Rail Tank Car Cleaning Solvent Recirculation System
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Solution Overview
Problem
Current industrial cleaning processes for petroleum residuum in rail tank cars are inefficient, requiring complex and expensive equipment, multiple operators, and water-based methods that generate hazardous effluents and necessitate personnel entry, leading to safety concerns and environmental issues.
Innovation Solution
A novel cleaning process using a blend of aliphatic hydrocarbons and polyglycol ethers, which eliminates the need for water rinsing, allows for rapid cleaning of rail tank cars in under 30 minutes without personnel entry, and utilizes a recirculation system with canister filters to extend solvent life and produce a reusable solvent that can be sold for fuel blending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water-based cleaning methods are used, then cleaning effectiveness is achieved, but large amounts of hazardous effluent are generated requiring special treatment and disposal
Solution Approach 1:
The invention changes the chemical parameters of the cleaning medium by using organic solvents (such as kerosene, diesel, or specialized cleaning solvents) instead of water-based chemicals. This parameter change transforms the cleaning process from generating hazardous aqueous effluent to producing recoverable hydrocarbon-based waste that can be reused or properly disposed of with less environmental impact
Solution Approach 2:
The invention implements a solvent recovery system where the organic cleaning solvent is collected, filtered, and reused multiple times. The system includes filtration equipment to remove contaminants from the solvent, allowing it to be recycled and applied to multiple tank cars, thereby reducing waste generation and disposal requirements
2Reliability
If personnel enter the tank car for final cleaning, then thorough cleaning is achieved, but safety risks increase due to IDLH environment requiring SCBA or fresh air
Solution Approach 1:
The invention enables the cleaning system to perform the cleaning function autonomously without requiring personnel entry into the tank car. The spray system, solvent circulation, and filtration operate automatically or with remote control, allowing the system to service itself and eliminate the need for human operators to enter hazardous confined spaces
Solution Approach 2:
The invention introduces an intermediary automated cleaning system that acts as a mediator between the operator (outside the tank) and the cleaning task (inside the tank). This intermediary system includes spray nozzles, solvent delivery mechanisms, and collection systems that perform the dangerous cleaning function without requiring direct human presence in the IDLH environment
3Reliability
If complex cleaning equipment with multiple components is used, then cleaning capability is improved, but device complexity and cost increase
Solution Approach 1:
The invention designs a multi-functional cleaning system that combines spray application, solvent circulation, contamination collection, and filtration into a single integrated apparatus. The system can clean different types of tank cars using the same basic equipment, and the solvent serves multiple purposes (cleaning, rinsing, and flushing) without requiring separate systems for each function
Solution Approach 2:
The invention merges multiple separate cleaning operations into a single integrated process. The spray system, collection system, and filtration system are combined into one continuous operation where solvent is sprayed, collected, filtered, and reused in a closed loop, eliminating the need for separate dispensing tanks, pumps, and filtration systems that would be required in traditional methods
4Reliability
If traditional cleaning processes are used, then cleaning is achieved, but cleaning time exceeds thirty minutes
Solution Approach 1:
The invention implements a continuous cleaning process where solvent is continuously sprayed onto the tank interior surfaces, continuously collected, continuously filtered, and continuously reused. This continuous circulation of fresh solvent maintains high cleaning effectiveness throughout the process, eliminating the need for multiple batches or interruptions that would extend cleaning time
Solution Approach 2:
The invention uses periodic or cyclic operation of the spray and collection systems to efficiently clean different sections of the tank. The system can move through different zones of the tank car in a systematic periodic pattern, ensuring complete coverage while maintaining a rapid overall cleaning pace that completes the job in under thirty minutes
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
This process significantly reduces cleaning time, eliminates the need for hazardous water rinsing, and produces a reusable solvent that can be sold for fuel blending, while ensuring safety by eliminating personnel entry and reducing environmental impact through efficient effluent management.
Implementation Method 1
The chemistry may be a blend of aliphatic hydrocarbons and polyglycol ethers
Implementation Method 2
The chemistry may be pumped via a multi-directional spray nozzle into the contaminated railcar, circulated through canister filters which remove particulates and heavy oils
Data Source
AI summary
A blend of aliphatic hydrocarbons and polyglycol ether(s) is used in a process for cleaning railroad tank cars that have been gravity drained of hydrocarbon fluids but may be left with a residuum containing heavy hydrocarbons, paraffin and noxious gas. A simple recirculation system is established between the chemical source, the contaminated railcar, canister filters and back to the chemical source. Contaminates are removed from the cleaning chemical by the filters and there is no water or steam used which might otherwise damage the railcar.