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MkIII Oily Waste Treatment
Plant
 The MkIII Plant
The Plant in the photo is
specifically designed for the treatment of a wide variety of oily waste
classifications from fresh slop oils stored in tanks to mixtures of
weathered oily waste held in pits, lagoons and lakes. Its capacity is
determined mainly by the viscosity of the feed. For example waste oils
with a viscosity in the range of Cst30 at 50°C can be treated at 10 m3/hr
whereas those having a Cst600 at 50°C can be treated at 2 m3/hr.
We therefore recommend treating at a temperature of 95°C to maximize the
plant capacity and to improve the overall separation performance thereby
producing the highest quality oil. A major variable in treating slops
are the concentrations of common contaminates, water & solids. This
plant can handle solids up to 40% in the feed and any combined ratio of
oil & water. This plant comes with a variety of options to choose from
that include: plant heat (hot water boiler or steam converter), buffer
tanks for receiving oily waste and tanks for clean oil and clean water.
Other important features are also included or quoted as options to the MKIII. This include heat exchangers, treating chemical dosing systems,
sludge solids thickeners, pit excavation assemblies, cabins for storage
of tools and spare parts, site laboratory, site office and site
sanitation. The primary supply included with the
G-force
MKIII Plant is an 8-g elliptical screen separator where coarse particles
and floating debris are separated before feed to the primary separation
equipment. G-force
applies 3000-g 2-phase decanters to handle any load of solids normally
associated with oily waste. This plant is designed to handle solid
contaminates from any range up to 40% in the feed without affecting
performance. The job assigned to the 2-phase decanter is to remove the
majority of solids from the screened effluent. Following the 2-phase
decanter the G-force
system is
designed to raise the decanter effluent temperature to >95°C, apply the
proper mix of treating chemicals at our RTR500 residence time reactor
(to insure minimization yet performance optimization of treating
chemicals) and then to feed directly into the 6000-g 3-phase centrifuges
to separate the water and any remaining sediments from the oil phase for
the purpose of achieving the highest quality treated oil in the smallest
operational footprint. The 3-phase 6000-g vertical disc-stack centrifuge
used by G-force
is unique for the treatment of difficult to separate oily waste. This
is especially evident when compared to 3-phase horizontal 3000-g range
scroll decanters, in that 3-phase decanters are more sensitive to
changes in oil and water feed ratios typical of oily waste thereby
resulting in off-spec oil and water. Typically 3-phase decanters, with
their low g-force (3000-g compared to 6,000-g) require pre-treatment in
special residence tanks for batch feed preparation all of which consumes
time and personnel. The G-force system eliminates the requirement of
batch blending residence tanks and as a result produces a consistent
higher quality treated oil phase. The MKIII plants are designed to the
new EU ATEX electrical specifications and/or Class I Div 2 zoning for
compliance involving Oilfield operations. A special design feature of
the MKIII is the interconnecting pipe & pump works (what we call the
logic box) where all plant components centrally flange thereby
minimizing space requirements, making installation and commissioning a
quick, simple and easy task and providing excellent operations logic and
safety monitoring as required for the treatment of the various
classifications of oily waste. This allows the plant operator total
flexibility when routing and treating the various oily waste streams.
G-force
is the only company providing this operational freedom through its logic
flow design box.
Principle of Operations
The feedstock is picked up by the MKIII plant-installed pumps (either
from the clients tanks or open dump site) for feeding into the plant
process. Process heat is provided by G-force
through our provision of a Hot Water Boiler, or clients steam via our
Site Steam Converter (clients choice of options) and by way of the MKIII
installed Heat Exchangers whereby hot water is utilized to heat the oily
waste to the required range of 95°C by the time it is fed to the 6000-g
3-phase Oil Purifying Centrifuge. To begin the process the waste oil
feed is first pumped across the screen separator and then into the
2-phase decanter. The primary application of the decanter is to
remove 97% to 99 % of the solids. After the solids are removed the
decanted effluent is ready for treatment in the 6000-g 3-phase
centrifuge. Depending on the contamination volume of water contained in
the oil phase, the oil-water droplet sizes and the volume of particle
sizes in the range of 5 mµ to 10 mµ determines if Treating Chemicals are
required in the separation process. Normally at 6000-g treatment of
oily waste can be accomplished without the use of Treating Chemicals
thereby significantly reducing cost. However in most cases treating
chemicals are required to improve the capacity flow and separation
performance of the plant. Therefore the MKIII is delivered with a
static mixer where treating chemicals are first injected to mix with the
contaminated oil. Immediately following the static mixer the feed
enters the G-force
RTR Dynamic Residence Blender to insure the treating chemicals come into
direct contact with the water phase droplets and the sediment particles
so as to de-emulsify or
coalesce them for separation. The treated oily waste leave the RTR
Blender and immediately enter the 6000-g High Speed 3-phase Centrifuges
to separate the oil &water, along with the remaining sediments. The
separated oil is immediately transfer to the clean oil export tank and
ready to be returned to the client or sold into the market place. The
separated water directly dispatched from the 6000-g centrifuge contains
oil-in-water in a range of 500 ppm to 2% oil. In many cases this water
specification is acceptable for delivery or pumping to the client’s
wastewater treatment facility (WWTF). Most refineries for example have
their own WWTF systems. However if required,
G-force
as provided with the MKIII plant shown in this photo, will include its
12,000-g Water Concentration Centrifuge (WCC) to treat the water
separated from the 6,000-g 3-phase Oil Purifying Centrifuge so that it
meets the disposal regulation for land or sea. Water is normally
dispatched from the 12,000-g WCC in the range of 5 ppm to 10 ppm
oil-in-water. Solids separated from the 3-phase centrifuges represent a
minor portion of the solids as the majority of solids are separated
up-stream at the screen separator and decanter. These minor portions
of solids discharged from the 6000-g centrifuge are pumped into a
G-force
designed sludge
thickener. The solids removed from the 3-phase centrifuges are
dispatched through side ports by means of a self cleaning mechanism
using a water operated hydraulic bowl where a small ~10 liter water
cushion leaves with the solids during each ejections interval. Solids
are ejected from the bowl approximately each 10 minutes and this time
interval is set according to the solids content in the feed to the
centrifuge. The ejected solids, along with the water cushion, are
deposited into a solids conveyor and transferred into the Sludge
Thickener where the solids are thickened (dried) and conveyed into a
waste skip for final disposal and the free water is collected and
returned to the process. Finally the total of solids separated from the
screen separator, the decanter and the centrifuges are directly conveyed
into waste skips for final disposal and declassification. Where clients
are interested G-force
accepts to provide the declassification of oily solids. This is an
important option of our services. Finally the MKIII Plant as shown in
the photos represents one of several plant designs standard to our
product line. If required G-force
specializes
in the design and manufacture of custom
plants to meet any defined capacities specific to the needs of our
customers. This is achieved by the simple addition of multiples of the
main components to either achieve a greater capacity or performance
specification.
 Installation & Serviceability
G-force plants
are supplied with one-year of spares and come with a recommended
maintenance schedule based on each 2000 hours of operations (4 times per
year). All primary equipment is supplied as a complete package
including special tools and is ready for installation on a level
concrete pad. Further to our service a team of
G-force
engineers supervise the plant installation
and commissioning on site, which
normally takes ~14-days. The client is expected to provide a level
plant installation concrete pad (all civil data are supplied by
G-force),
a 15 ton forklift to unstuff the shipping containers, and a 50 ton crane
to lift and place all the plant module into place on the concrete pad.
Installation tools and special equipment servicing tools are also
provided with the delivery of the plant. Immediately following plant
commissioning the actual operations are ready to commence. No other
requirements for installation are needed except for the client to bring
service points (electricity, water, waste feed and clean oil-water take
off pipes) to the concrete pad for hook up purposes.
G-force
provides all
utility details and placement. If required
G-force
also supplies all climate buildings dimensionally specific for the plant
footprint as delivered. Following plant-commissioning
G-force
will provide on site training to the clients assigned Plant Operator to
insure a smooth handover. This is done by arranging training contracts
with clients whereby our operations engineer remains at the clients site
for as long as necessary to train the local staff up to operational
competence and full take-over. In our experience we have commissioned
plants where the clients engineers took over immediately after
commissioning, this we consider exceptional. Normally training requires
an additional 30 to 90 days period after commissioning for the local
engineers to reach operational competency.
Dimensions & Utilities
Basically, if the client orders a plant with a heat supply from
G-force,
the only utility requirements is electrical power, diesel for the Hot
Water Boiler and plant operations water. If the client has a steam heat
supply only electricity and water are needed. The kW and water depend
on plant size and options chosen, details of which are provided with our
full quotations. For the MKIII plant shown in the photo the electrical
requirement is 120 kW of installed power and the footprint is ~L20m x
~W15m (includes walkways).
Delivery timeframe, plant certification & equipment
warrantees
Delivery, from the time of approved order placement up to ex-works,
requires G-force
12 weeks to construct the plant shown in the photos. BUT delivery is
mainly dependent upon the delivery timeframe of the major components.
Therefore in most circumstances we advise clients to plan for a delivery
period of 22 to 26 weeks up to our Ex-works. It is the policy of
G-force
that before
shipment the plant is fully assembled at the factory so that it
undergoes a complete Factory Mechanical Completion Certification. The
buyer is asked to attend this certification. During the last 14-day
period of plant fabrication G-force
invites two of the
Buyers assigned engineers to our manufacturing facility in Holland for
schooling and hands on training at our cost.
G-force
provides the
Buyer a Mechanical Warranty to certify that the plant delivered is under
warranty for 100% of the supply against any defects for the first year
of operations, starting from the date of commissioning, or for a period
of 18 months from the date of ex-works delivery, whichever comes first.
We have experiences with delivery and installation all over the world. |
