WO1998019764A1

WO1998019764A1 - Method and apparatus for processing contaminated materials

Info

Publication number: WO1998019764A1
Application number: PCT/US1997/020117
Authority: WO
Inventors: William H. Bryant; Jerry W. Frazier
Original assignee: Separatherm, Inc.
Priority date: 1996-11-05
Filing date: 1997-11-05
Publication date: 1998-05-14
Also published as: AU5429598A

Abstract

A method and apparatus for processing contaminated material are provided. The apparatus is intended to process many types of contaminated material, all of which consist of: one or more hydrocarbons, and water and/or one or more inert solids. The objective of the invention is to reduce waste disposal costs by separating the ingredients of the contaminated material (i.e., hydrocarbons, and water and/or inert solids) and directing the separated ingredients to distinct containers. The apparatus broadly comprises a coalescer unit, an organics recovery unit, and a solids separation unit. The contaminated material is first heated and blended into a coalescent slurry by the coalescer unit. The coalesced slurry is then processed by the organics recovery unit which separates the hydrocarbons, solids and water from one another based upon their respective specific gravities. The hydrocarbons are discharged from the organics recovery unit into a hydrocarbon recovery container. The solids and water are discharged to the solids separation unit. The solids are discharged from the solids separation unit into a solids recovery container. The water is pumped from the solids separation unit to a water recovery container.

Description

METHOD AND APPARATUS FOR PROCESSING CONTAMINATED MATERIALS

RELATED APPLICATIONS

This application claims the benefit of U. S. Provisional Application No. 60/030,373, filed November 5, 1996.

BACKGROUND OF THE INVENTION

1. Field Of The Invention

This invention relates generally to waste management technology and equipment, and more particularly to a method and apparatus for processing contaminated materials.

2. Description Of The Related Art It is known that various forms of waste or contaminated material are generated in the petrochemical, refinery, marine and similar industries. Examples of such contaminated materials may include tank bottom sludge, contaminated soil, wastewater, sump system sludge, spilled hydrocarbon product, marine wastewater, bilge water, and the like. Contaminated materials of this type must be disposed of in accordance with applicable federal, state, county and municipal regulations. The disposal costs associated with complying with such regulations can be very significant. Thus, it is desirable to develop an approach to reducing these disposal costs. Accordingly, the primary objective of the present invention is to provide a method and apparatus for processing contaminated materials which will reduce their associated disposal costs. One approach to lowering disposal costs is to simply reduce the amount of contaminated material to be disposed of. However, the amount of contaminated material in need of disposal is very seldom a controllable factor. Another approach to reducing disposal costs, which is the approach employed by the present invention, is to separate the reusable components of the contaminated material from the undesirable or waste components of the contaminated material. Under this approach, the volume of waste to be disposed of is reduced, as are the associated disposal costs. In addition, disposal costs are reduced under this approach in those instances where each individual component of the contaminated material must be disposed of. This is because it is substantially less expensive to dispose of the individual components of the contaminated material separately than to dispose of a mixture of raw contaminated materials. To be more specific, contaminated material generally includes at least one or more hydrocarbons (e.g., benzene, crude oil, diesel fuel). In addition, contaminated material will also generally include water and/or one or more inert solids (e.g., rust, grit, or scale from the bottom of a storage tank, soil). The hydrocarbons and the water generally represent the reusable components of the contaminated material, and the inert solids represent the undesirable or waste components of the contaminated material. Thus, a more particular object of the apparatus and method of the present invention is to separate the hydrocarbons, inert solids, and water in the contaminated material from one another, and to direct each of these ingredients into separate containers. In this manner, the hydrocarbons may be reused, resold, or disposed of, the water may be reused or disposed of. and the inert solids may be disposed of or reprocessed. Thus, the amount of waste to be disposed of is decreased, as are the associated disposal costs. In addition, even in those instances where all ingredients must be disposed of, disposal costs are reduced by use of the present invention because it is significantly less expensive to dispose of the separated water, organics and solids individually than to dispose of the raw contaminated material.

SUMMARY OF THE INVENTION The present invention is directed generally to a method and apparatus for processing contaminated materials. In a broad aspect, the processing apparatus of the present invention comprises three components: a coalescer unit; an organics recovery unit; and a solids separation unit. The broad object of the present invention is to decrease contaminated material disposal costs by providing an apparatus and method for processing contaminated material. A contaminated material generally includes at least one or more hydrocarbons plus water and/or one or more inert solids. A more particular objective of the present invention is to separate the hydrocarbons, inert solids, and water from one another, and to direct each of these three ingredients into separate containers. These objectives are accomplished by first feeding raw contaminated material into the coalescer unit wherein the contaminated material is agitated, heated and mixed into a coalesced slurry. A fourth ingredient, namely, a commercial processing agent of some type, should also be added at this stage to assist in dissolving the contaminated material. The coalesced slurry is then transmitted into the organics recovery unit, wherein the hydrocarbons, inert solids and water (and any commercial processing agents) are separated from one another based upon their respective specific gravities. The hydrocarbons are discharged from the top of the organics recovery unit through a hydrocarbon recovery conduit and into a hydrocarbon recovery container. These recovered hydrocarbons may then be reused, resold, or disposed of. The inert solids, along with some commingled water, are discharged from the bottom of the organics recovery unit through a solids recovery header assembly and pumped by a solids recovery pump into the solids separation unit. A separate stream of water is also discharged by gravity feed from the organics recovery unit through a seal leg conduit to the solids separation unit. The solids separation unit broadly comprises two components: (1) a shaker screen, and (2) a solids separation unit tank (SSU tank). The inert solids (and commingled water) are pumped to the shaker screen, and the separate stream of water from the seal leg conduit is directed by gravity feed to the SSU tank. The solids and corrirningled water are then separated by the shaker screen. The solids are directed from the shaker screen to a recovered solids container for disposal or reprocessing, and the water is directed by gravity flow from the shaker screen into the SSU tank. The recovered water in the SSU tank is then available to be pumped by a water recovery pump (a) to an ancillary water storage tank for reuse or treatment and/or (b) back through the organics recovery unit. At this point, the contaminated material ingredients — hydrocarbons, solids, and water — have been successfully separated and directed to three distinct containers. The recovered hydrocarbons may now be reused, resold, or disposed of; the recovered water may now be reused, treated, or disposed of; and the separated solids may now be disposed of or reprocessed through the apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a top view of the apparatus of the present invention. Figure 2 is a side elevation view of the coalescer unit of the present invention. Figure 3 is an exploded, elevation view of one of the plurality of valve/nozzle assemblies through which fluid communication is established between the main coalescer header conduit and the coalescer enclosed container.

Figure 4 is a side elevation view of the organics recovery unit of the present invention. Figure 5 is a end elevation view showing the coalescer unit (as shown in Figure 2) and organics recovery unit (as shown in Figure 4) mounted on a skid. This end view is of the pump end of the coalescer unit, and of the outlet end of the organics recovery unit.

Figure 6 is a end elevation view, similar to Figure 5, showing the coalescer unit and organics recovery unit mounted on the skid. This end view is of the inlet ends of the coalescer unit and organics recovery unit.

Figure 7 is an end elevation view of one of the solids collection pyramids provided as part of the organics recovery unit, including an exploded view of the solids recovery header assembly.

Figure 8 is a side elevation view of the solids separation unit of the present invention. Figure 9 is a top view of the apparatus 10 of the present invention. Figure 10 is a side elevation view of the steam header assembly which is connected between the coalescer unit and the organics recovery unit.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings in detail, wherein like numerals denote identical elements throughout the several views, there is shown in Figure 1 a specific embodiment of a contaminated material processing apparatus 10 constructed in accordance with the present invention. With reference to Figure 1, the apparatus 10 of this specific embodiment broadly comprises three components: (1) a coalescer unit 12; (2) an organics recovery unit 14; and, (3) a solids separation unit 16. These three components may be mounted upon a skid 18. In a specific embodiment, the skid 18 may be of a conventional type and approximately 40 feet long x 8 feet wide x 6 inches tall. As will be more fully described below, the coalescer unit 12, organics recovery unit 14, and solids separation unit 16 are interconnected by a series of conduit, and a group of pumps is provided to pump the contaminated material being processed through the conduit, and throughout the apparatus 10. All components may be connected together in a conventional manner, as by welding. Before describing the structure and operation of the apparatus in detail, the objective and overall operation of the present invention will be briefly summarized.

The broad object of the present invention is to decrease contaminated material disposal costs by providing an apparatus and method for processing contaminated material. For purposes of this invention, "contaminated material" is a term used to describe various forms of waste and/or contaminated products generated in the petrochemical, refinery, marine, and similar industries. Examples of contaminated material may include tank bottom sludge, contaminated soil, wastewater, sump system sludge, spilled hydrocarbon product, marine wastewater, bilge water, and the like. The apparatus 10 of the present invention is designed to process various contaminated materials with a wide range of consistencies and characteristics, including, but not limited to, ranges in: viscosity, pH, water content, hydrocarbon content, Btu, flashpoint, Chemical Oxygen Demand (COD), Biochemical Oxygen Demand (BOD), Total Suspended Solids

(TSS), and regulatory classification. For purposes of the present invention, a contaminated material generally includes at least one or more hydrocarbons (e.g., benzene, crude oil, diesel fuel); additionally, contaminated material will also generally include water and/or one or more inert solids (e.g., rust, grit, or scale from the bottom of a storage tank, soil). In general, the inert solids and/or hydrocarbons are adhered to one another, often in the form of large chunks or globs.

A more particular objective of the present invention is to separate the hydrocarbons, inert solids, and water from one another, and to direct each of these three ingredients into separate containers. Referring now to Figure 1, these objectives are accomplished by first feeding the raw contaminated material into the coalescer unit 12, as indicated by dashed line 20, wherein the contaminated material is agitated, heated and mixed into a coalesced slurry. A fourth ingredient, namely, a commercial processing agent of some type, should also be added at this stage to assist in dissolving the globs of solids and/or hydrocarbons. The coalesced slurry is then transmitted into the organics recovery unit 14, wherein the hydrocarbons, inert solids and water (and any commercial processing agents) are separated from one another based upon their respective specific gravities. (All references hereinbelow to "water" shall encompass "water and any commercial processing agents entrained therein.") The hydrocarbons are discharged from the top of the organics recovery unit 14 through a hydrocarbon recovery conduit 22 and into a hydrocarbon recovery container (not shown). These recovered hydrocarbons may then be reused, resold, or disposed of. The inert solids, along with some commingled water, are discharged from the bottom of the organics recovery unit 14 through a solids recovery header assembly 24 and pumped by a solids recovery pump 26 into the solids separation unit 16. A separate stream of water is also discharged by gravity feed from the organics recovery unit 14 through a seal leg conduit 28 to the solids separation unit 16. While both the inert solids (with coπimingled water) and separate water stream are directed to the solids separation unit 16, they are directed to different parts of the solids separation unit 16. The solids separation unit 16 broadly comprises two components: (1) a shaker screen 30, and (2) a solids separation unit tank (SSU tank) 32. The inert solids (and commingled water) are pumped to the shaker screen 30, and the separate stream of water from the seal leg conduit 28 is directed by gravity feed to me SSU tank 32. The solids and commingled water are then separated by the shaker screen 30. The solids are directed from the shaker screen 30 to a recovered solids container (not shown) for disposal or reprocessing, and the water is directed by gravity flow from the shaker screen 30 into the SSU tank 32. The recovered water in the SSU tank 32 is then available to be pumped by a water recovery pump 34 (a) to an ancillary water storage tank (not shown) for reuse or treatment and/or (b) back through the organics recovery unit 14. At this point, the contaminated material ingredients — hydrocarbons, solids. and water — have been successfully separated and directed to three distinct containers. The recovered hydrocarbons may now be reused, resold, or disposed of; the recovered water may now be reused, treated, or disposed of; and the separated solids may now be disposed of or reprocessed through the apparatus 10. Thus, by processing contaminated material pursuant to the present invention, the waste generator (e.g., petrochemical facility or refinery) need not dispose of a large body of contaminated material, but only a relatively smaller body of inert solids. Because it is cheaper to dispose of a small body of inert solids than a relatively large body of contaminated material, it can be seen that.use of the present invention results in cost savings, potentially significant, to the waste generator. In addition to these cost savings, by processing contaminated material with the present invention, the waste generator will recognize further economic benefits by recovering the hydrocarbons and water which had been entrained in the contaminated material. Further, in those instances where it is desired to dispose of all three ingredients, these disposal costs are reduced because it is substantially less expensive to dispose of these ingredients individually than to dispose of the raw contaminated material. The foregoing paragraph sets forth a very broad and general description of the operation of the present invention. A more detailed explanation of the operation of the present invention will be provided below in conjunction with a detailed description of the structure and operation of the apparatus 10 of the present invention. The structure and operation of the apparatus 10 will now be described in detail, beginning with a detailed description of the structure and operation of the coalescer unit 12.

The Coalescer Unit With reference to Figure 2, a specific embodiment of the coalescer unit 12 may comprise an enclosed container 36 having an inlet end 38, a pump end 40, an upper surface 42, a lower surface 44, a first side surface 46, and a second side surface 48 (not shown in Figure 2). In a specific embodiment, the container 36 may be a metal cylinder. In a specific embodiment, the metal cylinder may be constructed from approximately 3/8 inch thick metal, and measure approximately 42 inches in diameter and 20 feet in length. In a specific embodiment, the container 36 is provided with a raw contaminated material inlet conduit 50, an inlet valve 51, a coalescer header assembly 52, a heating coil 54, a suction conduit 56, a coalescer circulation pump 58, a coalescer transfer conduit 60, a coalescer transfer valve 68, and a commercial processing agent inductor stem 62. In a specific embodiment, the container 36 may also be provided with a coalescer sump 64, a coalescer cleaning conduit 66, a blind flange 70, a pressure sensitive check valve 72, one or more manways 74, one or more vapor abatement ports 76, a coalescer recirculation conduit 78, a coalescer recirculation valve 80, and a plurality of support members 82. The coalescer unit may also be provided with one or more temperature gauges 69, one or more pressure gauges 71, a water level sample valve 73, a maximum slurry level valve 75, and one or more slurry level valves 77. In a specific embodiment, the raw contaminated material inlet conduit 50 is attached to and through the inlet end 38 of the container 36. The inlet conduit 50 may be a flanged, metal pipe approximately four inches in diameter, and may be provided with a four-inch hose connection to assist in feeding raw contarninated material into the coalescer unit 12. The inlet valve 51 should be connected in line with the inlet conduit 50. In a specific embodiment, the inlet valve 51 may be a four-inch butterfly valve of the type manufactured by Nibco, of Elkhart, Indiana, such as Model WD 200 19 96. The inlet conduit 50 should be provided with a commercial processing agent inductor stem 62. In a specific embodiment, the stem 62 may be a short section of approximately one-inch diameter pipe. The function of the processing agent inductor stem 62 is to allow for the addition of commercial processing agents to the contaminated material as it circulates through the coalescer unit 12. The user of the apparatus 10 may connect a manifold or conduit to the stem 62 for feeding one or more commercial processing agents into the coalescer unit 12. The purpose of adding such processing agents to the contaminated material is to assist in dissolving globs of solids and/or hydrocarbons. Examples of commercial processing agents which may be used for this purpose may include, cleaning agents, surfactants (e.g., detergents), and hydrocarbon cutter stocks (e.g., diesel, gasoline). In a specific embodiment, the commercial processing agent may be "Nature's Way UC (Ultra Concentrate)", available from Nature's Way Technologies, Inc., of Houston, Texas. The inductor stem 62 may be connected to many alternative conduits provided on the coalescer unit 12. In a specific embodiment, the coalescer header assembly 52 may comprise a main header conduit 84 and a plurality of valve/nozzle assemblies 86. The main header conduit 84 may be provided with a plurality of apertures (not shown) which correspond to each valve/nozzle assembly 86. In a specific embodiment, the main header conduit 84 may be a metal pipe approximately four inches in diameter and approximately 20 feet in length. In a specific embodiment, the coalescer header assembly 52 may be provided with ten valve/nozzle assemblies 86. Alternative embodiments may be provided with more or fewer valve/nozzle assemblies 86. Irrespective of the number of valve/nozzle assemblies 86 provided, the assemblies 86 should be connected to the main header conduit 84 such that fluid communication is established from the interior of the main header conduit 84, through the apertures therein, into the interior of each valve/nozzle assembly 86, and, ultimately, into the interior of the container 36. Each channel may be individually opened and closed, either fully or partially, by the valves 96 (see Figure 3); as will be more fully explained below, the capacity to individually open and close each channel enables the operator to "tune" the coalescer unit 12 for optimum operation. In a specific embodiment, the valve/nozzle assemblies 86 may be positioned approximately equidistant from one another.

An exploded view of a specific embodiment of the valve/nozzle assembly 86 is shown in Figure 3 attached to the main header conduit 84. Referring to Figure 3, a specific embodiment of a valve/nozzle assembly 86 may comprise a first nipple 88, a first flange 90, a second flange 92, a second nipple 94, a valve 96, a third nipple 98, a third flange 100, a fourth flange 102, a fourth nipple 104, a coupling 106, a fifth nipple 108, and a nozzle 110. In a specific embodiment, the nipples 88, 94, 98, 104, and 108 may be short sections of approximately two-inch diameter pipe. The upper end of the first nipple 88 is connected to the main header conduit 84 such that a channel for fluid communication exists from the interior of the main header conduit 84, through an aperture (not shown), and into the interior of the first nipple 88. The lower end of the first nipple 88 is connected to the first flange 90. The upper end of the second nipple 94 is connected to the second flange 92. The first and second flanges 90, 92 are connected, either by welding or by bolts (not shown). The lower end of the second nipple 94 is connected to the upper end of the valve 96. The valves 96 may be two-inch ball valves of the type manufactured by Watts Industries, Inc., of North Andover, Maine, such as Series 7800. The lower end of the valve 96 is connected to the upper end of the third nipple 98. The third nipple 98, third flange 100, fourth flange 102 and fourth nipple 104 are connected in the same manner as described above with respect to the first nipple 88, first flange 90, second flange 92 and second nipple 94. The lower end of the fourth nipple 104 is connected to the upper end of the coupling 106. The coupling 106 is connected to and through the wall of the container 36 such that a channel of fluid communication exists into the interior of the container 36. The upper end of the fifth nipple 108 is connected to the lower end of the coupling 106. The nozzle 110 is connected to the lower end of the fifth nipple 108. In a specific embodiment, the inner diameter of the lower end of the nozzle 110 may be approximately one inch. Alternative diameters may also be provided. The nozzles 110 may be of the type manufactured by J. B. Smith, of Houston, Texas, such as a 2 inch x 1 inch standard model. The length of the fifth nipple 108 may be shortened or lengthened to adjust the position of the nozzle within the container 36, and thereby adjust the location within the container 36 at which pressurized fluid exits the nozzles 110. The above-listed components of this embodiment of the valve/nozzle assemblies 86 are connected such that a plurality of channels of fluid communication exist from the interior of the main header conduit 84 through the valve/nozzle assemblies 86 and into the interior of the container 36. The present invention is not limited to the specific embodiment of the valve/nozzle assembly 86 described above. For example, the valve/nozzle assembly 86 may be provided without the flanges 90, 92, 100, and 102, and/or without the coupling 106. Alternatively, the valve/nozzle assembly 86 could be provided with flanged valves which would eliminate flanges 92 and 100, and nipples 94 and 98. Other constructions of the valve/nozzle assembly 86 are within the scope of the present invention.

Referring to Figure 2, in a specific embodiment, the heating coil 54 may be secured to the interior of the container 36, and be provided with an inlet fitting 112 and an outlet fitting 114, each of which may be connected to and through the wall of the container 36. In a specific embodiment, the heating coil 54 may comprise approximately 95 feet of two-inch diameter schedule 40 steam pipe. In this specific embodiment, heat may be provided to the interior of the container 36 by circulating steam through the heating coil 54. Steam is provided to the heating coil 54 through the inlet and outlet fittings 112, 114 which, as more fully explained below, are connected to the steam header assembly 258 (see Figure 10). In this embodiment, the temperature inside the container 36 will generally vary from approximately ambient temperature to over 200 degrees Fahrenheit, depending on the characteristics of the contaminated material.

In a specific embodiment, the suction conduit 56 may be attached to and through the pump end 40 of the container 36. In a specific embodiment, the suction conduit 56 may be a metal pipe approximately six inches in diameter. In a specific embodiment, the suction conduit 56 may be provided with a 90 degree bend 59 and a lower end 61. This embodiment of the suction conduit 56 may be positioned such that the 90 degree bend 59 is located inside the container 36 and the lower end 61 is positioned near to and directly above the lower surface 44 of the container 36. In a specific embodiment, the lower end 61 of the suction conduit 56 may be positioned approximately three inches above the lower surface 44 of the container 36. A suction conduit valve 57 may be provided in a portion of the suction conduit 56 exterior to the container 36 to control fluid flow through the suction conduit 56. In a specific embodiment, the valve 57 may be a six-inch butterfly valve of the type manufactured by Nibco of Elkhart, Indiana, such as Model No. WD 200 19 96.

In a specific embodiment, the coalescer circulation pump 58 is provided with an input side 122 and a discharge side 124. The input side 122 of the pump 58 is connected to the suction conduit 56 and the discharge side 124 of the pump 58 is connected to the coalescer header assembly 52. In a specific embodiment, the diameter of the suction conduit 56, which is connected to the inlet side 122 of the pump 58, may be greater than the diameter of the conduit on the discharge side 124 of the pump 58 (i.e., the main header conduit 84). In a specific embodiment, the diameter of the suction conduit 56 may be approximately six inches, and the diameter of the main header conduit 84 may be approximately four inches. This difference in conduit diameters creates a "restrictive discharge" effect such that the fluid pressure is increased on the discharge side 124 of the pump 58 and in the coalescer header assembly 52. In a specific embodiment, the pump 58 may be a 6 x 5 (six inch by five inch) centrifugal pump capable of pumping fluid at the rate of 960 gallons per minute (GPM), and may be of the type manufactured by Halco, Inc., of Houston, Texas, such as Model Series 2500. In a specific embodiment, the coalescer transfer conduit 60 may be connected to the main header conduit 84 at the inlet end 38 of the container 36. The transfer conduit 60 may be a metal pipe approximately four inches in diameter. The coalescer transfer valve 68 should be provided in line with the transfer conduit 60. The transfer valve 68 may be a four- inch ball valve of the type manufactured by Nibco of Elkhart, Indiana, such as Model No. WD 2100 DI 34 96. The function of the valve 68 is to control the flow of coalesced slurry from the coalescer unit 12 to the organics recovery unit 14.

In a specific embodiment, the coalescer unit 12 should be provided with a coalescer sump 64. The sump 64 may be connected to the lower surface 44 of the container 36 and at the inlet end 38 of the container 36. In a specific embodiment, the sump 64 may be a metal cylinder having a diameter of approximately 20 inches and a height of approximately eight inches. In a specific embodiment, the coalescer unit 12 should also be provided with a coalescer cleaning conduit 66. The cleaning conduit 66 may be connected between the sump 64 and the suction conduit 56. In a specific embodiment, the conduit 66 may be a flanged metal pipe having a diameter of approximately four inches. In a specific embodiment, a valve 67 should be provided in line with the cleaning conduit 66. In a specific embodiment, the valve 67 may be a four-inch butterfly valve of the type manufactured by Nibco of Elkhart, Indiana, such as Model No. WD 2100 DI 34 96. In this embodiment, the lower surface 44 of the container 36 is provided with an aperture (not shown) such that fluid communication is established from the interior of the container 36 through the sump 64 and the cleaning conduit 66, and into the suction conduit 56. As more fully explained below, this embodiment provides an additional path through which contaminated material may be recirculated through the coalescer unit 12. In addition, when no raw contaminated material remains, and it is desired to clean the interior of the coalescer unit 12, water may be fed into the container 36 and circulated through the sump 64 and cleaning conduit 66.

In a specific embodiment, the coalescer unit 12 should be provided with a coalescer recirculation conduit 78. The upper end of the recirculation conduit 78 may be connected to the main header conduit 84 at the inlet end 38 of the container 36, and the lower end of the recirculation conduit 78 may be connected to the raw contaminated material inlet conduit 50. In a specific embodiment, a coalescer recirculation valve 80 should be provided in line with the recirculation conduit 66. In a specific embodiment, the conduit 78 may be a metal pipe having a diameter of approximately four inches, and the coalescer recirculation valve 80 may be a four- inch ball/butterfly valve of the type manufactured by Nibco of Elkhart, Indiana, such as Model No. WD 2100 DI 34 96. As more fully explained below, this embodiment provides an additional path through which contaminated material may be recirculated through the coalescer unit 12. In addition, the coalescer recirculation valve 80 may be used in conjunction with the coalescer transfer valve 68 to control the rate at which coalesced slurry flows from the coalescer unit 12 to the organics recovery unit 14.

In a specific embodiment, the coalescer unit 12 may be provided with a plurality of vapor abatement ports 76. In a specific embodiment, the ports 76 may be four-inch blinded flanges and located on the upper surface 42 of the container 36. The ports 76 may be attached to a vapor abatement system (not shown), exterior to the apparatus 10, for removing vapors from the interior of the container 36. Vapors may be created as a result of heating the contaminated material being processed. The function of a vapor abatement system is to feed air into the coalescer unit 12 through one of the ports 76 and draw air out of the coalescer unit through the other port 76 so as to create an airstream through the coalescer unit 12 to remove vapors therefrom. As an alternative to air, nitrogen may be used to abate the vapors. In the event nitrogen is used, the coalescer unit 12 may be provided with a pressure sensitive check valve 72. In a specific embodiment, the check valve 72 may be connected to the upper surface 42 of the container 36. The check valve 72 may be a four-inch hinged closure with pressure release valve of the type manufactured by J. M. Huber Corporation, of the United States, such as Model No. Figure 500. The purpose of the check valve 72 is to allow for the release of pressurized nitrogen above approximately 3 pounds per square inch (p.s.i.). The nitrogen is pressurized by restricting the discharge line (not shown) leading from the port 76 from which the nitrogen is exiting the coalescer unit 12. In this manner, a "nitrogen purge" effect is created to purge the interior of the coalescer unit 12 of oxygen. As explained below, the organics recovery unit 14 is also provided with vapor abatement ports 163 (see Figure 4). A single vapor abatement system may be used to simultaneously abate vapors from both the coalescer unit 12 and the organics recovery unit 14.

The coalescer unit 12 should also be provided with one or more temperature gauges 69, one or more pressure gauges 71, a water level sample valve 73, a maximum slurry level valve 75, and one or more slurry level valves 77. In a specific embodiment, the coalescer unit 12 may be provided with a temperature gauge 69 on the pump end 40 of the container 36 to monitor the temperature of the water and/or slurry. In a specific embodiment, the temperature gauge 69 may comprise three components (not shown): (1) a thermocouple; (2) a thermal well; and (3) a thermometer. The thermocouple is permanently connected to the container 36. The thermal well is threadably attached to the thermocouple. The thermometer is threadably attached to the thermal well. The thermal well is a threaded brass fitting of the type available from W. W. Grainger Company, of Houston, Texas. The thermometer may be of the type manufactured by Weksler, of the United States, such as Model No. AA5H9. In a specific embodiment, the coalescer unit 12 may be provided with a pressure gauge 71 on the main header conduit 84 to monitor the pressure of the slurry. In a specific embodiment, the pressure gauge may be of the type manufactured by BICC, of China, such as Model No. LC-25-SBS-2-LS400.

In a specific embodiment, the coalescer unit 12 should be provided with a water level sample valve 73. In a specific embodiment, the sample valve 73 may be a 1 '/2-inch ball valve of the type manufactured by Matco Norea, of Italy, such as Model No. 600 WOG-150 SWP 754. As explained below, upon initial start up of the coalescer unit 12, the container 36 is first filled with enough water to cover the heating coil 54. The purpose of the water level sample valve 73 is to assist the operator in determining when the water has covered the heating coil 54. Thus, the water level sample valve 73 should be connected to and through the wall of the container 36 at a point slightly above the heating coil 54. Thus, before water is initially fed into the contained 36, the valve 73 should be opened. In this manner, when water begins exiting the container 36 through the valve 73, the operator will know the water is at its proper level for initial start up. The operator will then discontinue feeding water into the container 36, and close the valve 73. In a specific embodiment, the sample valve 73 may be connected to and through the pump end 40 of the container 36. In another embodiment, the coalescer unit 12 may be provided with one or more sight glasses (not shown) to monitor the level of the water upon initial start up. In a specific embodiment, the coalescer unit 12 should also be provided with a maximum slurry level valve 75. The function and operation of the maximum slurry level valve 75 is very similar to that of the water level sample valve 73. The maximum slurry level valve 75 should be connected to and through either the inlet end 38 or the pump end 40 of the container 36 at a point on a vertical line through the center of the inlet end 38 or pump end 40 and approximately four inches below the upper surface 42 of the container 36. As explained above, the coalescer unit 12 should be connected to a vapor abatement system. In order to generate an air (or nitrogen) stream through the interior of the coalescer unit 12, there must be an open cavity, not occupied by slurry, through which the air (or nitrogen) stream may flow. Thus, the maximum slurry level valve 75 may be used to monitor the maximum level of the slurry. In a specific embodiment, the coalescer unit 12 may also be provided with one or more slurry level valves 77 for monitoring the level of the slurry in the container 36. The valves 77 may be of the same type as the maximum slurry level valve 75, and should be connected to the container 36 below the maximum slurry level valve 75. In another embodiment, the coalescer unit 12 may be provided with one or more sight glasses (not shown) to monitor the level of the slurry during operation.

In a specific embodiment, the coalescer unit 12 may be provided with a blind flange 70 to which an additional raw contaminated material inlet conduit (not shown) may be attached. In a specific embodiment, the blind flange 70 may be connected to and through the pump end 40 of the container 36. The flange 70 should be sealably enclosed when not in use. In a specific embodiment, the container 36 may be provided with two manways 74. In a specific embodiment, the manways 74 may be approximately 20 inches in diameter and positioned on the upper surface 42 of the container 36. The manways 74 may provide a passageway through which a human may enter the interior of the container 36. In a specific embodiment, the coalescer unit 12 may be provided with six support members 82. The upper ends of the support members 82 may be connected to the lower surface 44 of the container 36 and the lower ends of the support members 82 may be connected to the upper surface of the skid 18.

Having provided a detailed description of the construction of the coalescer unit 12, its operation will now be described in detail.

The function of the coalescer unit 12 is to violently agitate the raw contaminated material such that large chunks or globs of solids and/or hydrocarbons are dissolved into many, tiny individual molecules of solids and/or hydrocarbons; these tiny molecules are blended with water into a coalesced slurry. Before the raw contaminated material is fed into the coalescer unit 12, all valves on the coalescer unit 12, except for the water level sample valve 73, should be closed, and water should be fed into the container 36. As explained above, when water begins exiting the water level sample valve 73, the operator should discontinue feeding water into the container 36 and the valve 73 should be closed. At this point, the container 36 has now been filled with water to a level slightly above heating coil 54. Steam should now be circulated through the heating coil 54 until the desired temperature is reached. The desired temperature range may be from ambient temperature to over 200 degrees Fahrenheit, depending on the characteristics of the contaminated material. As more fully explained below, the organics recovery unit 14 should be filled with water at the same time the coalescer unit 12 is filled with water; steam should also be circulated through the heating coil 148 (see Figure 9) on the organics recovery unit 14 at this time.

At this point, the coalescer recirculation valve 80 and all header valves 96 should be opened. The coalescer circulation pump 58 should then be activated, at which time water will be circulated through the header assembly 52 and the coalescer unit 12, such that high-pressure jets of water will be exiting the nozzles 110. The inlet valve 51 and the maximum slurry level valve

75 should then be opened, and raw contaminated material should be pumped from its source (e.g., tank bottom, sump system) via a remote pump (not shown and not part of the apparatus 10) through the inlet conduit 50 and into the coalescer unit container 36. The raw contaminated material should be passed through a conventional pre-screening device to screen out solids larger than approximately one inch in diameter before being fed into the coalescer unit 12. When fluid has risen to the level of the maximum slurry level valve 75, the inlet valve 51 should be closed. As the contaminated material and water circulate through the header assembly 36 and the coalescer unit 12, the header valves 96 may then be "tuned" or adjusted, beginning with the header valve 96 nearest the pump end 40 of the container 36. The slurry should be allowed to circulate through the coalescer unit 12 until the slurry reaches the desired temperature. When the coalesced slurry has reached the desired temperature, the process of transferring the slurry to the organics recovery unit 14 should be commenced. At this time, the coalescer circulation valve 80 should be closed and the coalescer transfer valve 68 should be opened. As slurry begins to flow from the coalescer unit 12 to the organics recovery unit 14, additional raw contaminated material should be added to the coalescer unit 12 through the inlet conduit 50. The rate at which the raw contaminated material is fed into the coalescer unit 12 should be regulated to approximately equal the rate at which the coalesced slurry is transferred to the organics recovery unit 14 such that the upper level of the slurry within the coalescer unit 12 is maintained at a distance of approximately four inches from the upper surface 42 of the container 36 (recall above explanation of need for cavity needed to abate vapors). The level of the upper surface of the slurry may be monitored by the maximum slurry level valve 75, the slurry level valve 77, or by one or more sight glasses (not shown). As further explained below, the rate at which the raw contaminated material is fed into the coalescer unit 12 and the rate at which the coalesced slurry is transferred from the coalescer unit 12 to the organics recovery unit 14 should also be regulated so as maintain an equilibrium with the combined volume of (a) water discharged through the seal leg conduit 28 and (b) hydrocarbons discharged through the hydrocarbon recovery conduit 22. The contaminated material and water is pumped by the pump 58 at high pressures (e.g.,

125 p.s.i.) and high flow rates (e.g, 960 GPM), into the coalescer header assembly 52. In a specific embodiment, wherein the diameter of the suction conduit 56 leading into the pump 58 is greater than the diameter of the conduit leading from the pump 58 to the coalescer header assembly 52, a "restrictive discharge" effect is created such that the fluid pressure is increased on the discharge side 124 of the pump 58 and in the coalescer header assembly 52. A commercial processing agent may be added to the contaminated material through the inductor stem 62. As explained above, the purpose of adding a commercial processing agent (e.g., surfactant, hydrocarbon cutter stock) to the contaminated material is to assist in dissolving the globs of solids and/or hydrocarbons. The contaminated material and water mixture is forced by pump 58 through the coalescer header assembly 52 under high pressures and at high flow rates. The contaminated material and water mixture may travel along the main header conduit 84 and down into one of the valve/nozzle assemblies 86. The contaminated material and water mixture which travels down into the valve/nozzle assemblies 86 exits the nozzles 110 in the form of high pressure, high velocity jets. The valves 96 may be used to "tune" the coalescer header assembly 52. If additional pressure is desired, the valves 96 may be partially closed. For example, if solids are not circulating in a given area of the coalescer unit 12, and a sludge blanket begins forming, the valves 96 in the area where the sludge blanket is forming may be kept fully open while all other valves 96 may be partially or completely closed. In view of the small inner diameter of the nozzles 110, the pressure at which the jets exit the nozzles 110 is increased relative to the pressure through the valves 96. These jets of contaminated material and water mixture are directed downwardly into contact with other contaminated material and water. The contaminated material and water within the coalescer unit 12 is thereby agitated to an extreme degree, and then recirculated through the pump 58 and coalescer header assembly 52. As the contaminated material and water circulates through the coalescer unit 12, it is heated by the heating coil 54 and violently agitated by the jets exiting the nozzles 110 such that any chunks or globs of solids and/or hydrocarbons are dissolved into many, tiny individual molecules of solids and/or hydrocarbons, which are then blended with water into a coalesced slurry. The coalesced slurry may be recirculated through the pump 58 either through the suction conduit 56 and/or through the sump 64 and coalescer cleaning conduit 66. If the suction conduit 56 is closed by closing the valve 57, and the cleaning conduit 66 is opened by opening the valve 67, then the slurry will be recirculated to and through the pump 58 only through the sump 64 and the coalescer cleaning conduit 66. Likewise, if the coalescer cleaning conduit 66 is closed by closing the valve 67, and the suction conduit 56 is opened by opening the valve 57, then the slurry will be recirculated to and through the pump 58 only through the suction conduit 56. If both valves 57 and 67 are open, then the slurry may be recirculated through both the suction conduit 56 and the coalescer cleaning conduit 66. In addition, slurry which travels from the pump 58 down the full length of the main header conduit 84 without entering one of the valve/nozzle assemblies 86 may be recirculated into the container 36 through the coalescer recirculation conduit 78, and the inlet conduit 50, by opening the coalescer recirculation valve 80. The valve 80 may be also used in conjunction with the coalescer transfer valve 68 to assist in controlling the rate at which coalesced slurry flows to the organics recovery unit 14. The coalesced slurry is transferred through the coalescer transfer conduit 60 to the organics recovery unit 14, wherein the hydrocarbons, inert solids, and water in the coalesced slurry are separated from one another based upon their respective specific gravities.

The rate at which coalesced slurry is transferred to the organics recovery unit 14 is controlled primarily by the coalescer transfer valve 68. The valve 68 also offers the ability to operate the apparatus 10 in continuous or "batch" modes. If the transfer valve 68 is completely closed, then the container 36 may be filled with a "batch" of contaminated material which may be circulated through the coalescer unit 12. When that "batch" of contaminated material has been mixed into a coalesced slurry, then the valve 68 may be opened and the "batch" of coalesced slurry may be transferred to the organics recovery unit 14. The valve 68 may then be closed again, and another "batch" of contaminated material may be processed in the coalescer unit 12. Alternatively, if the valve 68 is maintained in an opened position, then contaminated material may be continuously processed. In this continuous mode, contaminated material may be fed into the coalescer unit 12 through the inlet conduit 50 at a continuous rate (e.g., 100 GPM), and the valve 68 may be set so as to transfer coalesced slurry to the organics recovery unit 14 at approximately the same rate. However, the pump 58 circulates the contaminated material through the coalescer unit 12 at a rate (e.g., 960 GPM) much higher than the rate (e.g., 100 GPM) at which coalesced slurry flows through the valve 68.

Having set forth a detailed description of the structure and operation of the coalescer unit 12, the structure and operation of the organics recovery unit 14 will now be described in detail. The structure of the organics recovery unit 14 will be described first, followed by a detailed description of its operation.

The Organics Recovery Unit With reference to Figure 4, a specific embodiment of the organics recovery unit 14 may comprise a vessel 126 having an inlet end 128, an outlet end 130, an upper surface 132, a lower peripheral edge 134, a first side surface 136, and a second side surface 138 (not shown in Figure 4). The top of the vessel 126 is enclosed by its upper surface 132, and its bottom is enclosed by one or more solids recovery pyramids 142. In a specific embodiment, the vessel 126 may be a rectangularly-shaped, metal box, approximately 9 feet tall, 3 Vz feet wide, and 20 feet long. In a specific embodiment, the vessel 126 is provided with a coalesced slurry inlet conduit 140, one or more solids recovery pyramids 142, a solids recovery header assembly 24, an organics recovery weir 144, a hydrocarbon recovery conduit 22, an air vent 23, a seal leg conduit 28, an interface valve 146, a solids recovery pump 26, a solids transfer conduit 186, and a heating coil 148 (see Figure 9). In a specific embodiment, the vessel 126 may also be provided with one or more regulator baffles 150, one or more coalescence louvers 152, one or more inverted solids dispersion pyramids 154, a recovered water inlet conduit 155, one or more solids sample valves 156, one or more liquid sample valves 158, one or more sight glasses 159, one or more manways

160, one or more service water couplings 162, one or more vapor abatement ports 163, one or more temperature gauges 153, and a polymer induction stem 228.

In a specific embodiment, the coalescer slurry inlet conduit 140 may be attached to and through the inlet end 128 of the vessel 126. In a specific embodiment, the inlet conduit 140 may be a metal pipe having a diameter of approximately four inches. In a specific embodiment, the inner end 141 of the inlet conduit 140 may be configured as a tee such that coalesced slurry being fed from the coalescer unit 12 will be dispersed within the vessel 126 in two directions, substantially perpendicular to the longitudinal axis of the conduit 140. Alternative embodiments of the inlet conduit 140 may also be provided to disperse the coalesced slurry in more than two directions within the vessel 126, and at other angles relative to the conduit 140.

In a specific embodiment, the vessel 126 is provided with one or more solids recovery pyramids 142 for the collection of settled solids. The upper edges of the solids recovery pyramids 142 should be connected to the lower peripheral edge 134 of the vessel 126 such that the vertex of each pyramid 142 is pointed downward. In a specific embodiment, the height of the pyramids 142 may be approximately 30 inches, and the width of the upper edges of the pyramids 142 should be equal to the width of the vessel 126. As best shown in Figure 7, in a specific embodiment, each solids recovery pyramid 142 should be provided with an inverted solids dispersion pyramid 154, one or more solids sample valves 156, and a capture chamber 176. Each capture chamber 176 should be provided with an aperture (not shown) in its upper surface, a flange 174, and a cleaning coupling 178. In the event the capture chamber 176 should become clogged with solids, the clog may be cleared by feeding pressurized air into the capture chamber 176 through the cleaning coupling 178. A separate air manifold (not shown), having a valve for controlling the flow of pressurized air to each capture chamber 176, may be provided to more conveniently supply air to the capture chambers 176. The capture chambers 176 may also be unclogged by feeding pressurized water therethrough. Each capture chamber 176 should be connected to its corresponding pyramid 142 such that the aperture in each capture chamber 176 is positioned adjacent a corresponding aperture in the vertex of the pyramid 142. The valves 156 are connected to and through any side of the solids collection pyramid 142. In a specific embodiment, the valves 156 may be two-inch ball valves of the type manufactured by Matco Norea, of Italy, such as Model No. 600 WOG-150 SWP 754. The valves 156 may be used to determine the level of settled solids within the solids recovery pyramids 142. With reference to Figure 7, each solids dispersion pyramid 154 is connected by four support posts 226 to the bottom of each solids collection pyramid 142 such that the vertex of each solids dispersion pyramid 154 points upwardly. The upwardly pointing vertex of the solids dispersion pyramid 154 is positioned approximately directly above the downwardly pointing vertex of the solids recovery pyramid 142. The posts 226 should be of sufficient length so as to provide sufficient space between the lower edges of the solids dispersion pyramid 154 and the walls of the solids collection pyramid 142 through which collected solids may be suctioned by the solids recovery pump 26. In a specific embodiment, the distance between the lower edges of the solids dispersion pyramid 154 and the walls of the solids collection pyramid 142 may be approximately one inch. In a specific embodiment, the width of the lower edges of the solids dispersion pyramids 154 may be approximately 10 inches and the height of the solids dispersion pyramids 154 may be approximately 12 inches. With reference to Figure 4, in a specific embodiment, the vessel 126 is provided with a solids recovery header assembly 24. As best shown in Figure 7, the solids recovery header assembly 24 should be connected to the vertex of each solids collection pyramid 142. In a specific embodiment, the solids recovery header assembly 24 may comprise a solids recovery header conduit 164 and one or more solids recovery valve assemblies 166. The number of solids recovery valve assemblies 166 will correspond to the number of solids recovery pyramids 142. In a specific embodiment, the solids recovery header conduit 164 may be a metal pipe having a diameter of approximately four inches. As shown in Figure 4, in a specific embodiment, the solids recovery header conduit 164 may be provided with a threadably removable end cap 165. The end cap 165 may be removed in the event it becomes necessary to unclog the header conduit 164. As shown in Figure 7, in a specific embodiment, each solids recovery valve assembly 166 may comprise a first nipple 168, a first flange 170, and a solids recovery valve 172. The first nipple 168, the first flange 170, and the solids recovery valve 172 of each solids recovery valve assembly 166 are connected in a conventional manner. The first nipple 168 is connected to the solids recovery header conduit 164. The solids recovery valve 172 is connected to the flange 174 of the capture chamber 176. Thus, each solids recovery valve assembly 166 is connected to the solids recovery header conduit 164 and to a corresponding solids recovery pyramid 142 so as to provide a channel of fluid communication between the interior of the solids recovery header conduit 164 and the interior of each solids recovery pyramid 142. In a specific embodiment, the nipple 168 and capture chamber 176 may be short sections of approximately four-inch diameter metal pipe. In a specific embodiment, the solids recovery valve 172 may be a four-inch butterfly or ball valve of the type manufactured by Milwaukee Valve Company, of Milwaukee, Wisconsin, such as Model No. MW 223 BAN. Alternative constructions of the valve assembly 166 are within the scope of this invention.

With reference to Figure 4, in a specific embodiment, the organics recovery unit 14 is provided with a solids recovery pump 26 for pumping solids to the solids separation unit 16. The pump 26 is provided with an inlet side 180 and a discharge side 182. The inlet side 180 of the pump 26 is connected to the solids recovery header conduit 164, and the discharge side 182 of the pump 26 is connected to a solids transfer conduit 186. In a specific embodiment, the solids transfer conduit 186 may be a metal pipe having a diameter of approximately four inches. Alternatively, as described below, the transfer conduit 186 may comprise a section of four-inch diameter metal pipe and a section four-inch diameter flexible hose. In a specific embodiment, the pump 26 may be a 4 x 3 (four inch by three inch) centrifugal pump, rated at 100 GPM, and capable of pumping solids slurry as heavy as 14 pounds specific gravity, of the type manufactured by Halco, Inc., of Houston, Texas, such as Model Series 2500.

In a specific embodiment, the organics recovery unit 14 is provided with an organics recovery weir 144, a hydrocarbon recovery conduit 22, and a seal leg conduit 28. All three of these components should be connected to the outlet end 130 of the vessel 126. The organics recovery weir 144 may be a rectangular sheet of metal having an upper edge 188, a lower edge 190, a first side edge 192 (see Figure 9), and a second side edge 194. The width of the weir 144 should be equal to the width of the vessel 126. The recovery weir 144 should be connected to the interior of the vessel 126 such that its first side edge 192 is connected to the first side surface 136 of the vessel 126, its second side edge 194 is connected to the second side surface 138 of the vessel 126, and its lower edge 190 (see Figure 4) is connected to the outlet end 130 of the vessel 126. The recovery weir 144 should be connected to the vessel 126 so as to incline upwardly from its lower edge 190 to its upper edge 188. In a specific embodiment, the angle of incline may be approximately 45 degrees. The hydrocarbon recovery conduit 22 may be attached to and through the outlet end 130 of the vessel 126 adjacent the lower edge 190 of the recovery weir 144. In a specific embodiment, the recovery conduit 22 may be a metal pipe having a diameter of approximately four inches, and may be fitted for ancillary hose connections. As more fully explained below, recovered hydrocarbons flow over the weir 144, through the recovery conduit 22 and into a recovered organics container (not shown). In a specific embodiment, the hydrocarbon recovery conduit 22 may be provided with an air vent 23. The air vent 23 may be a short J-shaped section of pipe having an approximate diameter of two inches. One end of the air vent 23 should be connected to and though the wall of the hydrocarbon recovery conduit 22 on a point exterior of the vessel 126. The other end of the air vent 23 should be connected to and through the upper surface 132 of the vessel 126. In a specific embodiment, the seal leg conduit 28 may comprise two sections of conduit, namely: (1) a U-shaped section of conduit having an inner leg 196, an upper bend 198, and an outer leg 200; and (2) a water recovery conduit 202. In a specific embodiment, the seal leg conduit 28 may be a metal pipe having a diameter of approximately six inches. The seal leg conduit 28 is connected to the outlet end 130 of the vessel 126 such that the U-shaped section is inverted, and the inner leg 196 is located -completely within the vessel 126, the outer leg 200 is located completely outside the vessel 126, and the upper bend 198 is attached to and through the outlet end 130 of the vessel 126 and positioned adjacent the lower edge 190 of the recovery weir 144. In a specific embodiment, a lower end 197 of the inner leg 196 may be approximately 24 inches above the lower peripheral edge 134 of the vessel 126. As explained below, in a specific embodiment, the lower end 197 of the inner leg 196 may be approximately at the same horizontal level as the lower edges 210 of the baffles 150. One end of the water recovery conduit 202 is connected to a lower end 201 of the outer leg 200, and its other end is connected to the SSU tank 32 (see Figure 8) on the solids separation unit 16. An interface valve 146 (Figure 4) is connected in line with the seal leg conduit 28. In a specific embodiment, the interface valve 146 may be a six-inch butterfly valve of the type manufactured by Nibco, of Elkhart, Indiana, such as Model No. WD200 DI 1996. As shown in Figure 9, in a specific embodiment, the organics recovery unit 14 is provided with a heating coil 148. The heating coil 148 may be secured to the interior of the vessel 126, and be provided with an inlet fitting 204 and an outlet fitting 206, each of which may be connected to and through the wall of the vessel 126. In a specific embodiment, the heating coil 148 may comprise approximately 95 feet of two-inch diameter schedule 40 steam pipe. In this specific embodiment, heat may be provided to the interior of the vessel 126 by circulating steam through the heating coil 148. Steam may be provided to the heating coil 148 by connecting the inlet and outlet fittings 204, 206 to the steam header assembly 258 (see Figure 10).

As best shown in Figure 10, a steam header assembly 258 is connected between the coalescer unit 12 and the organics recovery unit 14. The steam header assembly 258 may comprise an inlet conduit 260, a coalescer unit inlet valve 262, an organics recovery unit inlet valve 264, a main inlet fitting 266, a coalescer unit steam trap 268, an organics recovery unit steam trap 270, a coalescer unit outlet conduit 271, an organics recovery unit outlet conduit 272, a coalescer unit condensate discharge conduit 273, and an organics recovery unit condensate discharge conduit 274. The inlet conduit 260 connects the inlet fitting 112 on the coalescer unit 12 to the inlet fitting 204 on the organics recovery unit 14. The inlet conduit 260 is provided with a main inlet fitting 266. A steam hose (not shown) should be connected to the main inlet fitting 266. Steam is fed from a steam source (not shown) through the steam hose (not shown) and inlet conduit 260 to the interiors of the coalescer unit 12 and the organics recovery unit 14. The inlet conduit 260 is provided with a coalescer unit inlet valve 262 and an organics recovery unit inlet valve 264. The coalescer unit inlet valve 262 is connected in line with the inletxonduit 260 between the coalescer unit 12 and the main inlet fitting 266. The organics recovery unit inlet valve 262 is connected in line with the inlet conduit 260 between the organics recovery unit 14 and the main inlet fitting 266. The inlet valves

262 and 262 control the rate at which steam is fed to the coalescer unit 12 and organics recovery unit 14, respectively. The coalescer unit steam trap 268 is connected to the outlet fitting 114 on the coalescer unit 12 via the coalescer unit outlet conduit 271. The organics recovery unit steam trap 270 is connected to the outlet fitting 206 on the organics recovery unit 14 via the organics recovery unit outlet conduit 272. The coalescer unit condensate discharge conduit 273 is connected to the coalescer unit steam trap 268, and leads downwardly into a condensate conduit 21. The condensate conduit 21 extends through an aperture 19 in the skid 18. The steam exiting the outlet fittings 114 and 206 (on the coalescer unit 12 and organics recovery unit 14, respectively) will be condensed in the steam traps 268 and 270. The condensate will drain through the condensate discharge conduits 272 and 274. In a specific embodiment, the inlet conduit 260 and the outlet conduits 271 and 272 may each be a metal pipe having an approximate diameter of two inches. The condensate discharge conduits 273 and 274 may each be a metal pipe having an approximate diameter of one inch. The steam traps 268 and 270 may be of the type manufactured by Clark Reliance, of Strongsville, Ohio, such as Model No. FD-3. The inlet valves 262 and 264 may be two-inch ball valves of the type manufactured by Bonney Forge, of Albano, Italy, such as Model No. HL103. The main inlet fitting 266 may be a concentric reducer of the type manufactured by J. B. Smith Mfg. Co. , of Houston, Texas, such as Model No. WPBS-9 REC GF.

Referring again to Figure 4, in a specific embodiment, the vessel 126 may also be provided with one or more regulator baffles 150 and one or more coalescence louvers 152. The baffles 150 may be provided to aid in the regulation and flow of slurry movement within the organics recovery unit 14. As more fully explained below, the louvers 152 may be provided to decrease slurry velocity created by the baffles 150 and to encourage the consolidation of hydrocarbon molecules so they will rise to the organic supernatant. The baffles 150 and louvers 152 should be connected to the interior of the vessel 126 and positioned between the first and second side surfaces 136, 138 of the vessel 126. In a specific embodiment, the baffles 150 and louvers 152 may be positioned approximately directly above the intersecting upper edges of the solids collection pyramids 142. Each baffle 150 may be a rectangular sheet of metal having an upper edge 208, a lower edge 210. a first side edge 212 (see Figure 9), and a second side edge 214. The width of each baffle 150 should be equal to the width of the vessel 126. Each baffle 150 should be connected to the interior of the vessel 126 such that its first side edge 212 is connected to the first side surface 136 of the vessel 126, its second side edge 214 is connected to the second side surface 138 of the vessel 126, its upper edge 208 is positioned below the upper surface 132 of the vessel 126, and its lower edge 210 is positioned above the lower peripheral edge 134 of the vessel 126. In a specific embodiment, each baffle 150 is positioned substantially vertically. In a specific embodiment, the upper edge 208 of each baffle 150 may be located approximately six inches below the upper surface 132 of the vessel 126, and the lower edge 210 of each baffle 150 may be located approximately 30 inches above the lower peripheral edge 134 of the vessel 126. In a specific embodiment, the upper edges 208 of the baffles 150 may be at approximately the same horizontal level as the upper edge 188 of the organics recovery weir 144. As explained above, in a specific embodiment, the lower edges 210 of the baffles 150 may be at approximately the same horizontal level as the lower end 197 of the inner leg 196 of the seal leg conduit 28. In an alternative specific embodiment (not shown), additional louvers 152 may be provided in place of the baffles 150.

As shown in Figure 4, in a specific embodiment, the louvers 152 may be L-shaped sections of metal (or sections of "angle-iron"). Alternatively, the louvers 152 may be rectangular sections of metal (not shown). Each louver 152 may be provided with a leading edge 216, at least one trailing edge 218, a first side edge 220 (see Figure 9), and a second side edge 222. In the event the louver 152 comprises a rectangular section of metal, then only one trailing edge 218 will be provided. The width of each louver 152 should be equal to the width of the vessel 126. In a specific embodiment, the distance between the leading edge 216 and the trailing edge 218 of each louver 152 should be approximately two inches. Each louver 152 should be connected to the interior of the vessel 126 such that its first side edge 220 is connected to the first side surface 136 of the vessel 126, its second side edge 222 is connected to the second side surface 138 of the vessel 126, and its leading edge 216 is positioned nearer the inlet end 128 of the vessel 126 than is its trailing edge 218. In a specific embodiment, the louvers 152 are positioned so as to provide one or more inclined surfaces 224 (see Figure 4). In a specific embodiment, the surfaces 224 may incline upwardly away from the leading edges 216 of the louvers 152 at an angle of approximately 45 degrees. In a specific embodiment, one or more louvers 152 are positioned coplanar with each baffle 150, below the lower edge 210 of each baffle 150, and above the lower peripheral edge 134 of the vessel 126.

In a specific embodiment, the organics recovery unit 14 may be provided with one or more sample valves 158 (see Figure 4). In a specific embodiment, the valves 158 may be attached to and through the vessel 126 near its outlet end 130. In a specific embodiment, the valves 158 may be two-inch ball valves of the type manufactured by Matco Norea, of Italy, such as Model No. 600 WOG 150 SWP. As will be more fully explained below, the function of the valves 158 is to determine the level of: the organics phase; the interface between the water phase and the hydrocarbon phase; and the various ranges of clarity within the water phase. The valves 158 should be positioned to satisfy that function. In a specific embodiment, to satisfy the same function, the organics recovery unit 14 may also be provided with one or more liquid sight glasses 159. The sight glasses 159 may be circular glass inserts, approximately 3 Vi inches in diameter, of the type manufactured by Duraflex, of France, such as Model No. 6. The glasses 159 should be sealably connected to and through the wall of the vessel 126. A seal leg sight glass 161 may be connected to and through the outlet end 130 of the organics recovery unit 14 to enable the operator to monitor the clarity of the water flowing into the lower end 197 of the inner leg 196.

In a specific embodiment, the vessel 126 may be provided with one or more manways 160 for providing human access to the interior of the vessel 126. In a specific embodiment, the vessel

126 may be provided with four manways 160, each of which is provided with a diameter of approximately 20 inches.

In a specific embodiment, the vessel 126 may be provided with one or more service water couplings 162 for filling the organics recovery unit 14 with service water. In a specific embodiment, a service water coupling 162 may be attached to the outlet end 130 of the vessel 126. In a specific embodiment, the coupling 162 may be a two-inch coupling, fitted for connection with a two-inch hose. The coupling 162 may be of the type manufactured by APG, of Taiwan, such as Model No. APT.

In a specific embodiment, the coalescer transfer conduit 60, which provides fluid communication between the coalescer unit 12 and the organics recovery unit 14, may be provided with a polymer induction stem 228. The function of the polymer induction stem 228 is to allow for the addition of polymers to the coalesced slurry after it leaves the coalescer unit 12 and before it enters the organics recovery unit 14. The purpose of adding polymers to the coalesced slurry is to encourage the attraction of tiny inert solid molecules to one another, and to thereby form larger, coagulated solid particles. In this manner, upon entry into the organics recovery unit 14, the coagulated solids will sink more readily into the solids collection pyramids 142. Examples of polymers which may be used for this purpose include commercially purchased ionic, nonionic and cationic polymers. In a specific embodiment, the polymer induction stem 228 may be a metal pipe having an inner diameter of approximately one inch. Polymers may be added in the same manner as described above regarding the addition of processing agents to the coalescer unit 12.

In a specific embodiment, the organics recovery unit 14 may be provided with one or more temperature gauges 153 for monitoring the temperature of the fluid in the vessel 126. The temperature gauges 153 may be of the same type and construction as the temperature gauge 69 on the coalescer unit 12. In a specific embodiment, the organics recovery unit 14 may be provided with a recovered water inlet conduit 155. As more fully explained below, the recovery water inlet conduit 155 should be connected to a water recirculation conduit 278, through which water recovered by the solids separation unit 16 may be recirculated to the organics recovery unit

14. In a specific embodiment, the organics recovery unit 14 may be connected to the skid 18 by a plurality of support members (not shown).

Having provided a detailed description of the construction of the organics recovery unit 14, its operation will now be described in detail.

With the interface valve 146 open, the organics recovery unit 14 should be filled with water until water flows through the seal leg conduit 28 and into the SSU tank 32. Thus, upon initial start up of the organics recovery unit 14, the water level will be at the same level as the upper bend 198 of the seal leg conduit 28. Steam should be circulated through the heating coil

148 until desired temperature is reached. These steps — filling the organics recovery unit 14 with water and heating the water — should be taken at the same time as the coalescer unit 12 is filled with water and that water is heated. Coalesced slurry may then be transferred from the coalescer unit 12 through the coalescer transfer conduit 60 and the coalesced slurry inlet conduit 140 into the organics recovery unit 14. The rate at which the slurry enters the organics recovery unit 14 is regulated by the coalescer transfer valve 68, and, therefore, is equal to the rate at which the coalesced slurry exits the coalescer unit 12. Polymers may be added to the slurry via the polymer induction stem 228 before the slurry enters the organics recovery unit 14. As explained above, the purpose of adding polymers to the coalesced slurry is to encourage the attraction of tiny inert solid molecules to one another, and to thereby form larger, coagulated solid particles. In this manner, upon entry into the organics recovery unit 14, the coagulated solids will sink more readily into the solids collection pyramids 142. As the slurry enters the organics recovery unit 14, it is dispersed in one or more directions depending on the configuration of the inner end 141 of the inlet conduit 140. If the inner end 141 of the conduit 140 is configured as a tee, then the slurry will be dispersed in two, opposite directions, substantially perpendicular to the inlet conduit 140. The reason for dispersing the slurry in this manner is assist in creating a non-turbulent environment within the organics recovery unit 14, as opposed to the highly turbulent environment created by the coalescer unit 12. This distinction points to a fundamental difference in the functions of the coalescer unit 12 and the organics recovery unit 14. As explained above, the function of the coalescer unit 12 is to violently agitate the raw contaminated material such that large chunks or globs of material consisting of solids and/or hydrocarbons are dissolved (with the assistance of commercial processing agents) into many, tiny individual molecules of solids and hydrocarbons, and to blend those tiny molecules with water into a coalesced slurry. The function of the organics recovery unit 14, on the other hand, is to separate the tiny molecules of hydrocarbons, water, and solids within the coalesced slurry from one another; this function is best accomplished in a non-turbulent environment.

The hydrocarbons, solids and water are separated within the organics recovery unit 14 based upon their respective specific gravities. This separation process may be referred to as "phase" separation. Because the hydrocarbons are lighter than the water and the solids, the hydrocarbons will naturally float to the top of the water and form a layer of hydrocarbons; this layer may also referred to as an organics supernatant or hydrocarbon phase. Similarly, because the solids are heavier than the water and the hydrocarbons, the solids will settle or sink to the bottom of the vessel 126, and into the solids recovery pyramids 142. The water, being lighter than the solids, but heavier than the hydrocarbons, will form a water phase above the settled solids and below the organics supernatant. It is important that the upper surface of the water phase be maintained at all times no lower than the lower end 197 of the inner leg 196 of the seal leg conduit

28 (or the lower edges 210 of the baffles 150, which are at approximately the same level as the lower end 197 of the inner leg 196).

As the coalesced slurry enters the organics recovery unit 14, the separation process will commence as the slurry flows toward the outlet end 130 of the vessel 126. The temperamre of the slurry will begin to rise as heat is transferred from the heating coil 148 and the pre-heated water to the slurry. The slurry will encounter the first baffle 150 and either flow over the upper edge 208 of the baffle 150, or beneath the lower edge 210 of the baffle 150 and over one or more of the louvers 152. Some of the solids will immediately drop into the first solids recovery pyramid 142. The remaining solids will flow past the louvers 152 before sinking into one of the other solids recovery pyramids 142. The function of the baffles 150 is to aid in the regulation and flow of slurry movement within the organics recovery unit 14, and to foster the development of a non-turbulent environment within the organics recovery unit 14. The louvers 152 are provided instead of extending the lower edges 210 of the baffles 150 down to the lower peripheral edge 134 of the vessel 126. If the lower edges 210 of the baffles 150 were at the same level as the lower peripheral edge 134, points of increased fluid velocity would be created. Thus, the lower edges 210 are elevated and the louvers 152 are used to eliminate these points of increased fluid velocity. An additional function of the louvers 152 is to provide additional surface area within the water phase for the slurry to contact which will thereby aid in the consolidation of organic molecules so that they will rise to the organics supernatant.

As the slurry flows around the baffles 150, around the louvers 152, and toward the outlet end 130 of the vessel, an organics supernatant will develop above the water phase, and an interface (or "rag layer") between the water phase and the organics supernatant will form. The rag layer will comprise a mixture of water and hydrocarbons. By increasing the temperature of the hydrocarbons, the heating coil 148 reduces the thickness of the rag layer. Because the top of the water phase is maintained at the same level as the upper bend 198 of the seal leg conduit 28, the interface will likewise be located at that same level. As the amount of coalesced slurry within the organics recovery unit 14 increases, the thickness of the organics supernatant will increase (i.e., the upper surface of the organics supernatant will gradually rise toward the upper edge 188 of the organics recovery weir 144). The operator may monitor the level of the upper surface of the organics supernatant by looking through the sight glasses 159, or by intermittently opening the sample valves 158. To use the sample valves 158, the operator may simply position a small container adjacent the outlet end of any of the valves 158, open the valve 158, extract a sample of the liquid within the vessel 126, and then close the valve 158. If no liquid is discharged through the valve 158, then the operator knows that the upper surface of the organics supernatant is below the particular valve. The sample valves 158 may also be used to monitor the various levels of water clarity within the water phase. The upper surface of the organics supernatant will eventually rise above the upper edge 188 of the organics recovery weir 144, at which time hydrocarbons will flow over the recovery weir 144, through the hydrocarbon recovery conduit 22 and into a hydrocarbon recovery container (not shown). The recovered hydrocarbons can be reused, resold, and/or disposed of independently of the remaining media. When all coalesced slurry has been emptied from the coalescer unit 12, and, thus, there is no longer any coalesced slurry being fed into the organics recovery unit 14, it will be desired to remove the organics supernatant. At this point, the organics supernatant will have reached its maximum thickness, extending from the interface, which is located at the same level as the upper bend 198 of the seal leg conduit 28, to the upper edge 188 of the recovery weir 144. The hydrocarbons forming the organics supernatant may be removed from the organics recovery unit 14 by closing the interface valve 146 and feeding more water (such as through the service water coupling 162) into the organics recovery unit 14. With the interface valve 146 closed, the additional water will first fill the seal leg conduit 28, and then gradually raise the interface and thereby push the organics supernatant upwardly. In this manner, the hydrocarbons forming the organics supernatant will flow over the upper edge 188 of the recovery weir 144. Water should be added until all of the hydrocarbons forming the organics supernatant have been completely discharged. When water begins flowing from the hydrocarbons recovery conduit 22, the operator will know that all hydrocarbons in the organics supernatant have been completely discharged.

As the level of the solids begins to rise in the solids recovery pyramids 142, the solids should be intermittently removed via the solids recovery header assembly 24. The operator may monitor the level of the solids by opening the solids sample valves 156 in the same manner as discussed above regarding the liquid sample valves 158. When each particular pyramid 142 is ready to be emptied, the solids recovery pump 26 and the shaker screen 30 should be activated. Each of the solids recovery valves 172 may then be briefly opened until all solids within the particular pyramid 142 have been suctioned out by the solids recovery pump 26. The pump 26 suctions the solids, along with some intermingled water, through the solids recovery header conduit 164, and pumps same through the solids transfer conduit 186 to the shaker screen 30 on the solids separation unit 16. The pump 26 may be deactivated after each pyramid 142 has been emptied. The shaker screen 30 may be deactivated when the solids and intermingled water have been separated, and the solids have been discharged to a solids recovery container (not shown), and the intermingled water has flowed into the SSU tank 32. By providing the solids recovery pyramids 142 with inverted solids dispersion pyramids 154, the amount of water suctioned out with the solids may be minimized. This is because, in the absence of the solids dispersion pyramids 154, the pump 26 will suction (or "tunnel through") a body of the solids directly above the capture chamber 176 and extending to the lower surface of the water phase such that, after that first body of solids has been removed, the pump 26 will suction more water than solids from the body of solids adjacent the walls of the solids recovery pyramids 142. However, if the solids recovery pyramids 142 are provided with -inverted solids dispersion pyramids 154, the pump 26 will suction solids equally through the spaces between the lower edges of the solids dispersion pyramids 154 and the walls of the solids recovery pyramids 142.

Having set forth a detailed description of the structure and operation of the coalescer unit 12 and the organics recovery unit 14, the structure and operation of the solids separation unit 16 will now be described in detail.

The Solids Separation Unit With reference to Figure 8, a specific embodiment of the solids separation unit 16 may comprise a shaker screen 30, a solids separation unit tank (SSU tank) 32, and a water recovery pump 34. In a specific embodiment, the shaker screen 30 may be provided with a solids entry conduit 236, a solids intake hopper 237, a plurality of support members 238, and one or more water deflectors 240. In a specific embodiment, the SSU tank 32 may be provided with a plurality of support sleeves 244, a sump 246, a water inlet conduit 248, a water outlet conduit 250, and a plurality of retainer pins 252.

In a specific embodiment, the shaker screen 30 may be a linear motion filtration screen of the type manufactured by Brandt Company, of Conroe, Texas, such as Model No. ATL-1000. The shaker screen may be provided with a plurality of support members 238. In a specific embodiment, the shaker screen is provided with four support members 238 which extend vertically downwardly from the lower surface of the shaker screen 30. In a specific embodiment, the solids entry conduit 236 may be a metal pipe having an approximate diameter of four inches. The solids entry conduit 236 is connected to the solids transfer conduit 186. A solids entry valve 239 may be provided in line with the solids entry conduit 236. As explained above, the solids transfer conduit 186 may be a metal pipe, a flexible hose, or part metal pipe and part flexible hose. If all or part of the solids transfer conduit 186 is a flexible hose, then the solids entry conduit 236 may be provided with a suitable hose connection. By using a flexible hose as all or part of the solids transfer conduit 186, the solids separation unit 16 is provided with the ability to raise and lower the shaker screen 30 (explained below). In a specific embodiment, the shaker screen 30 may be provided with one or more water deflectors 240. In a specific embodiment, the water deflectors 240 may be trapezoidal- shaped sheets of metal attached to the lower sides of the shaker screen 30 for funneling water from the shaker screen 30 into the temporary water storage tank 32. In a specific embodiment, the SSU tank 32 may be a rectangular metal box having an open upper portion. The SSU tank 32 serves as a reservoir for temporary collection of commingled water drained from the organics recovery unit 14 through the seal leg conduit 28 and from the shaker screen 30. The SSU tank 32 may be provided with a plurality of support sleeves 244. In a specific embodiment, the SSU tank is provided with four support sleeves 244. The support sleeves 244 are positioned such that the support members 238 on the shaker screen 30 may be slidably inserted into the corresponding sleeves 244. The sleeves 244 and members 238 may be provided with one or more mating apertures (not shown) for receiving the retainer pins 252. The floor of the SSU tank 32 may be provided with a sump 246. In a specific embodiment, the sump 246 may be a cylinder having an approximate diameter of 20 inches and an approximate height of six inches. The sump 246 is provided to collect water from the SSU tank 32 from where it can be pumped by the water recovery pump 34 through the water outlet conduit 250 to a remote water container (not shown) or back to the organics recovery unit 14. In a specific embodiment, the water outlet conduit 250 may be a metal pipe having an approximate diameter of four inches. One end of the water outlet conduit 250 is connected to the water recovery pump 34, and the other end should be positioned within the sump 246.

In a specific embodiment, the water recovery pump 34 is provided with an input side 254 and a discharge side 256. The input side 254 of the pump 34 is connected to the water outlet conduit 250. The discharge side 256 of the pump 34 is connected to a T-shaped conduit 276. One side of the T-shaped conduit 276 connects to the water recirculation conduit 278 (recall Figure 4), and the other side of the T-shaped conduit 276 connects to a water recovery conduit 280. The water recirculation conduit 278 connects the T-shaped conduit 276 to the recovered water inlet conduit 155 on the organics recovery unit 14. The water recovery conduit 280 leads to a remote water storage tank (not shown). A water recirculation valve 282 is connected in line with the water recirculation conduit 278. A water recovery valve 284 is connected in line with the water recovery conduit 280.

In a specific embodiment, the water recovery pump 34 may be a 4 x 3 (four inch by three inch) centrifugal water/organics pump sized at 100 GPM. of the type manufactured by Halco, Inc., of Houston, Texas, such as Model Series 2500. In a specific embodiment, the T-shaped conduit 276, the water recirculation conduit 278 and the water recovery conduit 280 may each be a metal pipe having an approximate diameter of three inches. In a specific embodiment, the water recirculation valve 282 and the water recovery valve 284 may each be a three-inch butterfly valve of the type manufactured by Nibco. of Elkhart, Indiana, such as Model No. WD 2100-3. In a specific embodiment, the solids separation unit 16 may also be provided with a plurality of ratchet load binders 253. When the shaker screen 30 is in the raised position, a ratchet load binder 253 may be connected between each of the upper corners of the SSU tank 32 and each of the corresponding lower corners of the shaker screen 30. The purpose of the ratchet load binders 253 is to provide additional stability when the solids separation unit 16 is in operation. In a specific embodiment, the ratched load binders 253 may be of the type manufactured by Campbell Company, of the United States, such as Model No. 620-7805.

Having provided a detailed description of the construction of the solids separation unit 16, its operation will now be described in detail. Solids and commingled water are pumped from the organics recovery unit 14 by the solids recovery pump 26 through the solids transfer conduit 186 and into the shaker screen 30. More particularly, the solids are pumped through the solids entry conduit 236 and into the solids intake hopper 237. The shaker screen 30 separates the solids from the commingled water by a conventional linear filtration process. The solids are discharged via a solids discharge trough 242 into a solids container (not shown). These solids may now be disposed of and/or stored temporarily to be processed through the apparatus 10 again, if required. The water that had been commingled with the solids feeds by gravity into the SSU tank 32, where it is commingled with water received from the organics recovery unit 14 through the water inlet conduit 248. The water deflectors 240 prevent the water feeding through the shaker screen 30 from splashing outside of the SSU tank 32. As the water level rises in the SSU tank 32, water may be intermittently pumped out of the SSU tank 32 by the water recovery pump 34 through the water outlet conduit 250 and T-shaped conduit 276; the water may be pumped either through the water recovery conduit 280 to a remote water storage tank (not shown), and/or through the water recirculation conduit 278 to be recirculated through the organics recovery unit 14. The destination of the water pumped from the SSU tank 32 is controlled by the water recirculation valve 282 and the water recovery valve 284. If all or part of the solids transfer conduit 186 is a flexible hose, the shaker screen 30 may be lowered into the interior of the SSU tank 32 for transportation of the apparatus 10. The shaker screen 30 may be lowered by removing the retainer pins 252 and allowing the support members 238 to slide down into the corresponding support sleeves 244. The retainer pins 252 may be replaced at appropriate locations through the members 238 and sleeves 244 so as to secure same. The shaker screen 30 may be provided with a hooking mechanism (not shown) such that the shaker screen 30 may be raised and lowered with a fork truck. Alternatively, the shaker screen 30 may be provided with a hydraulic lifting mechanism (not shown) whereby the shaker screen 30 may hydraulically raised and lowered. The apparatus 10 is provided with an appropriate electrical system (not shown) and associated control panel (not shown) to enable an operator to control various aspects of the apparatus 10 from a central location. The apparatus 10 may also be provided with a series of "catwalks^'' (not shown) to assist in the operation of the apparatus 10. The catwalks on the shaker screen 30 may be removably attached to allow for the lowering of the shaker screen 30 into the SSU tank 32. All equipment on the apparatus 10 should be grounded. This may be done by placing a metal rod (not shown) in the ground adjacent the apparatus 10 and attaching same to the skid 18. The skid 18 may be provided with a metal safety strap (not shown) to ground the skid 18 to the metal rod (or to any other grounded object). All components of the apparatus 10 are grounded to the skid 18. The outer periphery of the upper surface of the skid 18 may be provided with a retainer wall (not shown). The purpose of the retainer wall is to contain any spilled liquid from flowing off the skid 18 and contaminating any surrounding soil. The retainer wall (not shown) may comprise three-inch sections of angle iron. The condensate conduit 21 is provided adjacent the aperture 19 in the skid 18 to prevent the drainage of any spilled liquid through the aperture 19.

It is to be understood that the invention is not limited to the exact details of construction, operation, exact materials or embodiments shown and described, as obvious modifications and equivalents will be apparent to one skilled in the art.

Claims

CLAIMS 1. An apparatus for processing contaminated materials comprising: an enclosed container having a container inlet end, a container outlet end, a coalescer pump connected to the container outlet end and to a first end of a header conduit, and a plurality of channels of fluid communication from the header conduit into the container; a vessel having a vessel inlet end, a vessel outlet end, at least one solids collection container, a hydrocarbon recovery conduit connected to the vessel outlet end, a fluid recovery conduit connected to the vessel outlet end, a solids recovery conduit connected between the solids collection container and a solids pump, the vessel being connected to a second end of the header conduit; and a shaker screen attached to a tank, the shaker screen being connected by a solids transfer conduit to the solids pump, and the tank being connected to the fluid recovery conduit.

2. The apparatus of claim 1, further including a fluid passageway through which a processing agent may be added to the container.

3. The apparatus of claim 1, further including a heating coil disposed within the container.

4. The apparatus of claim 1, further including a circulation conduit connected between the second end of the header conduit and the container inlet end.

5. The apparatus of claim 1, further including means for abating vapors from the container.

6. The apparatus of claim 1, further including a fluid passageway through which a polymer may be added to the vessel.

7. The apparatus of claim 1, further including a heating coil disposed within the vessel.

8. The apparatus of claim 1, further including at least one regulator baffle disposed within the vessel.

9. The apparatus of claim 1, further including at least one coalescence louver disposed within the vessel.

10. An apparatus for processing contaminated materials comprising: a coalescer unit including an enclosed container having an interior, a coalescer inlet end, a pump end, a coalescer inlet conduit connected to the coalescer inlet end, a suction conduit connected to the pump end, a coalescer circulation pump connected between the suction conduit and a coalescer header assembly, the coalescer header assembly including a main header conduit and a plurality of nipples establishing fluid communication from the main header conduit to the interior of the enclosed container, a coalescer transfer conduit connected to the main header conduit, and a coalescer transfer valve connected to the transfer conduit for controlling fluid flow from the coalescer unit; an organics recovery unit including a vessel having a vessel inlet end, a vessel outlet end, at least one solids recovery container attached to a lower peripheral edge of the vessel, a vertex of the container pointing downwardly, a solids recovery conduit connecting the at least one solids recovery container to a solids recovery pump, a solids transfer conduit connected to the solids recovery pump, an organics recovery weir having a lower edge connected to the vessel outlet end and an upper edge, the recovery weir being within the vessel and inclined upwardly from its lower edge to its upper edge, a hydrocarbon recovery conduit connected to the vessel outlet end adjacent the lower edge of the recovery weir, and a seal leg conduit having an inverted U-shaped section connected to the vessel outlet end, an upper bend of the U-shaped section being positioned adjacent the lower edge of the recovery weir, the coalescer transfer conduit being connected to the vessel inlet end; and a solids separation unit including a shaker screen positioned above and attached to a tank, the seal leg conduit being connected to the tank, the solids transfer conduit leading from the solids recovery pump being connected to the shaker screen.

11. The apparatus of claim 10, wherein the coalescer unit further includes an inlet valve connected to the coalescer inlet conduit for controlling fluid flow through the coalescer inlet conduit.

12. The apparatus of claim 10, wherein the coalescer unit further includes a fluid passageway for adding at least one processing agent to the contaminated material as it circulates through the coalescer unit.

13. The apparatus of claim 10, wherein each of the plurality of nipples on the coalescer header assembly includes a valve for controlling fluid flow therethrough.

14. The apparatus of claim 10, wherein each of the plurality of nipples on the coalescer header assembly includes an end located within the enclosed container, and each end includes a nozzle for increasing the pressure at which fluid exits the nipples.

15. The apparatus of claim 10. wherein the coalescer unit further includes a heating coil disposed within the enclosed container.

16. The apparatus of claim 15, wherein the coalescer unit further includes a water level sample valve positioned above the heating coil.

17. The apparatus of claim 10, wherein an end of the suction conduit inside the container is positioned adjacent a lower surface of the container.

18. The apparatus of claim 10, wherein the suction conduit includes a bend of approximately ninety degrees and a lower end, the bend being disposed within the container with the lower end being positioned near to and directly above a lower surface of the container.

19. The apparatus of claim 10, wherein the coalescer unit further includes a sump connected to a lower surface of the container.

20. The apparatus of claim 19, wherein the coalescer unit further includes a coalescer cleaning conduit establishing fluid communication between the sump and the coalescer circulation pump.

21. The apparatus of claim 10, wherein the coalescer unit further includes a coalescer recirculation conduit connected between the main header conduit at the container inlet end and the inlet conduit.

22. The apparatus of claim 21, wherein the coalescer unit further includes a coalescer recirculation valve for controlling fluid flow through the recirculation conduit.

23. The apparatus of claim 10, wherein the coalescer unit further includes a plurality of vapor abatement ports attached to an upper surface of the container.

24. The apparatus of claim 23, further including a pressure sensitive check valve connected to the upper surface of the container.

25. The apparatus of claim 10, wherein the coalescer unit further includes means for monitoring the level of fluid within the container.

26. The apparatus of claim 10, wherein the organics recovery unit further includes a vessel inlet conduit connected to the vessel inlet end and connected to the coalescer transfer conduit.

27. The apparatus of claim 26, wherein the vessel inlet conduit includes an inner end disposed within the vessel, the inner end being configured to disperse fluid in a plurality of directions.

28. The apparatus of claim 10, wherein the at least one solids recovery container further includes an inverted solids dispersion member connected to the at least one solids recovery container with a vertex of the solids dispersion member pointing upwardly and being positioned approximately directly above the downwardly pointing vertex of the at least one solids recovery container, and lower edges of the solids dispersion member being spaced apart from walls of the at least one solids recovery container to permit passage of collected solids therearound.

29. The apparatus of claim 28, wherein the at least one solids recovery container and the solids dispersion member are pyramid-shaped.

30. The apparatus of claim 28, wherein the at least one solids recovery container and the solids dispersion member are cone-shaped.

31. The apparatus of claim 10, wherein the at least one solids recovery container further includes at least one solids sample valve.

32. The apparatus of claim 10, wherein the at least one solids recovery container further includes a capture chamber attached between the vertex of the at least one solids recovery container and the solids recovery conduit.

33. The apparatus of claim 32, wherein the capture chamber includes a cleaning coupling through which a pressurized medium may be injected to clear clogged solids from the capture chamber.

34. The apparatus of claim 10, wherein the solids recovery conduit is connected to the vertex of the at least one solids recovery container.

35. The apparatus of claim 10, wherein the solids recovery conduit includes a solids recovery header conduit and a solids recovery valve assembly for each at least one solids recovery container, each solids recovery valve assembly connecting the solids recovery header conduit to its corresponding solids recovery container and including a section of conduit with a valve connected thereto.

36. The apparatus of claim 10, wherein the organics recovery unit includes an enclosed upper surface and an air vent connected to and through the hydrocarbon recovery conduit and to and through the enclosed upper surface.

37. The apparatus of claim 10, wherein the organics recovery unit further includes a heating coil disposed within the vessel.

38. The apparatus of claim 10, wherein the organics recovery unit further includes at least one regulator baffle disposed within the vessel.

39. The apparatus of claim 10, wherein the organics recovery unit further includes a plurality of coalescence louvers disposed within the vessel.

40. The apparatus of claim 10, wherein the organics recovery unit includes means for monitoring the level and clarity of fluids within the vessel.

41. The apparatus of claim 10, wherein the organics recovery unit includes means for monitoring the clarity of fluid flowing into a lower end of an inner leg of the seal leg conduit.

42. The apparatus of claim 10, wherein the organics recovery unit further includes a polymer induction stem for adding at least one polymer to fluid flowing into the organics recovery unit.

43. The apparatus of claim 42, wherein the polymer induction stem is connected to the coalescer transfer conduit.

44. The apparatus of claim 10, wherein the organics recovery unit further includes a recovered water inlet conduit in fluid communication with the tank on the solids separation unit.

45. The apparatus of claim 10, further including a steam header assembly connected between the coalescer unit and the organics recovery unit, the steam header assembly having a steam inlet conduit connecting an inlet fitting on the coalescer unit to an inlet fitting on the organics recovery unit, a coalescer outlet conduit connected to an outlet fitting on the coalescer unit, and an organics recovery unit outlet conduit connected to an outlet fitting on the organics recovery unit.

46. The apparatus of claim 10. wherein the shaker screen further includes a solids entry conduit connected to the solids transfer conduit, and a plurality of support members for mating with a plurality of support sleeves connected to the tank.

47. The apparatus of claim 10, wherein the solids transfer conduit includes a section of pipe connected to the solids recovery pump and a section of flexible hose connected to the shaker screen.

48. The apparatus of claim 10, wherein the tank further includes a water outlet conduit extending from inside the tank through a wall of the tank and being connected to a water recovery pump.

49. The apparatus of claim 48, wherein an end of the water outlet conduit inside the tank is positioned in a sump in the floor of the tank.

50. The apparatus of claim 10, wherein the solids separation unit further includes a water recovery pump for pumping fluids from the tank.

51. The apparatus of claim 50, wherein a discharge side of the water recovery pump is connected by a water recirculation conduit to the organics recovery unit.

52. The apparatus of claim 50, wherein a discharge side of the water recovery pump is connected to a water recirculation conduit and to a water recovery conduit, the water recirculation conduit having a valve for controlling fluid flow therethrough and being connected to the organics recovery unit, the water recovery conduit having a valve for controlling fluid flow therethrough.

53. A coalescer unit for mixing contaminated material into a coalesced slurry comprising : an enclosed container having an interior, a container inlet end, a pump end. a container inlet conduit connected to the container inlet end, and a suction conduit connected to the pump end; a coalescer circulation pump connected between the suction conduit and a coalescer header assembly; the coalescer header assembly including a main header conduit and a plurality of nipples establishing fluid communication from the main header conduit to the interior of the enclosed container; a coalescer transfer conduit connected to the main header conduit; and a coalescer transfer valve connected to the transfer conduit for controlling fluid flow from the coalescer unit.

54. The coalescer unit of claim 53, further including an inlet valve connected to the container inlet conduit for controlling fluid flow through the container inlet conduit.

55. The coalescer unit of claim 53, further including a fluid passageway for adding at least one processing agent to the contaminated material as it circulates through the coalescer unit.

56. The coalescer unit of claim 53, wherein each of the plurality of nipples on the coalescer header assembly includes a valve for controlling fluid flow therethrough.

57. The coalescer unit of claim 53, wherein each of the plurality of nipples on the coalescer header assembly includes an end located within the enclosed container, and each end includes a nozzle for increasing the pressure at which fluid exits the nipples.

58. The coalescer unit of claim 53, wherein the coalescer unit further includes a heating coil disposed within the enclosed container.

59. The coalescer unit of claim 58, wherein the coalescer unit further includes a water level sample valve positioned above the heating coil.

60. The coalescer unit of claim 53, wherein an end of the suction conduit inside the container is positioned adjacent a lower surface of the container.

61. The coalescer unit of claim 53, wherein the coalescer unit further includes a sump connected to a lower surface of the container.

62. The coalescer unit of claim 61. wherein the coalescer unit further includes a coalescer cleaning conduit establishing fluid communication between the sump and the coalescer circulation pump.

63. The coalescer unit of claim 53, wherein the coalescer unit further includes a coalescer recirculation conduit connected between the main header conduit at the container inlet end and the container inlet conduit.

64. The coalescer unit of claim 53, wherein the coalescer unit further includes a plurality of vapor abatement ports attached to an upper surface of the container.

65. The coalescer unit of claim 64, further including a pressure sensitive check valve connected to the upper surface of the container.

66. The coalescer unit of claim 53, wherein the coalescer unit further includes means for monitoring the level of fluid within the container.

67. An organics recovery unit for separating a contaminated material into hydrocarbon, fluid and solids components comprising: a vessel having a vessel inlet end, and a vessel outlet end; a vessel inlet conduit connected to the vessel inlet end; at least one solids recovery container attached to a lower peripheral edge of the vessel, a vertex of the container pointing downwardly; a solids recovery conduit connecting the at least one solids recovery container to a solids recovery pump; an organics recovery weir having a lower edge connected to the vessel outlet end and an upper edge, the recovery weir being within the vessel and inclined upwardly from its lower edge to its upper edge; a hydrocarbon recovery conduit connected to the vessel outlet end adjacent the lower edge of the recovery weir; and a seal leg conduit having an inverted U-shaped section connected to the vessel outlet end. an upper bend of the U-shaped section being positioned adjacent the lower edge of the recovery weir.

68. The apparatus of claim 67, wherein the vessel inlet conduit includes an inner end disposed within the vessel, the inner end being configured to disperse fluid in a plurality of directions.

69. The apparatus of claim 67, wherein the at least one solids recovery container further includes an inverted solids dispersion member connected to the at least one solids recovery container with a vertex of the solids dispersion member pointing upwardly and being positioned approximately directly above the downwardly pointing vertex of the at least one solids recovery container, and lower edges of the solids dispersion member being spaced apart from walls of the at least one solids recovery container to permit passage of collected solids therearound.

70. The apparatus of claim 69, wherein the at least one solids recovery container and the inverted solids dispersion member are pyramid-shaped.

71. The apparatus of claim 69, wherein the at least one solids recovery container and the inverted solids dispersion member are cone-shaped.

72. The apparatus of claim 67, wherein the at least one solids recovery container further includes a capture chamber attached between the vertex of the at least one solids recovery container and the solids recovery conduit.

73. The apparatus of claim 72, wherein the capture chamber includes a cleaning coupling through which a pressurized medium may be injected to clear clogged solids from the capture chamber.

74. The apparatus of claim 67, wherein the solids recovery conduit is connected to the vertex of the at least one solids recovery container.

75. The apparatus of claim 67, wherein the solids recovery conduit includes a solids recovery header conduit and a solids recovery valve assembly for each at least one solids recovery container, each solids recovery valve assembly connecting the solids recovery header conduit to its corresponding solids recovery container and including a section of conduit with a valve connected thereto.

76. The apparatus of claim 67, wherein the organics recovery unit includes an enclosed upper surface and an air vent connected to and through the hydrocarbon recovery conduit and to and through the enclosed upper surface.

77. The apparatus of claim 67, wherein the organics recovery unit further includes a heating coil disposed within the vessel.

78. The apparatus of claim 67, wherein the organics recovery unit further includes at least one regulator baffle disposed within the vessel.

79. The apparatus of claim 67, wherein the organics recovery unit further includes a plurality of coalescence louvers disposed within the vessel.

80. The apparatus of claim 67, wherein the organics recovery unit includes means for monitoring the level and clarity of fluids within the vessel.

81. The apparatus of claim 67, wherein the organics recovery unit includes means for monitoring the clarity of fluid flowing into a lower end of an inner leg of the seal leg conduit.

82. The apparatus of claim 67, wherein the organics recovery unit further includes a polymer induction stem for adding at least one polymer to fluid flowing into the organics recovery unit.

83. The apparatus of claim 82, wherein the polymer induction stem is connected to the coalescer transfer conduit.

84. The apparatus of claim 67, wherein the organics recovery unit further includes a recovered water inlet conduit in fluid communication with the tank on the solids separation unit.

85. A method of using an integrated apparatus to process contaminated materials, the apparatus including an enclosed container, a vessel, a shaker screen, and a tank, the method comprising the steps of: flowing a fluid into the enclosed container; pumping a contaminated material into a container inlet end of the enclosed container; mixing the contaminated material and fluid into a fluid mixture by pumping the contaminated material and fluid from the enclosed container and back into the enclosed container, the fluid mixture including at least one hydrocarbon, the fluid, and at least one solid; transferring the fluid mixture into the vessel through a vessel inlet end thereof; separating the fluid mixture within the vessel into separate layers of the hydrocarbons, the fluid, and a mixture of the fluid and the solids, based upon their respective specific gravities; transferring the hydrocarbons to a hydrocarbon recovery container; transferring the fluid to the tank; transferring the mixture of the fluid and the solids to the shaker screen; using the shaker screen to separate the solids from the fluid; transferring the solids to a solids recovery container; and, transferring the fluid to the tank.

86. The method of claim 85, further including the step of partially filling the enclosed container with the fluid before the step of pumping the contaminated material into the enclosed container.

87. The method of claim 86, further including the step of heating the fluid in the container before the step of pumping the contaminated material into the enclosed container.

88. The method of claim 85. further including the step of heating the fluid mixture.

89. The method of claim 85, further including the step of passing the contaminated material through a screen before the step of pumping the contaminated material into the enclosed container.

90. The method of claim 85, wherein the mixing step further includes the step of circulating the fluid mixture back into the enclosed container through a plurality of nipples in a wall of the enclosed container.

91. The method of claim 90, further including the step of adjusting the rate at which the fluid mixture is pumped through each of the plurality of nipples.

92. The method of claim 90, wherein the mixing step further includes the step of circulating a portion of the fluid mixture back into the enclosed container through the inlet end of the enclosed container.

93. The method of claim 92, further including the step of adjusting the rate at which the fluid mixture is pumped through the inlet end of the container.

94. The method of claim 85. further including the step of circulating the fluid through the enclosed container by continuously pumping the fluid from the enclosed container and back into the enclosed container before the step of pumping the contaminated material into the enclosed container.

95. The method of claim 85, further including the step of adjusting the rate at which the fluid mixture is pumped back into the enclosed container.

96. The method of claim 85, further including the step of stopping the pumping of contaminated material into the container after the mixing step and before the step of transferring the coalesced slurry to the vessel.

97. The method of claim 85, further including the step of allowing the fluid mixture to reach a predetermined temperature before the step of transferring the coalesced slurry to the vessel.

98. The method of claim 85, further including the step of partially filling the vessel with fluid before the step of transferring the fluid mixture to the vessel.

99. The method of claim 98, further including the step of heating the fluid in the vessel before the step of transferring the fluid mixture to the vessel.

100. The method of claim 85, wherein the fluid mixture is dispersed in separate directions upon entering the inlet end of the vessel.

101. The method of claim 85, further including the step of continuously flowing a fluid into the vessel.

102. The method of claim 85, wherein the step of transferring the fluid mixture into the vessel further includes the step of flowing a fluid into the vessel.

103. The method of claim 85, further including the step of stopping the transfer of the separated fluid from the vessel to the tank after the supply of fluid mixture being transferred from the enclosed container has been exhausted, and flowing a fluid into the vessel to remove all hydrocarbons from the vessel.

104. The method of claim 85, further including the step of heating the fluid mixture within the vessel.

105. The method of claim 85, wherein the contaminated material is pumped into the enclosed container at approximately the same rate as the fluid mixture is transferred from the enclosed container to the vessel.

106. The method of claim 85, further including the step of adding at least one processing agent to the enclosed container before the step of transferring the fluid mixture to the vessel.

107. The method of claim 85, wherein the step of transferring the fluid mixture to the vessel further includes the step of adding at_. least one polymer to the fluid mixture.

108. The method of claim 85, wherein the fluid that is separated from the hydrocarbons and the solids includes at least one processing agent.

109. The method of claim 85, wherein the fluid that is separated from the hydrocarbons and the solids includes at least one polymer.

110. The method of claim 85, wherein the fluid that is placed into the enclosed container and the vessel is water.

111. The method of claim 85, wherein the mixture of the solids and the fluid are intermittently pumped from solids collection containers attached to the vessel to the shaker screen.

112. The method of claim 85, further including the step of pumping the fluid from the tank back into the vessel.

113. The method of claim 85, further including the step of pumping the fluid from the tank back to a remote water recovery container.

114. The method of claim 85, further including the step of abating vapors from the container.

115. The method of claim 85, further including the step of abating vapors from the vessel.

116. The method of claim 85, wherein each of the steps are continuously implemented until the contaminated material has been exhausted.