em a c o

group

emaco group Italy, servicing the Marine industry and the oilfield sectors of
Drilling, Production and Refinery operations for the purposes of design, manufacture, installation & operation of custom or standard build separation systems for treatment of oily waste and slop oil. Emaco Oily Waste Separation Systems provide benefit to clients seeking an environmentally sound Waste Management Program. This is to comply with the standard practices of the Environmental 3R's - Reduce, Recycle, Re-use. Emaco treated oily waste is:

Reduced (minimized) to solids by removal of liquids, and Recycling of Oil and Water, and Re-use of oil as a product with water returned to nature.

Emaco therefore, sells, manufactures, installs and operates treatment systems required in the Marine industry and the Oil & Gas Industry to clean oily waste generated as a by-product of their operations. These wastes are identified from drilling, production and completion fluids, operations fuel oils and diesel oils, produced water, crude oil refinery & transport vessels slops and sludge, refinery emulsions, API separator sludge, tank bottom sediments, stored oil waste pits, polluted soils, ships slops, bildge water, dirty lube oils and the like. Emaco separation systems are either fixed or portable installations to be found on drilling rigs, production facilities, crude oil gathering stations, crude oil refineries, waste plants servicing land base and marine port reception facilities, tank farms, oily waste dump sites and oil polluted soil sites. The separation systems manufactured by Emaco come in standard skid modules or if required are manufactured to fit custom applications. They are designed as ready to go fully integrated "plug-in" skid modules to minimizing installation time and cost. The skid modules are manufactured to fit into standard 20' or 40' containers providing the most economical means of transport by either truck or sea freight. Standard container packages allow for noEmacoal lifting equipment thereby greatly reducing handling cost and facilitate easy plant movement from site to site. Common equipment type and sizes of separation systems manufactured by Emaco vary with the application and waste source to be treated. Below is a sampling of common waste by classification to different types of Oilfield operations.

Drilling Fluids These skids are manufactured in accordance to rig operator requirements and involve De-gassers, Shale Shakers, De-Sanders, DeSilters, Mud Cleaners, Cuttings Dryers, Decanter Centrifuges, Flocculation Units, and Drill Cuttings Conveyors. These are supplied in single units, in multiple units, or combinations thereof, which are fully incorporated and integrated into a functional skid for rig installation. Oily Water

em a c o
Oily Slops

group

These skids are manufactured in accordance to water treatment requirements and application. The system noEmacoally involves the incorporation of feed pumps, screen filters and high-speed 3 phase centrifuges. In general a single centrifuge for the treatment of oily water could range from 15 to 50 m/hr per unit supplied. Greater capacity is achieved by multiples of units installed in tandem.

These plants are manufactured in accordance to the definition of slops, which vary from diesel oil to crude oil, or in mixture of several types of oils. The system involves the incorporation of a heat supply, feed pumps, screen separators, (possibly) 2-phase decanters and high-speed 3-phase centrifuges. The 3phase centrifuge is the piece that determines the plant capacity. In general a single centrifuge for the treatment of oily slops would range from 5 to 10 m/hr per unit supplied. Greater capacity is achieved by multiples of units installed in tandem. Oily Sludges These plants are manufactured in accordance to the definition of sludge to be treated. Sludge vary widely in composition coming from all sources of oily waste streams. They can be single source sludges of crude oil tank bottom cleanings dumped and stored in a tank or an earth pit. Or they can be an endless combination of oily waste coming from all different sources - mixed, dumped and stored together awaiting treatment. Sludges are commonly inconsistent, contaminated with miscellaneous debris, are thick and viscous complicating their treatment, especially as they influence equipment thruput capacity. The sludge treatment system involves the incorporation of a heat supply, feed pumps, (possibly) bulk hoppers with conveyors, screen separators, 2-phase decanters and high-speed 3-phase centrifuges. In sludge treatment the final 3-phase centrifuge is the piece of equipment that deteEmacoines the plant capacity. In general a single centrifuge for the treatment of sludges would range from 2 to 7 m/hr per unit supplied. Greater capacity is achieved by multiples of units installed in tandem.

Polluted Oily Semi Solids These plants are manufactured in accordance to the definition of oily materials to be treated, which range from drill cuttings to polluted soils. These materials are generally earth solids with oily liquid retained on the solids particles. NoEmacoally oily solids are not pumpable and are only considered for treatment in a Emaco separation system if the polluted solids are saturated with free liquids capable of being separated by conveyor, screen separators and 2-phase decanters. The use of 3phase centrifuges is applied only if the solids waste is washed creating liquid volumes needing separation from the wash water. This allows for the wash water to be recycled. Tractor bucket, skips and conveyors generally handle the mobilization of these materials. The solids treatment system noEmacoally involves the incorporation of bulk hoppers with conveyors, wash tanks, screen separators, 2-phase decanters and possibly high-speed 3-phase centrifuges. In general oily semi solids are treated more in line with residence time on or through the equipment employed and in this system the 2-phase decanter generally dictates the thruput capacity. In general a single decanter for the treatment of fluidized semi solids would range from 2 to 4 m/hr per unit supplied. Greater capacity is achieved by multiples of units installed in tandem.

em a c o

group

Organization Emaco Oil&Gas was established through an organizational change in 2000 made by Alfa Laval going from a privately held (after 122 years in business) to a public holding company. This led to the closure of Alfa Lavals Oilfield Division and resulted in the set up of Emaco as an Alfa Laval OEM (Original Equipment Manufacturer) for the purpose of fabricating full-scale oily waste treatment plants using exclusively Alfa Lavals Centrifuges and Heat Exchangers. The Alfa Laval exclusivity under the OEM was maintained for our first three years of business. In January 2004, to better serve our clients, Emaco subsidiary decided to become an independent manufacture free to utilize any equivalent competitive components to Alfa Lavals equipment. This new arrangement allows Emaco to select the best technical and commercial supply options available as separation components for use in our manufacturing process and/or to provide any component specifically requested by the Client.

We still offer the same equipment warranties and performance guarantees as we did under Alfa Lavals OEM Agreement. Emaco separation systems are manufactured in the Netherlands in partnership Alfa Laval modules for the past 30 years, the Alfa Laval BV Service Center is located at Tekoma. Therefore certificates of origin and conformity to codes and regulations are issued in accordance to Dutch and European Community standards. Emaco Oil&Gas is in compliance to ISO 9002 certification through our partnership with Emaco group it being the workshop where our plants are manufactured. Emaco separation systems are manufactured (if required by the Clients specifications) to meet explosion proof regulations required for equipment supplied to the Oilfield sectors. Bioremediation of oily solids Environmental Remedies (EMACO) a sister company of Emaco Engineers BV was establish in March 2000 for the purpose of completing the process of oily waste treatment through decommissioning the solids waste removed from the liquid waste treated in Emaco Plants.

Regulations under USEPA EMACO is unique in that it specializes only in the treatment of oily solids waste utilizing the method of Compost Bioremediation. This method allows for the decommissioning of oily solids through a natural process of hydrocarbon decomposition by microbial action. The finished product, after the removal of oil, is a commercial grade product if declassified under the USEPA 503 Rule. By meeting this USEPA specification the compost material can be bagged and market through the Agriculture and Ornamental Horticulture business sectors.

em a c o

group

The process Composting of oily solids requires approximately 4 months to reach declassification. Oily waste solids having an oil content in the range of 5% to 50% are suitable for composting. This is similar to a faEmacoing operation where rows are laid out and tended to throughout the oil decomposition period to insure optimum microbial activity. This involves row building, the addition of nutrients and most importantly periodic watering and the daily induction of oxygen by custom designed equipment. Recording keeping is paramount to track all incoming oily waste and outgoing treated compost to comply with audits and regional environmental regulations. This also involves analytical and field laboratory testing to benchmark initial and final oil content and trace element measurements required for closure. EMACO provide the know-how, the specialized equipment and/or the full services to operate the Waste Facility handling all composting requirements at a fixed rate per m. Please contact us for technical details involving the complete process, the required equipment and the full turnkey services provided. Free pore space (FPS) = 100(1-BD/SG) x Dry Mass BD = Bulk Density & SG = Specific Gravity Maximum Oxygen consumption (equated to maximum microbial activity) in a composting operation occur at approximately 65% moisture and a FPS of 30% The plants we manufacture are designed to receive and treat all forms of oily waste from produced water to polluted soil. Most of our main applications involve the treatment of refinery slops & sludges, oil storage tank bottoms and marine bilge, slops & sludges. Emaco is unique in that we offer declassification solutions for all three of the separated phases: oilwater-solids. Oil is the simplest because it is a fully recyclable material suitable for return to the client or to market. Water is treated to meet environmental authority regulatory specifications so that it is recycled to back nature. Solids, representing the minimized waste, are further treated to meet USEPA or the local environmental authority specifications for declassification. This involves oily solids passing USEPA CFR 261 to be bioremediated to reach the CFR 503 specification for a commercial grade biosolid, which is then marketed into the Agriculture sector. Those oily solids failing the CFR 261 specifications are to be stabilized using USEPA approved trace element bonding agents for declassifying the materials as construction landfill. In most cases where oily waste has been dumped into unlined earthen pits one of the main environmental requirements is to treat the polluted soil contaminated by oil. By offering these recycling and declassifying solutions Emaco supports the Clients Waste Management Program to fulfil their environmental obligations with the local environmental authority. This proposal in intended to give potential Clients a first hand view of the technology we offer including our budgetary price. For Clients interested to receive details specific to their actual type waste and waste volumes we kindly request you to contact us directly.

em a c o
Online Sludge Removal

group

As legislation continues to tighten alternative sludge removal techniques are required to reduce and eliminate man entry into confined spaces. Online Sludge Removal from Tanks

Roof mounted nozzle system to reduce/remove sludge banks Focused on problem areas identified by the SPOT Combined with proven centrifuge technology to intercept solids, avoiding them being

Online Sludge Removal from Pits & API's

em a c o

group

The hydro-dredger is a suction device which can be operated at slow speeds to avoid disturbance to overhead water system, removing sediment/sludge from pits, APIs and water treatment areas whilst online.

Mechanical Sludge Removal

Over the past 14 years, Emaco Oil Services manufacturing division has designed and built a range of hydraulically driven sludge removal equipment. Using feedback from the contracting division, the systems have been modified and updated.

The emphasis remains on safety by minimising/eliminating man-entry into confined spaces. The standard system comprises of a robotic or manually driven hydrodozer, a range of purpose built pumping equipment and power packs. Emaco tailor solutions to customers specific requirements adapting standard equipment to solve difficult problems, such as low level pipetrack cleaning. The standard hydrodozer can be converted into a dredger for use online in pits and API Separator bays Mobile Sludge Processing

em a c o

group

Ever increasing environmental awareness and legislation is demanding that oily sludge is treated at source, as it is no longer acceptable for it to be sent to landfill/lagoons. Emaco Oil Services has designed a range of mobile processing equipment which enables sludge to be treated at tank/lagoon side, recovering oil and minimising waste. Pre-treatment of sludge is key to high quality separation. Emaco have a variety of systems tailored to meet the specific contract requirements. The focus of the Emaco sludge processing system is on returning the valuable recovered hydrocarbons to the refinery, ensuring that they are not sent off site. In some cases the high oil content in the sludge, combined with the quality of the oil that can be separated by our system, can result in the projects being self-funding or offering a payback. Emaco Oil Services R&D department are constantly designing a range of centrifuge technology to deal with a variety of difficult to treat sludges, ranging from tight emulsions containing fine particles, biological sludges, through to high solids contaminated sludges.

This unique technology provides high quality and effective separation of this difficult waste product into three phases;

Oil 2% BS&W, Water 1% Oil/Solids Dry Sediment 1% Leachable Free Oil. These are typical achievable qualities which can be improved if required, by the addition of appropriate secondary treatment. Secondary Treatment

em a c o

group

Indirect heat theEmacoal desorption system to reduce volumes to an absolute minimum low and high temperature systems. New systems under R & D including waste to energy technologies to offer further environmental solutions to the treatment of post centrifuge cake and other suitable wastes.

Applications Removal and treatment of tank bottom sludge: Safe and efficient removal of tank bottom sludge Sludge treatment and oil recovery directly from tank to reduce off site waste

The hydraulically driven EMACO tank cleaning equipment removes tank bottom sludge safely and quickly. The system reduces the number of men in the tank to a minimum for safe and efficient cleaning operations. The EMACO sludge treatment system recovers up to 95% of the hydrocarbons in waste sludge and can reclaim up to five barrels of good oil from every cubic metre of waste sludge treated. EMACO on site treatment of sludge is the most environmentally friendly and cost effective solution for this application and has been proven in refineries around the world. Equipment
o o o o o

Hydraulically driven equipment for fast and safe removal of crude oil sludge Portable equipment for cost effective on site treatment of wide range of sludge materials Mechanical sludge treatment system, fast processing rates, recovers up to 95% good oil

em a c o
o o

group
Services

from tank bottom sludge

Project engineering solutions for individual tank cleaning and sludge treatment applications o cleaning and sludge treatment projects o On site contracting service for wide range of tank

The EMACO integrated package is specifically designed to remove and treat sludge on a continuous basis. Sludge is treated directly it is removed from storage tanks, reducing off site transport and disposal costs. EMACO offer a wide range of engineering and contracting services to suit client requirements, please contact EMACO for full details. Benefits of EMACO On-Site Sludge Treatment

System designed specifically to treat crude oil sludge Fast and efficient treatment of large volumes of sludge Environmentally friendly High oil recovery rates Cost effective

Benefits of EMACO On Site Sludge Treatment System Treatment Method Off Site Disposal Yes Yes No Recovered Oil No No Yes Recovered Value

LandfaEmaco/Bioremediation Incineration EMACO on site treatment Tank Bottoms Treatment

None None 4-5,000 bbls of re-usable oil for every 1,000 cubic metres of sludge treated

em a c o

group

The sludge that is recovered from the bottom of crude tanks is generally a mixture of silt, sands, clay and crude oil. The conventional method of treating this, involves heating the oil sludge to create a pumpable slurry, then passing it through a centrifuge. This process normally gives a solid residual waste containing 6-15% hydrocarbons and a recovery of 90-93% of the crude oil. EMACO Oil Services have developed and patented a process for treating either the oil sludge direct from the tank or the residual from the centrifuge. The process uses high shear forces to separate the oil from the solids in to three distinct phases, solids, oil and hydrocarbons. Then the three phases are separated using standard hydro-cyclone technologies. The outcome of which is that the solids from the tank bottoms are left with less than 1000 ppm (0.1%) of hydrocarbons. The water produced from the process is fully recycled, and then passed through EMACO25, to give less then 5 mg/l TPH, for discharge to refinery waste water treatment plant or off-site disposal. The benefits to the refinery are: It is easier and less expensive to dispose of the sludge residual, the sludge will be classed as non-hazardous and volume for disposal will be less, giving a saving of at least 50% in sludge disposal costs. 99% plus of the hydrocarbons are recovered vs. 92-93%. The water from the process is cleaned to less than 5 mg/l TPH. Using the EMACO process leads to a total cost saving of between 25-35% versus using a centrifuge. EMACO Media EMACO25 is one of a family of media, which is specifically aimed at treating dissolved, emulsified hydrocarbons, such as oil, BTEX, Phenols, Alkyl Phenols and PAH. Other media for the treatment of heavy metals and in-organics are also available. EMACO25 is a starch granule coated with a surfactant. It can be used as a direct replacement for activated carbon in the removal of dissolved and emulsified oil from the liquid phase. The surfactant can be modified to remove phenols, alkyl phenols, BTEX, PAH and PCB, so that the product is tailored to the water that is being treated. It is ideal at removing from 100- 200 mg/l of hydrocarbons down to 0.5-10 mg/l. One lb of media can absorb between 1-1.5 lbs of hydrocarbons, depending on the nature of the hydrocarbon. Leading to small system footprints, which lend itself to use offshore, where space is a premium. Also the high absorption capacity means that the change-out frequency is normally restricted to once or twice a year, minimising labour costs.

em a c o

group

em a c o

group

SERBATOI
emacogroup

corrosione esterna rivestimento protezione lamiera

RISANAMENTI
Questa tecnologia permette di risanare i serbatoi mediante lapplicazione di rivestimenti protettivi interni, specifici per il materiale contenuto possibile scegliere fra due distinte metodologie di rivestimento; la scelta delluna rispetto allaltra si fonda su una serie di considerazioni di carattere tecnico, amministrativo, economico, quali: la durata residua del serbatoio ai sensi delle disposizioni di legge il vantaggio gestionale indotto dalla trasformazione del serbatoio semplice in una a doppia parete con sistema di monitoraggio dell intercapedine.In adempimento al DM 246 del 24/05/1999 e successive modifiche, questa trasformazione esclude il serbatoio da ulteriori controlli, abolendo il termine di dismissione le difficolt di rimozione evitare lavori di scavo e di rifacimento degli impianti ridurre al minimo i tempi di fermo

corrosione interna

copertura antistatica 2 rivestimento

laminato-fibra di vetro foglio bugnato di alluminio intercapedine 1 rivestimento lamiera serbatoio

emacogroup

TIPI DI RIVESTIMENTO
Parete semplice Applicazione a spessore del rivestimento, utilizzando prodotti a base di resina epossidica o poliestere. Doppia parete Realizzazione in opera, di una parete interna multistrato, munita di intercapedine, realizzata dalla sovrapposizione di pi materiali, collegata ad un sistema di monitoraggio. Il sistema di risanamento coperto da brevetto ed omologato da Enti Statali Internazionali.

Fasi intervento: bonifica prova di tenuta eventuali controlli non distruttivi eseguiti sul metallo sabbiatura applicazione internamente del rivestimento protettivo

emacogroup

GENERALITA
Normative regionali e nazionali, sovrapponendosi fra loro, regolamentano ladeguamento degli impianti di stoccaggio esistenti, nonch la loro corretta gestione e manutenzione. La Edam interviene nelle principali problematiche ambientali delle citate leggi e circolari. In relazione ai prodotti contenuti nei serbatoi gli interventi sono da inquadrare in: - INTERVENTI A BASSO RISCHIO Combustibili (gasolio, olio combustibile, etc.) - INTERVENTI AD ALTO RISCHIO materie altamente infiammabili o lavori in zone pericolose materiali tossici e/o cancerogeni rifiuti prodotti corrosivi La Edam specializzata ad intervenire con personale ed attrezzature proprie in zone o condizioni ad alto rischio. In questi casi, in relazione alla pericolosit del prodotto contenuto nei serbatoi, indipendentemente dalle operazioni da effettuare, fondamentale intervenire con: Personale specializzato, specificatamente addestrato e formato Attrezzature e strumentazione, omologate per zone ad alto rischio

NORMALIZZAZIONE POZZETTI DI CARICO

Razionalizzazione dei sistemi di scarico e di sfiato, sistemazione del passo duomo con controllo delle guarnizioni e saldature, installazione o manutenzione delle valvole limitatrici, predisposizione degli attacchi per prove di tenuta. In generale tutto quanto serve per riportare limpianto a norma.

BONIFICA
Lampia dotazione di attrezzature e tecnologie consente alla Edam di occuparsi della bonifica di serbaoi contenenti le pi disparate sostanze. Lintervento seguito con due metodologie: Manuale Ingresso di operatori perfettamente equipaggiati dotati di dispositivi di protezione e specifiche attrezzature per la bonifica. Automatica Impiego di macchinari per il lavaggio e disincrostazione, eseguite ad altissima pressione, mediante lutilizzo di apposite testine rotanti.

Il personale informato relativamente ai rischi lavorativi specifici ed formato soprattutto sulle procedure da applicare. assicurato presso lINAL contro i rischi relativi agli interventi durante la bonifica di: serbatoi aree industriali e macchinari manufatti con amianto

INERTIZZAZIONE
Dopo la bonifica, qualora sintende lasciare i serbatoi interrati in sede, si procede alla loro inertizzazione. Con questa procedura si esegue la messa in sicurezza, mediante il loro riempimento con materiali inerti. Preferibilmente loperazione effettuata con materiali leggeri (argille espanse) che, nel caso di una successiva rimozione del serbatoio, facilitano gli interventi di svuotamento e smaltimento.

emacogroup

RILIEVO DELLA TENUTA MEDIANTE ULTRASUONI

Il sistema rileva la presenza della pi piccola foratura od incrinatura, consentendo di valutare lo stato del serbatoio in modo efficiente ed affidabile. Il principio su cui si basa consiste nel sottoporre un serbatoio ad una leggera depressione (sufficiente a vincere la spinta idrostatica del prodotto contenuto) e nel rilevare gli ultrasuoni generati dalle eventuali forature o crepe presenti. I principali vantaggi offerti possono essere cos riassunti: Rapidit dintervento non richiede lo svuotamento del serbatoio, ci consente di ridurre notevolmente i costi e i tempi per la sua esecuzione: Assenza dimpatto ambientale lutilizzo di un sistema a depressione non permette la fuoriuscita di prodotto dai fori o crepe eventualmente presenti nel serbatoio: Efficienza ed affidabilit il sistema, basato su componenti tecnologicamente avanzati, certificato dai principali Enti Internazionali e risponde ai requisiti tecnici previsti dalla normativa Italiana. Sicurezza tutte le apparecchiature utilizzate sono omologate per operare in zona ad alto rischio ed in presenza di prodotti infiammabili.

DEMOLIZIONE
Il taglio costituisce una fase molto delicata; per la sua esecuzione sono applicate norme e procedure internazionali al fine di evitare i rischi dovuti alla presenza di miscele di gas infiammabili. Le attrezzature utilizzate rispettano le specifiche dimpiego in funzione al tipo di rischio. Taglio a freddo In relazione alla pericolosit del materiale precedentemente contenuto ed in funzione alla zona di lavoro, si utilizzano tecnologie particolari di taglio quali lidrotaglio (taglio ad acqua), o quello con roditrice pneumatica.

emacogroup

MACCHINARI E ATTREZZATURE
Impianti idrodinamici ad altissima pressione Disponiamo di pi versioni dunit ad alta pressione; ogni allestimento idoneo ad affrontare in modo specifico diverse problematiche. Sistemi mobili per abbattimento dei vapori Impianti di depurazione ad umido, scrubber, o a secco, filtro a carboni attivi, per abbattere i vapori, aspirati, durante le fasi di svuotamento e bonifica. Sistemi mobili daspirazione Cisterne mobili di dimensioni contenute, autonome, allestite con sistema di riempimento a depressione. Sistema di fluidificazione resistenze elettriche corazzate. serpentine idonee al passaggio di vapore. Ponteggio interno tipo Snap-out Ponteggio telescopico, in lega dalluminio, omologato, specificatamente realizzato per essere introdotto dal passo duomo e montano allinterno di serbaoi, in modo semplice e veloce senza lausilio dutensili. Impianto produzione aria respirabile Apparecchiatura autonoma, da abbinare ai dispositivi di respirazione assistita utilizzati dagli operatori in ambienti confinati. Il sistema modulare ed ha la capacit di 4.300 l/m. corredato di: triplice filtro, essicatore a ciclo frigorifero, bombole demergenza.

Tute scafandrate Dispositivi di protezione, specifici contro il rischio desposizione ad agenti tossici e/o cancerogeni. Le tute sono realizzate con materiali ad alta densit e bassa permeabilit, idonei ad impedire la trasudazione delle sostanze allinterno della tuta. Le caratteristiche costruttive garantiscono gli operatori contro il rischio dinalazione per via aerea e di quello derivante dallassorbimento cutaneo e conseguente bioaccumulo di sostanze nellorganismo.

emacogroup

DECONTAMINAZIONE SUOLO E SOTTOSUOLO

Serbatoi e cisterne sono una potenziale fonte di contaminazione del suolo, del sottosuolo e della falda. Linquinamento generato, oltre che dalla mancanza di tenuta, anche da perdite accidentali prodotte durante le operazioni di carico e scarico. Nel caso di contaminazione, lazienda, immediatamente, deve informare gli Enti competenti, provvedere alla messa in sicurezza della zona, svolgere delle indagini ambientali e predisporre un piano di bonifica idoneo al risanamento del sito. La Edam dispone di uno staff tecnico ed operativo in grado di applicare le pi moderne tecnologie relative a: interventi preliminari di messa in sicurezza carotaggi e campionamenti di terreno e sottosuolo indagini conoscitive sviluppo dei dati ottenuti con software idonei a dimensionare la zona contaminata definire un modello teorico despansione dellinquinamento analisi delle diverse tecniche di bonifica applicabili, confrontando costi e risultati predisposizione del piano di caratterizzazione intervenire con tecniche di risanamento in sito o smaltimento dei terreni contaminati.

RIFIUTI
I rifiuti contenuti nei serbatoi, e/o generati dalla fase di bonifica sono smaltiti in impianti autorizzati italiani ed esteri contrattualmente convenzionati od in esclusiva.

emacogroup

SG5 1RT

RM25 The treatment of dissolved and emulsified oils in produced water

RM25 is a starch granule, coated in a surfactant which has an affinity for the TPH, Phenols and BTEX. It is used in flow through vessels to absorb the dissolved and emulsified hydrocarbons from the water prior to discharge of the water.

Recognised by Shell as Best Available Technology Not Entailing Excessive Costs (BATNEEC)# for the removal of emulsified and dissolved oils from produced water, which will give lower compliance limits against mechanical treatment processes. Have a higher activity percentage active ingredient than any other absorbent media which potentially means a smaller footprint. The media can be tailored to target BTEX, Phenols and PAH as well as hydrocarbons. The media can be supplied in bulk, cartridge, canisters and can be supplied with interchangeable canisters up to 5 tons, the media can also be retro fitted to other systems s u c h a s c a n i s t e r s a n d S T R A Tu n i t s ( s t a n d a r d 4 0 c a r t r i d g e o r b a g f i l t e r s ) . Equipment can be supplied as a service contract or permanent systems. Note; # A BATNEEC study on Produced Water Treatment For Dissolved HCs and Phenols
Cor Kuijvenhoven, Shell International, The Netherlands Sander de Krujif, Shell International, The Netherlands

emacogroup

Advantages of the Sludge Removal Equipment

Well proven technology Safe and efficient system Minimises or eliminates people in confined spaces Many sizes and configurations Either remotely or manually controlled depending on application Hydraulically driven for safe operation in hazardous areas Designed to go through 18 manway if required Remote suction dredger can operate under oil / water in some cases while refinery system is still online Reduces time required to remove sludge compared with conventional methods

Sludge Removal Systems

emacogroup

Non - intrusive tank cleaning

Nozzle system on tank roof

Sludge Removal Equipment

Willacy Oil Services Ltd produce a range of equipment to enable the safe and efficient removal of oily sludges from confined spaces.

Mechanical tank cleaning

Mechanical Sludge Removal

The equipment is made in various sizes depending on the application, and can be fixed or in component form to go through an 18 manhole. The tracks can be used to agitate the sludge, pushing it to the pump section. In the remote version the pump can be mounted on the hydrodozer transferring the sludge directly through a fish tail type suction adaptor. The remote controlled hydrodozer can be operated as a suction dredger, removing sludge from pits, lagoons, API separators online while the systems are still in service. The pumps and hydrodozers are hydraulically driven which is a safe system for hazardous areas. The diesel driven power pack can be situated in a safe area powering the equipment.

Range of hydrodozers & dredgers

Non Intrusive Tank Cleaning

Using a unique fluidic nozzle system, developed in house, Willacy are able to clean heavy hydrocarbon deposits in large diameter floating roof crude tanks. The fluidic action of the nozzle places the dense hydrocarbons in suspension thus enabling maximum recovery of hydrocarbons contained in the sludges. The system has been developed to avoid the exposure to tank cleaning personnel carrying out hazardous cleaning activities in confined spaces. A recent case study showed that 6500 tonnes of sludge was removed using this non-intrusive technique in 4 weeks of running. Personnel were only required to enter the tank for the final phase of cleaning. Safe and efficient compared to traditional methods of manual sludge removal.

R28 lobe pump

Remote hydrodozer with cannon attachment

emacogroup

Screw Pump

Advantages of the Oil Recovery System

Vast operating experience and satisfied customer reference list Well proven technology Different options of sludge pre-treatment system to allow wide range of sludges to be treated Purpose built centrifuge designed specfically to separate difficult oil sludges A certified control panel with multi-sensing, allows good quality control System can give high quality three phase separation adjustable on line without stopping the machine High oil recovery rates, often up to 97% of free oil present in sludge Quality of recovered oil suitable to be returned to refinery High volume reductions of sludge is possible maximising oil recovered and minimising waste into a dry stackable cake Containerised system for easy efficient transporting to site

Oily Sludge Treatment

emacogroup

Standard VHSS pre-treatment unit High solids pre-treatment unit (HSPU)

Mobile oily sludge separation system

Electrical control panel
Following over 17 years of design, manufacturing and operation, Willacy Oil Services Ltd is now producing the most efficient range of proven separation equipment on the market without compromising safety. The oil recovery system comprises of the following:1. Pre-treatment Unit Willacy offers a range of pre-treatment units engineered to meet the clients' requirements for pre-screening, heating and homogenising the sludge in controlled conditions. Centrifuge Equipment The separation is carried out by a purpose built decanter centrifuge, which can produce quality separation into two or three phases. The liquid separation takes place in a secondary chamber within the centrifuge using a unique adjustable system to give optimum recovered oil quality. Chemical Dosing System The chemical dosing system is included for inline injection of appropriate chemicals to assist separation where required. Control Panel A specifically designed control panel, built by Willacy Oil Services Ltd manages the total sludge processing system with multiple control of motors, tank liquid levels, centrifuge and many safety monitoring devices for temperature flow and pressure. This ensures process operators can maintain maximum throughout with high quality results. The control panel is constructed entirely in stainless steel to combat the harsh environments and most importantly, along with all associated control equipment, is ATEX certified for use in hazardous area zones.

Three-phase decanter

2.

3.

4.

Oil recovery system treating lagoon sludge 3 Phase Separation

The flexibility of the total system with different pre-treatment options allows a wide range of sludges from high solids to fine tight emulsions to be successfully separated. The environmental and economical advantages can often be vast, by recovering the maximum amount of oil and minimising or eliminating waste for offsite disposal.

emacogroup

Recovered oil

Water

Dry stackable sediment

Advantages of Fixed/Semi Permanent Installation

Treating sludge at source on a daily basis Recovering valuable oil from sludge Optimising crude runs by improving slop oil quality Minimising offsite disposal Reducing environmental impact Reduce down stream fouling problem Maximising use of the equipment Improving water treatment plant performance by removing suspended solids

Fixed & Semi Permanent Installations

'Take the solution to the problem,

emacogroup

Permanent Facility BP Oil Refinery- Australia

Project Engineering
Willacy Oil Services has designed and built fixed and semi-permanent installations, in order to maximise the equipment usage. Set in a suitable location in the refinery, these installations are used to receive and process a variety of sludges that are produced on a daily basis. The type of installation can be designed according to the customer's requirement, either by utilising any existing storage facilities or by purpose building new tanks and pipework. In order to keep the equipment mobile, flexible pipes can be supplied to interconnect the equipment and link up to the refinery services. The equipment can be supplied in a more permanent installation, where it can be interconnected using fixed pipework, which can be designed to comply with any fixed plant regulations that the refinery may have.

Semi Permanent Installation - China

Installation - Kuwait

3D - Autocad Facilities

emacogroup

Advantages of Sludge Profiler for Oil Tanks

Accurate Time saving Safe Tank surveyed while the tank is full of oil Full ATEX Certification Totally nitrogen filled Automatic power shut down mechanism Instant read out Full 3D plot rotation facility

Sludge Profiler for Oil Tanks

'Take the solution to the problem, don't transfer the problem elsewhere'

emacogroup

Mobile system

Inserting probe retracted position

Sludge Profiler for Oil Tanks

The unique Sludge Profiler for Oil Tanks (SPOT) has been designed to accurately locate and quantify sludge build up in the bottom of floating roof crude oil storage tanks. The system is based on sonar and during a 360 sweep 240,000 soundings are used to assess the sludge build up. The Sludge Profiler replaces the inaccurate and time-consuming manual dipping method. In identifying the location and height of sludge banks in crude storage tanks, maintenance programmes can be prioritised, stock control can be improved, and representative samples can be taken from the sludge banks identified in the tank. When landing floating roofs, they can be at risk when large sludge banks are present, in using SPOT system the risk of damage can be reduced. Mixer running patterns can also be monitored by using the system on a regular basis. The equipment requires a 4 internal diameter entry position into the crude. Therefore, roof legs, man-ways, vents or dip hatches etc could be used. The survey is carried out with the tank full of oil which eliminates the potential confine space problems which can be associated with working on floating roofs in their lowered position. Normally between one and three entry positions are all that is required to survey a tank with a diameter of up to 100m, eliminating the need to remove large numbers of roof legs. A tank can usually be surveyed in one working day, providing that permits etc are available without delays. The number of people required to carry out the work is minimal. Once the tool is assembled the survey is carried out from the ground level and there would be no personnel on the roof. The system is intrinsically safe, as it is a totally sealed vessel that is completely nitrogen filled. The system has an automatic power shut down mechanism where if the pressure should drop the power to the system is cut off. The SPOT system has full ATEX certification and the technology is well proven both in the UK and overseas.

Automatic power shutdown mechanism Computer controlled

Sonar probe deployed (working) position

Self contained mobile system

Typical graphical information

emacogroup