Sludge in COS Tank

8/13/2019 Sludge in COS Tank

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em a c o group

emacogroup Italy, servicing the Marine industry and the oilfield sectors ofDrilling, Production and Refinery operations for the purposes of design,

manufacture, installation & operation of custom or standard build separation systems for treatment ofoily waste and slop oil. Emaco Oily Waste Separation Systems provide benefit to clients seeking anenvironmentally sound Waste Management Program. This is to comply with the standard practices ofthe Environmental 3R's - Reduce, Recycle, Re-use. Emaco treated oily waste is:

Reduced (minimized) to solids by removal of liquids, and

Recycling of Oil and Water, and Re-use of oil as a product with water returned to nature.

Emaco therefore, sells, manufactures, installs and operates treatment systems required in theMarine industry and the Oil & Gas Industry to clean oily waste generated as a by-product of theiroperations. These wastes are identified from drilling, production and completion fluids, operationsfuel oils and diesel oils, produced water, crude oil refinery & transport vessels slops and sludge,refinery emulsions, API separator sludge, tank bottom sediments, stored oil waste pits, polluted soils,

ships slops bildge water dirty lube oils and the like Emaco separation systems are either fixed or
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ships slops bildge water dirty lube oils and the like Emaco separation systems are either fixed or

em a c o groupThese skids are manufactured in accordance to water treatment requirements and application. Thesystem noEmacoally involves the incorporation of feed pumps, screen filters and high-speed 3 -phase centrifuges. In general a single centrifuge for the treatment of oily water could range from 15to 50 m/hr per unit supplied. Greater capacity is achieved by multiples of units installed in tandem.

Oily SlopsThese plants are manufactured in accordance to the definition of slops, which

vary from diesel oil to crude oil, or in mixture ofseveral types of oils. The system involves theincorporation of a heat supply, feed pumps,screen separators, (possibly) 2-phase decantersand high-speed 3-phase centrifuges. The 3-

phase centrifuge is the piece that determines theplant capacity. In general a single centrifuge forthe treatment of oily slops would range from 5 to10 m/hr per unit supplied. Greater capacity is

achieved by multiples of units installed in tandem.

Oily SludgesThese plants are manufactured in accordance to the definition of sludge to be treated. Sludge vary

widely in composition coming from all sources of oily waste streams. They can be single sourcesludges of crude oil tank bottom cleanings dumped and stored in a tank or an earth pit. Or they canbe an endless combination of oily waste coming from all different sources - mixed, dumped andstored together awaiting treatment. Sludges are commonly inconsistent, contaminated withmiscellaneous debris, are thick and viscous complicating their treatment, especially as they influenceequipment thruput capacity. The sludge treatment system involves the incorporation of a heatsupply, feed pumps, (possibly) bulk hoppers with conveyors, screen separators, 2-phase decantersand high-speed 3-phase centrifuges. In sludge treatment the final 3-phase centrifuge is the piece of

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em a c o groupOrganization Emaco Oil&Gas was established through an organizational change in 2000made by Alfa Laval going from a privately held (after 122 years in business) toa public holding company. This led to the closure of Alfa Lavals Oilfield

Division and resulted in the set up of Emaco as an Alfa Laval OEM (OriginalEquipment Manufacturer) for the purpose of fabricating full-scale oily wastetreatment plants using exclusively Alfa Lavals Centrifuges and Heat

Exchangers. The Alfa Laval exclusivity under the OEM was maintained for our first three years ofbusiness.

In January 2004, to better serve our clients, Emaco subsidiary decided to become an independentmanufacture free to utilize any equivalent competitive components to Alfa Lavals equipment. This

new arrangement allows Emaco to select the best technical and commercial supply options availableas separation components for use in our manufacturing process and/or to provide any componentspecifically requested by the Client.

We still offer the same equipment warranties and performance guarantees as we did under AlfaLavals OEM Agreement. Emaco separation systems are manufactured in the Netherlands inpartnership Alfa Laval modules for the past 30 years, the Alfa Laval BV Service Center is located at

Tekoma. Therefore certificates of origin and conformity to codes and regulations are issued inaccordance to Dutch and European Community standards.

Emaco Oil&Gas is in compliance to ISO 9002 certification through our partnership with Emaco groupit being the workshop where our plants are manufactured. Emaco separation systems aremanufactured (if required by the Clients specifications) to meet explosion proof regulations requiredfor equipment supplied to the Oilfield sectors.

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em a c o groupThe processComposting of oily solids requires approximately 4 months to reach declassification. Oily wastesolids having an oil content in the range of 5% to 50% are suitable for composting. This is similar to afaEmacoing operation where rows are laid out and tended to throughout the oil decomposition period

to insure optimum microbial activity. This involves row building, the addition of nutrients and mostimportantly periodic watering and the daily induction of oxygen by custom designed equipment.Recording keeping is paramount to track all incoming oily waste and outgoing treated compost tocomply with audits and regional environmental regulations. This also involves analytical and fieldlaboratory testing to benchmark initial and final oil content and trace element measurements requiredfor closure. EMACO provide the know-how,the specialized equipment and/or the fullservices to operate the Waste Facility

handling all composting requirements at afixed rate per m.

Please contact us for technical detailsinvolving the complete process, the requiredequipment and the full turnkey servicesprovided.

Free pore space (FPS) = 100(1-BD/SG) xDry MassBD = Bulk Density & SG = Specific Gravity

Maximum Oxygen consumption (equated to maximum microbial activity)in a composting operation occur at approximately65%moisture and a FPS of 30%

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em a c o groupOnline Sludge Removal

As legislation continues to tighten alternative sludge removal

techniques are required to reduce and eliminate man entry into confined spaces.

Online Sludge Removal from Tanks

Roof mounted nozzle system to reduce/remove sludge banks

Focused on problem areas identified by the SPOT

Combined with proven centrifuge technology to intercept solids, avoiding them being


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em a c o group The hydro-dredger is a suction device which can be operated at slow speeds to avoid

disturbance to overhead water system, removing sediment/sludge from pits, APIs and water

treatment areas whilst online.

Mechanical Sludge Removal

Over the past 14 years, Emaco Oil Services manufacturing division has

designed and built a range of hydraulically driven sludge removal equipment. Using feedback from

the contracting division, the systems have been modified and updated.

The emphasis remains on safety by minimising/eliminating

man entr into confined spaces


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em a c o group

Ever increasing environmental awareness and legislation is demanding that oily

sludge is treated at source, as it is no longer acceptable for it to be sent to landfill/lagoons.

Emaco Oil Services has designed a range of mobile processing equipment which enables sludge to

be treated at tank/lagoon side, recovering oil and minimising waste.

Pre-treatment of sludge is key to high quality separation. Emaco have a variety of systems tailored to

meet the specific contract requirements.

The focus of the Emaco sludge processing system is on returning the valuable recovered

hydrocarbons to the refinery, ensuring that they are not sent off site. In some cases the high oilcontent in the sludge, combined with the quality of the oil that can be separated by our system, can

result in the projects being self-funding or offering a payback.

Emaco Oil Services R&D department are constantly designing a range of centrifuge technology to

deal with a variety of difficult to treat sludges, ranging from tight emulsions containing fine particles,


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em a c o group

Indirect heat theEmacoal desorption system to reduce volumes to

an absolute minimum low and high temperature systems.

New systems under R & D including waste to energy technologies to offer further environmental

solutions to the treatment of post centrifuge cake and other suitable wastes.

Appl ications

Removal and treatment of tank bottom sludge:

Safe and efficient removal of tank bottom sludge

Sludge treatment and oil recovery directly from tankto reduce off site waste


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em a c o groupfrom tank bottom sludge

o

Services

o Project engineering solutions for individualtank cleaning and sludge treatmentapplications

o cleaning and sludge treatment projectso On site contracting service for wide range of

tank

The EMACO integrated package is specifically designed to remove and treat sludgeon a continuous basis.

Sludge is treated directly it is removed from storage tanks, reducing off site transport

and disposal costs.

EMACO offer a wide range of engineering and contracting services to suit clientrequirements, please contact EMACO for full details.

Benefits of EMACO On-Site Sludge Treatment

System designed specifically to treat crude oil sludge

F t d ffi i t t t t f l l f l d


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em a c o groupThe sludge that is recovered from the bottom of crude tanks is generally a mixture of silt, sands,clay and crude oil. The conventional method of treating this, involves heating the oil sludge tocreate a pumpable slurry, then passing it through a centrifuge. This process normally gives a solidresidual waste containing 6-15% hydrocarbons and a recovery of 90-93% of the crude oil.

EMACO Oil Services have developed and patented a process for treating either the oil sludgedirect from the tank or the residual from the centrifuge. The process uses high shear forces toseparate the oil from the solids in to three distinct phases, solids, oil and hydrocarbons. Then thethree phases are separated using standard hydro-cyclone technologies. The outcome of which isthat the solids from the tank bottoms are left with less than 1000 ppm (0.1%) of hydrocarbons.

The water produced from the process is fully recycled, and then passed through EMACO25, togive less then 5 mg/l TPH, for discharge to refinery waste water treatment plant or off-sitedisposal.

The benefits to the refinery are: It is easier and less expensive to dispose of the sludge residual, the sludge will be classed

as non-hazardous and volume for disposal will be less, giving a saving of at least 50% insludge disposal costs.

99% plus of the hydrocarbons are recovered vs. 92-93%. The water from the process is cleaned to less than 5 mg/l TPH. Using the EMACO process leads to a total cost saving of between 25-35% versus using a

centrifuge.

EMACO Media

EMACO25 is one of a family of media, which is specifically aimed at treating dissolved, emulsifiedhydrocarbons, such as oil, BTEX, Phenols, Alkyl Phenols and PAH. Other media for the treatmentof heavy metals and in-organics are also available.

EMACO25 is a starch granule coated with a surfactant. It can be used as a direct replacement for

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em a c o group


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em a c o group


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ERB

ATO

I


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RISANAMENTIQuesta tecnologia permette di risanare i serbatoi mediantelapplicazione di rivestimenti protettivi interni, specifici peril materiale contenuto

possibile scegliere fra due distinte metodologie di rivesti-mento; la scelta delluna rispetto allaltra si fonda su unaserie di considerazioni di carattere tecnico, amministrativo,economico, quali:

la durata residua del serbatoio ai sensi delle disposizioni di legge il vantaggio gestionale indotto dalla trasformazione del

serbatoio semplice in una a doppia parete con sistema di monitoraggio dell intercapedine.In adempimento al DM 246 del 24/05/1999 e successive modifiche, questa trasformazione esclude il serbatoio da ulteriori controlli, abolendo il termine di dismissione le difficolt di rimozione evitare lavori di scavo e di rifacimento degli impianti ridurre al minimo i tempi di fermo

laminato-fibra di vetro

foglio bugnato di alluminio

intercapedine

1 rivestimento

lamiera serbatoio

2 rivestimento

copertura antistatica

corrosioneinterna

rivestimentoprotezione lamiera

corrosioneesterna


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Parete semplice

Applicazione a spessore del rivestimento, utilizzandoprodotti a base di resina epossidica o poliestere.

Doppia par ete

Realizzazione in opera, di una parete interna multistrato,munita di intercapedine, realizzata dalla sovrapposizionedi pi materiali, collegata ad un sistema di monitoraggio.I l sistema di risanamento coperto da brevetto ed omologato da Enti Statali Internazionali.

Fasi intervento: bonifica prova di tenuta eventuali controlli non distruttivi eseguiti sul metallo sabbiatura applicazione internamente del rivestimento protettivo

TIPI DI RIVESTIMENTO


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BONIFICA

GENERALITA

La Edam specializzata adintervenire con personale edattrezzature proprie in zone ocondizioni ad alto rischio.In questi casi, in relazione allapericolosit del prodotto contenutonei serbatoi, indipendentementedalle operazioni da effettuare, fondamentale intervenire con:Personale specializzato,specificatamente addestrato eformatoAttrezzature e strumentazione,

Normative regionali e nazionali, sovrapponendosi fra loro,regolamentano ladeguamento degli impianti di stoccaggio esistenti,nonch la loro corretta gestione e manutenzione.

La Edam interviene nelle principali problematiche ambientali dellecitate leggi e circolari.In relazione ai prodotti contenuti nei serbatoi gli interventi sonoda inquadrare in:

- INTERVENTI A BASSO RISCHIO

Combustibili (gasolio, olio combustibile, etc.)

- INTERVENTI AD ALTO RI SCHIO

materie altamente infiammabili o lavori in zone pericolosemateriali tossici e/o cancerogeni rifiuti prodotti corrosivi

NORMALIZZAZIONEPOZZETTI DI CARICO

Razionalizzazione dei sistemi di scarico e di sfiato, sistemazione

del passo duomo con controllo delle guarnizioni e saldature,installazione o manutenzione delle valvole limitatrici,predisposizione degli attacchi per prove di tenuta.In generale tutto quanto serve per riportare limpianto a norma.

Lampia dotazione di attrezzature e tecnologie consente alla Edamdi occuparsi della bonifica di serbaoi contenenti le pi disparate

sostanze.Lintervento seguito con due metodologie:

Manuale

Ingresso di operatori perfettamente equipaggiati dotati di dispositividi protezione e specifiche attrezzature per la bonifica.

Automatica

Impiego di macchinari per il lavaggio e disincrostazione, eseguite


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RILIEVO DELLA TENUTAMEDIANTE ULTRASUONI

Il sistema rileva la presenza della pi piccola foratura od incrinatura,consentendo di valutare lo stato del serbatoio in modo efficienteed affidabile. Il principio su cui si basa consiste nel sottoporre unserbatoio ad una leggera depressione (sufficiente a vincere la spintaidrostatica del prodotto contenuto) e nel rilevare gli ultrasuonigenerati dalle eventuali forature o crepe presenti.I principali vantaggi offerti possono essere cos riassunti:

Rapidit dintervento non richiede lo svuotamento del

serbatoio, ci consente di ridurre notevolmente i costi e i tempi per la sua esecuzione: Assenza dimpatto ambientale lutilizzo di un sistema a depressione non permette la fuoriuscita di prodotto dai fori o crepe eventualmente pr esentinel serbatoio: Efficienza ed affidabilit il sistema, basato su componenti tecnologicamente avanzati, certificato dai principali Enti Int ern azionali e r isponde ai requ isiti tecnici previsti dalla

normativa Italiana.

Sicurezza tutte le apparecchiature utilizzate sono omologate per operar e in zona ad alto r ischioed in presenza di prodotti infiammabili.

DEMOLIZIONE

Il taglio costituisce una fase molto delicata; per la sua esecuzionesono applicate norme e procedure internazionali al fine di evitare

i rischi dovuti alla presenza di miscele di gas infiammabili. Leattrezzature utilizzate rispettano le specifiche dimpiego in funzioneal tipo di rischio.

Taglio a freddo

In relazione alla pericolosit del materiale precedentementecontenuto ed in funzione alla zona di lavoro, si utilizzano tecnologieparticolari di taglio quali lidrotaglio (taglio ad acqua), o quellocon roditrice pneumatica.


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MACCHINARI EATTREZZATURE

Impianti idrodinamici ad altissima pressione

Disponiamo di pi versioni dunit ad alta pressione; ogniallestimento idoneo ad affrontare in modo specifico diverseproblematiche.

Sistemi mobili per abbattimento dei vapori

Impianti di depurazione ad umido, scrubber, o a secco, filtro acarboni attivi, per abbattere i vapori, aspirati, durante le fasi disvuotamento e bonifica.

Sistemi mobili daspirazione

Cisterne mobili di dimensioni contenute, autonome, allestite consistema di riempimento a depressione.

Sistema di fluidificazione

resistenze elettriche corazzate. serpentine idonee al passaggio di vapore.

Ponteggio interno tipo Snap-outPonteggio telescopico, in lega dalluminio, omologato,specificatamente realizzato per essere introdotto dal passo duomoe montano allinterno di serbaoi, in modo semplice e veloce senzalausilio dutensili.

Impianto pr oduzione aria respirabile

Apparecchiatura autonoma, da abbinare ai dispositivi di respirazioneassistita utilizzati dagli operatori in ambienti confinati. Il sistema


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DECONTAMINAZIONESUOLO E SOTTOSUOLO

Serbatoi e cisterne sono una potenziale fonte di contaminazione

del suolo, del sottosuolo e della falda. Linquinamento generato,oltre che dalla mancanza di tenuta, anche da perdite accidentaliprodotte durante le operazioni di carico e scarico.

Nel caso di contaminazione, lazienda, immediatamente, deveinformare gli Enti competenti, provvedere alla messa in sicurezzadella zona, svolgere delle indagini ambientali e predisporre unpiano di bonifica idoneo al risanamento del sito.

La Edam dispone di uno staff tecnico ed operativo in grado diapplicare le pi moderne tecnologie relative a:

interventi preliminari di messa in sicurezza carotaggi e campionamenti di terreno e sottosuolo indagini conoscitive sviluppo dei dati ottenuti con software idonei a dimensionare la zona contaminata

definire un modello teoricodespansione dellinquinamento analisi delle diverse tecniche di bonifica applicabili, confrontando costi e risultati predisposizione del piano di caratterizzazione intervenire con tecniche di risanamento in sito o smaltimento

RIFIUTI

I rifiuti contenuti nei serbatoi, e/o generati dalla fase di bonificasono smaltiti in impianti autorizzati italiani ed esteri contrattualmenteconvenzionati od in esclusiva.


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RM25The treatment of dissolved and emulsified oils in produced water

RM25is a starch granule, coated in a surfactant which has an affinity for the TPH, Phenols

and BTEX. It is used in flow through vessels to absorb the dissolved and emulsified

hydrocarbons from the water prior to discharge of the water.

Recognised by Shell as Best Available Technology Not Entailing Excessive Costs(BATNEEC)# for the removal of emulsified and dissolved oils from produced water, which

will give lower compliance limits against mechanical treatment processes.

Have a higher activity percentage active ingredient than any other absorbent media which

potentially means a smaller footprint.

Th di b il d BTEX Ph l d PAH ll h d b


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Advantages of the

Sludge RemovalEquipmentWell proven technology

Safe and efficient system

Minimises or eliminates people in confi

spaces

Many sizes and configurations -

Either remotely or manually controlleddepending on application

Hydraulically driven for safe operation i

hazardous areas


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Sludge Removal Equipment

Willacy Oil Services Ltd produce a range of equipment to enable the safe and efficient removal

of oily sludges from confined spaces.

Mechanical Sludge Removal

The equipment is made in various sizes depending on the application, and can be fixed or incomponent form to go through an 18 manhole. The tracks can be used to agitate the sludge,

pushing it to the pump section. In the remote version the pump can be mounted on the

hydrodozer transferring the sludge directly through a fish tail type suction adaptor. The remote

controlled hydrodozer can be operated as a suction dredger, removing sludge from pits,

lagoons, API separators online while the systems are still in service.

The pumps and hydrodozers are hydraulically driven which is a safe system for hazardous areas.

The diesel driven power pack can be situated in a safe area powering the equipment.

Mechanical tank clean

Non - intrusive tank cle


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Advantages of the

Oil Recovery System Oily

Sludge

TreatmentVast operating experience and satisfied customer reference list

Well proven technology

Different options of sludge pre-treatment system to allow

wide range of sludges to be treated

Purpose built centrifuge designed specfically to separate

difficult oil sludges

A certified control panel with multi-sensing, allows good

quality control

System can give high quality three phase separation

adjustable on line without stopping the machine

High oil recovery rates, often up to 97% of free oil

present in sludge

Quality of recovered oil suitable to be returned to refinery

High volume reductions of sludge is possible maximising oilrecovered and minimising waste into a dry stackable cake

Containerised system for easy efficient transporting to siteemacogroup


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Mobile oily sludge separation system

Following over 17 years of design, manufacturing and operation, Willacy Oil Services Ltd i s now

producing the most efficient range of proven separation equipment on the market without

compromising safety.

The oil recovery system comprises of the following:-

1. Pre- treatment UnitWillacy offers a range of pre-treatment units engineered to meet the clients' requirements

for pre-screening, heating and homogenising the sludge in controlled conditions.

2. Centrifuge Equipment

The separation is carried out by a purpose built decanter centrifuge, which can produce

quality separation into two or three phases. The liquid separation takes place in a

secondary chamber within the centrifuge using a unique adjustable system to give

optimum recovered oil quality.

3. Chemical Dosing System

The chemical dosing system is included for inline injection of appropriate chemicals to

assist separation where required.

4. Control Panel

A specifically designed control panel, built by Willacy Oil Services Ltd manages the total

sludge processing system with multiple control of motors, tank liquid levels, centrifuge

and many safety monitoring devices for temperature flow and pressure. This ensures

process operators can maintain maximum throughout with high quality results. The

control panel is constructed entirely in stainless steel to combat the harsh environments

and most importantly, along with all associated control equipment, is ATEX certified for

use in hazardous area zones.

The flexibility of the total system with different pre-treatment options allows a wide range of

sludges from high solids to fine tight emulsions to be successfully separated. The environmental

and economical advantages can often be vast, by recovering the maximum amount of oil

and minimising or eliminating waste for offsite disposal.

Standard VHSS pre-treatment

unit

High solids pre-treatment unit (HSPU)

Three-phase decanter

Electrical control panel

Oil recovery system treating

lagoon sludge

Recovered oil Water Dry stackable sediment

3 Phase Separation

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Treating sludge at source on a daily

basis

Recovering valuable oil from sludge

Optimising crude runs by improving

slop oil quality

Minimising offsite disposal

Reducing environmental impact

Reduce down stream fouling proble

Advantages of Fixed/S

Permanent Installation


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Project Engineering

Willacy Oil Services has designed and built fixed and semi-permanent installations, in order to maximise

the equipment usage. Set in a suitable location in the refinery, these installations are used to receive and

process a variety of sludges that are produced on a daily basis.

The type of installation can be designed according to the customer's requirement, either by utilising any

existing storage facilities or by purpose building new tanks and pipework.

In order to keep the equipment mobile, flexible pipes can be supplied to interconnect the equipmentand link up to the refinery services.

The equipment can be supplied in a more permanent installation, where it can be interconnected using

fixed pipework, which can be designed to comply with any fixed plant regulations that the refinery

may have.

Permanen

BP Oil Refinery- A


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Sludge

Profiler for

Oil TanksAccurate

Time saving

Safe

Tank surveyed while the tank is full of oil

Full ATEX Certification

Totally nitrogen filled

Automatic power shut down mechanism

Instant read out

Full 3D plot rotation facility

'Take the solution to the problem,

don't transfer the problem elsewhere'

Advantages of Sludge

Profiler for Oil Tanks

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Automatic power

shutdown

mechanismSludge Profiler for Oil Tanks

The unique Sludge Profiler for Oil Tanks (SPOT) has been designed to accurately locate and

quantify sludge build up in the bottom of floating roof crude oil storage tanks. The system is

based on sonar and during a 360 sweep 240,000 soundings are used to assess the sludge

build up. The Sludge Profiler replaces the inaccurate and time-consuming manual dipping

method.

In identifying the location and height of sludge banks in crude storage tanks, maintenance

programmes can be prioritised, stock control can be improved, and representative samples

can be taken from the sludge banks identified in the tank. When landing floating roofs, they

can be at risk when large sludge banks are present, in using SPOT system the risk of damage

can be reduced. Mixer running patterns can also be monitored by using the system on a

regular basis.

The equipment requires a 4 internal diameter entry position into the crude. Therefore, roof

legs, man-ways, vents or dip hatches etc could be used. The survey is carried out with the tank

full of oil which eliminates the potential confine space problems which can be associated with

working on floating roofs in their lowered position. Normally between one and three entry

positions are all that is required to survey a tank with a diameter of up to 100m, eliminating the

need to remove large numbers of roof legs.

A tank can usually be surveyed in one working day, providing that permits etc are available

without delays. The number of people required to carry out the work is minimal. Once the tool

is assembled the survey is carried out from the ground level and there would be no personnel

on the roof.

The system is intrinsically safe, as it is a totally sealed vessel that is completely nitrogen filled.

The system has an automatic power shut down mechanism where if the pressure should drop

the power to the system is cut off. The SPOT system has full ATEX certification and the

technology is well proven both in the UK and overseas.

Inserting probe -retracted position

Mobile system

Self contained mobile

system

Sonar probe deployed

(working) position

Typicalgraphical

information

Computer controlled

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Sludge in COS Tank

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