A system for oil removal and segregation

Abstract

The present disclosure relates to a system (100) for oil removal and segregation. The system (100) comprises a separation unit (102) filled with a mixture of first fluid (104) and a second fluid (106). A sensor unit (108) with at least one sensor (108a, 108b) coupled to the separation unit (102) to monitor fluid data in real time. A control unit (112) receives and evaluates the fluid data from the sensor unit (108) to generate a trigger signal. A rotary drive unit (114) receives the trigger signal from the control unit (112) and operates an extraction means (116) in a predetermined direction to extract the first fluid (104) from the separation unit (102), enabling efficient and automated fluid separation based on real-time sensing and control. The system (100) improves the efficiency and accuracy of the extraction of the first fluid with real-time monitoring.

Description

[0001] A SYSTEM FOR OIL REMOVAL AND SEGREGATION

[0002] FIELD

[0003] The present disclosure relates to an effluent treatment plant. More particularly, an automation system for the detection and extraction of free oil layer or emulsion from effluent.

[0004] DEFINITIONS

[0005] As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.

[0006] Tilted Plate Interceptor: The term “Tilted Plate Interceptor” refers to the unit used to separate free oil & emulsion from water.

[0007] Untreated effluent: The term “untreated effluent” refers to a wastewater fluid or sewage that has a mixture of free oil, emulsion, water, and other impurities.

[0008] Treated effluent: The term “treated effluent” refers to a wastewater fluid or sewage that has been treated, and the free oil or emulsion layer is separated as per the efficiency of the unit from the effluent.

[0009] Trigger signal: The term “trigger signal” refers to the signal that triggers a particular event to happen.

[0010] The above definitions are in addition to those expressed in the art.

[0011] BACKGROUND

[0012] The background information here in below relates to the present disclosure but is not necessarily prior art.

[0013] Conventionally, systems such as Tilted Plate Interceptor (TPI), Corrugated Plate Interceptor (CPI), and units conforming to American Petroleum Institute (API) specifications are employed for the separation of free oil and emulsified oil from industrial effluents. In such systems, particularly the TPI units, the effluent is directed through a series of inclined plates that facilitate the coalescence and upward migration of free oil, forming an oil layer on the surface of the liquid. To extract this free oil layer, a de-oiling pipe or slotted pipe is generally employed. The deoiling pipe is partially submerged within the TPI chamber and typically configured such that its slots are oriented upwards in a resting position. When oil removal is required, the operator manually rotates the pipe so that the slots engage with the uppermost free oil layer, allowing the oil to flow into the pipe and be conveyed to an oil collection tank.

[0014] This manual operation introduces several drawbacks. Firstly, the dependency on human intervention reduces the consistency and efficiency of oil removal, leading to operational inaccuracies. Secondly, the manual process is time-consuming and does not allow for continuous or responsive operation. Importantly, the TPI unit is often located in environments that contain toxic hydrocarbon vapors and are classified as hazardous zones. As such, the need for manual handling in these areas poses significant health and safety risks to personnel.

[0015] Therefore, there is felt a need to provide a system for oil removal and segregation that can be operated without human intervention, that obviates the drawbacks mentioned hereinabove or at least provides an alternative solution.

[0016] OBJECTS

[0017] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.

[0018] An object of the present disclosure is to ameliorate one or more problems of the background or to at least provide a useful alternative.

[0019] Another object of the present disclosure is to provide a system for oil removal and segregation.

[0020] Yet another object of the present disclosure is to provide a system that has a sensor unit for detecting oil and / or emulsion layers in the effluent, which facilitates real-time monitoring and automated operation.

[0021] Another object of the present disclosure is to provide a system that enables real-time control of oil removal based on detected effluent characteristics.

[0022] Still another object of the present disclosure is to provide a system that improves the efficiency and accuracy of the extraction of oil and emulsion from effluent. Yet another object of the present disclosure is to provide a system that minimizes the time required for oil removal and segregation operations.

[0023] Still another object of the present disclosure is to provide a system that is operable in hazardous or health-compromising environments, thereby minimizing human exposure and enhancing operational safety.

[0024] Yet another object of the present disclosure is to provide a system that is structurally simple, operationally efficient, and environmentally sustainable, and is adaptable for use in various types of effluent treatment plants.

[0025] Still another object of the present disclosure is to provide a system that can be easily integrated with existing effluent treatment infrastructure to improve overall process automation and performance.

[0026] Yet another object of the present disclosure is to provide a system that enhances oil recovery efficiency while reducing operational costs, maintenance expenditures, and effluent treatment expenses.

[0027] Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.

[0028] SUMMARY

[0029] The present disclosure relates to a system for oil removal and segregation. The system comprising; at least one separation unit configured with at least one inlet port to receive untreated effluent containing a mixture of a first fluid and a second fluid, at least one outlet port to discharge treated effluent and at least one extraction port to extract the first fluid, at least one sensor unit coupled with the at least one separation unit to sense fluid data in realtime, a control unit operatively coupled with the at least one sensor unit to receive the sensed fluid data and evaluate to generate a trigger signal, and at least one rotary drive unit in communication with the control unit and an extraction means, the at least one rotary drive unit configured to receive the trigger signal from the control unit to operate the extraction means in a predetermined direction to extract the first fluid from the at least one separation unit. In an embodiment, the at least one sensor unit comprises at least two sensors, a base plate, a sensor cover, a sensor clamp, and a cable connector.

[0030] In another embodiment, the at least one sensor unit comprises at least two sensors, a mounting plate, a sensor cover, a cable connector, a sensor holder, a knob, a guide rod and a rotary bearing.

[0031] In an embodiment, the at least one sensor unit and the extraction means are mounted on one or more mounting assemblies, each of the one or more mounting assemblies being coupled to the rotary drive unit and configured to position the at least one sensor unit and the extraction means at a predefined height with respect to the separation unit.

[0032] In an embodiment, the predefined height allows the sensors to sense fluid data corresponding to the first fluid and the second fluid within the at least one separation unit.

[0033] In an embodiment, the predefined height allows the extraction means to be partially immersed in the mixture of the first fluid and the second fluid to facilitate the extraction of the first fluid.

[0034] In an embodiment, the first sensor is configured to detect a first level of the first fluid, and the second sensor is configured to detect a second level of the first fluid, in real-time.

[0035] In an embodiment, the control unit is configured to determine the presence or levels of the first fluid based on a threshold value associated with the first fluid or the second fluid to generate a trigger signal.

[0036] In another embodiment, the control unit is configured to determine the presence or levels of the first fluid based on an indication of the presence of the first fluid or the second fluid to generate a trigger signal.

[0037] In an embodiment, the trigger signal is operative to initiate and / or terminate operation of the rotary drive unit for actuating the extraction means in real-time to extract the first fluid.

[0038] In an embodiment, the rotary drive unit is configured with a rotary motor. The rotary motor is coupled with a gear assembly to transmit rotational force to the extraction means.

[0039] In an embodiment, the extraction means is selected from a group consisting of a de-oiling pipe and a slotted pipe. In an embodiment, the at least one separation unit is selected from a group consisting of Tilted Plate Interceptors (TPI), American Petroleum Institute (API) separators, and Corrugated Plate Interceptors (CPI).

[0040] In an embodiment, the first fluid comprises oil, emulsion, and floats over the second fluid, and the second fluid comprises water.

[0041] In an embodiment, the fluid data includes at least one parameter selected from the group consisting of capacitance range, densities, and viscosity of the first fluid and the second fluid.

[0042] In an embodiment, the control unit comprises a microprocessor, a repository, a converter unit, and a computing module. The microprocessor is configured to execute a set of predefined instructions to operate one or more modules. The repository is configured to store the fluid data, the set of predefined instructions, a set of converter rules, and a set of computing rules. The converter unit is configured to convert the fluid data into machine -readable data using the set of converter rules, and the computing module is configured to evaluate the machine- readable data by means of the set of computing rules to generate a trigger signal.

[0043] In an embodiment, the predetermined direction of the extraction means is either clockwise or anticlockwise.

[0044] In an embodiment, the extraction means is mounted either adjacent to a side wall or intermediate position within the separation unit.

[0045] In an embodiment, the extraction means is adapted to rotate in a predetermined direction selected from either a clockwise or an anticlockwise direction when mounted adjacent to the side wall of the separation unit.

[0046] In another embodiment, the extraction means is adapted to rotate in both clockwise and anticlockwise directions when mounted in an intermediate position within the separation unit.

[0047] In an embodiment, the sensor unit is coupled to at least one of a first side or a second side of the separation unit.

[0048] In an embodiment, the rotary drive unit is operated to position the extraction means at a predefined angle using one or more control elements selected from, a limit switch adapted to stop rotation of the extraction means upon reaching a predefined angular position; and / or a timer adapted to stop rotation of the extraction means after a predetermined time interval or when the extraction means reaches a predefined angular position.

[0049] In an embodiment, the extraction means is configured to rotate through an angular range between 15 degrees and 75 degrees.

[0050] BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

[0051] The present disclosure will now be described with the help of the accompanying drawing, in which:

[0052] Figure la illustrates a sectional view (A-A) of a system for oil removal and segregation from effluent in accordance with the present disclosure;

[0053] Figure lb illustrates a sectional view (A-A) of a system for oil removal and segregation from effluent in accordance with an embodiment of the present disclosure;

[0054] Figure 2 illustrates a top view of four units of the separation unit of a system in accordance with the present disclosure;

[0055] Figure 3a illustrates a front view of a sensor unit that comprises a first sensor and a second sensor in accordance with an embodiment of the present disclosure;

[0056] Figure 3b illustrates an isometric view of the sensor unit that comprises the first sensor and the second sensor in accordance with an embodiment of the present disclosure;

[0057] Figure 3c illustrates an exploded view of the sensor unit of Figures 3a and 3b in accordance with an embodiment of the present disclosure;

[0058] Figure 4a illustrates an isometric view of the sensor unit that comprises a first sensor and a second sensor in accordance with another embodiment of the present disclosure;

[0059] Figure 4b illustrates an exploded view of the sensor unit of Figure 4a that comprises the first sensor and the second sensor in accordance with another embodiment of the present disclosure;

[0060] Figure 5 illustrates a block diagram of the system depicting all the system components in accordance with the present disclosure; Figure 6a-6h illustrates different operating stages of the system for oil removal and segregation for treating effluent, in which the extraction means is mounted in an intermediate position within the separation unit, in accordance with an embodiment of the present disclosure; and

[0061] Figure 7 illustrates a sectional view (A-A) of a system for oil removal and segregation from effluent, in which the extraction means is mounted adjacent to a side wall of the separation unit, in accordance with another embodiment of the present disclosure.

[0062] LIST OF REFERENCE NUMERALS

[0063] 100 / 100’ system

[0064] 102 separation unit

[0065] 102a inlet port

[0066] 102b outlet port

[0067] 102c extraction port

[0068] 104 first fluid

[0069] 104a first level

[0070] 104b second level

[0071] 106 second fluid

[0072] 108 / 108’ sensor unit

[0073] 108a / 108a’ first sensor

[0074] 108b / 108b’ second sensor

[0075] 110 microprocessor

[0076] 112 control unit

[0077] 112a repository 112b converter unit

[0078] 112c computing module

[0079] 114 rotary drive unit

[0080] 116 extraction means 118 sludge outlet

[0081] 120 second fluid level

[0082] 122 first side of the separation unit

[0083] 124 second side of the separation unit

[0084] 126 clockwise direction 128 anticlockwise direction

[0085] 130 cable connector

[0086] 130’ cable gland

[0087] 132 sensor clamp

[0088] 134a base plate 134a’ mounting plate

[0089] 134b / 134b’ sensor cover

[0090] 136 mounting assembly

[0091] 138 limit switch set

[0092] 140 sensor holder 142 knob

[0093] 144 guide rod 146 rotary bearing

[0094] DETAILED DESCRIPTION

[0095] Embodiments of the present disclosure will now be described with reference to the accompanying drawing.

[0096] Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

[0097] The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and / or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.

[0098] When an element is referred to as being “engaged to,” "connected to," or "coupled to" another element, it may be directly engaged, connected, or coupled to the other element. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed elements.

[0099] As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed elements. The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure, as the aforementioned terms may be only used to distinguish one element, component, region, layer, or section from another component, region, layer, or section. Terms such as first, second, third, etc., when used herein, do not imply a specific sequence or order unless clearly suggested by the present disclosure.

[0100] Conventionally, systems such as Tilted Plate Interceptors (TPI), Corrugated Plate Interceptors (CPI), and API-specified units are used to separate free oil from industrial effluents. In TPI units, inclined plates promote oil coalescence and surface accumulation, which is manually removed using a de-oiling pipe rotated by an operator. This manual operation has several limitations. Such as the dependence on human intervention compromises the consistency and efficiency of oil removal, often resulting in operational inaccuracies.

[0101] Additionally, the oil removal process is time-intensive and lacks the ability to support continuous or real-time operation. Moreover, since TPI units are typically situated in environments containing toxic hydrocarbon vapors, classified as hazardous zones, manual handling in such conditions poses serious health and safety risks to operating personnel. To address the issues of the existing systems, the present disclosure envisages a system (100, 100’) for oil removal and segregation.

[0102] The present disclosure will now be described in detail with reference to Figures 1 through Figure 7. The present embodiment does not limit the scope and ambit of the present disclosure.

[0103] The present disclosure provides a system (100, 100’) for oil removal and segregation. The system (100, 100’) comprises at least one separation unit (102), at least one sensor unit (108), a control unit (112), at least one rotary drive unit (114), an extraction means (116), a second fluid level (120), a mounting assembly (136), a limit switch set (138), and a sludge outlet (118).

[0104] Referring to Figure la and Figure lb. The at least one separation unit (102) is configured with at least one inlet port (102a) to receive untreated effluent containing a mixture of a first fluid (104) and a second fluid (106), at least one outlet port (102b) to discharge treated effluent and at least one extraction port (102c) to extract the first fluid (104). The at least one sensor unit (108, 108’) is coupled with the at least one separation unit (102) to sense fluid data of the mixture of a first fluid (104) and a second fluid (106) present in the separation unit (102) in real-time.

[0105] The control unit (112) is operatively coupled with the at least one sensor unit (108, 108’) to receive the sensed fluid data and evaluate the sensed fluid data to generate a trigger signal.

[0106] The at least one rotary drive unit (114) is in communication with the control unit (112) and an extraction means (116). The at least one rotary drive unit (114) is configured to receive the trigger signal from the control unit (112) to operate the extraction means (116) in a predetermined direction to extract the first fluid (104) from the at least one separation unit (102).

[0107] In an embodiment, the at least one separation unit (102) is selected from a group consisting of Tilted Plate Interceptors (TPI), American Petroleum Institute (API) separators, and Corrugated Plate Interceptors (CPI).

[0108] In an embodiment, Figure 2 depicts the four units of Tilted Plate Interceptors (TPI) that have an inlet port (102a) to receive untreated effluent containing a mixture of a first fluid (104) and a second fluid (106) and outlet ports (102b) for discharge of treated effluent. Further, the Tilted Plate Interceptors (TPI) have the extraction port (102c) to extract the first fluid (104). Further, the TPI unit has a mounting arrangement for the extraction means (116) and the sensor unit (108).

[0109] In an embodiment, the first fluid (104) comprises oil, emulsion, and floats over the second fluid (106), and the second fluid (106) comprises water.

[0110] In an embodiment, as depicted in Figures 3a to 3c, the at least one sensor unit (108) comprises at least two sensors (108a, 108b), a base plate (134a), a sensor cover (134b), a sensor clamp (132), a cable connector (130).

[0111] In an embodiment, as depicted in Figures 4a and 4b, the at least one sensor unit (108’) comprises at least two sensors (108a’, 108b’), a mounting plate (134a’), a sensor cover (134b’), a cable gland (130’), a sensor holder (140), a knob (142), a guide rod (144) and a rotary bearing (146). The first sensor (108a, 108a’) and the second sensor (108b, 108b’) are mounted in parallel within the sensor unit (108, 108’) and at a different height with respect to the fluid of the separation unit (102). Further, the sensors (108a, 108a’, 108b, 108b’) are operatively connected to a cable connector (130). The cable connector (130) is configured to securely transmit sensor signals while preventing fluid ingress or disconnection during operation.

[0112] The sensors (108a, 108b) of the sensor unit (108) are supported and fixed in position by using a sensor clamp (132) to maintain the vertical alignment of the sensors and prevent displacement or vibration during fluid separation and measurement operations.

[0113] Further, the sensors (108a’, 108b’) of the sensor unit (108’) are supported and fixed in position by using a sensor holder (140), a guide rod (144) and rotary bearing (146) to maintain the vertical alignment of the sensors (108a’, 108b’) and prevent displacement. Further, the sensor holder (140) also facilitates modularity for sensor replacement or repositioning. The guide rod (144) is incorporated to assist in the linear alignment and vertical movement of the sensing components, ensuring smooth operation and positional accuracy. The rotating bearing (146) is positioned in cooperation with the guide rod (144) and sensor holder (140) to facilitate rotation or limited mechanical movement of the sensor unit (108), enabling fine adjustment and reducing mechanical stress during operation.

[0114] In an embodiment, a sensor cover (134b, 134b’) is provided to enclose and protect the sensing components from external contaminants, mechanical damage, or environmental exposure. The structural support to the sensor unit (108) is provided by a base plate (134a) in the sensor unit (108). The base plate (134a) is configured to hold the entire sensor assembly in place and facilitate mounting onto the separation unit (102) or an external frame.

[0115] In the sensor unit (108’), the mounting plate (134a') is configured to serve as the structural base for supporting the sensor assembly. The mounting plate (134a’) includes predefined openings and attachment features to receive the sensor holder (140), guide rods (144), and associated hardware.

[0116] In an embodiment, the least one sensor unit (108, 108’) and the extraction means (116) are mounted on one or more mounting assemblies (136), each of the one or more mounting assemblies (136) being coupled to the rotary drive unit (114). The mounting assemblies are configured to position the at least one sensor unit (108, 108’) and the extraction means (116) at a predefined height with respect to the separation unit (102). In an embodiment, the sensor unit (108, 108’) and the extraction means (116), along with a limit switch set (138) are mounted on the same mounting assembly (136).

[0117] In another embodiment, the sensor unit (108, 108’) and the extraction means (116), along with the limit switch set (138), are mounted on a separate mounting assembly (126). The sensor unit (108) is mounted on a first mounting assembly and the extraction means (116) along with the limit switch set (138) are mounted on a second mounting assembly, both the mounting assemblies are configured independently to support their respective components over the separation unit (102) at predefined positions based on project-specific requirements.

[0118] The mounting assembly (136) is configured in such a way that it is securely positioned in the separation unit (102) to support the associated components, ensuring proper alignment, vibration damping, and structural integrity during operation.

[0119] In an embodiment, the extraction means (116) is positioned in the separation unit (102) through a wall support, and the gear of the rotary drive unit (114) is connected to the mounting assembly (136).

[0120] In an embodiment, the first sensor (108a) and the second sensor (108b) of the sensor unit (108, 108’) are positioned at different heights with respect to the top surface of the fluid present in the separation unit (102).

[0121] In an embodiment, the predefined height of the sensor unit (108) allows the sensors (108a, 108b) to sense fluid data corresponding to the first fluid (104) and the second fluid (106) within the at least one separation unit (102).

[0122] In an embodiment, the predefined height of the extraction means (116) allows the extraction means (116) to be partially immersed in the mixture of the first fluid (104) and the second fluid (106) to facilitate the extraction of the first fluid (104).

[0123] In an embodiment, the first sensor (108a, 108a’) is configured to detect a first level (104a) of the first fluid (104) and the second sensor (108b, 108b’) is configured to detect a second level (104b) of the first fluid (104), in real-time.

[0124] In an embodiment, the fluid data sensed by the at least one sensor (108a, 108a’, 108b, 108b’) includes at least one parameter selected from the group consisting of capacitance range, densities and viscosity of the first fluid (104) and the second fluid (106). In an embodiment, the sensor unit (108, 108') is coupled to at least one of a first side (122) or a second side (124) of the separation unit (102).

[0125] The control unit (112) is operatively coupled to the at least one sensor unit (108, 108’) for receiving the sensed fluid data. The control unit (112) is responsible for the generation of a trigger signal based on the sensed fluid data.

[0126] In an embodiment, the control unit (112) is configured to determine the presence or levels (104a, 104b) of the first fluid (104) based on a threshold value associated with the first fluid (104) or the second fluid (106).

[0127] In another embodiment, the control unit (112) is configured to determine the presence or levels (104a, 104b) of the first fluid (104) based on direct indication of the presence of the first fluid (104) or the second fluid (106) to generate atrigger signal.

[0128] In an embodiment, the trigger signal operates to activate the rotary drive unit (114) in realtime, thereby actuating the extraction means (116) to extract the first fluid (104).

[0129] In another embodiment, the trigger signal operates to terminate the rotary drive unit (114) in real-time, thereby deactivating the extraction means (116) to stop the extraction of the first fluid (104).

[0130] The sensor unit (108, 108’) is configured to detect the first fluid (104) and the second fluid (106) based on one or more fluid properties, such as the capacitance range, viscosity of the fluid, the density, and the like, either independently or in combination. In an exemplary embodiment, the detection of the first fluid (104) and the second fluid is carried out based on the capacitance of the fluid.

[0131] In an embodiment, the first sensor (108a, 108a’) and the second sensor (108b, 108b’) of the sensor unit (108, 108’) are configured to detect the first level (104a) and the second level (104b) respectively of the first fluid (104) generated on the second fluid (106), based on the sensor reading the generated fluid layer is extracted by using the extraction means (116). In order to detect the exact levels of the first fluid (104), the sensor unit (108), more preferably the sensors (108a, 108b) of the sensor unit (108) are programmed to measure the capacitance of the fluid based on the capacitance principle, and the measured capacitance is converted into the percentage value, and then based on the percentage value the first fluid (104) and the second fluid (106) are detected by the sensor unit (108, 108’).

[0132] In an exemplary embodiment, when the percentage value is greater than or equal to 78%, then the detected fluid is fall in the category of the second fluid (106), when the percentage value is less than or equal to 50%, then the detected fluid is fall in the category of the first fluid (104), and when the percentage value is in between 78% to 50% then the detected fluid is fall in the category of emulsion fluid.

[0133] In an embodiment, the percentage value increases with a decrease in viscosity and vice versa. In an exemplary embodiment, the first fluid (104) is oil and the second fluid (106) is water, as oil is more viscous than water, the oil has a lesser percentage value, that is less than or equal to 50%, whereas water is having low viscosity, therefore the percentage value for water is greater than or equal to 78%.

[0134] In another embodiment, the sensor unit (108, 108’) directly senses the presence of the first fluid (104) and the second fluid (106) and transfers the sensed fluid to the control unit (112) to generate a trigger signal. In this case, the control unit (112) determines the presence of the fluid or levels (104a, 104b) of the first fluid (104) based on direct indication of the presence of the first fluid (104) or the second fluid (106) to generate a trigger signal.

[0135] In an exemplary embodiment, upon receiving a direct indication of the first fluid (104), the control unit (112) activates the rotary drive unit (114) to actuate the extraction means (116) for extracting the first fluid (104).

[0136] In another exemplary embodiment, upon receiving a direct indication of the second fluid, the control unit (112) deactivates the rotary drive unit (114) to stop the extraction means (116) from extracting the first fluid (104).

[0137] Referring to Figure 5, the block diagram depicts the system components and the working sequence in order to extract the first fluid (104) floated over the second fluid (106). The sensor unit (108) is coupled to the separation unit (102) to sense the fluid data. The sensor unit (108) further cooperates with the control unit (112), wherein the control unit (112) is capable of collecting the sensed fluid data, evaluating it, and based on the evaluation, generating the trigger signal. The rotary drive unit (114) is coupled to the control unit (112) and cooperates to receive the generated trigger signal, and based on the trigger signal, operates the extraction means (116) to extract the first fluid (104).

[0138] In an embodiment, the control unit (112) comprises a microprocessor (110), a repository (112a), a converter unit (112b), and a computing module (112c). The microprocessor (110) is configured to execute a set of predefined instructions to operate one or more modules. The repository (112a) is configured to store the fluid data, the set of predefined instructions, a set of converter rules, and a set of computing rules. The converter unit (112b) is configured to convert the fluid data and into machine-readable data using the set of converter rules, and the computing module (112c) is configured to evaluate the machine -readable data by means of the set of computing rules to generate a trigger signal.

[0139] In an embodiment, the set of predefined instructions consists of an instruction set to fetch and execute the system modules till instructions are stopped or reached, and the set of converter rules consists of an instruction set to convert the fluid data into machine-readable data.

[0140] In an embodiment, the set of computing rules is a set of instructions to determine the first level (104a) of the first fluid (104) and the second level (104b) of the first fluid (104) in accordance with a threshold value of the first fluid (104) and the second fluid (106) and operate the rotary drive unit (114) in real-time to extract the first fluid (104) layer generated on the second fluid (106).

[0141] In another embodiment, the set of computing rules is a set of instructions to determine the first level (104a) of the first fluid (104) and the second level (104b) of the first fluid (104) in accordance with a direct indication of the first fluid (104) and the second fluid (106) and operate the rotary drive unit (114) in real-time to extract the first fluid (104) layer generated on the second fluid (106).

[0142] In an embodiment, the rotary drive unit (114) is configured with a rotary motor. The rotary motor is coupled with a gear assembly to transmit rotational force to the extraction means (116).

[0143] In an embodiment, the rotary drive unit (114) is operated to position the extraction means (116) at a predefined angle using one or more control elements. In an embodiment, a limit switch set (138) is used. The limit switch set (138) is operatively connected to the extraction means (116) and the rotary drive unit (114), wherein the limit switch set (138) is configured to define or restrict the operational range of motion of the extraction mechanism, thereby providing safety, precision, and fail-safe operation during the extraction of the first fluid (104).

[0144] The rotary drive unit (114) actuates the extraction means (116) at a predefined angle using the limit switch. The limit switch is adapted to stop rotation of the extraction means (116) upon reaching a predefined angular position.

[0145] In another embodiment, a timer is used for the operation of the extraction means (116). The rotary drive unit (114) actuates the extraction means (116) at a predefined angle using the timer. The timer is adapted to stop rotation of the extraction means (116) after a predetermined time interval or when the extraction means (116) reaches a predefined angular position.

[0146] In an embodiment, the extraction means (116) is selected from a group consisting of a deoiling pipe and a slotted pipe.

[0147] In an embodiment, the predetermined direction of the extraction means (116) is either clockwise (126) or anticlockwise (128).

[0148] In an embodiment, the extraction means (116) is mounted either adjacent to the side wall of the separation unit or intermediate position within the separation unit (102).

[0149] In an embodiment, the extraction means (116) is adapted to rotate in a predetermined direction selected from either clockwise (126) or anticlockwise (128) direction, when mounted adjacent to the side wall of the separation unit (102); and

[0150] In another embodiment, the extraction means (116) is adapted to rotate in both clockwise (126) and anticlockwise (128) directions when mounted in an intermediate position within the separation unit (102).

[0151] In an embodiment, the extraction means (116) is configured to rotate through an angular range between 15 degrees and 75 degrees. The level of the second fluid (106) within the separation unit (102) is detected and monitored as the second fluid level (120), enabling the control logic to prevent over-extraction or improper mixing of fluids.

[0152] The system (100, 100’) further includes a sludge outlet (118) positioned at a lower region of the separation unit (102). The sludge outlet (118) is configured to discharge accumulated solid or semi-solid residue resulting from effluent treatment.

[0153] Referring to Figure 6a through Figure 6h, the system (100) operates with different components to extract the first fluid layer generated on the second fluid (106).

[0154] In an embodiment, the separation unit (102) is filled with a mixture of the first fluid (104) and the second fluid (106), and the sensor unit (108, 108’) is mounted over the separation unit (102) to detect the first fluid (104) and the second fluid (106) and provide the sensed fluid data. Further, the control unit (112) is in communication with the sensor unit (108, 108’) to receive the sensed fluid data and determine the first level (104a) and the second level (104b) of the first fluid (104). Furthermore, the rotary drive unit (114) is operatively coupled to the control unit (112) and the extraction means (116). The control unit (112), based on the sensed fluid data, triggers the signal to operate the extraction means through the rotary drive unit (114).

[0155] The first fluid (104) layer is always maintained on the top surface of the separation unit (102). In an exemplary embodiment, the first fluid layer is oil.

[0156] In an exemplary embodiment, as illustrated in Figures 6b-6h, the first fluid layer corresponds to an oil layer that forms above the second fluid (106), which is water, within the separation unit (102). The oil layer (104) consistently accumulates over the water layer (106) in small amounts. As the thickness of the oil layer increases, the first sensor (108a, 108a’) detects the first level (104a) of the oil layer (104) in real time and transmits the corresponding fluid data to the control unit (112). Upon continued accumulation, the oil layer (104) further thickens and approaches the second level (104b). At this stage, the second sensor (108b, 108b’), forming part of the sensor unit (108, 108’), detects the second level (104b) and also transmits fluid data to the control unit (112). The control unit (112) evaluates the fluid level data received from both the first sensor (108a, 108a’) and second sensors (108b, 108b’), and upon determining that the oil layer (104) has reached the desired extraction threshold, generates a trigger signal to initiate the rotary drive unit (114). The rotary drive unit (114) is operatively coupled to the extraction means (116), then actuates the extraction means (116) to extract the oil layer (104) from predetermined directions within the separation unit (102), thereby preventing excessive accumulation or undesired mixing with the water layer.

[0157] In an embodiment, the trigger signal is generated when the second sensor (108b, 108b’) detects the second level (104b) of the first fluid (104).

[0158] In an embodiment, the predetermined direction of the extraction means (116) is either clockwise (126) or anticlockwise (128) in real time.

[0159] In an embodiment, the extraction means (116) is a type that is selected from a group consisting of a de-oiling pipe and a slotted pipe.

[0160] In an embodiment, the extraction means (116) is operated in a clockwise (126) direction based on the trigger signal for extracting the first fluid (104) from a first side (122) of the separation unit (102) for a first predetermined time.

[0161] In an embodiment, the extraction means (116) is operated in an anticlockwise (128) direction for extracting the first fluid (104) from a second side (124) of at least one separation unit (102) for a second predetermined time.

[0162] In an embodiment, the extraction means (116) is rotated in the anticlockwise (128) direction when the first sensor (108a) detects the second fluid (106). Due to the extraction of the first fluid (104) from the first side (122) of the separation unit (102), the first fluid (104) present on the first side (122) starts depleting and once a sufficient amount of the first fluid (104) is extracted the thickness of the first fluid (104) reduces, as a result, the second fluid (106) comes in contact with the first sensor(108a), the first sensor (108a) detects the second fluid (106) and sends the respective sensed fluid data to the control unit (112). Based on the received fluid data, the control unit (112) rotates the extraction means (116) in a reverse direction, i.e., anticlockwise (128) with the help of the rotary drive unit (114).

[0163] In an embodiment, where the extraction means (116) is positioned adjacent to a side wall on either the first side or the second side of the separation tank (102), the first fluid (104) is extracted from only one side of the separation unit (102), by rotating the extraction means (116) either clockwise direction (126) or anticlockwise direction (128), depending on its mounting orientation relative to the separation tank (102). In an exemplary embodiment, the extraction means (116) has a rotation angle between 15° to 75°. The rotation angle varies with the use of the separation unit (102) and the level of the first fluid (104) layer generated on the second fluid (106).

[0164] In an exemplary embodiment, if the first fluid layer is less, then the rotation angle is near 75°, and if the thickness of the first fluid layer is greater, then the rotation angle will be near 15°.

[0165] The limit switch set (138) is used to stop the extraction means (116) at the defined angle. The limit switch set (138) has at least 2 numbers of limit switches. With the adjustment of limit switches, the rotation angle is fixed as per the site conditions.

[0166] In an embodiment, the sensor unit (108, 108’) is coupled to the first side (122) of the separation unit (102).

[0167] In another embodiment, the sensor unit (108, 108’) is coupled to the second side (122) of the separation unit (102).

[0168] In an embodiment, the first predetermined time refers to the time interval between the detection of the second level (104b) of the first fluid (104) by the second sensor (108b, 108b’) and the subsequent detection of the second fluid (106) by the first sensor (108a, 108a’), which results in termination of the trigger signal. This time interval begins when the second sensor (108b, 108b’) detects the second level (104b) of the first fluid (104), prompting the generation of the trigger signal and initiation of the extraction process. The extraction means (116), positioned at the first side (122) of the separation unit (102), is activated by the rotary drive unit (114) to begin extracting the first fluid (104). As extraction proceeds, the thickness of the first fluid (104) layer decreases, eventually allowing the second fluid (106) to reach and be detected by the first sensor (108a, 108a’). Upon this detection, the control unit (112) terminates the trigger signal, and the rotary drive unit (114) reverses the direction of rotation of the extraction means (116) toward the reverse direction (128).

[0169] In an embodiment, the second predetermined time refers to a predefined time interval determined based on the quantity of the first fluid (104) present at the second side (124) of the separation unit (102). This time interval begins when the extraction means (116) is actuated to rotate in the anticlockwise direction (128) to extract the first fluid (104) from the second side (124) of the separation unit (102). As the extraction progresses, the first fluid (104) gradually depletes. Upon completion of the predefined time interval, the extraction means (116) is repositioned to its original or neutral position. Notably, if the thickness of the first fluid (104) layer at the second side (124) is greater, the duration required for extraction, i.e., the second predetermined time, will correspondingly be longer to ensure complete removal, thereby completing the extraction cycle.

[0170] In an embodiment, the described operation is only applicable when the first fluid (104) is removed from both the first side (122) and the second side (124) of the separation unit (102). The decision to extract from one or both sides depends on the location and configuration of the extraction means (116) with the separation unit (102). The extraction of the first fluid (104) from the separation tank is solely dependent on the mounting arrangement of the extraction means (116) and the requirements of the operation in the particular field of effluent treatment. Extraction of the first fluid can be performed from both sides, either from the first side (122) or the second side (124) of the separation tank, or in combination.

[0171] Referring to Figure 7 illustrates a sectional view (A-A) of a system (100, 100’) for oil removal and segregation from effluent, in which the extraction means (116) is mounted adjacent to the side wall of the separation unit (102) and the extraction of the first fluid (104) is carried out only from one side of the separation tank (102).

[0172] In an embodiment, the extraction means (116), which is mounted adjacent to a side wall of the separation unit (102), allows for space-efficient integration, especially in constrained installations. In such configurations, rotation may be limited to one side only, and the design accommodates this by adjusting the number and position of limit switches or by implementing a timer-based control system.

[0173] In an embodiment, the first fluid (104), having a lower density, accumulates over the second fluid (106), forming a distinct interface represented as the second fluid level (120). The interface level (120) serves as a reference for the positioning and operation of fluid detection and extraction components.

[0174] The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure. TECHNICAL ADVANCEMENTS AND ECONOMIC SIGNIFICANCE

[0175] The present disclosure described herein above has several technical advantages including, but not limited to, the realization of: a system for oil removal and segregation that;

[0176] • facilitates real-time monitoring and automated operation for the removal of oil and emulsion;

[0177] • improves the efficiency and accuracy of the extraction of the oil and / or emulsion;

[0178] • enables real-time control of oil removal based on detected effluent characteristics;

[0179] • minimizes the time required for oil removal and segregation operations;

[0180] • is operable in hazardous or health-compromising environments, thereby minimizing human exposure and enhancing operational safety;

[0181] • is structurally simple, operationally efficient, and environmentally sustainable, and is adaptable for use in various types of effluent treatment plants;

[0182] • can be integrated with existing effluent treatment infrastructure to improve overall process automation and performance; and

[0183] • enhances oil recovery efficiency while reducing operational costs, maintenance expenditures, and effluent treatment expenses.

[0184] Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

[0185] The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the invention to achieve one or more of the desired objects or results. While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Variations or modifications to the formulation of this invention, within the scope of the invention, may occur to those skilled in the art upon reviewing the disclosure herein. Such variations or modifications are well within the spirit of this invention.

[0186] The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations, and it is envisaged that the values higher / lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary. While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment, as well as other embodiments of the disclosure, will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Claims

CLAIMS:

1. A system (100, 100’) for oil removal and segregation, comprising;• at least one separation unit (102) configured with at least one inlet port (102a) to receive untreated effluent containing a mixture of a first fluid (104) and a second fluid (106), at least one outlet port (102b) to discharge treated effluent and at least one extraction port (102c) to extract said first fluid (104);• at least one sensor unit (108, 108’) coupled with said at least one separation unit (102) to sense fluid data in real-time;• a control unit (112) operatively coupled with said at least one sensor unit (108, 108’) to receive said sensed fluid data and evaluate to generate a trigger signal; and• at least one rotary drive unit (114) in communication with said control unit (112) and an extraction means (116), said at least one rotary drive unit (114) configured to receive said trigger signal from said control unit (112) to operate said extraction means (116) in a predetermined direction to extract said first fluid (104) from said at least one separation unit (102).

2. The system (100, 100’) as claimed in claim 1, wherein said at least one sensor unit (108) comprises at least two sensors (108a, 108b), a base plate (134a), a sensor cover (134b), a sensor clamp (132) and a cable connector (130).

3. The system (100, 100’) as claimed in claim 1, wherein said at least one sensor unit (108’) comprises at least two sensors (108a’, 108b’), a mounting plate (134a’), a sensor cover (134b’), a cable gland (130’), a sensor holder (140), a knob (142), a guide rod (144) and a rotary bearing (146).

4. The system (100, 100’) as claimed in claim 1, wherein said at least one sensor unit (108, 108’) and said extraction means (116) are mounted on one or more mounting assemblies (136), each of said one or more mounting assemblies (136) being coupled to said rotary drive unit (114) and configured to position said at least one sensor unit (108, 108’) and said extraction means (116) at a predefined height with respect to said separation unit (102).

5. The system (100, 100’) as claimed in claim 4, wherein said predefined height allows said sensors (108a, 108a’, 108b, 108b’) to sense fluid data corresponding to said first fluid (104) and said second fluid (106) within said at least one separation unit (102).

6. The system (100, 100’) as claimed in claim 4, wherein said predefined height allows said extraction means (116) to be partially immersed in said mixture of said first fluid (104) and said second fluid (106) to facilitate extraction of said first fluid (104).

7. The system (100, 100’) as claimed in claims 2 and 3, wherein a first sensor (108a, 108a’) of said sensor unit (108, 108’) is configured to detect a first level (104a) of said first fluid (104) and a second sensor (108b, 108b’) of said sensor unit (108, 108’) is configured to detect a second level (104b) of said first fluid (104), in realtime.

8. The system (100, 100’) as claimed in claim 1, wherein said control unit (112) is configured to determine the presence or levels (104a, 104b) of said first fluid (104) based on at least one of: o a threshold value associated with said first fluid (104) or said second fluid (106) to generate a trigger signal; and / or o an indication of the presence of said first fluid (104) or said second fluid (106) to generate a trigger signal.

9. The system (100, 100’) as claimed in claim 8, wherein said trigger signal is operative to initiate and / or to terminate operation of said rotary drive unit (114) for actuating said extraction means (116) in real-time to extract said first fluid (104).

10. The system (100, 100’) as claimed in claim 1, wherein said rotary drive unit (114) is configured with a rotary motor; said rotary motor is coupled with a gear assembly to transmit rotational force to said extraction means (116).

11. The system (100, 100’) as claimed in claim 1, wherein said extraction means (116) is selected from a group consisting of a de-oiling pipe and a slotted pipe.

12. The system (100, 100’) as claimed in claim 1, wherein said at least one separation unit (102) is selected from a group consisting of Tilted Plate Interceptors (TPI), American Petroleum Institute (API) separators, and Corrugated Plate Interceptors (CPI).

13. The system (100, 100’) as claimed in claim 1, wherein said first fluid (104) comprises oil, emulsion, and floats over said second fluid (106), and said second fluid (106) comprises water.

14. The system (100, 100’) as claimed in claim 1, wherein said fluid data includes at least one parameter selected from the group consisting of capacitance range, densities and viscosity of said first fluid (104) and said second fluid (106).

15. The system (100, 100’) as claimed in claim 1, wherein said control unit (112) comprises: o a microprocessor (110) configured to execute a set of predefined instructions to operate one or more modules; o a repository (112a) configured to store said fluid data, said set of predefined instructions, a set of converter rules, and a set of computing rules; o a converter unit (112b) configured to convert said fluid data into machine- readable data using said set of converter rules; and o a computing module (112c) configured to evaluate said machine -readable data by means of said set of computing rules to generate a trigger signal.

16. The system (100, 100’) as claimed in claim 1, wherein said predetermined direction of said extraction means (116) is either clockwise (126) or anticlockwise (128).

17. The system (100, 100’) as claimed in claim 1, wherein said extraction means (116) is mounted either adjacent to a side wall or intermediate position within said separation unit (102), and wherein: o said extraction means (116) is adapted to rotate in a predetermined direction selected from either clockwise (126) or anticlockwise (128)direction, when mounted adjacent to said side wall of said separation unit (102); and o said extraction means (116) is adapted to rotate in both clockwise (126) and anticlockwise (128) directions, when mounted intermediate position within the separation unit (102).

18. The system (100, 100’) as claimed in claim 1, wherein said sensor unit (108, 108') is coupled to at least one of a first side (122) or a second side (124) of said separation unit (102).

19. The system (100, 100’) as claimed in claim 1, wherein said rotary drive unit (114) is operated to position extraction means (116) at a predefined angle using one or more control elements selected from: o a limit switch adapted to stop rotation of the extraction means (116) upon reaching a predefined angular position; and / or o a timer adapted to stop rotation of the extraction means (116) after a predetermined time interval or when said extraction means (116) reaches a predefined angular position.

20. The system (100, 100’) as claimed in claim 1, wherein said extraction means (116) is configured to rotate through an angular range between 15 degrees and 75 degrees.

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