Thermal desorption unit is also known as TDU, which overcomes oil sludge treatment problem. Through thermal desorption technology, complex composition and contaminated oil sludge is converted into fuel oil. It achieves efficient and clean recycling, and attains profitability and sustainability. Follows us to find the detailed solution to oil sludge thermal desorption.
Oil Sludge – Classification and Component
Oil sludge mainly comes from the extraction, gathering, transportation and refining process of oil. Unlike scrap tyre or waste plastic, this waste has a complex composition. It can be divided into various types based on its origin and composition. Each type has a different water, oil and solids content. The following is an overview of oil sludge classification and sources:
| Source | Type | Water Content % | Oil Content % | Solid Content % |
|---|---|---|---|---|
 Drilling and Oil Extraction |
Oil-based Cuttings | 8~15 | 15~25 | 60~80 |
| Waste Oil-based Mud | 40~50 | 10~20 | 30~40 | |
| Oil-contaminated Soil | 5~25 | 5~10 | 70~90 | |
 Oil Gathering&Transportation |
Tank Bottom Oil Sludge | 40-70 | 20-40 | 5-40 |
| Oil-contaminated Soil | 5~25 | 5~10 | 70~90 | |
 Oil Refining |
Oil-water Separator Sludge | 60~70 | 10~15 | 25~35 |
| Air Flotation Tank Sludge | 75~90 | 5~10 | 3~10 | |
| Activated Oil Sludge | 75~85 | ＜5 | 10~20 |
Numbers Revealing Global Oil Sludge Disposal Crisis
With the rapid development of the petroleum industry, the accumulation of oil sludge has sharply increased per year. However, due to the lack of recycling solutions, oil sludge disposal still faces a big crisis. Here are data for your reference:
4.5 Billion
tons Oil Production per year
60 Million
tons Oil Sludge Production per year
5 Million
hectares of Oil-contaminated Soil
1 Billion
tons Oil Sludge Accumulation Existing
70%
Oil Sludge Can’t be Treated Properly
Thermal Desorption Unit: Game-Changer in Oil Sludge Recovery
Thermal desorption unit uses anaerobic combustion to volatilize the oil-based part in the oil sludge and separate it from the solid matrix. This thermal desorption process (also called oil sludge pyrolysis) forms fuel oil, syngas and solid residue. The process has no specific requirements on the oil & water content of the oil sludge. Therefore, this unit is suitable for all types of oily waste. This oil sludge recycling solution has the following characteristics:
Reduction
By separating fuel oil and syngas, thermal desorption technology significantly reduces the volume of oil sludge. It also reduces the oil and water content in the solid residue.
Resource Utilization
TDU unit can achieve high recovery rate and high quality fuel oil syngas. In addition, energy utilization efficiency is further improved by recycling the heat energy of syngas.
Harmless Treatment
Waste residue, wastewater and waste gas can all be discharged and reused in compliance with standards. Moreover, this recycling method doesn’t produce secondary pollution.
Customers’ Feedback on Beston Thermal Desorption System
As a provider of waste recycling solutions, Beston Group’s pyrolysis equipment have been exported to more than 100 countries around the world. Rich export experience enables us to fully understand the needs of customers worldwide. Therefore, it enables Beston Group to customize oil sludge recovery solutions to meet the specific needs of customers from different regions. Below are successful cases of TDU unit for your reference.
Refinery Oil Sludge Thermal Desorption Solutions in Africa
Problems Faced
Oil extraction produces massive oil sludge, which is difficult to discharge in compliance with standards
Waste recycling companies have high processing costs and limited processing scale.
Customer’s Expectations
Comply with emission regulations and reduce pollution.
Increase treatment volume and reduce costs.
Make bricks from oil sludge residue.
Solutions
Customized discharge systems help customers obtain EIA certification.
Provide semi-continuous equipment with a daily capacity of 20 tons.
Assist customers in establishing an oil sludge recycling center.
Added Value
Reduce processing costs with your own oil sludge recycling center
Make bricks from harmless oil sludge residue to increase revenue.
Unified treatment center reduces security investment.
Deep Dive into TDU Workflow – Feeding to Discharging
01Raw Material Feeding
Three feeding methods for different oil sludge liquid contents:
- Below liquid content 40% : belt conveyor
- 40%-60% liquid content: shaftless spiral
- More than 75% liquid content: sludge pump
02Oil Sludge Thermal Desorption
Thermal desorption reaction occurs in a high-temperature microaerobic reaction environment. During the reaction, oil sludge undergoes the following changes in thermal desorption equipment:
- Under high temperature conditions, long-chain hydrocarbons in oil sludge are broken into small molecular hydrocarbons.
- Condensable components in the oil gas can be cooled through the condenser to form fuel oil.
- Non-condensable oil gas are purified by water sealing to form syngas, which provides energy for reactor.
03Oil Distillation(Optional)
Fuel oil is converted into higher quality non-standard diesel through the oil distillation equipment. In this equipment, fuel oil goes through the following stages:
- Distillation: heating the fuel oil and separating components with different boiling points.
- Condensation: cooling and liquefying the evaporated components.
- Acid & alkali washing: removing acidic and alkaline impurities and improving oil quality.
04Exhaust Gas Treatment
The high-temperature exhaust gas passes through the flue condenser and spray tower for cooling and dust removal. In addition, we provide high-end exhaust gas treatment systems, including electrostatic dust removal, activated carbon dust removal, and desulfurization&denitrification treatment. The flue gas emitted by high-end exhaust gas treatment can meet EU standards.
05Solid Residue Discharge
Some solid substances in oil sludge cannot participate in the thermal desorption process and eventually form solid residues. The solid residue is discharged through the water-cooled screw conveyor.
Profits Analysis of Oil Sludge Thermal Desorption Project
Profit from Recycled Fuel Oil
Profit from Solid Residue
Subsidy from Government
The fuel oil has diversified applications that make recycled fuel oil popular in the market. This gives it a wide range of sales channels. Therefore, selling this oil can bring considerable economic benefits. See the following uses:
- Directly used as an alternative energy source for factories/mechanical facilities with large energy consumption;
- Obtain higher value non-standard diesel oil by distillation treatment.
- After distillation, the heavy oil components are obtained to generate electricity for heavy oil generators;
- Further processing in the refinery to produce commercial gasoline and diesel.
The solid residues produced by thermal desorption unit also generate incomes as long as placement properly:
- Sell to brick factory to make bricks;
- Sold to oil field companies for use as oil well anti-collapse agents.
Due to the significant hazards and serious pollution caused by oil sludge, government departments in various regions provide substantial financial support for oil sludge recycling projects. Common application procedure is as follows:
- First, the project need to obtain industrial waste(water, gas, solid) emission qualification granted by the government’s EIA department.
- After certification, a certain subsidy will be granted for each quantified amount of oil sludge recycling project.
Models of Thermal Desorption Unit for Sale – 6 Options
Beston Group’s comprehensive product system provides customers with 6 models to choose from. They can meet the different production needs of customers. In addition, the diverse equipment options ensures that customers get the most suitable solution at a reasonable thermal desorption unit price.
Skid-mounted Type
- Model: BLJ-3
- Less transportation costs
- Modular design
- Simple to install and operate
Batch Type
- Model: BLJ-6/10/16
- Flexible model selection
- One furnace a day
- Cost-effective machine price
Continuous Type
- Model: BLL-30
- Continuous feeding & discharging
- Intelligent control
- High return on investment
| Model | BLJ-3 | BLJ-6 | BLJ-10 | BLJ-16 | BLL-16 | BLL-30 | |
|---|---|---|---|---|---|---|---|
| Capacity | 1-3t/d | 4-6t/d | 8-10t/d | 12-16t/d | 8t/d (only for rubber powder) | 30-35t/d | |
| Working Process | Batch | Batch | Batch | Batch | Semi-continuous | Fully continuous | |
| Reactor Size | φ1400*4900mm | φ2200*6000mm | φ2600*6600mm | φ2800*7100mm | φ2800*7100mm | φ1800*18500mm | |
| Reactor Material | Q345R | Q345R | Q345R | Q345R | Q345R | 310S stainless steel | |
| Drive System | 350 reducer+4kw drive motor | 400 reducer+5.5kw drive motor | 400 reducer+5.5kw drive motor | 500 reducer+7.5kw drive motor | 500 reducer+7.5kw drive motor | ZQH650-50 reducer+15kw frequency conversion motor | |
| Land (L*W*H) | 18m*4.2m*6m | 30m*12m*8m | 30m*13m*8m | 33m*13m*8m | 33m*13m*8m | 70m*20m*10m | |
| Power | 16.65kw | 37.85kw | 44.3kw | 55.6kw | 55.6kw | 256kw | |
| Burner | 2*200,000 kcal | 2*300,000 kcal | 2*300,000 kcal | 2*400,000 kcal | 2*400,000 kcal | 2.5 million kcal per set | |
| Total Weight of Shipped Materials | About 18t | About 24.5t | About 28t | About 34.5t | About 34.5t | About 150t | |
| Number of Containers | 1*40HQ | 1*40FR+1*40HQ+1*20 GP | 1*40FR+2*40HQ | 1*40FR+2*40HQ | 1*40FR+2*40HQ | 25m*8m bulk cargo+8*40HQ | |
| Noise (dB) | ≤60 | ≤60 | ≤60 | ≤60 | ≤60 | ≤60 | |
| Heating Materials | Fuel oil (including tyre/plastic pyrolysis oil), natural gas, LPG, diesel, etc. | ||||||
| Condensing System | Vertical Condenser | φ426*3000 Single piece condensing area 7.58m2 | φ630*3600 Single piece condensing area 17.8m2 | φ630*3600 Single piece condensing area 17.8m2 | φ820*3600 Single piece condensing area 35.6m2 | φ820*3600 Single piece condensing area 35.6m2 | φ920*3200 2 sets of vertical condenser |
| 3-in-1 Condenser | 3000*2200*2250 Condensing area 17.51m2 | 5800*2260*2500 Condensing area 35.85m2 | 5800*2260*2500 Condensing area 35.85m2 | 8000*2260*2500 Condensing area 49.5m2 | 8000*2260*2500 Condensing area 49.5m2 |
||
Technical Advantages of Beston Thermal Desorption Plant
High Combustion Efficiency
- The entire system makes full use of the syngas generated in the reactor for secondary combustion. This reduces energy consumption. Combustible gas is purified by water seal to ensure clean combustion.
- BLL-30 continuous equipment uses efficient hot air heating. In addition, the syngas produced by the reaction is mixed with high-temperature hot air. Air volume ratio enables precise temperature control.
Anti-coking Design
- Batch thermal desorption system uses friction blocks and materials to rotate with the equipment in the main furnace at the same time. This slows coking by increasing thermal conductivity.
- Continuous equipment uses hot air heating to solve the coking problem caused by overheating. In addition, high temperature catalyst also prevents coking. Moreover, mesh chain friction in the reactor to remove coke.
Efficient Emission Control
- The waste gas generated by Beston equipment is processed by a high-end exhaust gas treatment system to meet EU emission standards. Moreover, if the emission standards in your area are higher, it is a good option for your project.
- The discharging system is designed with water-cooled discharging method to reduce dust pollution. In addition, the continuous thermal desorption unit can achieve continuous discharging without leaking oil gas.
Smart Operation Mode
- PLC (standard configuration on BLL-30) and DCS(Distributed Control System) guarantee intelligent operation. They have high control efficiency. Therefore, this saves manpower and improves the working environment.
- In addition, you can also choose an Internet of Things real-time monitoring system. It can realize timely online monitoring of the Internet of Things. This facilitates customers’ overall operational control.
Thermal Desorption Unit Drives Petroleum Industry Transition
Formation of Closed-loop Value Chain
Oil sludge originates from petroleum industry. Meanwhile, Beston thermal desorption unit recovers this waste into materials that can be reintegrated into the petroleum industry’s supply chain, such as refining oil and oil well fill materials. This closed-loop approach enhances the industry’s value chain. Thus, through a “waste to resource” production mode, the machine lays the foundation for a circular economy within the petroleum industry.
Win-win Between Profitability & Sustainability
Profitability
Fuel oil meets market demand for alternative energy trading.
Oil sludge disposal can get funding from sustainable policies.
Thermal desorption projects boost local economies by creating jobs.
Sustainability
Clean fuel production optimizes energy structure and reduces fossil energy use.
TDU achieves sustainable recycling, easing burden on environment.
Harmless treatment aligns with sustainable strategy of petroleum industry.
Thermal Desorption Unit Alleviates Ecological Burden
Oily sludge contains 5-50 of petroleum, polycyclic aromatic hydrocarbons (PAHs), dioxins, and radionuclides, heavy metals etc. So, it is toxic and flammable. Oil sludge pollutes the soil, water, and air resources that causes serious harm to the ecological environment even human health. Currently, oil sludge is classified as hazardous waste. Its disposal is regulated by environmental protection agencies worldwide. See the detailed hazards:
Reduce Soil Hazards
TDU realizes large-scale reduction of oily sludge. Thus, it reduces the waste of land resources caused by excessive discharge.
The equipment reduces the amount of harmful components penetrate into the soil. Thus, problems such as soil degradation and surface vegetation destruction are solved.
Mitigate Water Hazards
Thermal desorption recovery prevents harmful substances from entering water resources. This optimizes water quality and the growth environment of aquatic organisms.
Application of TDU prevents oil sludge from entering the human food chain, eliminating hidden dangers to human health.
Eliminate Air Hazards
Thermal desorption technology reduces volatile pollutants into the atmosphere, optimizing air quality.
Oily sludge stored in the open air is flammable when exposed to fire. Thermal desorption recovery reduces the risk of release of sulfur-containing gases from burning.
Get Customized Oil Sludge Treatment Solution
Beston thermal desorption unit has become the optimal choice for oil sludge treatment. Our innovative technology helps customers extract economic value from oil sludge. Furthermore, integrated solutions from Beston Group guide customers from A to Z on their path to sustainable development. Just contact us to get your customized solution. Also, you can follow us on Facebook for more oil sludge recycling information.