An oil sludge three-phase separator and a separation method, a computer device and a storage medium

Abstract

This application provides a three-phase separation agent for oil sludge, comprising a demulsifier, an extractant, and a coagulant aid. A three-phase separation method for oil sludge includes the following steps: Step 1: Establishing a component analysis and evaluation system for clean tank sludge based on its visual characteristics; Step 2: Adjusting the proportions of each component in the three-phase separation agent based on the component analysis and evaluation system; Step 3: Adding the prepared three-phase separation agent to the clean tank sludge for homogenization treatment; Step 4: Separating oil, water, and solid phases from the homogenized clean tank sludge. A computer device includes: a camera for capturing images of oil sludge; a memory storing a computer program for the three-phase separation method for oil sludge; and a processor for executing the computer program. A storage medium storing a computer program for the three-phase separation method for oil sludge. The oil yield after separation in this application is high and relatively stable.

Description

Technical Field

[0001] This application relates to the field of oil sludge treatment technology, and in particular to an oil sludge three-phase separator and separation method, computer equipment, and storage medium. Background Technology

[0002] Oil sludge is the sludge generated during crude oil extraction, storage, gathering, processing, and the treatment of produced fluids. It is mainly classified into: landfill sludge, tank cleaning sludge, and flotation scum. Tank cleaning sludge is the sludge that accumulates at the bottom of oil tanks over a long period, such as the bottom sediment of crude oil storage tanks and refined oil storage tanks. The solid phase of tank cleaning sludge is mainly composed of corrosion products and gum / asphaltite, with fine particle size, few impurities, but high organic matter content, accounting for approximately 30%–50%. The oil phase is mainly composed of heavy oil and gum / asphaltite, accounting for approximately 20%–50%. The aqueous phase is mainly composed of emulsified water encapsulated by an oil film, accounting for approximately 20%–40%. The initial state of tank cleaning sludge is generally a thick oil layer on top, a turbid emulsion in the middle, and a clump of solid phase at the bottom. Although the initial state of tank cleaning sludge also presents a three-phase structure, these three phases are mixed with oil, water, and solid, and are not pure. Therefore, it is necessary to first add a three-phase separator, and then use physical means such as stirring to homogenize the tank cleaning sludge so that the tank cleaning sludge is in a suspension state. Then, the oil, water and solid phases are separated by means such as sedimentation and centrifugation.

[0003] In actual processing, the content of each phase in tank sludge varies significantly from different sources. When using a three-phase separator to separate the sludge into three phases, the dosage is difficult to control and needs to be added based on experience. This leads to fluctuations in the separation effect, potentially causing a decrease in oil yield. Furthermore, it may result in waste of the separator, increasing its usage cost. Summary of the Invention

[0004] In view of this, this application proposes a composite three-phase separation agent for oil sludge, which improves the three-phase separation effect by adjusting the proportion of each component to homogenize oil sludge of different contents.

[0005] This application also proposes a three-phase separation method for oil sludge, which improves the separation effect by visually analyzing the content of the three phases of oil sludge and adjusting the ratio of the separating agent.

[0006] This application also proposes a computer device and a storage medium.

[0007] An oil sludge three-phase separation agent includes a demulsifier, an extractant, and a coagulant aid.

[0008] A method for three-phase separation of oil sludge includes the following steps: Step 1: Based on the visual characteristics of tank cleaning sludge, establish a component analysis and evaluation system for tank cleaning sludge; Step 2: Based on the compositional analysis and evaluation system of the tank cleaning sludge, adjust the proportions of each component in the three-phase separator; Step 3: Add the prepared three-phase separator to the clean tank sludge for homogenization treatment; Step 4: Separate the oil, water and solid phases from the homogenized tank sludge.

[0009] A computer device, comprising: A camera used to capture images of oily mud; A memory that stores a computer program for a three-phase separation method for oil sludge; The processor that executes the computer program.

[0010] A storage medium storing a computer program for a three-phase separation method for oil sludge.

[0011] The technical advantages of this application are as follows: This application addresses the problem that the content of each phase of tank cleaning sludge varies greatly from different sources. Based on the differences in visual characteristics of different sludge, a component analysis and evaluation system for tank cleaning sludge is established. By adjusting the ratio of the three-phase separator, the three-phase separator is adapted to the oil conditions. As a result, the yield of the separated oil is higher and more stable. Detailed Implementation

[0012] The embodiments of the technical solution of this application will be described in detail below. The following embodiments are only used to illustrate the technical solution of this application more clearly, and are therefore only examples, and should not be used to limit the scope of protection of this application.

[0013] An oil sludge three-phase separation agent includes a demulsifier, an extractant, and a coagulant aid.

[0014] A method for three-phase separation of oil sludge includes the following steps: Step 1: Based on the visual characteristics of tank cleaning sludge, establish a component analysis and evaluation system for tank cleaning sludge; Step 2: Based on the compositional analysis and evaluation system of the tank cleaning sludge, adjust the proportions of each component in the three-phase separator; Step 3: Add the prepared three-phase separator to the clean tank sludge for homogenization treatment; Step 4: Separate the oil, water and solid phases from the homogenized tank sludge.

[0015] In a preferred embodiment, the visual characteristics of the tank sludge include the stratification and thickness after standing, color and gloss, viscosity and fluidity.

[0016] Analyzing and evaluating the composition of tank cleaning sludge based on visual characteristics significantly shortens the analysis time compared to chemical detection, thereby mitigating the lag in adding three-phase separators. Compared to adding three-phase separators based on experience, this application enables automated preparation and addition of the three-phase separator, reducing personnel costs. In a preferred embodiment, the aforementioned static stratification, its thickness, color and gloss, viscosity and flowability can be evaluated after the visual sensor captures images of the tank cleaning sludge, thus establishing a compositional analysis and evaluation system for the tank cleaning sludge. The specific steps are as follows: Step 11: Preprocess the images acquired by the vision sensor to eliminate noise and environmental interference in the images; Step 12: Capture key visual information from the images and extract the layering features, color gloss features, viscosity and flowability features of the clean tank sludge; Step 13: Analyze the composition of the tank cleaning sludge based on the extracted layering characteristics, color gloss characteristics, viscosity and flowability characteristics, and establish the correspondence between the layering characteristics, color gloss characteristics, viscosity and flowability characteristics and the composition of the tank cleaning sludge. Step 14: Compare the composition of the tank cleaning sludge obtained from the analysis with the standard sludge sample to calibrate the composition analysis and evaluation system of the tank cleaning sludge.

[0017] In a preferred embodiment, the preprocessing of the images acquired by the vision sensor is specifically as follows: A combination of Gaussian filtering and median filtering is used to eliminate noise caused by on-site oil and dust; lens distortion is corrected through checkerboard calibration to ensure that the scale is consistent with the actual size; histogram equalization is used to improve the contrast of low-light images and avoid color deviation.

[0018] After image preprocessing, the extraction of layered features begins by identifying the layer interfaces. In grayscale images, the grayscale level at the layer interfaces will show a significant change; in color images, the color level at the layer interfaces will show a significant change. After identifying the layer interfaces, the thickness of the liquid phase is determined based on the grayscale or color characteristics.

[0019] The upper oil layer is generally darker in color, and the penetrating power of natural light may be insufficient to clearly see the layering of the oil sludge. To improve image recognition, in a preferred embodiment, a laser is used as a light source to illuminate the oil sludge in the tank, and the thickness of the oil and water layers is determined by observing the refraction of the laser. To improve the accuracy of the assessment, multiple light sources can be used to illuminate different locations of the oil sludge in the tank. In another preferred embodiment, multiple observation windows can be provided on the side wall of the trough to observe the layering of the oil sludge from the side. Given the viscosity of the oil layer, the side walls of the observation windows can be cleaned between feeding intervals. The frequency of cleaning depends on the cleanliness of the observation windows.

[0020] Since the aqueous, oil, and solid phases have not yet undergone homogenization, they are mixed together. In this case, judging the ratio of the three phases of oil sludge based solely on the stratification of the sludge would result in a large error. Therefore, this application also uses color gloss characteristics and viscosity and flowability characteristics for a comprehensive judgment.

[0021] For color and gloss characteristics, color space parameters such as hue, saturation, and brightness are extracted from the surface. If it is a grayscale image, gloss is calculated using the grayscale values ​​of the reflective areas; the higher the grayscale value, the stronger the gloss. Oil sludge has a complex composition. If the liquid phase content is high, the surface layer of the sludge is the liquid phase layer; if the solid phase content is high, the liquid phase is likely to mix with the solid phase, forming sludge or mud, in which case the surface layer of the sludge is the solid phase layer. The hue, saturation, and brightness of the liquid and solid phase layers differ significantly. Color and gloss characteristics can be used to determine oil content and composition. For example, dark brown with high gloss corresponds to high oil content, primarily heavy oil. Grayish brown with no gloss corresponds to high solid content, primarily clay particles.

[0022] Regarding viscosity and flow characteristics, the flow of solid and liquid phases can be clearly observed during the pouring of sludge from the tank bottom into the hopper, allowing for the estimation of the solid-liquid ratio. Furthermore, for dynamic imaging, the flow velocity of the sludge can be calculated using optical flow and mapped to a viscosity grade. Specifically: high viscosity: flow velocity < 0.5 cm / s; medium viscosity: 0.5–2 cm / s; low viscosity: > 2 cm / s.

[0023] By acquiring the layered features, color gloss features, viscosity and flowability features, and training with historical features, it is possible to derive the correspondence between visual features and the composition of the clean tank sludge.

[0024] The following are the correspondences between several typical visual features of this application and the composition of the sludge from the cleaning tank.

[0025] The upper oil phase, after standing and separating, is thick, dark brown in color, and non-flowing, corresponding to a high oil content and heavy oil. Specifically, the high oil content mentioned in this application refers to an oil content >30%. The oil product mentioned in this application refers to liquid oil or heavy oil, specifically heavy oil referring to oil with a resin / asphalt content >70%.

[0026] The water phase in the middle layer of the static layer is turbid, grayish-brown and dull, and easily flows, corresponding to low oil content and high water content; the low oil content mentioned in this application specifically refers to an oil content of <20%, and the high water content mentioned in this application specifically refers to an water phase ratio of >40%.

[0027] It exhibits no obvious layering, is a paste-like, viscous gel-like substance, corresponding to low oil content and fine solid phase.

[0028] The three types of sludge described above are some of the more common types of sludge encountered by the applicant in daily sludge treatment. Sludge produced under different oil conditions varies, and companies can establish a relationship between visual characteristics and sludge composition based on their own specific circumstances. The sum of all visual characteristics and their corresponding sludge composition constitutes the compositional analysis and evaluation system for tank cleaning sludge.

[0029] Then, based on the compositional analysis and evaluation system of the sludge from the tank cleaning, a corresponding three-phase separator was prepared.

[0030] In a preferred embodiment, based on the composition evaluation system of the tank cleaning sludge, the proportional relationship of each component of the three-phase separator is as follows: High oil content, heavy oil: 20-30% demulsifier, 50-60% extractant, 5-10% coagulant aid; Low oil content, high water content: 40%–50% demulsifier, 10%–20% extractant, 5%–10% coagulant aid; Low oil content, fine solid phase: 20-30% demulsifier, 20-30% extractant, 10-20% coagulant aid.

[0031] At the same time, different demulsifiers, extractants, and coagulants are used depending on the oil condition.

[0032] For oil sludge with high oil content and heavy oil, diesel or kerosene is the preferred extractant. In oil sludge with high oil content and heavy oil, the oil phase is difficult to separate, and heavy extractants such as diesel and kerosene have better compatibility with heavy oil.

[0033] For oil sludge with high water content, the preferred demulsifier is a cationic surfactant, such as hexadecyltrimethylammonium bromide. With a high proportion of aqueous phase, the liquid is mainly emulsified water, and the emulsion is relatively stable. The oil phase is dispersed in the form of tiny oil droplets. By increasing the content of the demulsifier and using a cationic surfactant as the demulsifier, it is easier to break the negatively charged film at the oil-water interface.

[0034] For fine solid sludge, polyacrylamide with a molecular weight greater than 10 million is preferred as a coagulant. Fine solid sludge is difficult to settle, while high molecular weight polyacrylamide has stronger bridging ability and is more likely to capture fine particles.

[0035] After pouring the sludge into the reactor, add the three-phase separating agent before starting the agitator. Dilute the separating agent and slowly spray it onto the surface of the sludge, allowing it to stand for 10-15 minutes to penetrate the sludge. Then, stir to achieve homogenization. After homogenization, centrifuge to separate the oil and water, and then press to separate the solid and liquid phases.

[0036] To achieve the above solution, this application also provides a computer device, including: A camera used to capture images of oily mud; A memory that stores a computer program for a three-phase separation method for oil sludge; The processor that executes the computer program.

[0037] The camera transmits images of the sludge to the processor, which then configures a three-phase separating agent according to a computer program for the three-phase separation method of sludge, thereby achieving homogenization of the sludge and separation of the water, oil, and solid phases.

[0038] A storage medium storing a computer program for a three-phase separation method for oil sludge.

[0039] The effectiveness of the proposed solution will be verified below with reference to embodiments and comparative examples.

[0040] To simulate tank cleaning sludge from different sources in real-world applications, crude oil (heavy oil), distilled water, and simulated solid phases (corrosion products Fe2O3 and gum / asphaltite) were mixed in a specific ratio and allowed to stand for 24 hours. Three types of sludge were prepared: high oil phase (40% oil, 30% water, 30% solids), high water phase (20% oil, 50% water, 30% solids), and high solids phase (30% oil, 20% water, 50% solids). The water, oil, and solid phases of the three types of sludge were separated according to the method described in this application and conventional methods, as detailed below: Example 1 High-oil-phase sludge was irradiated with a laser, and its initial state was photographed using a high-definition camera. Based on the sludge's layering characteristics, color gloss characteristics, viscosity, and flowability characteristics, a correspondence between the sludge's composition and that of the tank-cleaning sludge was established, and a three-phase separating agent was prepared. The prepared three-phase separating agent was then poured into the sludge, and the mixture was stirred for 10 minutes using a magnetic stirrer until the sludge became a homogeneous suspension. After settling, solid-liquid separation was performed. The solid phase was dried to obtain waste residue, and the liquid phase was centrifuged to obtain water and oil.

[0041] Example 2 Similar to Example 1, high-aqueous phase oil sludge was separated.

[0042] Example 3 Similar to Example 1, high-solids sludge was separated.

[0043] Comparative Example 1 The three-phase separator previously used by the company, namely 20% citric acid, 10% demulsifier, 25% penetrant, 5% sodium silicate, and the remainder as solvent, was used to separate the high oil phase sludge. The separation process was the same as in Example 1.

[0044] Comparative Example 2 The three-phase separator previously used by the company, namely 20% citric acid, 10% demulsifier, 25% penetrant, 5% sodium silicate, and the remainder as solvent, was used to separate the high aqueous phase sludge. The separation process was the same as in Example 1.

[0045] Comparative Example 3 The three-phase separator previously used by the company, namely 20% citric acid, 10% demulsifier, 25% penetrant, 5% sodium silicate, and the remainder as solvent, was used to separate high-solids sludge. The separation process was the same as in Example 1.

[0046] Comparative Example 4 The three-phase separator of this application was randomly proportioned to separate high-oil-phase sludge, and the separation process was the same as in Example 1.

[0047] Comparative Example 5 The three-phase separator of this application was randomly proportioned to separate high-aqueous-phase oil sludge, and the separation process was the same as in Example 1.

[0048] Comparative Example 6 The three-phase separator of this application was randomly proportioned to separate high-solids sludge, and the separation process was the same as in Example 1.

[0049] The oil phase recovered in the above-described embodiments and comparative examples were compared, and the results are shown in Table 1.

[0050] Table 1: As shown in Table 1, compared with Comparative Examples 1-6, the oil phase yields separated in Examples 1-3 are higher and the fluctuations are smaller. This demonstrates that the three-phase separation method for oil sludge in this application can improve the oil phase yield and has better yield stability.

[0051] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A three-phase separation agent for oil sludge, characterized in that: This includes demulsifiers, extractants, and coagulants.

2. A method for three-phase separation of oil sludge, characterized in that: Includes the following steps: Step 1: Based on the visual characteristics of tank cleaning sludge, establish a component analysis and evaluation system for tank cleaning sludge; Step 2: Based on the compositional analysis and evaluation system of the tank cleaning sludge, adjust the proportions of each component in the three-phase separator; Step 3: Add the prepared three-phase separator from claim 1 to the clean tank sludge for homogenization treatment; Step 4: Separate the oil, water and solid phases from the homogenized tank sludge.

3. The three-phase separation method for oil sludge as described in claim 2, characterized in that: The visual characteristics of the cleaned sludge include static stratification and its thickness, color and gloss, viscosity and fluidity.

4. The three-phase separation method for oil sludge as described in claim 3, characterized in that: The establishment of a compositional analysis and evaluation system for tank cleaning sludge based on its visual characteristics includes the following steps: Step 11: Preprocess the images acquired by the vision sensor to eliminate noise and environmental interference in the images; Step 12: Capture key visual information from the images and extract the layering features, color gloss features, viscosity and flowability features of the clean tank sludge; Step 13: Analyze the composition of the tank cleaning sludge based on the extracted layering characteristics, color gloss characteristics, viscosity and flowability characteristics, and establish the correspondence between the layering characteristics, color gloss characteristics, viscosity and flowability characteristics and the composition of the tank cleaning sludge. Step 14: Compare the composition of the tank cleaning sludge obtained from the analysis with the standard sludge sample to calibrate the composition analysis and evaluation system of the tank cleaning sludge.

5. The three-phase separation method for oil sludge as described in claim 4, characterized in that: Step 11 specifically involves using a combination of Gaussian filtering and median filtering to eliminate noise caused by on-site oil and dust; correcting lens distortion through checkerboard calibration to ensure that the scale matches the actual size; and using histogram equalization to improve the contrast of low-light images and avoid color deviation.

6. The three-phase separation method for oil sludge as described in claim 2, characterized in that: Based on the composition evaluation system of tank cleaning sludge, the corresponding proportions of the components in the three-phase separator are as follows: High oil content, heavy oil: 20-30% demulsifier, 50-60% extractant, 5-10% coagulant aid; Low oil content, high water content: 40%–50% demulsifier, 10%–20% extractant, 5%–10% coagulant aid; Low oil content, fine solid phase: 20-30% demulsifier, 20-30% extractant, 10-20% coagulant aid.

7. The three-phase separation method for oil sludge as described in claim 6, characterized in that: For oil sludge with high oil content and heavy oil, diesel or kerosene is used as the extractant.

8. The three-phase separation method for oil sludge as described in claim 6, characterized in that: For oil sludge with high water content, cationic surfactants are preferred as demulsifiers.

9. A computer device, characterized in that: include: A camera used to capture images of oily mud; A memory storing a computer program for the three-phase separation method of oil sludge as described in any one of claims 3 to 8; The processor that executes the computer program.

10. A storage medium, characterized in that: The computer program contains a method for three-phase separation of oil sludge as claimed in any one of claims 3 to 8.

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