Tap a new oil well!

FLOTTWEG DECANTERS and TRICANTERS®

for oil sludge treatment

2

The processing of crude oil in

refineries and petrochemical

plants creates waste water

containing hydrocarbons.

Before this waste water goes

to the sewage treatment plant,

a floating layer is separated by

static oil separators. This layer,

commonly called slop oil,

contains hydrocarbons, solids,

and water. Slop oil normally

appears as an emulsion that is

not easily breakable. When the

slop oil contains resins, tar,

and surfactants, separation

becomes very difficult.

In a static settler, such an

emulsion may take up to

several hundred hours to

separate into its components if

at all. FLOTTWEG can provide

complete separation systems

for any type of slop oil.

For effective separation, the

pre-treatment of slop oil is

critical. Heating the oil reduces

its viscosity. The addition of

chemical emulsion breakers /

demulsifiers helps to improve

separation. At the core of our

grained. If necessary, a poly-

mer flocculant or chemicals

can be added directly into the

feed of the tricanter to improve

the separation.

Slop oil treatment

FLOTTWEGTRICANTER

®

slop oil

oil phase

water phaseto biologicaltreatment plant

demulsifyin

liquidproduct

g agent

condensate

flocculantwater

automaticpreparationof chemicals

steam

heatablereaction tank

heatablereaction tank

direct steam injection

solids

variablebowldrive

variablescrolldrive

*)

*) variable impeller system

Slop oil treatment

slop oil separation systems is

a FLOTTWEG TRICANTER®

which separates slop oil into

three components consisting

of oil, water, and solids. In

general, the solids released

from the emulsion are fine-

3

• The recovered oil can be

reused as crude oil.

• 90 % reduction in volume

dramatically reduces trans-

portation and land fill costs.

• Significant reduction of all

costs for waste disposal

because just 10 % of the

original volume remains for

disposal.

Benefits of slop oil treatmentusing a FLOTTWEG TRICANTER®

Slop oil treatment: Composition before and after separation(data based on 100 kg slop oil)

feedbeforeseparation

24,2

71,1

4,7

1,6

0,2

69,3

0,5

0,10,1

21,8

2,04,4

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 to the

refinery or processed and

utilized for lubrication

purposes.

• The solids waste separated

by the FLOTTWEG

TRICANTER® equates to only

10 % of the original volume.

The solids can be delivered

to an incinerator, if available.

• Automatic and continuous

operation even at varying

compositions of slop oil.

100

4

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 andsedimentation 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

complete systems to effectively

handle these lagoons and

ponds and recover useful 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

5

Benefits of oil recovery fromsedimentation ponds using theFLOTTWEG 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

tricanter is either incinerated

or disposed 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

- land fill and

- incineration

because only 10 to 20 % of the

original volume remains for

waste disposal

Treatment 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

1,8

0,2

46,5

0,5

0,20,3

33,4

6,2

10,9

100

6

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 5000 cubic

meters (1.3 Mio. gallons) to

130.000 cubic meters (34 Mio.

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 1000 metric tons of residuals

remain for disposal or incinera-

tion after cleaning. These

residuals can be processed

using a FLOTTWEG

TRICANTER® to recover the oil,

to deliver a water stream that

can be fed to the drain or a

sewage treatment plant, and to

reduce the volume of the solids

phase.

Cost-efficiency

7

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 tricanter is only

10 % of the original sludge

volume.

• The solids phase is suitable

for land filling, it can be

transported or incinerated

without high risk to the

environment.

• Automatic and continuous

operation even at varying

compositions of the tricanter

feed.

• The recovered oil can be

reused as crude oil, thus a

major part of the cleaning

costs are recovered.

• Dramatically reduced costs

for incineration.

• Reduced costs for

transportation and land fill.

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 Russia

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 decanter adapts

itself to varying feed conditions

such as solids load and flow

rate resulting in optimum dry

substance content in the solids

discharge.

FLOTTWEG Systems

Especially for oil recovery from

residuals containing hydro-

carbons, FLOTTWEG provides

decanter and tricanter systems

consisting of FLOTTWEG

DECANTER/TRICANTER®

pumps, oil suction unit, inter-

mediate tanks including pre-

treatment, flocculants dosage,

control unit, etc.. FLOTTWEG

systems are completely piped,

wired, tested, and commis-

sioned on site by FLOTTWEG

personnel.

10

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

All FLOTTWEG machines are

engineered and manufactured

according to established

ISO 9001: 2000 standards.

Especially for Russia: GOST

and GOSGORTECHNADSOR

11

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 of oil fromoil-sludge processing

A FLOTTWEG DISC STACK

CENTRIFUGE (centrifugal

separator) can be used in the

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 decanter is

collected in a special tank

where it is heated up 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.

Type Z32-3 Z4E-4 Z53-4 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 2245 x 1180 x 2980 x 1000 x 3540 x 1820 x 4527 x 1705 x 5147 x 1705 x(L x W x H) 890 mm 1200 mm 1060 mm 1500 mm 1500 mm

Gross weight* 3700 lb 5620 lb 9600 lb 17600 lb 20400 lb1680 kg 2550 kg 4350 kg 7980 kg 9230 kg

Motor for 20 hp 30 hp 60 hp 60 hp 75 hpbowl drive 15 kW 22 kW 45 kW 45 kW 55 kW

Motor for 7.5 hp 20 hp 30 hp 30 hp 30 hpscroll drive 5.5 kW 15 kW 22 kW 22 kW 22 kW(FLOTTWEGSIMP-DRIVE®)

Capacity* > 6610 lb/h > 16500 lb/h > 22000 lb/h > 33000 lb/h > 44000 lb/hbased on feed > 3000 kg/h > 7500 kg/h > 10000 kg/h > 15000 kg/h > 20000 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

Listed FLOTTWEG centrifuges are available in decanter version for 2-phase separation and tricanterversion 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:

Flottweg GmbH & Co. KGaAI n d u s t r i e s t r. 6 – 88 4 1 3 7 V i l s b i b u r gGermany

Telephone +49 8741 301-0Telefax +49 8741 301-300

m a i l @ f l o t t w e g . c o mw w w . f l o t t w e g . c o m P

R –

000

4 Q

– 1

0 1

06 /

05

FLOTTWEG DECANTERS and TRICANTERS®

for oil recovery from residuals containinghydrocarbonsFor 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 from:

• Slop oil

• 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.