous
operation even at varying
compositions of the
FLOTTWEG TRICANTER®
feed.
• The recovered oil can be
reused as valuable oil, thus
a major part of the cleaning
costs are repaid.
• Dramatically reduced costs
for incineration.
• Reduced costs for
transportation and disposal.
® = registered trademark in various countries
8
Special features of FLOTTWEGDECANTERS and TRICANTERS®
used for oil recovery from residualscontaining hydrocarbons
Experience
FLOTTWEG has been
developing and manufacturing
decanters for over 50 years
and is one of the world’s
leading decanter manufacturers.
FLOTTWEG has more exper-
ience and expertise than any
other decanter manufacturer
when it comes to applying and
using decanters for the purpose
of oil recovery from residuals
containing hydrocarbons.
Short payback period
Normally, FLOTTWEG
DECANTERS and
TRICANTERS®, when used for
oil recovery from residuals
containing hydrocarbons, pay
for themselves within one year
of operation.
Wear protection
Optimum wear protection is
crucial for the use of decanter
centrifuges for oil recovery
from residuals containing
hydrocarbons. All parts from
FLOTTWEG DECANTERS
exposed to wear are protected
by special tungsten carbide
hardfacing. All wear bushings
and inserts are made of silicon
carbide ceramic.
FLOTTWEG TRICANTER® SYSTEM for oil recovery in Romania
9
FLOTTWEG SIMP-DRIVE®
The FLOTTWEG SIMP-DRIVE®
automatically controls the
internal scroll differential speed
according to the torque gener-
ated from the feed stream. This
means the FLOTTWEG
DECANTER/TRICANTER®
adapts itself to varying feed
conditions such as solids load
FLOTTWEG SYSTEMS
Especially for oil recovery from
residuals containing hydro-
carbons, FLOTTWEG provides
systems consisting of
FLOTTWEG DECANTER/
TRICANTER®, pumps, oil
suction unit, intermediate
tanks including pretreatment,
flocculants dosage, control
unit, etc. FLOTTWEG SYSTEMS
are completely piped, wired,
tested, and commissioned on
site by FLOTTWEG personnel.
® = registered trademark in various countries
and flow rate resulting in
optimum dry substance con-
tent in the solids discharge.
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Explosion proof
All FLOTTWEG DECANTERS
and TRICANTERS® for oil re-
covery from residuals containing
hydrocarbons are in compliance
with the regulations ATEX 95
(for Europe) and IEC for Class I,
Division 2 and Group D.
References/Credentials
FLOTTWEG DECANTERS and
TRICANTERS® are in use
around the world in major
refineries and petrochemical
and recycling plants, where
crude oil is extracted or
processed.
FLOTTWEG products are
designed and manufactured
in GERMANY!
Certifications
FLOTTWEG is ISO 9001
certified and manufactures its
products in compliance to the
current technical standards.
Applicable to Russia: GOST
and GOSGORTECHNADSOR
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FLOTTWEGAC SEPARATOR
clean oilfor furthertreatment
oil sludge
oil phaseto bepurified
demulsifyin
liquidproduct
g agent
condensate
flocculant
water
automaticpreparationof chemicals
steam
heatablereaction tank
heatablereaction tank
direct steam injectionsludge
water phase tobiologicaltreatment plant
water phase
variablebowldrive
variablescrolldrive
*)
*) variable impeller system
FLOTTWEGTRICANTER®
Plant for processing residuals containing hydrocarbons using the FLOTTWEG DISC STACK CENTRIFUGE
Oil pond with floating suction unit
FLOTTWEGDISC STACK
CENTRIFUGE
FLOTTWEG DISC STACK CENTRIFUGESfor cleaning oil fromoil-sludge processing
A FLOTTWEG DISC STACK
CENTRIFUGE (centrifugal
separator) can be used in
cases where a high purity
of oil is required.
The feed stream for the
FLOTTWEG DISC STACK
CENTRIFUGE can only contain
small amounts of residual
water and solids. The oil
coming from the FLOTTWEG
TRICANTER® is collected in a
special tank where it is heated
to 90 °C before being delivered
to the disc stack centrifuge via
an eccentric-screw pump.
Generally, a residual BSW
water/solids content less
than 100 PPM is achieved
after separation.
® = registered trademark in various countries
Type Z32-3 Z4E-4 Z5E-4 Z6E-3 Z6E-4
Materials All product wetted parts are made of high grade stainless steel of construction such as 1.4463 (Duplex), 1.4571 (AISI 316 Ti), etc.
Dimensions 2 245 x 1 180 x 2 980 x 1 000 x 4600 x 1700 x 4 527 x 1 705 x 5 147 x 1 705 x(L x W x H) 890 mm 1 200 mm 1 500 mm 1 500 mm 1 500 mm
Gross weight* 3 700 lb 5 620 lb 14,400 lb 17,600 lb 20,400 lb1 680 kg 2 550 kg 6 220 kg 7 980 kg 9 230 kg
Motor for 20 hp 30 hp 50 – 75 hp 60 hp 75 hpbowl drive 15 kW 22 kW 37 – 55 kW 45 kW 55 kW
Motor for 7.5 hp 20 hp 20 – 30 hp 30 hp 30 hpscroll drive 5.5 kW 15 kW 15 – 22 kW 22 kW 22 kW(FLOTTWEGSIMP-DRIVE®)
Capacity* > 6 610 lb/h > 16,500 lb/h > 22,000 lb/h > 33,000 lb/h > 44,000 lb/hbased on feed > 3 000 kg/h > 7 500 kg/h > 10 000 kg/h > 15,000 kg/h > 20,000 kg/h
Optional Available also for installation in explosion hazard areasClass I, Division 2, Group D or ATEX 95 (for Europe).
Hydraulic drive for bowl and scroll
The listed centrifuges are available as FLOTTWEG DECANTER for 2-phase separation and FLOTTWEG TRICANTER® for 3-phase separation
* The listed figures are to be understood as guidelines.
Actual capacity will depend on the individual characteristics of the feed product.
Technical data
Representative:
PR
– 0
004
Q –
10
3
07 /
09
FLOTTWEG DECANTERS and TRICANTERS®
for oil recovery from residuals containinghydrocarbons
For many years, FLOTTWEG
DECANTERS, TRICANTERS®,
and SYSTEMS have been in
operation at major refineries
and petrochemical plants all
over the world.
Oil recovery from oil sludge
• Industrial waste water
• Sedimentation ponds and
lagoons
• Tank cleaning
Cost-efficiency
• Re-use of the recovered oil
• Reduced costs of transpor-
tation and disposal of the
separated solids phase.
® = registered trademark in various countries