Vertical Separator Sludge Control for Water Oil Separation
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Solution Overview
Problem
Existing water-oil-sludge separation plants are inefficient as they require large-scale energy consumption for oil separation and result in high pollution levels in the oil-polluted water entering membrane filtration plants, with the decanter centrifuge being dimensioned to handle all liquid and sludge from the slop tank, leading to suboptimal performance.
Innovation Solution
A water-oil-sludge separation plant with a vertical separator that coarsely separates oil, oil-polluted water, and sludge, where the oil is separated at the top, reducing the load on the decanter centrifuge and membrane filtration plant, and utilizing a control valve and sensor system to manage sludge flow, allowing for efficient recirculation of retentate and reduced particle pollution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a decanter centrifuge is dimensioned to handle all liquid and sludge from the slop tank, then complete separation is achieved, but energy consumption increases and processing efficiency decreases
Solution Approach 1:
The invention divides the separation process into two stages: a vertical separator handles the bulk separation of oil, water, and sludge from the slop tank, while a decanter centrifuge processes only the concentrated sludge stream. This segmentation allows each device to be optimized for its specific function, reducing the energy burden on the centrifuge while maintaining complete separation effectiveness.
Solution Approach 2:
The vertical separator performs preliminary separation of the incoming slop water, removing the majority of oil and water phases before the sludge enters the decanter centrifuge. This preliminary action reduces the volume and complexity of material requiring high-energy centrifugal separation, thereby lowering overall energy consumption.
2Reliability
If a decanter centrifuge is dimensioned to handle all liquid and sludge from the slop tank, then complete separation is achieved, but device complexity and operational burden increase
Solution Approach 1:
The separation system is segmented into two specialized units: a vertical separator for bulk phase separation and a decanter centrifuge for sludge dewatering. This segmentation allows each device to be simpler and more specialized, rather than requiring one oversized complex device to handle all functions.
Solution Approach 2:
The vertical separator acts as an intermediary device between the slop tank and the decanter centrifuge, pre-processing the incoming material to remove oil and water phases. This intermediary step simplifies the burden on the centrifuge, allowing it to focus solely on sludge dewatering without handling the full complexity of the original mixture.
3Reliability
If all oil-polluted water is directed to membrane filtration plant, then thorough filtration is achieved, but particle contamination increases and processing efficiency decreases
Solution Approach 1:
The vertical separator performs preliminary removal of sludge particles and heavy constituents from the oil-polluted water before it enters the membrane filtration plant. This preliminary action prevents excessive particle contamination of the membrane system, maintaining filtration quality while improving processing efficiency and reducing membrane fouling.
4Productivity
If heavy constituents such as mud, cement residues, cuttings and metal particles are not pre-separated, then all materials are processed together, but energy consumption and processing time increase
Solution Approach 1:
The vertical separator performs preliminary separation of heavy constituents (mud, cement residues, cuttings, metal particles) from the oil-polluted water stream. By removing these dense materials first through gravitational settling in the vertical separator, the system avoids the need to process them through high-energy centrifugal separation, thereby reducing both energy consumption and processing time.
Solution Approach 2:
The processing stream is segmented into different phases: heavy constituents settle in the vertical separator, oil and water are separated in the upper sections, and only the clarified sludge stream proceeds to the decanter centrifuge. This segmentation allows each component to be handled by the most appropriate separation mechanism, optimizing both speed and energy efficiency.
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 configuration significantly reduces energy consumption, decreases the load on the decanter centrifuge, and results in cleaner oil-polluted water entering the membrane filtration plant, enabling continuous and efficient separation of oil-polluted mud and water, with reduced particle contamination and the ability to recycle valuable oil fractions.
Implementation Method 1
a vertical separator (1) comprising a vertical, substantially cylindrical tank (11) having a tangential intake (12), an upper oil outlet (27) at the top of the vertical tank (11), a middle, horizontal, tangential outlet (22) for oil-polluted water, and a lower pipe (44) for a sludge outlet at the bottom of the vertical tank (11)
Implementation Method 2
slop water enters through a wall (20) of the vertical separator (1) and subsequently through the tangential intake (12), horizontally in the interior of the upwards-tapering conical frustum (2) surrounded by the vertical tank (11)
Implementation Method 3
a membrane filtration plant (6)... the membrane filtration plant (6) is arranged to let out the permeate comprising cleansed water and to lead the concentrated retentate back to the vertical separator (1) or to the slop tank (0)
Implementation Method 4
a decanter centrifuge (5) arranged to separate dehydrated solids and to lead water treated in the decanter centrifuge (5) back to the vertical separator (1) or the slop tank (0)
Data Source
Figure 1
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AI summary
The invention relates to a water-oil-sludge separation plant comprising: a slop tank (0) for water/oil/sludge, an outlet for slop water to a vertical separator (1) comprising a vertical, substantially cylindrical tank (11), wherein the vertical separator (1) leads to an upper oil outlet (27); a middle, horizontal, tangential outlet (22) for oil-polluted water to a membrane filtration plant (6); and a lower pipe (44) for sludge outlet to a decanter/centrifuge (5); wherein the decanter / centrifuge (5) is arranged -to separate dehydrated solids, and - to lead water treated in the centrifuge back to the vertical separator (1) or the slop tank (0); wherein the membrane filtration plant (6) is arranged - to lead the concentrated retentate back to the vertical separator (1) or to the slop tank (0) or remove from the process; - wherein the permeate comprising cleansed water is let out; wherein the sludge outlet (44) from the vertical separator (1) comprises a control valve (3) controlled by a control unit (41) that, based on a sensor (4) for density of sludge in a lower portion of the vertical separator (1), continuously adjusts outlet of sludge to the decanter/centrifuge (5).