Refinery Sludge Thermal Treatment via Plasma Vitrification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for disposing of refinery sludge, such as dumping, biological treatment, solvent extraction, and thermal treatment systems, face challenges including high costs, long process times, incompatibility with increasing material volumes, and safety issues due to the physico-chemical characteristics of the sludge, which require a more efficient and economical solution.
Innovation Solution
A continuous thermal treatment process comprising four phases: drying, gasification, combustion, and inertization, using a gasification system with incremental oxygen and water vapor injection, and vitrification with plasma torches, which reduces solid volumes by over 80% and produces self-sustaining syngas, eliminating the need for external heating sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If dumping is used for sludge disposal, then disposal is simple and economical, but it is no longer allowed due to legislation changes and dump saturation
Solution Approach 1:
The patent changes the physical-chemical parameters of sludge through thermal treatment (heating to 700-950°C), transforming it from a hazardous waste with high calorific power into an inert solid product with low calorific power, thereby meeting legislative requirements for dump disposal
Solution Approach 2:
The patent replaces biological treatment mechanisms with thermal treatment mechanisms (combustion and gasification), achieving faster processing times and producing inert products that can be safely disposed of, while also generating energy through syngas production
2Object-affected harmful factors
If biological treatment is used for sludge disposal, then treatment is environmentally friendly, but process times are long (order of days) and plants are complex
Solution Approach 1:
The patent replaces biological decomposition mechanisms with thermal combustion and gasification mechanisms, reducing processing time from days to minutes while maintaining environmental benefits through complete oxidation of organic matter and energy recovery
Solution Approach 2:
The patent changes the treatment temperature parameter from ambient (biological) to high temperature (700-950°C thermal treatment), dramatically accelerating the treatment process and producing inert products faster than biological methods
3Quantity of substance
If solvent extraction is used for oil recovery, then oil can be recovered, but the process is complex and not compatible with increasing material volumes
Solution Approach 1:
The patent replaces solvent extraction mechanisms with thermal gasification mechanisms, directly converting organic matter to gas and inert residue without requiring complex extraction solvents, thereby simplifying the process and handling larger volumes more efficiently
Solution Approach 2:
The patent extracts the oil fraction through thermal decomposition and gasification, separating it from the solid residue, and recovers it as syngas which can be used for energy production, achieving both simplification and scalability
4Productivity
If fixed bed or bubbling ovens are used for thermal treatment, then treatment can be performed, but safety issues arise from dangerous emissions and rheological characteristics of solid product
Solution Approach 1:
The patent optimizes temperature parameters (700-950°C for gasification, 850-1200°C for combustion) and residence time parameters to ensure complete oxidation of organic matter, minimizing dangerous emissions while maintaining high productivity
Solution Approach 2:
The patent incorporates feedback mechanisms through syngas recycling to the gasification zone and combustion product recycling to drying and gasification phases, maintaining safe operating conditions and optimizing treatment efficiency continuously
5Volume of stationary object
If thermal treatment is used for sludge, then volume reduction is achieved, but external heating sources are required
Solution Approach 1:
The patent implements self-service heating by recycling syngas produced during gasification to the combustion zone and combustion products to the drying and gasification phases, allowing the system to sustain itself thermally without external heating sources while achieving significant volume reduction
Solution Approach 2:
The patent establishes continuous recycling of thermal energy through syngas and combustion products throughout the treatment process, ensuring uninterrupted thermal treatment and maximizing volume reduction efficiency without requiring external energy inputs
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves significant volume reduction and produces inert products, with syngas thermally sustaining the volume reduction process, ensuring efficient and economical treatment of refinery sludge without external heating contributions.
Implementation Method 1
gasification of the dried sludge, at a temperature ranging from 750 to 950°C, for a time of 30 to 60 minutes, in the presence of a gas containing oxygen and water vapour, fed with the incremental differentiated modality, with the associated production of synthesis gas (CO + H2)
Implementation Method 2
inertization of the solid residue, at a temperature ranging from 1,300 to 1,500°C, by vitrification with plasma torches
Implementation Method 3
inertization of the solid residue, at a temperature ranging from 1,300 to 1,500°C, by vitrification with plasma torches
Implementation Method 4
combustion of the synthesis gas at a temperature ranging from 850 to 1,200 °C and recycling of the combustion products for the drying and gasification phases
Implementation Method 5
drying of the refinery sludge, possibly mixed with pet-coke (petroleum coke), at a temperature ranging from 110 to 120°C
Data Source
Figure 1
Figure 2
AI summary
A continuous process for the thermal treatment of a refinery sludge, comprising the following operations: a. drying of the refinery sludge, possibly mixed with pet-coke, at a temperature ranging from 110 to 120°C; b. gasification of the dried sludge, at a temperature ranging from 750 to 950°C, for a time of 30 to 60 minutes, in the presence of a gas containing oxygen and water vapour, with the associated production of synthesis gas (CO + H2) and a solid residue; c. combustion of the synthesis gas at a temperature ranging from 850 to 1,200°C and recycling of the combustion products for the drying and gasification phases; and d. inertization of the solid residue, at a temperature ranging from 1,300 to 1,500°C, by vitrification with plasma torches.