The Oil Recovery System is specifically designed to recover valuable hydrocarbons from crude oil tanks with significant volumes of sludge. Its key features and components are as follows:
- Hydrocarbon recovery and recycling: The system ensures a minimum of 97% recovery of oil entrained in the sludge, with historical recovery rates of up to 99% achievable. Kleensafe provides accurate flow meter-based recovery rates through daily project reports, allowing customers to track the progress of oil recovery.
- Waste transport and disposal reduction: The system significantly reduces the need for onsite and offsite waste transport and disposal. By recovering and recycling the oil from the sludge, the volume of waste generated is minimized.
- Equipment within the bund wall:The equipment mobilized within the bund wall includes a piping system, primarily consisting of 2" stainless steel piping. Victaulic couplings with oil-resistant NBR gaskets are used for connections. Prior to start-up, the piping undergoes QC and hydro testing to 1.5 times the working pressure.
- Tank suction pumps and filtration: A self-priming pump is positioned within 6 meters of the suction point on the tank. It is a robust, heavy-duty centrifugal feed pump that transfers the sludge to a skid equipped with two basket strainers. These strainers effectively remove large impurities such as rust scales, rags, and stones. One strainer operates while the other is cleaned, ensuring continuous operation.
- Three phase separation module: The three-phase separation module employs a tricanter to separate oil, water, and solids. With a throughput capacity ranging from 8 to 12 m3/hr, the tricanter ensures efficient separation. The module includes control and monitoring systems that automatically shut down the tricanter and trigger audible and visible alarms if the liquid level in the recovered oil and water tank exceeds the recommended limit.
- Equipment outside the bund wall: Non-Ex equipment, placed in a safe zone area, supports the separation operation.
- Electrical generator: A 200KVA diesel-powered electrical generator is required to supply power to the equipment. It directly connects to the main electrical cabinet, which in turn supplies power to the pumps and modules.
- Air compressor for the Automated Tank Cleaning System: An air compressor, located in the Utility and Workshop Container within the safe zone area, provides the necessary safe purge and instrument air for the system.
- Main electrical panel: The main electrical cabinet supplies power to the skids and modules. It also includes a central grounding buzz bar, ensuring that the tank and all process equipment are grounded at the same electrical potential, effectively eliminating the risk of static build-up.
The Oil Recovery System combines efficient hydrocarbon recovery, waste reduction, and robust equipment to enable effective oil recovery processes.