oil sludge treatment

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

3

• 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.

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 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

5

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.



compositions of the

TRICANTER® feed.

• Elimination of environmental

and human health hazards

generated by the oil sedi-

mentation ponds.


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


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 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

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 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.



compositions of the

FLOTTWEG TRICANTER®

feed.


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.


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.


and flow rate resulting in

optimum dry substance con-

tent in the solids discharge.

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

FLOTTWEG is ISO 9001

certified and manufactures its

products in compliance to the

current technical standards.

Applicable to 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 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.


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.


oil sludge treatment

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