MegaMacs process description
The cleaning process in general is the same for tank bottoms, processing drummed sludge or cleaning up a lagoon or separator pond. Idea is to liquefy sludge by washing/diluting agent, extract it from reservoir and bring to MegaMacs.
MegaMacs main process tank is filled to 80% capacity with water, which is circulated through the heat exchanger and returned to the tank using the wash pump. This re-circulation continues until solution temperature reach approximately 180° F (82° C) then wash pump is switched to cleaning mode and delivers cleaning solution to reservoir to be cleaned. Heated, by on board heat exchanger, water cuts and dilutes sludge to the ratio 4:1 creating mix of oil, water and solids. This mix is then pumped back to MegaMacs up to 500' (150 m) away.
As the mix enters the machine it goes trough the vibrating separator where solids larger than 1/4" (6 mm) are removed and conveyed to the debris box where they are collected for further disposal. Remaining mix of oil, water and fine solids delivered to main tank where next step of separation takes place. Majority of solids is settling to the bottom of the tank and water/oil mix (60% oil and 40% water) rise to surface. Floating skimmer pump removes this lighter fraction and evacuates it for further handling. The rest of the liquid is reheated and re-circulated back to reservoir closing the loop.
There are two ways to handle this 60% oil and 40% water mix. It could be sold as a final product or directed to Tri-Phase centrifuge for further separation, to remove fine solids and separate oil and water. As the feed material enters the unit three separated phases come out from centrifuge.
| Oil phase | 95.0%-99.0% oil | 1.0% - 4.0% water | 0.1% - 0.5% solids |
|---|---|---|---|
| Water phase | 0.5% - 1.0% oil | 98.0%-98.5% water | 0.5% - 1.0% solids |
| Solid phase | 0.5% - 1.0% oil | 50.0%-65.0% water | 40.0% -50.0% solids |
^ TopTank and lagoon cleaning process diagram
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The oil phase containing at least 95% of oil is a sellable product and brings substantial profit.
Depending on peripheral equipment and configuration system can process up to 15 tons of sludge per hour.
Different oil products may require specific cleaning solution (water or cutter stock) which will slightly alter described above process and create different sellable byproduct. Decision which solution or equipment to use should be made based on your specific conditions and environment.
Using MegaMacs you will save time, money and minimize environmental impact of oil tanks and reservoirs cleaning. Which is a win-win situation for your operations bottom line and environment!