RU2588134C2 - Composite medium for water treatment processes and methods for use thereof - Google Patents

Abstract

FIELD: chemistry.

SUBSTANCE: invention relates to methods of processing of the initial stream containing hydrocarbon liquid and water-based liquid. One of the versions involves feeding initial flow in inlet tank containing composite medium consisting of single-phase homogeneous particle shape, wherein each particle contains a mixture of cellulose-based material and polymer; and contact of initial flow with composite medium to obtain a processed stream, wherein the treated stream contains specified target concentration of hydrocarbon fluid. Invention also relates to a system.

EFFECT: used composite medium is more effective.

34 cl, 10 tbl, 7 ex, 15 dwg

Description

Cross reference to related application

In accordance with paragraph 119 (e) of section 35 of the United States Code, this application claims priority in relation to provisional patent application US No. 61 / 448,821, entitled "Use of a volumetric composite medium consisting of wood and plastic to separate oil from water" and filed March 03, 2011, the entire description of which in its entirety is incorporated into this document by this link.

FIELD OF THE INVENTION

Aspects of the present invention relate generally to the treatment of liquids and, more particularly, to methods for coalescing hydrocarbon liquids and separating hydrocarbon liquids from water-based liquids.

SUMMARY OF THE INVENTION

In accordance with one or more embodiments, a method is provided for treating a feed stream comprising a hydrocarbon liquid and a water based liquid. This method includes introducing a feed stream into the inlet of a reservoir containing a composite medium, the composite medium comprising a mixture of cellulose-polymer-based material and contacting the feed stream with the composite medium to produce a treated stream, the treated stream containing a predetermined target concentration of hydrocarbon liquid. In other aspects, the method further comprises measuring at least one property of the treated stream. In at least one aspect, the measured property is at least one property of the concentration of the hydrocarbon liquid in the treated stream and the flow rate of the treated stream. In at least one aspect, the method further includes backwashing the composite medium based on at least one measured property of the treated stream to produce an outgoing hydrocarbon liquid. In another aspect, the method further includes returning the hydrocarbon effluent to the feed stream.

In one or more embodiments, contacting the feed stream with the composite medium includes filtering the feed stream, the predetermined target concentration of the hydrocarbon fluid in the treated stream being less than the concentration of the hydrocarbon fluid in the feed stream. In yet another embodiment, the predetermined target concentration of the hydrocarbon liquid in the treated stream is less than about 30 ppm. In certain aspects, contacting the feed stream with the composite medium includes coalescing the feed stream, the predetermined target concentration of the hydrocarbon fluid in the treated stream being a reduced concentration of emulsified hydrocarbon fluid compared to the feed stream. In yet another embodiment, the concentration of emulsified hydrocarbon liquid in the treated stream is reduced by more than about 50% compared to the original stream. In certain aspects, the treated stream includes drops of hydrocarbon liquid in which the diameter is at least about 20 microns.

In accordance with one or more embodiments, there is provided a method for treating a feed stream comprising a hydrocarbon liquid and an aqueous liquid, comprising passing the feed stream at a first flow rate through a coalescing device containing a composite medium, the composite medium comprising a mixture of cellulose-based material and polymer to produce a coalesced stream, and passing the coalesced stream at a second flow rate through a filter device located combined with a coalescing device and containing a composite medium to produce an exit stream. In certain embodiments, the first flow rate is in the range of from about 100 to about 200 gallons per minute per square foot (6.79 to 13.58 m / s). In at least one embodiment, the second flow rate is less than about 40 gallons per minute per square foot (2.72 m / s). In yet another embodiment, the method further comprises maintaining the concentration of hydrocarbon fluid in the effluent at a predetermined target percentage reduction. In at least one aspect, the method further includes backwashing the at least one device from a coalescing device and a filter device. In certain embodiments, the method further includes backwashing the at least one device from the coalescing device and the filter device based on a predetermined time interval.

In one or more embodiments, the method further comprises measuring at least one property of the coalesced stream. Another embodiment includes backwashing the coalescing device based on at least one measured property of the coalescing stream to produce an outgoing hydrocarbon liquid. In certain aspects, the method of the at least one measured property is the flow rate of a coalesced stream.

In certain aspects, the method includes measuring at least one property of the effluent. In at least one aspect, the method further includes backwashing the filter device based on at least one measured property of the effluent to produce an effluent hydrocarbon fluid. In yet another aspect, the at least one measured property is at least one property of the flow rate of the effluent and the concentration of hydrocarbon fluid in the effluent.

In accordance with one or more embodiments, there is provided a method for treating a feed stream comprising a hydrocarbon liquid and a water-based liquid, comprising passing a feed stream through a coalescing device containing a composite medium comprising a mixture of cellulose-based material and a polymer to produce a coalescing stream, wherein coalesced stream includes a reduced concentration of emulsified hydrocarbon fluid compared to the original stream, and separation of coalescence soda stream by passing a coalesced stream through a separation device to obtain at least one stream from a hydrocarbon liquid stream and a water stream. In one aspect, the coalesced stream comprises hydrocarbon liquid droplets in which the diameter is at least about 20 microns. In a further aspect, the separation device is at least one of the following devices: a hydrocyclone, a gravity precipitation device, a filter device, and a flotation device.

In certain aspects, the method further includes measuring at least one property of the coalesced stream. In at least one aspect, the method further includes backwashing the coalescing device based on at least one measured property of the coalescing stream to produce an outgoing hydrocarbon liquid. In yet another embodiment, the at least one measured property is the flow rate of the coalesced stream.

In accordance with one or more embodiments, there is provided a system for treating a feed stream comprising a hydrocarbon liquid and an aqueous liquid, comprising at least one coalescing device in conjunction with the feed stream and comprising a composite medium comprising a mixture of cellulose-based material and a polymer, and at least one separation device in conjunction with a coalescing device. In at least one embodiment, the separation device is at least one of the following devices: a filter device, a gravity precipitation device, a hydrocyclone, and a flotation device. In certain embodiments, the separation device is a filter device comprising a composite medium. In one or more embodiments, the composite medium comprises cellulose-based material in a concentration of at least about 50% by weight. In one embodiment, the cellulose-based material comprises maple wood. In certain aspects, the polymer includes high density polyethylene. In other aspects, the composite medium includes many particles of a uniform shape.

In accordance with one or more embodiments, a method is provided that allows a processing system to separate a feed stream into a hydrocarbon liquid and a water-based liquid, the treatment system comprising at least one reservoir in conjunction with the feed stream, and the method includes manufacturing a composite medium comprising a mixture of cellulose-polymer-based material and placed in a reservoir intended to contact the feed stream.

Brief Description of the Drawings

The accompanying drawings are not intended to adhere to the actual scale. In these drawings, each identical or almost identical component, which is illustrated in a variety of images, is represented by the same reference number. For purposes of clarity, not every component may be labeled in each image. Among these drawings:

FIG. 1 is a schematic diagram of a process flow in accordance with one or more aspects of the present invention;

FIG. 2 is a schematic diagram of a process flow in accordance with one or more aspects of the present invention;

FIG. 3 is a graph illustrating environmental studies in accordance with one or more aspects of the present invention;

FIG. 4 is a graph illustrating the results of an environmental study in accordance with one or more aspects of the present invention;

FIG. 5 is a graph illustrating the results of an environmental study in accordance with one or more aspects of the present invention;

FIG. 6 is a graph illustrating the results of an environmental study in accordance with one or more aspects of the present invention;

FIG. 7 is a graph illustrating environmental studies in accordance with one or more aspects of the present invention;

FIG. 8 is a schematic diagram of a process flow in accordance with one or more aspects of the present invention;

FIG. 9 is a schematic flow diagram in accordance with one or more aspects of the present invention;

FIG. 10 is a graph illustrating the results of an environmental study in accordance with one or more aspects of the present invention;

FIG. 11 is a graph illustrating environmental test results in accordance with one or more aspects of the present invention;

FIG. 12 is a graph illustrating the results of an environmental study in accordance with one or more aspects of the present invention;

FIG. 13 is a graph illustrating environmental test results in accordance with one or more aspects of the present invention;

FIG. 14 is a graph illustrating environmental test results in accordance with one or more aspects of the present invention; and

FIG. 15 is a graph illustrating environmental test results in accordance with one or more aspects of the present invention.

Detailed description

The definition of “approximately” when used in connection with quantity includes a certain value and makes sense dictated by the context (for example, it includes at least the degree of error associated with the measurement of a certain value). When used in the context of an interval, the definition of “approximately” should also be considered as a description of the interval defined by the absolute values of the two endpoints. For example, the interval “from about 2 to about 4” also describes the interval “from 2 to 4”.

In certain applications, individual fluid components can be physically processed before being used in subsequent processes. Physical processing technologies are based mainly on the physical properties of the individual components of the liquid and may include at least one of the following processes: coalescing, separation and filtering of the technology. For example, aqueous liquids may include suspended solids or liquids that can be processed using one or more processes, including filtering, coalescing, and separation. One or more of these processes may include contact of the liquid with the medium. In certain cases, the contact of the liquid with the medium can be accomplished by passing the liquid through a layer filled with medium.

The medium can be useful for a variety of processing technologies and applications, including filtering, coalescing, separation, extending the residence time of the liquid in the tank containing the medium, and functioning as an adsorbent or absorbent. For example, the medium can be used to separate liquids from gases, liquids from other liquids, and also to separate suspended solids, colloidal and finely divided materials from a moving stream. In addition, the medium can be used to coalesce small drops of one or more liquid components into larger drops. For example, media-containing filters can be used to remove suspended solids and free oil from one or more solutions. For example, media filters can use refineries and oil wells, petrochemical plants, chemical plants, natural gas processing plants, and other industrial processes for the separation of oil and water. Separation technologies in these industrial processes can be divided into categories of primary, secondary and tertiary stages. Primary separation technologies can use, for example, American Petroleum Institute (API) standard separators to collect oil from open sewage and gravity settlers to separate large quantities of oil and suspended solids from waste water. In certain examples, primary separation technologies are capable of lowering oil concentrations to levels of about 500 to about 200 ppm. Secondary separation technologies can use, for example, coalescing and flotation devices to separate additional quantities of oil from spent water. In certain examples, secondary separation technologies are capable of reducing oil concentrations to levels of from about 100 to about 20 ppm. Tertiary separation technologies can use, for example, filters containing a layer of the medium and are able to reduce oil concentrations to levels of restriction on discharge. For example, tertiary treatment technologies may be capable of removing free oil at baseline levels of from about 20 ppm to about 100 ppm, to levels that are less than about 10 ppm. Non-limiting examples of tertiary separation technologies include API flotation devices, dissolved air flotation (DAF) devices, dissolved gas flotation devices (DGF), compact flotation devices, hydrocyclones, and media containing filters, including those containing a walnut shell layer filters. Currently, there is a demand for tertiary media filters that use oil platforms (also called offshore) in order to comply with established waste water discharge requirements. The environmental impact and weight of the equipment are critical factors in determining whether equipment can be used on offshore oil platforms. Therefore, an environment that is more efficient in separating oil from water than the currently available medium can provide a significant reduction in size and weight of equipment. The medium containing filter may be located downstream of the primary and secondary processing. It is now known that a medium based on black walnut shells has a simultaneous affinity for oil and water, and it can be used as a medium for tertiary separation processes. For example, in refineries, walnut-containing shell filters use downstream of primary separation devices and secondary separation devices to reduce the remaining free oil level of about 20 to about 100 parts per million to levels of less than about 10 parts per million.

In certain embodiments of the present invention, it may be desirable to make an economical and low maintenance volumetric medium that may be suitable for backwashing. Backwashing can restore the medium and its suitability for reuse. In some embodiments, it may be desirable to produce a backwash medium that may have the ability to increase the flow rate and more efficiently separate the oil compared to a medium containing black walnut shells, such as for example eastern black walnut (Juglans nigra ) Filters containing walnut shell media may have a limited flow rate, which may limit the size of their structure and, therefore, limit their suitability for use on offshore platforms. In addition, sources of black walnut shells are prone to instability, as their availability is directly dependent on changes in yield from one season to another. In some embodiments, it may be desirable to reduce the frequency of backwashing to improve the performance of one or more processing systems. This reduction may also reduce the amount of water produced used for backwashing, which may give the system an additional advantage.

In certain applications, it may be difficult to physically separate individual components suspended in a liquid due to their quantity. For example, in oil drilling operations, water containing crude oil is usually obtained. Statutory requirements or technological conditions may determine that water must contain oil at a concentration below a certain threshold value so that it can be released into the environment or reused for other purposes. The difficulty of separating a mixture of oil and water may depend on the physical form of the oil. During processing and transportation operations, the pressure drops and oil droplets can form during movement, which are small enough so that they are not easily separated from the water. For example, oil may be dispersed in a volume of water in the form of small droplets whose diameters may be less than 20 microns. For varieties of oil whose density is close to that of water, it may be difficult to even separate droplets with diameters of more than 20 microns using traditional gravity separation processes. In mixtures of each of these types, oil is considered emulsified in water. In certain aspects, the emulsified oil may be oil that does not separate from water after performing gravitational separation for approximately 30 minutes under equilibrium. Processing water that contains emulsified oil can present some difficulties when using physical separation technologies. Devices such as hydrocyclones, API separators, flotation devices, gravity sedimentation devices and walnut shell filters may not be effective in separating mechanically emulsified oil from water. On the contrary, these technologies can be used to separate the “free” oil, which is unemulsified oil.

In accordance with one or more embodiments, the systems and methods described herein relate to a method for processing a source stream. The source stream may include one or more components. The feed stream may include one or more components that are in the same phase, for example, one or more liquids. The feed stream may include one or more components that are in different phases, for example, one or more combinations of gases and liquids and one or more combinations of solids and liquids. In certain applications, the feed stream may include one or more suspended solids, colloids, and finely divided solids. The feed stream may include a water-based liquid. In certain aspects, the feed stream may include a hydrocarbon liquid and a water-based liquid. In certain aspects, a system may receive one or more source streams from industrial sources. For example, refineries, oil wells, petrochemical plants, chemical plants, natural gas processing plants and other industrial facilities can produce the feed stream. In certain embodiments, a system may receive one or more feed streams, including a hydrocarbon fluid and a water based fluid. As used herein, the term “hydrocarbon” means an organic material with a molecular structure containing carbon bound to hydrogen. Hydrocarbons may also include other elements, including, but not limited to at least one of the following elements: halogens, metals, nitrogen, oxygen and sulfur. As used herein, the term “hydrocarbon liquid” means a liquid phase hydrocarbon fluid or a mixture of liquid phase hydrocarbon fluids. The hydrocarbon fluid may include additional substances, for example, solid particles. Non-limiting examples of hydrocarbon fluids may include, for example, crude oil, natural gas, shale oil, pyrolytic oil, and any combination thereof. As used herein, the terms “water-based liquid” and “water stream” mean liquids including water. The liquid may include additional substances, which may be solids, including suspended solids, liquids, gases, or any combination thereof. The methods and systems described herein may relate to a feed stream comprising a hydrocarbon liquid and a water-based liquid, but should not be limited to them. For example, it may be possible to process liquids of one or more other types using the methods and systems described herein.

In certain embodiments, the feed stream may be introduced into the inlet of the tank. The inlet may be located at the top of the tank, at the bottom of the tank, or at any other intermediate location that is suitable for using the methods and systems described herein. As used herein, the term “reservoir” in the broad sense means any structure suitable for containing one or more process components, including gaseous, liquid, and solid components, as well as mixtures thereof. The tank may be open to the environment, or it may be closed to work under pressure. In certain applications, a reservoir can be designed to create anaerobic or aerobic conditions for the components. The tank may have dimensions and shapes according to the desired application and volume of the starting material to be processed in order to provide at least one of the conditions for the desired throughput and the desired duration of operation before starting backwashing. The tank may contain a container for placing a layer of medium of the desired depth depending on the desired volume of the starting material to be processed and the medium selected for a particular application. Accordingly, the reservoir may contain a layer of medium of any depth, which is suitable for the purposes of the methods and systems described herein. The tank may be constructed using any material suitable for the purposes of the methods and systems described herein. Non-limiting examples of suitable materials include steel, stainless steel, fiberglass reinforced plastic, and polyvinyl chloride (PVC). One or more embodiments may include a reservoir having one or more side walls depending on the desired shape of the reservoir. For example, a cylindrical tank may have one side wall, while a square or rectangular tank may have four side walls. In certain embodiments, the reservoir may have a cylindrical shape having one continuous side wall located between the first and second walls. In other specific embodiments, the reservoir may be closed, one or more side walls extending between the first wall and the second wall. In certain aspects, the reservoir may comprise a medium. Any medium suitable for the methods and systems described herein may be used. The medium may be located in the tank at a predetermined depth and may fill the entire volume of the tank or be contained in a specific part of the tank. For example, a portion of the volume of the reservoir adjacent to one or more walls may not contain a medium. The medium can be held inside the tank by one or more separators, such as partitions or perforated plates, which can hold the medium in a desired position inside the tank, while allowing one or more liquids to flow through the medium in the tank.

In certain embodiments, the reservoir may comprise a composite medium. As used herein, the term “composite medium” means a combination of two or more different materials. In at least one embodiment, the composite medium comprises a mixture of cellulose-based material and a polymer. The composite medium may include a heterogeneous mixture of cellulose-polymer based material. A heterogeneous mixture may include ingredients or constituents such that the components are not evenly distributed throughout the mixture. As used herein, the term “heterogeneous mixture” means a composite of two or more dissimilar ingredients or constituents. The composite medium may include a homogeneous mixture of cellulose-polymer based material. In one embodiment, the composite medium may include cellulose-based material and a polymer such that the two materials are bonded to each other but not mixed together. As used herein, the term “homogeneous mixture” means a composite, which is a single-phase composite consisting of two or more compounds that are distributed in a uniform ratio or in an almost uniform ratio in the volume of the mixture, so that any part of the composite is the same ratio of two or more compounds. As used herein, the term “cellulose-based material” means any material, product or composition that contains cellulose. Non-limiting examples may include foliage-dropping wood and evergreen trees, including wood flour, wood pulp, wood particles, wood fibers, sawdust, wood shavings, wood chips, and any other wood product or cellulose-based product suitable for methods and systems, described herein, such as coconut, bagasse, peat, pulp waste, corn stalks, or any combination thereof. The medium may include any wood material suitable for the purposes of the methods and systems described herein. In certain embodiments, the cellulose-based material may be pine wood. In certain embodiments, the cellulose-based material may be maple wood. Non-limiting examples of polymers suitable for the methods and systems described herein may include polyolefins, including high density polyethylene (HDPE), polyethylene (PE), polypropylene (PP), PVC, ethylene propylene copolymers, fluoropolymers including teflon (Teflon®) and any combination thereof. In at least one embodiment, the polymer may be HDPE. In yet another embodiment, the polymer may be polypropylene.

In one or more embodiments, the composite medium may include cellulose-based material at a concentration of at least about 50%. In other embodiments, the implementation of the composite medium may include cellulose-based material in a concentration of at least about 60%. In certain embodiments, the composite medium may include cellulose-based material at a concentration of at least about 70%. In at least one embodiment, the composite medium may include maple wood at a concentration of about 50 wt.%. In yet another embodiment, the composite medium may include pine wood at a concentration of approximately 70 wt.%. The concentration of the cellulose-based material may be any percentage ranging from about 0% to about 100%, or any range of percentages between these percentages. In at least one aspect, the composite medium comprises a plurality of particles of a uniform shape. As used herein, the term “particles of uniform shape” means having exactly the same particle shapes and sizes and having substantially the same particle shapes and sizes, while some degree of shape difference is allowed, which is due, for example, to manufacturing inaccuracy. Suitable forms for a composite medium may include spheres and cylinders. For example, a composite medium may include a plurality of uniformly shaped cylindrical or cylinder-like particles. The composite medium may be any form that is capable of providing gaps in the pore spaces between the particles. In certain embodiments, the composite medium may include a plurality of irregularly shaped particle

The composite medium may include additional components, including chemical components. Non-limiting examples of components that may be suitable for incorporation into a composite medium include coagulants and flocculants. The composite environment may include any additional component that may be suitable for the purposes of the methods and systems described herein.

In accordance with certain embodiments, a medium is provided. You can use any medium provided that it can be suitable for at least one of the following processes: (1) coalescing at least one hydrocarbon liquid and (2) filtering at least one stream, including hydrocarbon liquid and aqueous liquid. One example of a medium suitable for the methods and systems described herein may be a composite medium. As used herein, the terms “composite medium” and “composite medium” are used interchangeably. The composite medium may include a mixture of cellulose-based material and a polymer. The medium may include at least one of a homogeneous and heterogeneous mixture of cellulose-polymer based material. The cellulose-based material and the polymer can be described and incorporated as discussed above. In at least one embodiment, the medium may be suitable for backwashing. In certain embodiments, the medium may be suitable for liquefying. In some embodiments, implementation, the medium may exhibit at least one of the properties of adsorption and absorption with respect to at least one liquid from a hydrocarbon liquid and an aqueous liquid.

In certain embodiments, the mass of oil that can be loaded into the composite medium before a breakthrough occurs can be a four-fold mass that can be loaded into other types of media. Other types of environmental materials may include, for example, wood, polymer (e.g. HDPE and polypropylene) and black walnut shells. In at least one embodiment, the wood and polymer components of the composite medium may not exhibit oil absorption capacity at or near the level of oil absorption capacity of the composite medium. Without being limited by theory, one possible explanation for the beneficial effects of the combination of wood and polymer may be that each of these two components gives different adsorption or absorption properties, and that synergy may result from a combination of the two materials. A second possible explanation is that the shape of the composite particles contributes to the separation process.

In certain embodiments, the reservoir may also include a feed inlet located above the medium and a filtrate outlet located below the medium. The tank may also include a first inlet, which is constructed and designed to direct the first fluid to the first end of the outlet pipe and to provide, during backwashing, the movement of the medium inside the outlet pipe from the first end of the outlet pipe to the second end of the outlet pipe while allowing the filter medium to move along the outer side wall of the discharge pipe from the second end of the discharge pipe to the first end of the discharge pipe. Further outlet pipes are discussed in more detail.

In certain embodiments, the composite medium comes into contact with the feed stream to produce a treated stream. In at least one embodiment, contacting the feed stream with the composite medium includes filtering the feed stream. As used herein, the terms “filtration” and “separation” broadly mean any process used to separate a constituent ingredient of a substance from other constituent ingredients of a substance. For example, filtering may mean the process of separating one or more phases from each other. In certain aspects, two liquid phases can be separated by filtration. In other aspects, the solid phase can be separated from the liquid phase by filtration. In at least one embodiment, filtration means the process of separating a hydrocarbon liquid from a water-based liquid. In certain aspects, filtering involves passing the feed stream through a filter device at a flow rate that may be less than about 40 gallons per minute per square foot (2.72 m / s). In other aspects, filtering involves passing the feed stream through a filter device at a flow rate that may be less than about 30 gallons per minute per square foot (2.04 m / s). In at least one aspect, filtering comprises passing the feed stream through a filter device at a flow rate that may be less than about 20 gallons per minute per square foot (1.36 m / s). In yet another aspect, the flow rate may be less than about 13.5 gallons per minute per square foot (0.92 m / s). The flow rate can be any flow rate of between about 1 and about 1000 gallons per minute per square foot (0.0679 to 67.9 m / s), or any range of flow rates between these flow rates. The flow rate may be any speed that is suitable for the purpose of implementing the described filtering function using the methods and systems described herein.

As used herein, the terms “filter device” and “separation device” mean any device suitable for performing filtering processes. In certain embodiments, a filter device and a separation device may be constructed and designed in such a manner as discussed above with respect to the reservoir. The filter device and separation device may be constructed of any material suitable for the specific purposes of the methods and systems described herein. For example, the filter device and the separation device may be constructed of any structural material, such as, for example, steel, stainless steel, fiberglass reinforced plastic and polyvinyl chloride material suitable for the manufacture of structures such as pipes or columns. In at least one aspect, the filter device and separation device may include a composite medium. At least one aspect includes a filter device comprising a protective material located at least at one end of the filter device for the purpose of holding the medium. In certain aspects, the movement of the fluid through the filter device and the separation device may occur in a downward direction. In other aspects, the movement of fluid through the filter device and the separation device may occur in the direction from the bottom up. In certain embodiments, one or more filter devices and one or more separation devices may be located downstream of one or more coalescing devices.

In other aspects, contacting the feed stream with the composite medium includes coalescing the feed stream. As used herein, the term "coalescing" in the broad sense means the combination and / or combination of one or more small droplets of a liquid or other phase to form at least one larger droplet, phase and interlayer. For example, in certain aspects, coalescing is capable of increasing a droplet size of a hydrocarbon liquid from a diameter of less than about 20 microns to a size of more than about 20 microns. In other specific aspects, coalescing is capable of increasing droplet size of a hydrocarbon liquid from a diameter of less than about 20 microns to a size of more than about 50 microns. In some aspects, coalescing is capable of producing droplets of hydrocarbon liquid that are larger than about 50 microns in size. In some aspects, coalescing is capable of producing droplets of hydrocarbon liquid, the size of which may be more than about 100 microns. As used herein, the term “coalesced stream” means a liquid in which droplets of a liquid or other phase form droplets in which the diameter is at least about 20 microns. In at least one aspect, a coalesced stream may mean a liquid in which droplets of a hydrocarbon liquid have a diameter of at least about 20 microns. In some aspects, a coalesced stream may mean a liquid in which droplets of a hydrocarbon liquid have a diameter of at least about 20 microns, a diameter of at least about 30 microns, and a diameter of at least about 30 microns a diameter of at least about 100 microns, and any combination thereof. In at least one aspect, coalescing comprises passing the feed stream through a coalescing device at a flow rate that can range from about 40 to about 250 gallons per minute per square foot (2.72 to 16.98 m / s). In yet another aspect, coalescing involves passing the feed stream through a coalescing device at a flow rate that can range from about 100 to about 200 gallons per minute per square foot (6.79 to 1.38 m / s). The flow rate may be any flow rate of from about 1 to about 2000 gallons per minute per square foot (0.0679 to 135.8 m / s), or any range of flow rates between these flow rates. The flow rate may be any speed that is suitable for the implementation of the described coalescing function using the methods and systems described herein.

As used herein, the term “coalescing device” means any device suitable for carrying out coalescing processes. In certain aspects, a coalescing device may be constructed and designed in such a way as discussed above with respect to the reservoir. The coalescing device may be constructed from any material suitable for the specific purposes of the methods and systems described herein. In certain embodiments, the coalescing device may be constructed, for example, from any one or more materials, such as steel, stainless steel, fiberglass reinforced plastic, and polyvinyl chloride material, suitable for fabricating a structure such as a pipe or column. In at least one aspect, the coalescing device may include a composite medium. Some aspects include a coalescing device comprising a protective material placed at least at one end of the coalescing device for retention purposes. In at least one aspect, the movement of fluid through a coalescing device may be in a downward direction. In yet another aspect, the movement of fluid through a coalescing device may be in the upward direction. In certain embodiments, one or more coalescing devices may be located upstream of one or more filter devices. In other embodiments, one or more coalescing devices may be located upstream of one or more separation devices.

In certain aspects, at least one device of a coalescing device and a filter device may comprise a composite medium. The composite medium may be partially or completely coated with a hydrocarbon liquid. The composite medium may be at least partially or completely coated with a hydrocarbon liquid during one or more processing processes, including backwashing, filtering, and coalescing procedures. In certain examples, one or more coalescing devices may comprise a composite medium, which may be partially coated with a hydrocarbon liquid. In some examples, one or more coalescing devices may comprise a composite medium that may be saturated with a hydrocarbon liquid. As used herein, the term “saturated” when used with respect to a composite medium means any degree of coverage of the composite medium with a hydrocarbon liquid, provided that coalescing can be carried out appropriately. In other examples, one or more filter devices may comprise a composite medium that is not a saturated hydrocarbon liquid. As used herein, the term “unsaturated,” when used with respect to a composite medium, means any degree of coverage of the composite medium, provided that filtering can be carried out appropriately. In certain aspects, one or more filter devices may comprise a composite medium, which may be substantially free of hydrocarbon fluid coating. In at least one embodiment, the composite medium in the coalescing device may be a saturated hydrocarbon liquid, and the composite medium in the filter device may be an unsaturated hydrocarbon liquid.

In accordance with certain methods and systems described herein, a processing system is provided, wherein one or more tanks may have the ability to function as at least one device from a coalescing device and a filter device during one or more processing processes. For example, a reservoir containing a composite medium is able to function as a filter device until the composite medium becomes saturated with a hydrocarbon liquid, and then it is able to function as a coalescing device. In other examples, a processing system may be provided comprising a first reservoir containing a composite medium that can be located upstream of a second reservoir containing a composite medium. The first tank is able to function as a coalescing device, and the second tank is able to function as a filtering device until the composite medium in the second tank becomes saturated with oil. The first tank can be backwashed and the flow through the processing system can be directed so that the second tank is located upstream relative to the first tank. After that, the second tank is able to function as a coalescing device, and the first tank is able to function as a filtering device until the composite medium in the first device becomes saturated with oil. After that, the second tank can be backwashed, and the flow through the processing system can be directed so that the first tank can be located upstream relative to the second tank. The processing system may include one or more tanks that can be used separately or together in at least one configuration, such as a serial, parallel and any other configuration, to obtain one or more desired effluent. In certain examples, the processing system may further include one or more additional separators. One or more additional separators may be located upstream or downstream relative to one or more tanks. A processing system may be located upstream or downstream with respect to at least one process from a primary, secondary or tertiary process, and it may be located as a standalone system or process or may be located within another system or process.

In accordance with the methods and systems described herein, one or more coalescing devices and filtering devices can be used separately or together in at least one configuration, such as a serial, parallel and any other configuration, to obtain one or more desired outgoing streams. In certain embodiments, one or more filter devices may be arranged in series with one or more parallel chains, including one or more filter devices in series. In certain aspects, one or more filter devices may be arranged in a first sequential configuration in parallel with a second sequential configuration. In certain embodiments, the first sequential configuration may be parallel with respect to the second serial configuration, which, in turn, is parallel with respect to the third serial configuration and may also be parallel with respect to one or more additional serial configurations. In at least one aspect, the first sequence may be designed to process 100% of the input source material, while the second sequence is replenished or independent. In at least one embodiment, the first set of four filter devices can be arranged in series configuration parallel to the second set of four filter devices arranged in series configuration. Similarly, in certain embodiments, the first combination of at least one coalescing device and at least one filter device can be arranged in series configuration in parallel with the second combination of at least one coalescing device and at least one filter device in serial configuration. In yet another aspect, the first sequence and the second sequence can be designed to process 100% of the input source material. In yet another aspect, the first sequence and the second sequence may be designed to process 50% of the input feed. In some aspects, a plurality of sequences may be designed to process a predetermined percentage of incoming feed, comprising, for example, from about 1% to about 100% of incoming raw material, including any percentage between data limits for a percentage or any range of percentages between data limits for a percentage correlation.

In certain aspects, one or more filter devices may be located upstream or downstream with respect to one or more coalescing devices. In other aspects, one or more coalescing devices may be located upstream or downstream with respect to one or more filter devices. In accordance with certain aspects, one or more filtering devices, coalescing devices, and any combination thereof, may be located downstream of at least one process from a primary, secondary, or tertiary treatment process, as described herein. In a further aspect, one or more filtering devices, coalescing devices, or any combination thereof, may be located upstream of at least one secondary or tertiary treatment process as described herein. One or more filter devices, coalescing devices, or any combination thereof, can be located anywhere in other systems or processes to obtain the desired effluent.

In certain aspects, the composite medium can be used in structures, systems, and processes that may not include a standalone reservoir containing the composite medium. For example, a composite medium can be positioned in a structure to perform, for example, filtering or coalescing, and this structure can be positioned at least partially inside another tank in which the medium may or may not be contained, and can be used for another purpose. different from filtering and coalescing. The design in which the medium is located may be a subdivision of a tank, pipe, or other channel that can be used in combination with a tank and a larger system. In certain embodiments, the reservoir can be used for at least one process, such as filtering and coalescing, and can be used in combination with the medium located in the structure to achieve the desired result.

In accordance with one or more embodiments, the composite medium may be able to function simultaneously as a coalescing emulsified oil device, and also as a free oil filter. The flow rate through the reservoir containing the composite medium may determine the behavior of the combination of medium and reservoir. In certain embodiments, a high flow rate of, for example, more than about 100 gallons per minute per square foot (6.79 m / s), can contribute to oil coalescing, and a low flow rate of, for example, less than about 30 gallons per minute per square foot (2.04 m / s), may allow the tank to function as a filter device. In at least one aspect, coalescing comprises passing the feed stream through a coalescing device at a flow rate that can range from about 40 to about 250 gallons per minute per square foot (2.72 to 16.98 m / s). In yet another aspect, coalescing involves passing the feed stream through a coalescing device at a flow rate that can range from about 100 to about 200 gallons per minute per square foot (6.79 to 13.58 m / s). In certain aspects, filtering involves passing the feed stream through a filter device at a flow rate that may be less than about 40 gallons per minute per square foot (2.72 m / s). In other aspects, filtering involves passing the feed stream through a filter device at a flow rate that may be less than about 30 gallons per minute per square foot (2.04 m / s). In at least one aspect, filtering comprises passing the feed stream through a filter device at a flow rate that may be less than about 20 gallons per minute per square foot (1.36 m / s). In certain embodiments, the arrangement of the coalescing device and the filter device in a sequential configuration may allow separation of emulsified oil in water from the feed stream.

In certain aspects, at least one device of the filter device and the coalescing device may be equipped with a discharge pipe system. This outlet pipe system may include one or more outlet pipes, and it can be constructed and designed to periodically backwash the medium by providing the desired volume and / or speed of movement used to backwash the fluid into the swing bed. As used herein, the term “swing bed” is defined as the movement of the medium during backwash, in which the medium at or near the second wall of the tank can partially or completely pass through a system of outlet pipes towards the first wall of the tank and back to the second wall reservoir. Alternatively or as an adjunct, the outlet pipe system can be used during at least one of the processes, such as filtering and coalescing processes. The backwash can be carried out using an in-place pipe system, or it can be carried out without a pipe system. The outlet pipe system may be sized and shaped to provide at least the desired volume of medium for backwashing and for working for a predetermined period of time for backwashing. The outlet pipe system may include one or more outlet pipes located in the medium. As used herein, the term "outlet pipe" means a structure having one or more side walls open at both ends, which, when positioned in the medium, provides a flow path for the medium to move during the backwash process. In certain embodiments, the reservoir may have a volume of medium that is from about four to about six times the volume of the outlet pipe or the sum of the volumes of the outlet pipes in the outlet pipe system.

The discharge pipe may be made of any material suitable for the specific purposes of the methods and systems described herein. For example, the outlet pipe may be made of the same material as the reservoir, or materials of lower or higher density or lower or higher cost may be used for its manufacture. For example, the outlet pipe can be made of plastics, including fiberglass reinforced plastics. The discharge pipe can be prefabricated for installation in a tank or made as part of a tank. Essentially, a discharge pipe can be designed to modernize existing devices for filtering and coalescing. The outlet pipe system can be installed on the second wall of the tank. Alternatively, the outlet pipe system can be mounted on a divider or holding medium plate, such as a baffle or perforated plate, designed to hold the medium inside the reservoir region while at the same time providing a flow of liquid and impurities into and out of the medium.

An individual outlet pipe may have dimensions and shapes according to at least one desired application and the volume of medium subjected to backwashing, and also work for a predetermined period of time for the backwash operation. The outlet pipe may also be of such dimensions and shapes as to provide suitable movement or rise of the medium during the filtering or coalescing process. The outlet pipe can also be sized and shaped to provide the desired level of mixing within the outlet pipe to partially or completely clean the medium, whereby at least a portion of the oil and suspended solids are released from the medium. The desired volume of the outlet pipe system can be provided by a single outlet pipe or a plurality of outlet pipes, in which the total volume is practically equal to the desired volume. An individual outlet pipe may have a cross section of any shape, such as round, elliptical, square, rectangular or any irregular shape. The individual outlet pipe may have any general shape, such as conical, rectangular and cylindrical. In one embodiment, the discharge pipe is a cylinder. The discharge pipe may be located in the medium so as to be completely covered by the medium, and also to be completely flooded with the medium. One or both ends of the outlet pipe can be constructed and designed to facilitate at least one of the medium flows into or out of the outlet pipe. For example, the side wall at the first end of the outlet pipe may include one or more cutouts forming ducts that allow a portion of the medium at or near the first end of the outlet pipe to enter through the side wall of the outlet pipe. The cutouts that form the ducts can be of any shape that allows a sufficient volume of medium to enter the discharge pipe. For example, cutouts may have a triangular, square, semicircular, or irregular shape. The plurality of ducts can be identical to each other and have a uniform arrangement around the first end of the discharge pipe to evenly distribute the flow of medium in the discharge pipe. The outlet pipe may also be open at the bottom, and additional cutouts may or may not be contained therein.

The discharge pipe or discharge pipes may be located at any suitable place within the medium. For example, one outlet pipe may, but need not necessarily, occupy a central position with respect to the side walls of the tank. Similarly, a plurality of outlet pipes in a single tank may have a statistical arrangement, or they may be arranged uniformly with respect to the side walls of the tank. In one embodiment, one outlet pipe is positioned in the medium with respect to the tank such that an axis extending from each end of the discharge pipe is coaxial with respect to an axis parallel to the side wall of the tank. Many outlet pipes in one tank may, but need not be, identical in volume or cross-sectional area. For example, one tank may include cylindrical, conical and rectangular outlet pipes having different heights and cross-sectional areas. In one embodiment, the reservoir may include a first outlet pipe centrally positioned and having a first cross-sectional area, as well as a plurality of second outlet pipes located close to the side wall of the tank, each of the second outlet pipes having a second cross-sectional area that is less than first cross-sectional area. In yet another embodiment, the reservoir includes a plurality of identical outlet pipes.

In yet another embodiment, the outlet pipe may include a baffle to prevent or reduce backflow within the outlet pipe. The partition may be of any size and shape suitable for a particular outlet pipe. For example, the partition may be a plate appropriately located on the inner surface of the discharge pipe, or a cylinder located in the discharge pipe. In one embodiment, the baffle may be a solid or hollow cylinder, occupying a central position within the outlet pipe.

In at least one aspect, upon contact of the feed stream with the composite medium, a treated stream is formed comprising a predetermined target concentration of a hydrocarbon liquid. In yet another aspect, contacting the composite medium includes filtering the feed stream, wherein the predetermined target concentration of the hydrocarbon fluid in the treated stream may be less than the concentration of the hydrocarbon fluid in the feed stream. In certain embodiments, a predetermined target concentration of hydrocarbon fluid in the treated stream may be less than about 10 ppm. In other embodiments, a predetermined target concentration of hydrocarbon liquid in the treated stream may be less than about 5 ppm. In some embodiments, the desired target concentration of hydrocarbon fluid in the treated stream may be less than about 30 ppm. The target concentration may be any target concentration that meets one or more of the specified requirements for emission concentrations. For example, the target concentration may be any target concentration ranging from about 0 ppm to about 200 ppm, or any range of target concentrations between these target concentration values.

In accordance with one or more embodiments, upon contact of the feed stream with the composite medium, a treated stream is formed comprising a predetermined target percentage reduction in hydrocarbon liquid in the feed stream. For example, in certain aspects, a given target percent reduction in hydrocarbon liquid may be more than about 40%, more than about 50%, more than about 60%, more than about 70%, more than about 80%, more than about 90%, more than about 95%, more than about 98%, and more than about 99%. The target percentage reduction can be any percentage between these percentages or any range of percentages between these percentages.

In accordance with certain embodiments, contacting the feed stream with the composite medium may include coalescing the feed stream, and the predetermined target concentration of the hydrocarbon fluid in the treated stream may be a reduced concentration of emulsified hydrocarbon fluid compared to the feed stream. As used herein, the term “emulsified hydrocarbon liquid” means a hydrocarbon liquid that contains drops of a hydrocarbon liquid in which the diameter is less than about 20 microns. In certain aspects, the treated stream may contain emulsified hydrocarbon liquid in a concentration that is less than about 35 ppm. In other aspects, the feed stream may comprise an emulsified hydrocarbon liquid in a concentration that is greater than about 40 ppm.

In certain embodiments, the feed stream may comprise a hydrocarbon liquid, wherein more than about 50% of the mass of the hydrocarbon liquid is emulsified hydrocarbon liquid. In at least one aspect, the concentration of emulsified hydrocarbon liquid in the treated or coalesced stream is reduced by more than about 50% compared to the original stream. In at least one embodiment, the feed stream may comprise a hydrocarbon liquid, wherein more than about 60% of the hydrocarbon liquid is an emulsified hydrocarbon liquid. In other embodiments, the feed stream may comprise a hydrocarbon liquid, wherein more than about 75% of the hydrocarbon liquid is an emulsified hydrocarbon liquid. The feed stream may comprise a hydrocarbon liquid, wherein from about 0% to about 100% of the hydrocarbon liquid is an emulsified hydrocarbon liquid. In certain aspects, the coalesced stream may comprise a hydrocarbon liquid, wherein less than about 10% of the hydrocarbon liquid is an emulsified hydrocarbon liquid. In at least one aspect, the coalesced stream may comprise a hydrocarbon liquid, wherein less than about 5% of the hydrocarbon liquid is an emulsified hydrocarbon liquid. The coalesced stream may comprise a hydrocarbon liquid, wherein from about 0% to about 100% of the hydrocarbon liquid is an emulsified hydrocarbon liquid.

In certain aspects, a method for processing an initial stream may further include measuring at least one property of the processed stream. In at least one aspect, the at least one measured property may be a concentration of a hydrocarbon liquid in a treated stream. In other aspects, the at least one measured property may be the speed of the processed stream. In yet another aspect, the at least one measured property may be the intensity of the treated stream. In accordance with certain embodiments, a method of treating a feed stream may further include backwashing the composite medium based on measuring at least one property of the treated stream to produce an outgoing hydrocarbon liquid. As used herein, the term "effluent hydrocarbon fluid" means a fluid that includes a hydrocarbon fluid. In certain aspects, backwashing of the composite medium may be included, started, or performed based on a measurement of the concentration of hydrocarbon liquid in the treated stream, which may include or begin a backwash step. In at least one aspect, backwashing of the composite medium can be carried out based on a concentration of hydrocarbon liquid in the treated stream of more than about 10 ppm. In yet another aspect, backwashing of the composite medium can be carried out based on a concentration of hydrocarbon liquid in the treated stream of more than about 30 ppm. Backwashing can restore the functionality of a composite medium with its action. In at least one aspect, the processing method of the feed stream may further include returning the effluent hydrocarbon liquid to the feed stream. In some aspects, the method may further include transferring the hydrocarbon effluent to one or more primary separation processes. In at least one aspect, one or more primary separation processes may be located upstream of the processing system. In other aspects, one or more primary separation processes may be located downstream of the processing system. The hydrocarbon effluent can be transferred to any one or more of the processes that are suitable for implementing the methods and systems described herein.

In accordance with certain embodiments, a method is provided for treating a feed stream containing a hydrocarbon liquid and an aqueous liquid, comprising passing the feed stream at a first flow rate through a coalescing device containing a composite medium to produce a coalescing stream. In at least one aspect, the method may further include passing a coalesced stream at a second flow rate through a filter device that is coupled to the coalescing device and containing a composite medium to produce an exit stream. The feed stream, coalescing device, composite medium, coalescing stream, filtering device, flow rates and effluent can be provided and characterized as discussed above. In certain aspects, the method may further include maintaining the concentration of the hydrocarbon liquid in the effluent. In yet another aspect, the concentration of hydrocarbon fluid in the effluent can be maintained at a predetermined target percentage reduction. In at least one aspect, the concentration of hydrocarbon liquid in the effluent can be maintained at a level of less than about 10 ppm. In other aspects, the method may further include backwashing the at least one device from the coalescing device and the filter device. In some aspects, the method may further include backwashing the at least one device from the coalescing device and the filter device based on a predetermined time interval. In one embodiment, the predetermined time interval may be approximately 4 hours. In certain embodiments, the predetermined time interval may be approximately 6 hours, approximately 8 hours, approximately 12 hours, or approximately 24 hours. The predetermined time interval may be any interval between these values or any interval of values between these intervals. The predetermined time interval may be any time interval that is suitable for implementing the methods and systems described herein.

In at least one aspect, the method may further include measuring at least one property of the coalesced stream. At least one measured property may be at least one property of flow rate, flow rate, and concentration of one or more components of a coalesced stream. In certain aspects, the method may further include backwashing the coalescing device. In certain aspects, the method may further include backwashing the coalescing device based on at least one measured property of the coalescing stream. In one aspect, the method may further include backwashing the coalescing device based on at least one measured property of the coalescing stream to produce an outgoing hydrocarbon liquid.

In yet another aspect, the method may further include measuring at least one property of the effluent. In certain aspects, the at least one measured property may be at least one property of flow rate, flow rate, and concentration of one or more components of the effluent. In other aspects, the at least one measured property may be a concentration of hydrocarbon liquid in the effluent. In certain aspects, the method may further include backwashing the filter device. In one aspect, the method may further include backwashing the filter device based on at least one measured property of the effluent. In one embodiment, the method may further include backwashing the filter device based on at least one measured property of the effluent to produce an effluent hydrocarbon fluid.

Backwashing of the composite medium can be carried out on the basis of additional operational characteristics of the processing system. For example, in certain aspects, backwashing of the composite medium can be carried out based on a pressure drop on at least one device from a coalescing device and a filter device. For example, the sensor may produce a signal indicating that the pressure drop across the medium layer of at least one device from the coalescing device and the filter device has reached a predetermined value. This signal may include a controller that interrupts or otherwise acts on one or more threads in the processing system to initiate a backwash procedure.

In accordance with certain embodiments, there is provided a method of treating a feed stream comprising a hydrocarbon liquid and an aqueous liquid, comprising passing the feed stream through a coalescing device containing a composite medium comprising a mixture of cellulose-based material and a polymer to produce a coalescing stream. A feed stream, a coalescing device, a composite medium, and a coalescing stream can be obtained and characterized as discussed above. In at least one embodiment, the coalesced stream may comprise an emulsified hydrocarbon liquid in a reduced concentration compared to the feed stream. For example, in certain aspects, the reduced percentage of emulsified hydrocarbon liquid may be more than about 10%, more than about 20%, more than about 30%, more than about 40%, more than about 50%, more than about 60%, more than about 70%, more than about 80%, more than about 90%, more than about 95%, more than about 98%, and more than about 99%. The reduced percentage can be any percentage between these percentages or any range of percentages between these percentages.

In certain aspects, the method may further include passing a coalesced stream through a separation device to produce at least one stream from a hydrocarbon liquid stream and a water stream. A hydrocarbon liquid stream, a water stream and a separation device can be obtained and characterized as discussed above. In at least one aspect, the coalesced stream may comprise hydrocarbon liquid droplets in which the diameter is at least about 20 microns. In at least one aspect, the coalesced stream may comprise hydrocarbon liquid droplets in which the diameter is at least about 50 microns. In at least one aspect, the separation device may include at least one device, such as a hydrocyclone, a filter device, a gravity precipitation device, and a flotation device. In certain embodiments, separating the coalesced stream into a hydrocarbon liquid stream and a water stream may include passing the coalesced stream through at least one device, such as a hydrocyclone device, a filter device, a gravity precipitation device, and a flotation device. Suitable hydrocyclones may include any models or types that function according to the methods and systems described herein. The hydrocyclone may include an inclined static mixer to amplify or create a cyclone type flow. Suitable flotation devices may include any models or types that operate according to the methods and systems described herein. Non-limiting examples of flotation devices include API, DAF, DGF, and compact flotation devices. Other examples of separation devices that are suitable for the purposes of the present invention include corrugated plate cutters (CPI). In certain embodiments, the separation may include passing a coalesced stream through a filter device, as discussed herein.

In accordance with certain aspects, the method may further include measuring at least one property of the coalesced stream. In yet another aspect, the method may further include backwashing the coalescing device based on at least one measured property of the coalescing stream to produce an outgoing hydrocarbon liquid. Measurement of at least one coalesced flow property and backwashing can be carried out and characterized, as discussed above.

In certain non-limiting embodiments, a system for treating a feed stream comprising a hydrocarbon liquid and an aqueous liquid may be provided. Hydrocarbon liquid and water-based liquid can be obtained and characterized, as discussed above. In at least one embodiment, the system may further include at least one coalescing device in conjunction with the feed stream. In certain aspects, the at least one coalescing device may comprise a composite medium comprising a mixture of cellulose-based material and a polymer. A coalescing device and a composite medium can be obtained and characterized, as discussed above. In certain embodiments, a system may further include at least one separation device in conjunction with a coalescing device. The separation device can be obtained and characterized, as discussed above.

In accordance with certain aspects, a facilitation method may be proposed. The method may provide assistance for a processing system. The method may facilitate one or more parts of a pre-existing processing system. The method may facilitate an independent processing system. In certain embodiments, a method may assist a processing system for separation. In other specific embodiments, the implementation of the method may facilitate a processing system for coalescing. In certain aspects, the method may facilitate a processing system for at least one process of coalescing and separation. The method may facilitate a processing system for separating a feed stream into a hydrocarbon liquid and a water based liquid. The method may facilitate a processing system for coalescing the feed stream. The processing system may include at least one reservoir. The facilitation method may include the manufacture of a composite medium containing a mixture of cellulose-polymer-based material and placed in a reservoir for contact with the feed stream.

FIG. 1 illustrates a schematic process flow of a processing system according to one or more embodiments of the methods and systems described herein. Processing system 10 includes a feed stream 100. Processing system 10 may include one or more tanks. In accordance with certain embodiments, one or more of the reservoirs may be a coalescing device 102 and a filtering device 104. The filtering device 104 may be connected and located downstream of the coalescing device 102. As discussed above, the feed stream 100 may pass through a coalescing device 102 for producing a coalescing stream 106. As discussed above, the coalescing stream can then be passed through a filter device ystvo 104 to produce a treated stream 108. In accordance with the preceding discussion, during backflushing operations, at least one device of the device 102 and the coalescing filter device 104 is able to produce a hydrocarbon effluent stream 110 and 112, respectively. Processing system 10 may further include one or more pumps or valves for passing through the system at least one of the streams 100, 106, 108, 110 and 112.

FIG. 2 illustrates a schematic process flow of a processing system according to one or more embodiments of the methods and systems described herein. Processing system 20 includes a feed stream 200 containing oil-contaminated waste water. Feed stream 200 may first be passed as inlet stream 212 through reservoir 202, where at least some of the oil in the spent water can be coalesced into larger droplets. Tanks 202 and 204 may be in conjunction with a dissolved air flotation device (DAF) 206. The coalesced effluent from tank 202 can then be introduced as a coalesced stream 214 into DAF 206 where larger drops of oil are separated. The effluent 216 from the DAF 206 can then be passed as inlet 220 through the reservoir 204, where the remaining oil can be filtered to obtain the treated aqueous stream 218.

Processing system 20 can be constructed and designed so that after oil saturation of reservoir 204, reservoir 202 can be backwashed using a backwash source 210. After backwashing the reservoir 202, the feed stream 200 can first be passed as inlet stream 220 through the reservoir 204, where at least some of the oil in the spent water can be coalesced. The coalesced effluent from tank 204 can then be introduced as a coalesced stream 214 into the DAF 206 to receive the effluent 216. The effluent 216 can then be passed as an inlet 212 through the reservoir 202, where the remaining oil can be filtered to obtain the treated water stream 218.

Similarly, when tank 202 becomes saturated with oil, tank 204 can be backwashed using a backwash source 208. After backwashing of the reservoir 204, the feed stream 200 can be passed as inlet flow 212 through the reservoir 202, and the above process is repeated in a cyclic manner. At least one of the advantages of using the processing system 20 is the flexible implementation of the process, which ensures the constant presence of a reservoir saturated with oil, which is able to function as a coalescing device. This can lead to an increase in the overall performance of the system, and can also reduce the costs associated with separating oil from spent water. Another advantage may be that backwashing is capable of separating solids, since solids can accumulate in tanks, creating high pressure drops and a subsequent decrease in productivity. The presence of the DAF 206 can increase efficiency by providing a longer operating time between backwashes of tanks 202 and 204, resulting in a decrease in backwash volumes. Potentially, system 20 is capable of eliminating the need for a primary separation process carried out upstream with respect to input of raw material 200. This can provide reduced environmental impact and lower operating costs, which is important for marine systems and processes.

Examples

The systems and methods described herein are further illustrated by the following examples, which are illustrative in nature and not intended to limit the scope of the present invention.

Example 1. Environmental performance indicators

This study was carried out to evaluate the separation efficiency for various types of media. Four different types of media were examined for oil separation efficiency, including black walnut shells, finely ground and sifted maple wood particles, high density polyethylene (HDPE), and a composite containing about 50-60 wt.% Maple wood and HDPE, making up the rest. The composite was made by mixing particles of wood and polyethylene with each other, extruding the mixture and then cutting the resulting material into granules. Table 1 briefly compares the particle size distribution of the types of media used.

Table 1
Description and particle size of each medium Material Medium Particle Size High Density Polyethylene (HDPE) ~ 5-10 mesh (2-4 mm) Composite ~ 5-10 mesh (2-4 mm) Black walnut shell ~ 12-16 mesh (1.2-1.7 mm) Maple Wood Particles ~ 10-30 mesh (0.6-2.0 mm)

Light Arabian crude oil was pumped into a stream of tap water downstream of the centrifugal pump. The mixture was then sheared using a fully open ball valve and a static mixer to produce finely divided drops of free oil in water at a concentration of 200 ppm. After that, the mixture of oil and water was passed through the column of medium from top to bottom. Studied the columns of two sizes. The first column, made of a polyvinyl chloride pipe with a diameter of 4 inches (10.16 cm), did not contain a discharge pipe. This design requires that the medium is removed from the column, placed in a container, and then mechanically mixed to perform a backwash operation. The second column, made of a 6-inch (15.24 cm) diameter polyvinyl chloride pipe, was equipped with a 2-inch (5.08 cm) discharge pipe located in the center of the six-inch pipe for backwashing operations. For this design, air was introduced into the outlet pipe to cause dilution and mixing of the medium.

A mixture of water and oil was directed through various types of media at a flow rate of 13.5 gallons per minute per square foot (0.92 m / s), and the total volume of the processed fluid was recorded. Samples of the effluent from the column were collected and examined using gravimetric analysis technology and hexane according to Method A of ASTM 1664 to determine the concentration of residual oil present in the water-based effluent. A result of more than 10 ppm of oil was considered as a breakthrough level, and at this point the study was terminated and the medium was backwashed to restore its effectiveness. The backwash effluent can be returned back to the system. For example, the backwash effluent can be returned to a point upstream of equipment such as a phase separator or API separator. A mass of loaded oil per cubic inch of medium was plotted against the concentration of oil in the effluent, which is shown in FIG. 3. The results showed that approximately four times the mass of oil can be loaded into the composite medium compared to any of the other materials before a breakthrough occurs. Each of the two individual components of the composite was investigated, wood and plastic (polymer), and none of them showed a loading ability that was any close to the ability of the composite. This was an unexpected result.

Without being limited by theory, one possible explanation for the beneficial effects of combining wood and HDPE is that the two components exhibit different adsorption properties, and that synergy is achieved by combining the two materials. A second possible explanation is that the shape of the composite particles contributes to the separation process. These results show that the composite material in its ability to load oil is four times superior to the current commercially available medium, including black walnut shells and individually taken wood or plastic (polymer).

In addition, a study was conducted using a scheme similar to that of the first study to determine if the composite medium was suitable for backwashing. A column was made of a PVC pipe with a diameter of 6 inches (15.24 cm), which was equipped with a discharge pipe with a diameter of 2 inches (5.08 cm) located in the center of the six-inch pipe for the purpose of performing backwashing operations. Consecutive flow studies were carried out using a stock solution containing water and oil, including 200 mg / l of oil, with a composite medium until a break in the effluent was observed. After this, the medium was backwashed, and flow experiments were repeated two more times to determine if there was a decrease in efficiency after each backwash, which indicated a deterioration in the quality of the medium.

A mass of loaded oil per cubic inch of medium was plotted against the concentration of oil in the effluent, which is shown in FIG. 4. The results showed that the composite medium was suitable for backwashing using the same procedure that is currently used in the monosep ™ system containing walnut shells from Siemens AG without showing a decrease in efficiency. In experiment 1, 3500 g of oil was charged into the composite medium before a breakthrough was observed. In experiment 2 and experiment 3, which ended after the introduction of 2200 g and 3100 g of oil, respectively, the concentration of oil in the effluent never exceeded 10 ppm. In each of the three experiments summarized in FIG. 4, there was a significant superiority of efficiency compared to other types of medium studied, including the medium containing black walnut shells. Other types of medium, as a rule, show a breakthrough after loading from 800 to 1200 g of oil into the medium. In addition, a study of environmental degradation did not show a significant degree of this degradation after approximately five months of mixing.

The results of the study showed that the composite medium is able to reduce the concentration of free oil in the initial solution from a value of 200 ppm to a value of less than 10 ppm, the concentration of free oil in the effluent from the column for an extended period of time. The study was also carried out with starting material containing 500 parts per million free oil (this is a typical maximum concentration of oil in secondary devices). These results showed that this composite medium has the potential for use not only in tertiary devices, but also in secondary devices, with the possibility of eliminating the need for tertiary treatment.

Although the study presents results for a composite environment comprising a mixture of maple wood and HDPE, and the percentage of wood in the composite mixture is approximately 50 wt.%, The methods and systems described herein are not limited to this percentage or these specific types of materials. In addition, the methods and systems described herein are not limited to these specific types of cellulose-based materials or polymers.

Example 2. Comparison of the effectiveness of the environment containing maple wood, and the environment containing shells of black walnuts

This study was carried out to compare the separation efficiency of media containing crushed maple wood and black walnut shells. The particle size of the crushed maple wood medium was approximately 10 to 30 mesh (0.6 to 2.0 mm). The particle size of the medium from the shell of black walnuts ranged from about 12 to 16 mesh (from 1.2 to 1.7 mm). The medium layer was made from a section of a polyvinyl chloride pipe with a diameter of 4 inches (10.16 cm), which was long enough to produce a medium layer 60 inches (152.4 cm) long, held by a partition located at the bottom. To perform the backwash operation, the medium was removed from the column, placed in a 5 gallon (18.9 L) container, and mechanically mixed with a spatula. During the study, the same medium was repeatedly backwashed and returned back to the medium layer. The initial solution was made from a mixture of water and oil, which was sheared, using two ball valves to obtain small drops of oil. A mixture of water and oil was passed through various types of medium at three different flow rates of 13.5, 20.25 and 27 gallons per minute per square foot (0.88, 1.37 and 1.83 m / s). The values of the total volume of the fluid mixture that was processed were recorded. Samples of the effluent from the column were collected and examined using gravimetric analysis technology and hexane to determine the concentration of residual oil present in the water-based effluent. A result of more than 10 ppm of oil was considered as a breakthrough level, and at this point the study was terminated and the medium was backwashed to restore its effectiveness.

A mass of loaded oil per cubic inch of medium was plotted against the concentration of oil in the effluent for each of the three flow rates, as shown in FIG. 5-7. The results show that it was possible to backwash the wood containing medium and reuse it without causing a decrease in efficiency. The wood-containing medium was superior to the walnut-shell-containing medium in terms of loading ability when tested under conditions including each of the three flow rates. In addition, it was determined, with an increase in flow rate from 13.5 gallons per minute per square foot (0.88, m / s) to 27 gallons per minute per square foot (1.83 m / s), the amount of oil that could be loaded into the walnut-containing shell medium before the breakout, decreased from 300 g to 250 g. On the contrary, when using the medium containing maple wood, a very slight decrease in efficiency was observed when the flow rate increased. The ability to increase the flow rate without causing a decrease in efficiency means that the environmental impact of the equipment can be significantly reduced, which is a major advantage over existing systems, especially for offshore oil refining.

Example 3. The combination of a coalescing device and a filter device

This study was carried out using feed water containing mechanically emulsified oil, including oil droplets whose diameter was less than 5-10 microns. For mechanical emulsification of oil in the source water, two centrifugal pumps were installed in series. Light Arabian crude was pumped to the suction side of the first pump and then through the second pump. The oil that passed through both pumps was then passed through a ball valve. The source water was pumped through a coalescing device containing a composite medium with a particle size of 5 to 10 mesh (2 to 4 mm), which was approximately 50% HDPE and 50% maple wood, at a high flow rate to produce a coalesced stream, including larger drops of oil. A coalescing device was fabricated using a polyvinyl chloride pipe containing a composite medium with a diameter of 4 inches (10.16 cm) and a length of 8 feet (243.8 cm). Source water was passed through a coalescing device at a flow rate of approximately 150 gallons per minute per square foot (10.19 m / s). The coalescing device was made in such a way that the flow direction could be switched from a top to bottom direction from a bottom to top direction every 4 hours.

The oil could be separated from the coalesced stream by pumping it through a filter device containing a composite medium at a lower flow rate to produce an exit stream. A filter device was fabricated using a polyvinyl chloride pipe containing a composite medium with a diameter of 12 inches (30.48 cm) and a length of 66 inches (167.64 cm). The filter device was equipped with a 4-inch (10.16 cm) outlet pipe and 4 feet (121.92 cm) long located at the bottom of the filter device and an air inlet. The flow direction in the filter device was reversed, and air was introduced to carry out a backwash process every 4-6 hours, depending on the efficiency. A coalesced stream was passed through a filter device at a flow rate of approximately 20 gallons per minute per square foot (0.136 m / s). Partitions were used simultaneously on a coalescing device and a filter device containing medium.

To determine the concentration of emulsified oil in the feed water and in the effluent, a Turner TD-500 ™ Fluorescence Oil Detector for Water from Turner Designs Hydrocarbon Instruments, Inc. was used. (Fresno, California). Samples were first collected in a separatory funnel and kept stationary to settle for 30 minutes. For measurement purposes, samples were then taken from the center of the separatory funnel and analyzed for oil content.

Data was collected from the coalescing device when it was filled with medium, as well as from the bypass of the coalescing device and switching to the filtering device. Source water samples were collected downstream of the feed pumps and ball valve and upstream of the coalescing device. Samples of the effluent were collected downstream of the filter device.

Table 2 presents the results of data collection during the bypass of the coalescing device and the direction of the source water directly to the filter device.

table 2
The results of the bypass of the coalescing device Time (hours) The total oil content in the feed stream
(parts per million) The total oil content in the effluent (parts per million) 0 1776 390 four 1025 105 5 817 244 6.5 1840 415 7 1115 232

The results show that the filter device was able to separate a certain amount of oil from the source water.

The coalescing device was then returned to the line, setting it upstream of the filter device. The results of the combination of the coalescing device and the filter device are presented in table 3.

Table 3
Results of a coalescing device followed by a filtering device Time (hours) The total oil content in the feed stream (parts per million) The total oil content in the effluent (parts per million) The content of emulsified oil in the feed stream (parts per million) The content of emulsified oil in the effluent (parts per million) 1.17 529.9 ^∗ 62 532.2 ^∗ 36,2 3.42 284.8 47.5 223.2 27.1 4,50 433.4 49.6 397.7 28,4 4.75 646.4 ^∗ 43,2 717.0 ^∗ 24.5

The results show that the composite medium is capable of simultaneously operating in a coalescing emulsified oil device, as well as in a free oil filter. The flow rate through the reservoir containing the composite medium may determine the behavior of the combination of medium and reservoir. A high flow rate through the reservoir of, for example, more than about 100 gallons per minute per square foot (6.79 m / s) can contribute to oil coalescing, and a lower flow velocity through the reservoir of, for example, less than about 27 gallons per minute per square foot (1.93 m / s), may allow the tank to function as a filter device. The sequential installation of a coalescing device and a filtering device makes it possible to separate highly emulsified highly oil in water from the flow of waste water.

The combination of a coalescing device and a filtering device provides a combination of secondary and tertiary separation with low environmental impact, which may be advantageous for offshore installations. The results of the study also show that a large amount of composite medium and a low pressure drop reduce the possibility of clogging of the medium layer in the coalescing device and filter device. In addition, the composite medium proved to be suitable for successful backwashing of the oil-separating medium. When the composite medium becomes clogged, backwashing with a discharge pipe is effective for removing solids and other impurities that create this possibility of clogging. This is a great advantage compared to a densely packed medium, such as walnut shells, or a stationary medium unsuitable for backwashing, which is used, for example, in corrugated plate separators.

Example 4. The combination of a coalescing device and a corrugated plate cutter

This study was carried out using feed water containing mechanically emulsified oil, including oil droplets whose diameter was less than 5-10 microns. For mechanical emulsification of oil in the source water, two centrifugal pumps were installed in series. Light Arabian crude was pumped to the suction side of the first pump and then through the second pump. After that, the oil that passed through both pumps was passed through a ball valve. The source water was pumped through a coalescing device containing a composite medium with a particle size of 5 to 10 mesh (2 to 4 mm), which was approximately 50% HDPE and 50% maple wood, at a high flow rate to produce a coalesced stream, including larger drops of oil. A coalescing device was fabricated using a polyvinyl chloride pipe containing a composite medium with a diameter of 6 inches (15.24 cm) and a length of 80 inches (203.2 cm). The pipe contained a flange at each end, and each flange was covered with a baffle to hold the medium in place inside the column. Source water was passed through a coalescing device at a flow rate of approximately 100 gallons per minute per square foot (6.79 m / s).

After that, the oil could be separated from the coalesced stream by passing it through a separator such as a corrugated plate cutter (CPI), which was located downstream of the coalescing device. The CPI device uses dividing plates to create a fixed zone, which allows for the flotation of oil droplets and to separate them from incoming water for purification. The separated oil was lifted along the separation plates to the top of the device, where it was removed using an adjustable measuring spillway. Pure water flowed up through the outlet, and then over an adjustable measuring spillway, before it exited the device.

To determine the concentration of emulsified oil in the source water and the effluent, a Turner TD-500 ™ fluorescent device was used, which determines the oil content in the water. Samples were first collected in a separatory funnel and allowed to stand for 30 minutes. For measurement purposes, samples were then taken from the center of the separatory funnel and analyzed for oil content.

Data was collected from the coalescing device when it was filled with medium, and also when it was empty before passing the coalescing stream through the CPI device. The results of a study performed under conditions in which the medium was absent in the coalescing device are presented in tables 4 and 5.

Table 4
The results of studies performed in the absence of medium in a coalescing device and in a downstream CPI device Time (hours) The total oil content in the feed stream (parts per million) The content of emulsified oil in the feed stream (parts per million) The total oil content at the release of the coalescing device (parts per million) The content of emulsified oil on the release of a coalescing device (parts per million) The total oil content at the release of the CPI device (parts per million) The content of emulsified oil on the release of the CPI device (parts per million) 1.3 141.4 78.9 107.6 73.5 84.6 92.3 2 158.9 100.8 99.6 57.2 72.6 66.7

Table 5
The content of emulsified oil according to studies performed in the absence of medium in a coalescing device and in a downstream CPI device The percentage of emulsified oil in the feed stream The percentage of emulsified oil at the release of the coalescing device 55.8 68.3 63,4 57.4

The results of a study performed with an empty coalescing device (in the absence of medium) showed that almost all of the oil in the source water was emulsified and did not separate in the system. This is confirmed by the fact that when comparing the percentage of emulsified oil in the feed stream and the percentage of emulsified oil in the effluent from the coalescing device, this ratio increased (as at time after 1.2 hours) or only moderately decreased (as at time after 2 hours).

Then, research data was collected after filling the tank with a composite medium and saturating with oil. The first study was carried out using the medium as a coalescing device and analyzing the initial stream and the exit stream from the coalescing device with respect to free and emulsified oil. The results of this study are presented in table 6. In contrast to the presented results of the experiment with no medium, the results using the medium showed a significant decrease in the concentration of emulsified oil in the coalesced stream compared to the initial stream

Table 6
Test results with a coalescing device filled with medium Time (hours) The total oil content in the feed stream (parts per million) The content of emulsified oil in the feed stream (parts per million) The total oil content at the release of the coalescing device (parts per million) The content of emulsified oil on the release of a coalescing device (parts per million) 0.25 132.7 92.6 149.5 35,4 2.75 151.2 105.8 111.5 34,4 5.75 132.0 142.5 198.6 21.8 8.00 171.6 57.6 143.6 25.7

The results of a study conducted with a coalescing device filled with a composite medium are presented in Tables 7 and 8. And in this case, the results using the medium showed a significant decrease over time of the concentration of emulsified oil in the coalescing stream compared to the starting material. In addition, the CPI device was able to drastically reduce the total concentration of oil in the coalesced stream while maintaining the oil in coalesced form.

Table 7
Results with a coalescing device filled with a composite medium and a downstream CPI device Time (hours) The total oil content in the feed stream (parts per million) The content of emulsified oil in the feed stream (parts per million) The total oil content in the effluent from the coalescing device (parts per million) The content of emulsified oil in the effluent from the coalescing device (parts per million) The total oil content in the effluent from the CPI device (parts per million) The content of emulsified oil in the effluent from the CPI device (parts per million) 1.42 101.5 40.6 128.2 35.3 22.5 20.6 3.42 102.7 71.3 203.3 30.6 25.9 19.5 5.42 157.5 90 178.3 32.8 20.8 15,2

Table 8
The content of emulsified oil according to the study with a coalescing device filled with a composite medium and a downstream CPI device The percentage of emulsified oil in the feed stream The percentage of emulsified oil in the effluent 40 27.5 69,4 15.1 57.1 18,4

Example 5. The combination of many short-layer coalescing devices

A hypothetical example of a process using multiple short-layer coalescing devices (MSBC) is illustrated in FIG. 8. Two chains, each containing 4 tanks, can be filled with a composite medium containing particles from 5 to 10 mesh (2 to 4 mm) in size and consisting of approximately 50% HDPE and 50% maple wood. Each tank may have a length of approximately 18 inches (45.72 cm). Each chain can be designed to contain 100% of the original water. During normal operation, two chains can be installed in parallel so that 50% of the initial flow enters each chain. The system can be designed so that one chain can be isolated for some time and take 100% of the original stream. This can help to clean the medium by doubling the flow rate, which can remove excess oil that accumulates in the medium by its action. A previous study showed that with an increase in flow rate above 40 gallons per minute per square foot (2.72 m / s), the composite medium is no longer able to filter out oil. As the flow rate through the tank increases, excess oil can be washed out.

The design may also allow a change in direction of the feed stream through each tank to reduce clogging with solids when each chain receives 50% of the feed stream. Previous research has shown that solids begin to collect on the inlet side of the tank. By changing the direction of flow through the tank, solids can be washed out of the system. The lower and upper part of each tank can be equipped with a partition to preserve the environment in the tank.

Example 6. The study of the coalescing device

A number of studies have been conducted to evaluate the ability of a composite medium to coalesce mechanically emulsified oil into larger droplets of oil that can be removed using flotation separation technology. As a general rule, flotation technologies are methods for removing only droplets whose diameter is more than 50 microns.

The study was carried out according to the flow chart illustrated in FIG. 9. The processing system 30 includes an initial stream 200 containing oil and water, which is first pumped to the feed line using pump 302. After passing through pump 302, the flow of oil and water passes through two centrifugal feed pumps 304 and 306, which are installed in series, moreover, the pump 306 is located downstream relative to the pump 304. Pumps 304 and 306 are used for mechanical emulsification of oil before pumping it into a coalescing device. The ball valve 308 is located downstream of the pumps 304 and 306. The emulsified stream 210 passes through the coalescing device 312 and exits the coalescing device as a coalescing stream 316. After passing through the coalescing device, the coalescing stream 316 is directed to a separator CPI 314 to obtain an exit stream 318 .

Background research data was obtained by pumping mechanically emulsified oil through an empty coalescing device. The coalescing device had a diameter of 6 inches (15.24 cm) and a length of 90 inches (228.6 cm). The flow rate was 50 gallons per minute (3.155 l / s), which corresponded to a flow rate of 240 gallons per minute per square foot (16.98 m / s). Samples of feed water and effluent from the CPI were collected and analyzed for oil concentration. Background research results are illustrated in FIG. 10. These data indicate that the empty tank did not efficiently coalesce the emulsified oil, as evidenced by the high concentration of oil in the effluent from the CPI. The CPI separator was able to remove only 48% of the total oil content in the feed stream when the coalescing tank was empty.

After that, the tank was filled with a composite medium to a length of 80 inches (203.2 cm) and the study was repeated. In the raw feed water, the initial oil concentration was approximately 125 mg / L, with an emulsified fraction of this oil averaging 75%. FIG. 11 illustrates the results of this study. These results showed that the coalescing device effectively coalesced the emulsified oil into larger droplets that could be separated using a CPI separator. The medium was found to be effective for coalescing emulsified oil into larger droplets that could be separated using a CPI device. The results indicate that the concentration of oil in the effluent from the CPI device was less than 25 mg / L for all collected samples. When the tank was empty, the oil concentration in the effluent from the CPI device averaged 78 mg / L. This means that a coalescing tank filled with a composite volumetric medium improved the efficiency of the CPI device, providing a total oil removal of 81%, compared to 48% for the case when the tank was empty.

Subsequent analysis of the oil concentration was carried out by collecting samples of the feed stream and the effluent from the coalescing device to a separatory funnel. Samples were collected in a separatory funnel, and the stopwatch was immediately turned on. Samples were then collected from the bottom of the separatory funnel to determine how quickly oil flotation began. Table 9 presents the results obtained during this study.

Table 9
Separation funnel flotation analysis Source stream time (minutes) The oil content in the feed stream (parts per million) Outflow time from a coalescing device (minutes) The oil content in the effluent from the coalescing device (parts per million) Total 92.6 Total 153.8 one 78.3 one 18.6 2 75.9 2 12.9 four 71.6 four 8.9 6 76.9 6 11.3 8 79 8 11.8 10 76.6 10 17.4 thirty 41 thirty 7.8

The results show that the oil in the feed stream was emulsified to a high degree (more than 50%), and its rise was not very fast. A sample from a coalescing device contained only 5% of emulsified oil. The bulk of the oil in the effluent from the coalescing device was capable of flotation after 1 minute, indicating the presence of very large drops of oil in the sample.

In addition, a study was conducted to analyze the size of oil droplets. In this study, a coalescing device 72 inches (182.88 cm) high and 6 inches (15.24 cm) in diameter was used. Instead of two centrifugal pumps, this process used one larger centrifugal pump, which returned 75% of the flow to a coalescing device to increase the concentration of mechanically emulsified oil in the feed stream.

Model VD4912-456 Liquid Particle Size Analyzer by JM Canty, Inc. (Buffalo, NY) was used to collect oil droplet size analysis data. This particle size analyzer was equipped with a high speed camera that recorded water samples. This video was analyzed using software that allowed each drop of oil to be measured. The particle size analyzer was capable of measuring droplets of oil, the diameter of which ranged from 0.7 to 2000 microns.

Data was collected during an eight-hour study conducted with a coalescing device that operated at a flow rate of 100 gallons per minute per square foot (6.79 m / s). Each hour, samples of the inlet and outlet stream were sent to a particle size analyzer from JM Canty, Inc. to obtain the results of an analysis of the size of oil droplets. FIG. 12 represents all the data collected during this time period. As a rule, traditional flotation technologies are able to guarantee the removal of oil droplets whose diameter is more than 50 microns, but usually they are unable to remove droplets whose diameter is less than 50 microns.

FIG. 12 represents the percentage of oil droplets in a given sample in which the diameter is more than 50 μm. During an eight-hour study, the average content of oil droplets with a diameter of more than 50 μm in the feed stream was 26.8%. After passing through a coalescing device, the droplets of oil in the effluent increased and on average 88.2% of them had a diameter of more than 50 μm. This shows that if untreated feed water was directed to a traditional flotation device, only 26.8% of the oil would be separated. If the same untreated feed water were instead passed through a coalescing device before the flotation device, 88.2% of the oil would be separated. By passing the crude feed stream through a coalescing device, the efficiency is increased by 329% compared to a conventional flotation device.

FIG. 13 and 14 represent the raw data that was obtained using a particle size analyzer from JM Canty, Inc. During the analysis, oil droplets were grouped according to size intervals, which provided a more efficient data analysis. FIG. 13 is a graph showing oil droplet size analysis results obtained in a particle size analyzer for samples of crude feed, and FIG. 14 is a graph showing oil droplet size analysis results obtained for samples of the effluent from a coalescing device.

During the analysis, photographs were taken of each test sample. These photographs showed that the feed stream contains a very high concentration of small drops of oil. In contrast, the effluent from the coalescing device contains a lower concentration of fine oil droplets. The number of oil droplets was less, and their size was much larger, for example, in at least one experiment a drop with a diameter of 121 microns was detected. The results of this study showed that a coalescing device is capable of producing a coalescing stream in which more than 50% of the droplets have a diameter of more than 50 μm. In addition, the coalescing device was able to produce consistent results over a period of at least six hours.

Example 7. The effectiveness of a composite environment containing pine wood and polypropylene

This study was carried out to evaluate the separation efficiency for a composite medium containing pine wood and polypropylene. This composite medium contained approximately 70% pine wood and approximately 30% polypropylene. The composite was made by co-mixing particles of wood and polypropylene, extruding the mixture and then grinding the resulting material into granules. Oil was pumped to the outlet of the feed pump. The mixture was then sheared using a fully open ball valve and a static mixer to obtain finely divided free oil droplets in water at a concentration of 200 ppm. After that, the mixture of oil and water was passed through the column of medium from top to bottom. The column had a diameter of 4 inches (10.16 cm) and the depth of the medium was 60 inches (152.4 cm).

Feed water was passed through the composite medium at a flow rate of 20 gallons per minute per square foot (1.36 m / s).

The pressure at the inlet and outlet of the column, the flow rate and the concentration of oil in the outlet stream were measured. The results of the study are presented below in table 10.

Table 10
Results of a study of a composite medium containing pine wood and polypropylene Time (hours) Flow rate (gallons per minute) Intake Pressure (psi) Outlet Pressure (psi) Oil Volume (ml) Amount of oil added (g) The calculated concentration of added oil (mg / l) The total oil content in the effluent (parts per million) 0,0 1.8 25 25 1800 0.5 1.8 25 25 1750 45 220,2 3.3 1,0 1.8 25 25 1700 90 220,2 2.6 1,5 1.8 25 25 1650 135 220,2 3.2

A mass of loaded oil per cubic inch of medium was plotted against the concentration of oil in the effluent, which is shown in FIG. 15. The results of the study showed that the composite medium containing pine wood and polypropylene is able to reduce the concentration of free oil in the initial solution from a value of 200 ppm of free oil to a value of less than 10 ppm in the effluent from the column, in over a long period of time. In addition, during this study, only a slight or zero pressure drop along the length of the column and a change in flow rate were observed.

This example demonstrates the effectiveness of another composite wood containing wood and polymer medium and represents that another 70:30 ratio of wood and polymer is capable of efficiently filtering and separating oil and water.

The systems and methods described herein are not limited in their application to the details of the construction and arrangement of the components that are presented in the description or illustrated in the drawings. The present invention is adapted to other embodiments, and may be practiced or carried out using a variety of ways. In addition, the phraseology and terminology used herein is intended for the purpose of description and should not be construed as limiting. The use of the terms “including”, “including”, “providing”, “having”, “containing”, “characterized”, “different” and the corresponding variations in this document is intended for distribution to the items listed after them, their equivalents, as well as alternative embodiments consisting solely of the items listed after them. The use of ordinal numbers, such as “first”, “second”, “third”, etc. in the claims to indicate its points in itself does not give these points any priority.

Although exemplary embodiments of the present invention have been described above, numerous modifications, additions, and exceptions can be made herein without departing from the idea and going beyond the scope of the present invention and its equivalents as defined in the following claims.

Those skilled in the art will be able to easily determine that the various parameters and configurations described herein are intended as examples, and that the actual parameters and configurations will depend on the particular application for which the systems and methods related to separation processing processes are intended using a composite medium according to the present invention. Those skilled in the art will recognize or can evaluate, using no more than standard experiments, the multiple equivalents of the specific embodiments described herein. For example, those skilled in the art may recognize that the device and its components according to the present invention may further include a network of systems or be a component of a separation processing process using a composite medium system. Thus, it should be understood that the above embodiments are presented solely as an example, and that, within the scope of the appended claims and corresponding equivalents, the described processes of separation processing using systems and methods based on a composite medium can be practically carried out in a different way than specific description. The systems and methods of the present invention relate to each individual distinguishing characteristic or method that is described herein. In addition, any combination of two or more of such distinctive characteristics, devices or methods, if such distinctive characteristics, devices or methods are not mutually contradictory, is included in the scope of the present invention.

In addition, it should be understood that a variety of changes, modifications, and improvements are quite obvious to specialists in this field of technology. Such changes, modifications, and improvements are part of the present invention and should be consistent with the idea and scope of the present invention. For example, an existing facility may be modified to use or implement any one or more of the aspects of the present invention. Thus, in some cases, these systems and methods may include connecting or configuring an existing facility to incorporate separation processes using a composite medium. Accordingly, the above descriptions and drawings are intended solely as examples. In addition, the images in the drawings do not limit the present invention to specific illustrated representations.

Claims (34)

1. A method of processing a feed stream comprising a hydrocarbon liquid and a water-based liquid, comprising:
introducing the feed stream into the inlet of the tank containing a composite medium consisting of single-phase particles of a uniform shape, each particle comprising a mixture of cellulose-based material and a polymer; and
contacting the feed stream with the composite medium to obtain a treated stream, wherein the treated stream contains a predetermined target concentration of hydrocarbon liquid. 2. The method of claim 1, wherein contacting the feed stream with the composite medium includes filtering the feed stream, wherein the predetermined target concentration of the hydrocarbon fluid in the treated stream is less than the concentration of the hydrocarbon fluid in the feed stream. 3. The method of claim 2, wherein the predetermined target concentration of the hydrocarbon liquid in the treated stream is less than about 30 ppm. 4. The method according to claim 1, wherein contacting the feed stream with the composite medium comprises coalescing the feed stream, the predetermined target concentration of the hydrocarbon fluid in the treated stream being a reduced concentration of emulsified hydrocarbon fluid compared to the feed stream. 5. The method according to p. 4, in which the concentration of emulsified hydrocarbon liquid in the treated stream is reduced compared with the original stream by more than approximately 50%. 6. The method of claim 5, wherein the treated stream comprises drops of hydrocarbon liquid in which the diameter is at least about 20 microns. 7. The method according to claim 1, further comprising measuring at least one property of the treated stream. 8. The method of claim 7, further comprising backwashing the composite medium based on at least one measured property of the treated stream to produce an outgoing hydrocarbon liquid. 9. The method of claim 8, further comprising returning the effluent hydrocarbon liquid to the feed stream. 10. The method according to p. 8, in which at least one measured property is at least one property of the concentration of hydrocarbon liquid in the treated stream and the flow rate of the treated stream. 11. The method according to any one of the preceding claims, wherein the step of contacting the feed stream with the composite medium includes:
passing the feed stream at a first flow rate through a coalescing device containing a composite medium, the composite medium comprising a mixture of cellulose-polymer-based material to produce a coalescing stream; and
passing a coalesced stream at a second flow rate through a filter device in communication with the coalescing device and containing a composite medium to produce an exit stream. 12. The method of claim 11, wherein the first flow rate is in the range of from about 100 to about 200 gallons per minute per square foot (6.79 to 13.38 m / s). 13. The method of claim 11, wherein the second flow rate is less than about 40 gallons per minute per square foot (2.72 m / s). 14. The method of claim 11, further comprising maintaining the concentration of the hydrocarbon liquid in the effluent at a predetermined percentage reduction rate. 15. The method according to p. 11, further comprising backwashing at least one device from a coalescing device and a filter device. 16. The method according to p. 15, in which the backwash of at least one device from the coalescing device and the filter device occurs on the basis of a predetermined time interval. 17. The method according to p. 13, further comprising measuring at least one property of the coalesced stream. 18. The method of claim 17, further comprising backwashing the coalescing device based on at least one measured property of the coalescing stream to produce an outgoing hydrocarbon liquid. 19. The method according to p. 18, in which at least one measured property is a flow rate of a coalesced stream. 20. The method according to p. 11, further comprising measuring at least one property of the output stream. 21. The method according to claim 11, further comprising backwashing the filter device based on at least one measured property of the effluent to produce an effluent hydrocarbon liquid. 22. The method according to p. 21, in which at least one measured property is at least one property of the flow rate of the effluent and the concentration of hydrocarbon liquid in the effluent. 23. The method according to any one of the preceding claims, wherein the step of contacting the feed stream with the composite medium includes:
passing the feed stream through a coalescing device comprising a composite medium comprising a mixture of cellulose-based material and a polymer to produce a coalescing stream, wherein the coalescing stream includes a reduced concentration of emulsified hydrocarbon liquid compared to the feed stream;
and the method further includes:
separating the coalesced stream by passing the coalesced stream through a separation device to produce at least one stream from a hydrocarbon liquid stream and a water stream. 24. The method according to p. 23, in which the coalesced stream includes drops of hydrocarbon liquid, in which the diameter is at least about 20 microns. 25. The method according to p. 23, in which the separation device is at least one of the following devices: hydrocyclone, filter device, gravity precipitation device and flotation device. 26. The method of claim 25, further comprising measuring at least one property of the coalesced stream. 27. The method of claim 26, further comprising backwashing the coalescing device based on at least one measured property of the coalescing stream to produce an outgoing hydrocarbon liquid. 28. The method of claim 27, wherein the at least one measured property is a flow rate of a coalesced stream. 29. A system for processing a feed stream comprising a hydrocarbon liquid and a water-based liquid, including:
at least one coalescing device in conjunction with the feed stream and containing a composite medium consisting of single-phase particles of a uniform shape, each particle comprising a mixture of cellulose-based material and a polymer; and
at least one separation device in conjunction with a coalescing device. 30. The system of claim 29, wherein the separation device is at least one of the following devices: a filter device, a hydrocyclone, a gravity precipitation device, and a flotation device. 31. The system of claim 30, wherein the separation device is a filter device comprising a composite medium. 32. The system of claim 29, wherein the composite medium comprises cellulose-based material in a concentration of at least about 50% by weight. 33. The system of claim 29, wherein the cellulose-based material comprises maple wood. 34. The system of claim 29, wherein the polymer comprises high density polyethylene.

Images