Modular processing plants for separating oily waste, extracting the hydrocarbon phase and purifying water and solid residues.
The modular plant treats oil sludge, oil-contaminated soil and other oily waste. Its process train prepares the feedstock, separates the hydrocarbon, water and solid phases, and treats and dewaters the recovered streams.
Each plant is assembled from functional modules selected for the feedstock, required throughput, site conditions and product specifications. Stationary and mobile configurations are available, together with design, supply, installation, commissioning and operational support.
Flowable mixtures of hydrocarbons, water and solids. Water may be free or present in a stable emulsion.
Hydrocarbon and water content, suspended solids, salts, sulfur and nitrogen compounds may vary. Feedstock density, viscosity, emulsion stability and solids content are assessed when selecting the treatment process.
Feedstock range: water content: up to 80%; mechanical and mineral impurities: up to 15%.
Highly viscous, poorly flowing or partially solidified oily waste, including bottom sediments and long-term stored oil sludge.
During storage, the proportion of light fractions decreases, oil–water emulsions may become more stable, and the content of asphaltenes, resins and paraffins increases. Such feedstocks typically require heating, mixing, blending and multistage separation of hydrocarbon, aqueous, and solid phases.
Feedstock range: water content: 45–50%; mineral solids: up to 30%.
Soil and mineral materials contaminated with oil or petroleum products as a result of spills, operation of storage tanks and industrial activities.
The feedstock may contain water, sand, clay, stones, plant debris and large solid objects. Before treatment, large objects are removed and the soil is crushed, heated and mixed to prepare it for separation and washing.
Feedstock range: water content: 5–70%; hydrocarbon content: 1–60%.
A mixture of drilled rock, residual drilling fluid, water, fine solids and process additives. The hydrocarbon content depends on the type of drilling fluid used.
Treatment is aimed at separating the liquid phase, removing residual components of the drilling fluid, washing and dewatering the cuttings. The resulting water, if it meets the established requirements, can be returned to the process.
Feedstock range: no fixed limits are set for water and hydrocarbon content; the composition is determined by the type of drilling fluid and the content of the mineral phase.
Dense deposits of high-molecular-weight hydrocarbons, including asphaltenes, resins and paraffins. They are formed in pipelines, tanks, oil treatment equipment and sludge reservoirs.
These deposits can be highly viscous and difficult to move at ambient temperature. They may also contain water and solids. Heating and blending prepare the material for separation and hydrocarbon recovery.
Feedstock range: water content: up to 50%; mineral solids: up to 30%.
Complex acidic refinery waste, including hydrocarbon, water and mineral components, as well as residual acids.
Storage tanks may contain both surface liquid layers and thick bottom sediments with mechanical impurities. The treatment process provides for acid-resistant materials, controlled neutralization and separate processing of the liquid and solid parts of the raw material.
Feedstock range: water content: up to 80%; mineral and solid phases: up to 50%; residual acid: up to 20%.
Water containing free, dispersed or emulsified petroleum products, as well as suspended mechanical impurities.
Such water can arise in sludge storage facilities, during the separation of oil sludge and at other stages of the process. The treatment scheme is selected taking into account the content of petroleum products, the stability of the emulsion, the amount of solid particles, salts and requirements for the further use of water.
Feedstock range: the ratio of water, oil products and mechanical impurities is determined by the actual composition of the flow and the results of preliminary analysis.
Bottom sediments and pumped mixtures of soil, water, hydrocarbons and mechanical impurities. They are characterized by a heterogeneous composition, a high content of solid particles and a change in properties along the depth of the storage tank.
Before the main processing, the sediments are removed, crushed, mixed and brought to a homogeneous state. Next, the separation of liquid and solid phases, extraction of hydrocarbons and dehydration of the residue are performed.
Feedstock range: water content: 45–50%; solids: up to 30%.
Concentrated hydrocarbon product isolated from the feedstock after separation of the main part of water and mechanical impurities.
Depending on the selected configuration, the product can additionally undergo centrifugation, separation and dehydration. The possibility of return to the production cycle, compounding or further processing is determined by its actual characteristics and analysis results.
Achievable parameter range: water content: 0.5–5%; mechanical impurities: 0.05–0.5%.
Water separated from hydrocarbons, solids and sediment during feedstock treatment.
If necessary, water undergoes additional gravity separation, filtration, sorption or membrane purification. The possibility of returning water to the process, using it for technical needs or other treatment is determined by the requirements of the project and the results of quality control.
Achievable parameter range: residual hydrocarbons: 0.05–350 mg/L.
Separated and dewatered soil, drill cuttings, sand and other mechanical impurities after removal of the bulk of water and hydrocarbons.
The possibility of using the material for backfilling, land leveling, road work, or the need for its further handling is determined by laboratory parameters and current regulatory requirements.
Achievable parameter range: residual hydrocarbons: 0.05–5%.
The stated ranges cover different feedstocks and plant configurations; they are not guaranteed performance values for every material. Actual results depend on feedstock composition, the selected configuration and operating conditions. Test methods, the basis of percentage values and project-specific limits must be agreed following feedstock analysis and testing.
The process line is configured for the feedstock's physical form, composition and contamination level.
Modular construction allows you to form a production line from individual functional units and adapt it to the conditions of a specific facility. If necessary, the complex can be supplemented with equipment for preliminary preparation, separation, purification, dehydration and automated control.
The process line comprises functional modules selected for feedstock properties, site conditions and target product specifications. If necessary, the line can be supplemented with new process stages and individual pieces of equipment.
The equipment is used for liquid and thick oil sludge, oil-contaminated soils, drill cuttings, paraffin and old oil-containing waste.
The process line prepares the feedstock, separates the hydrocarbon, water and solid phases, and treats the recovered streams.
The process recovers a hydrocarbon fraction for possible reuse or further treatment, subject to its properties.
Throughput can be adjusted by changing the number and configuration of functional modules. Specific parameters are determined by the characteristics of the feedstock, the required process flowsheet and project conditions.
The complex can be used for permanent operation at one site or be implemented in a mobile version for sequential operation at different production sites.
Monitoring process parameters, equipment control, alarms and safety interlocks are combined into a single automated complex control system.
The equipment package, process sequence and operating conditions are defined from feedstock analysis and, where needed, laboratory or pilot tests.
A complete process train may include feedstock receipt and preparation, heating and processing, hydrocarbon, aqueous and solids separation, petroleum product refining, sludge dewatering and process water purification.
The actual set and sequence of stages are determined by the type of raw material, the results of preliminary studies and the selected configuration.
The plant comprises functional modules selected for the feedstock, required treatment level and throughput, and target specifications for the hydrocarbon, water and solid streams. Individual modules can be used in different combinations as part of a complete or reduced configuration.
MODULE 1
Feed receipt and preparationDesigned for collecting liquid oil sludge and floating oil products from the surface of the storage tank and supplying feedstock to the production line.
MODULE 4
Feed receipt and preparationDesigned for extraction and supply of bottom sludge, thick sediments, contaminated soil and slurry to subsequent processing stages.
MODULE 5
Feed receipt and preparationProvides reception, heating, mixing and preparation of oil-contaminated soil or drill cuttings for subsequent cleaning.
MODULE 2
Liquid phase processingPrepares liquid oily feedstock for subsequent separation into hydrocarbon, water and solid phases.
MODULE 3
Liquid phase processingProvides final mechanical separation of the prepared stream and separation of the hydrocarbon phase, water and mechanical impurities.
MODULE 10
Liquid phase processingUses electro-dehydration to break the oil–water emulsion and reduce water content in the recovered hydrocarbon phase.
MODULE 6
Soil, sediment and water treatmentDesigned for processing thick oil sludge, oil-containing sediments, asphaltene–resin–paraffin deposits and contaminated soil with separation of hydrocarbon components.
MODULE 7
Soil, sediment and water treatmentProvides thickening of sludge, separation of the liquid phase and further dewatering of the solid residue.
MODULE 8
Soil, sediment and water treatmentDesigned for additional purification of the water stream after the main stages of separation of oil-containing feedstock.
MODULE 11
Soil, sediment and water treatmentProvides primary treatment and washing of oil-contaminated soil with separation of the main part of hydrocarbon contaminants.
MODULE 12
Soil, sediment and water treatmentDesigned for final acoustic treatment of soil and removal of residual hydrocarbon contaminants.
MODULE 9
Plant controlProvides centralized control of process modules, power equipment, pumps, conveyors and acoustic systems.
The final configuration is determined after analysis of the initial data. For complex and heterogeneous wastes, sampling and pilot testing may be required.
Work may include review of project requirements, development of a technical solution, design, manufacturing, supply of equipment, installation, commissioning and operational support.
To prepare a technical proposal, we need the feedstock composition and volume, required throughput and target product specifications.