Oil and Sludge Removal

Oil and Sludge Removal

Where does oil sludge come form?

Oil sludge is produced at various stages of the oil industry from exploration, production, transportation, processing, and storage. Majority of the sludge is produced at waste water treatment plants considering that large quantities of water are used at critical nodes of the refinery process including desalting, thermal cracking, distillation and catalytic cracking.

It is estimated that for every volume of crude oil processed, up to 1.6 times of wastewater is produced and for every 500 tons of crude oil processed, 1 ton of oil sludge is produced. Therefore, sludge produced during refinery processes has gained a lot of attention from policy makers and regulatory bodies. Traditionally, mechanical, electrochemical and biological processes have been used for petroleum wastewater treatment. However, secondary waste generated is generated from these processes creating difficulties in managing disposal.

Additionally, petroleum sludge is also generated from cleaning of oil storage tanks, equipment maintenance and oil-water separators. Therefore, there is a need to explore different alternative routes available for treatment and management of petroleum sludge waste from across the oil industry value chain.

Sludge Removal from Oil Tanks

NON-MAN ENTRY TANK CLEANING & OIL RECOVERY SYSTEMS

IPX Technologies specializes in automatic tank cleaning systems. Our equipment completely replaces annual tank cleaning and automatically recovers most hydrocarbons from the sludge. The result is less tank downtime, minimized disposal costs, and large amounts of oil for free.

Sludge Removal Solutions – Our environmental teams specialize in the engineering and implementation of safe to human’s sludge removal systems. This includes proprietary “Green” innovations to liquify and remove sludge from tanks, also recovering good oil.

With over 25 years of experience in sludge removal, oil recovery solutions. We are committed to provide our customer with the most advanced time saving, cost-effective technology available. Our versatile, customizable tank cleaning equipment serves the cleaning needs for a variety of applications — oil refineries, industrial and agricultural sectors.

During oil production and processing, large amounts of oily sludges are generated. These sludges are potential environmental contaminants and, at the same time, take up useful storage tank room. Oily sludge composition is variable and includes oil, coarse solids and water. Oily sludges settle on the bottom of storage tanks and their removal is a costly and time consuming process that depends on additional operations to ensure final sludge disposition in an environmentally sound manner.

The high stability of oily sludges is attributed to the adsorption of oil on to solid particles, leading to the build up of a protective layer. This stability is enhanced by the presence of polar fractions in the oil, especially resins and asphaltenes that are also responsible for the high viscosity of such sludges. Furthermore, this protective layer creates a favorable environment for microbial corrosion and may shelter a high and diverse microbial community, thus serving as a contamination reservoir each time the storage tank is used.

Oily sludge accumulation reduces tank storage capacity and this, together with the possibility of corrosion, makes it necessary to periodically remove these deposits. Conventional petroleum industry waste treatment strategies present various shortcomings, including high cost and need for specialized equipment and skilled personnel. Waste landfarming is a lengthy process and may cause groundwater contamination. In addition, it has been shown that recalcitrant organics in petroleum residues can accumulate in soil. For example, Bosert et al. characterized the fate of hydrocarbons during a laboratory study of oily sludge application to soil, simulating an active petrochemical plant landfarming operation. During intensive landfarming of petroleum waste, a gradual accumulation of petroleum hydrocarbons occurred in the soil over time, amounting to 13.8% .

Removal of oily sludge from storage tanks can be carried out by using nano technology to reduce viscosity and promote water/oil or oil/ water emulsification. This process facilitates sludge pumping and allows crude oil recovery after emulsion is broken. Nano -biosurfactants are amphipathic molecules containing hydrophilic and hydrophobic moieties, found mainly on the cell surface or excreted to culture medium by a broad range of microorganisms. These products increase the aqueous dispersion of poorly soluble compound by many orders of magnitude and change the affinity between microbial cells and hydrocarbons by increasing cell surface hydrophobicity.

Oily sludge accumulation reduces tank storage capacity and this, together with the possibility of corrosion, makes it necessary to periodically remove these deposits. Conventional petroleum industry waste treatment strategies present various shortcomings, including high cost and need for specialized equipment and skilled personnel. Waste landfarming is a lengthy process and may cause groundwater contamination. In addition, it has been shown that recalcitrant organics in petroleum residues can accumulate in soil. For example, Bosert et al. characterized the fate of hydrocarbons during a laboratory study of oily sludge application to soil, simulating an active petrochemical plant landfarming operation. During intensive landfarming of petroleum waste, a gradual accumulation of petroleum hydrocarbons occurred in the soil over time, amounting to 13.8% .

Bioremediation of Oil Sludge

The bioremediation of oil sludge is treated in defined steps. Bio Inoculum and optimized nutrients be used to treat the sludge that has formed as a result of a leak from shipping in the area.

Bioremediation is the process of using organisms to neutralize or remove contamination from waste. It is very important to understand that this form of waste remediation uses no toxic chemicals, although it may use an organism that can be harmful under certain circumstances.

At sites filled with waste organic material, nano particles and bacteria, and other microorganisms keep on breaking down organic matter to decompose the waste. If such environment is filled with oil spill, some organisms would die while some would survive. Bioremediation works by providing these organisms with different materials like fertilizer, oxygen and other conditions to survive. This would help to break the organic pollutant at a faster rate. In other words, bioremediation can help to clean up oil spills.

Ananda Mohan Chakrabarty the man who applied for a US patent on a genetically engineered Pseudomonas bacteria – a bug that has a voracious appetite for oil. Taking plasmids from three different kinds of bacteria, transplanted them into the fourth. The genes were shuffled, changing the characteristics of a bacteria that already existed.

The `new’ bacteria could guzzle the oil in case of oil-spills in seas or rivers, and on shore and in oil tanks, thus saving valuable marine life and preventing environmental degradation.

A pit that is 2000 sq mt in area has been dug inside the Kamarajar port and high-density polyethylene sheets have been laid inside it. Layers of earth, sand, sludge and contaminated soil collected from beaches would be laid and bio agents sprayed. Water would be sprayed once a week to ensure moisture levels. In a couple of months, the sludge would become like mud and safe

What IPX ENVIRONMENTAL Can We Do For You

IPX Earth Scientists, understand the core problems. After a lot of research, it has compared various separation methods to determine the best separation process route (some of these separation processes have obtained national patents). At the same time, the main equipment was industrialized and tested, and satisfactory results were achieved. The predetermined technical indicators were achieved and officially put into operation in 2015.

IPX’s sludge extraction equipment is mainly used to deal with oil sludge generated during the process of crude oil exploitation due to drilling, workover, oil recovery, gathering, storage, etc. Its function is to separate the waste sludge and extract the refined oil in the sludge, which not only solves the environmental pollution, but also realizes considerable economic value.

The equipment is armored for easy transportation, small footprint, modular device, low operating cost, good cleaning effect and easy operation. There is a mature sludge pretreatment device, which has rich experience in sludge pretreatment, automatic feeding and unloading, and automation. The oil content after solid-liquid separation treatment is three thousandths, and the treated solid phase can be used for paving, well site, brick making and other comprehensive utilization.

Advanced sludge, cuttings, oil-bearing soil follow-up treatment technology, to achieve standard discharge. The utilization rate of refined oil has been improved, which not only produces good economic benefits, but also solves the problem of sludge and sand polluting the environment.

The three-phase horizontal centrifuge is used for separation. The liquid-liquid-solid three-phase separation principle is adopted, and the oil, water and mud are separately separated by centrifugal force, and the oil phase oil content after separation by the three-phase horizontal screw centrifuge is greatly reduced.

The three-phase decanter centrifuge is a fully automatic, fully enclosed, continuous treatment process when the sludge is separated. The equipment has a small footprint, high automation, low labor intensity and clean working environment.

The system maximizes separation efficiency with low-cost pharmaceuticals and innovative high-automation machinery. The equipment abandons the old and imperfect production process of crude oil. For the first time, it adopts the domestic advanced physical, ultrasonic, separation and tri-integration treatment methods to fully decompose the sludge, and achieve complete separation of oil, water and mud sand.

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