Sludge Removal of Crude Oil Tanks and Re

1 | Content
Ministry of Higher Education and Scientific Research
Basrah University for Oil and Gas (BUOG)
Oil & Gas Engineering College
Chemical Engineering and Oil Refining Department
Project Name:
Sludge Removal of Crude Oil Tanks and Recovery of

Hydrocarbons
2019-2020
By
Fatima Z., Noor Al-Huda J., Noor A., Ahmed A. and
Sajad J.
Supervisors:
Dr. Mohammed Abdulwahab
Dr. Haider Abd Faraj
Basrah University for Oil and Gas (BUOG) IRAQ

‫‪2 | Content‬‬
‫بسم هللا الرمحن الرحي‬

‫وِت خ ْ ًَْيا َكثي ًْيا ۗ َو َما ي َ َّذكَّ ُر ا ََّّل ُأولُو ْ َاْللْ َب ياب{‬
‫} يُ ْؤ يِت الْ يح ْْكَ َة َم ْن يَشَ ا ُء ۚ َو َم ْن يُ ْؤ َت الْ يح ْْكَ َة فَقَدْ ُأ ي َ‬
‫ِ‬
‫صدق هللا العيل العظي‬

‫البقرة (‪)269‬‬
‫‪Basrah University for Oil and Gas (BUOG) IRAQ‬‬

‫الاهداء‬
‫اىل من تتسابق اللكامت لتخرج معربة عن مكنون ذاهتا‬

‫من علمتين وعانت الصعاب ي ِْل يصل اىل ما ِأان فيه‪ِ ....‬أيم‬
‫اىل من علمين النجاح والصرب‪ِ ....‬أيب‬
‫اىل لك من اضاء بعلمه عقل غْيه‬
‫او هدى ابجلواب الصحيح حْية سائليه‬
‫واظهر بسامحته تواضع العلامء‬
‫وبرحابته سامحة العارفني ‪....‬‬

‫امحلد رب العاملني والصالة والسالم عىل س يد املرسلني ﷴ و ِأههل بيته الطيبني الطاهرين‪.‬‬
‫من علينا بنعمة الاميان والعل‬

‫الشكر والتزنيه هلل العيل القدير اذلي َّ‬
‫ويرشفنا التقدم ابلشكر وا ِْلمتنان اجلزيل اىل " د‪ .‬محمد عبد الوهاب" و "د‪ .‬حيدر عبد فرج"‬
‫لتفضلهم ابَّلرشاف عىل هذا املرشوع وابخلصوص"د‪.‬حيدر" وتوجهياته القمية يف لك خطوة خنطوها‪.‬‬
‫كام نتقدم ابلشكر اىل لك من شد ِأزران وساندان‪.‬‬

5 | Content
Content
Chapter One: Introduction …………………………………………………………… 8

1.1. Crude oil.…………………………………………………………………… 8
1.2. crude oil compounds ………………………………………………………. 8
1.3. Oily sludge…………………………………………………………………. 12
1.4. Objectives of the study……………………………………………………... 14
Chapter Two: Sludge Treatment Methods…………………………………………. 15

2.1- Manual cleaning…………………………………………………………... 15
2.2- Steam cleaning …………………………………………………………… 16
2.3- Dispersion method………………………………………………………… 18
Chapter Three: Hydrocarbons Recovery from Oily Sludge………………………. 19

3.1- Removing sludge and recovering oil by atmospheric residue……………. 19
3.2- Centrifugation treatment…………………………………………………. 21
3.3- Zaopin technologies for crude oil tank cleaning system…………………. 23
Chapter Four: Selection and Design the Process…………………………………… 26

4.1- Process Description……………………………………………………….. 26
4.2- Material Balance…………………………………………………………... 36
4.3- Energy Balance……………………………………………………………. 43
Chapter Five: Equipment Design……………………………………………………. 50

5.1- Design gravity Settling Tank (Settler)…………………………………….. 50
5.2- Design of Rotary Drum Filter……………………………………………… 57
5.3- Design of Heat Exchanger…………………………………………………. 59
References……………………………………………………………………………… 72

6 | Content
page Figure list

8 Figure 1.1 the main classes of hydrocarbons.
16 Figure 2.1 block flow diagram of sludge removal by steam.
17 Figure 2.2 the distribution spray nozzles in the tank.
18 Figure 2.3 apparatus assembly used in the process.
18 Figure 2.4 apparatus assembly used in the cleaning process.
19 Figure 3.1 process flow diagram with atmospheric residue.
22 Figure 3.2 flow chart for centrifugation treatment.
24 Figure 3.3 block flow diagram for zaopin process.
29 Figure 4.1 the process flow diagram with kerosene.
31 Figure 4.2 properties of the crude oil tank in refineries.
34 Figure 4.3 specific heat capacity of oily sludge at variation of temperature.
36 Figure 4.4 a-material balance of the tank.
38 Figure 4.5 b-material balance of the tank with result.
38 Figure 4.6 a-material balance of filter.
40 Figure 4.7 b-material balance of filter with result.
40 Figure 4.8 a-material balance of gravity settling tank (settler).
42 Figure 4.9 b-material balance of gravity settling tank (settler) with result.
44 Figure 4.10 a-energy balance for pump p-2.
head pressure is represented by the height of kerosene and dissolved
44 Figure 4.11
sludge above suction line 2 m.
45 Figure 4.12 curve between the volumetric flow rate and pump efficiency.
46 Figure 4.13 b-energy balance for pump p-2 with result with result.
47 Figure 4.14 a-energy balance for pump p-1.
48 Figure 4.15 b-energy balance for pump p-1 with result.
49 Figure 4.16 energy balance for heat exchanger.
50 Figure 5.1 gravity settling tank.
55 Figure 5.2 designed settler with dimension.
57 Figure 5.3 rotary drum filter.
59 Figure 5.4 heat exchanger, where kerosene in shell side and water in tube side.
68 Figure 5.5 heat exchanger with head position.
70 Figure 5.6 saddles of heat exchanger.

7 | Content
Page Table list
12 Table 1.1 ranges of compounds for oily sludge which is from crude oil origin.
a: oily (petroleum) sludge composition. the samples were taken

27 Table 4.1.a along the depth of the storage pond so that sample ps1 was taken at
the surface and sample:
two samples from oily sludge for two tanks (dried solid, semi dry
27 Table 4.1.b
solid) from crude oil of Egypt.
the characterizations of kerosene which is used in the process as

27 Table 4.2
solvent.
28 Table 4.3 hydrocarbons recovery at various (kg sludge: liter solvent) ratios.
hydrocarbon recovery at various temp. at ideal (kg sludge: liter

28 Table 4.4
solvent) ratio.
30 Table 4.5 the process conditions with kerosene.
34 Table 4.6 specific heat with temperature of oily sludge.
37 Table 4.7 inlet and outlet stream of the tank.
59 Table 5.1 the physical properties of kerosene stream and water stream.
67 Table 5.2 summery for design of heat exchanger.
71 Table 5.3 the dimensions of typical “standard” saddle designs.

8 | Chapter One: Introduction
Chapter One: Introduction
1.1- Crude Oil
Crude oil is a complex fluid mixture of organic compounds, inorganic compounds and
some metals. The hydrocarbons are the main compounds in the crude oil. Figure 1.1 shows the
main classes of hydrocarbons [1]. The crude oil forms in the formation according to the
condition of high temperature and high pressure. The crude oil is produced from the wells to be
treated and processed to produce more valuable products [2].
Alkenes
Alkyenes
Unsaturated
HCs
Naphthenes
Aromatic The classes of Saturated

hydrocarbons hydrocarbons HCs
paraffins
Figure 1.1 the main classes of hydrocarbons [1].
1.2- Crude Oil Compounds
1.2.1- Paraffins: saturated hydrocarbons represent by two types which are n-alkane
(methane, ethane, propane, etc.) and iso-alkanes (iso-butane, iso-pentane, etc.). Some examples
for paraffins structure [1]:

paraffins are colorless and the state of paraffins depend on number of carbons atoms.
Where gas state for (C1-C4), liquid state for (C5-C15), soils state (C15+). Iso-alkane have a much
higher octane number than n-alkane [5].
1.2.2- Olefins: unsaturated hydrocarbons which are alkenes (contain double bonds
between two atoms from carbons) and alkynes (contain triple bonds between two atoms from
carbons). Some examples for olefins structure [1]:
Crude oil naturally doesn’t contain olefins but through the conversion processes for crude
oil lead to form Olefins which represent important feedstocks for the petrochemical [1].
1.2.3- Cycloalkanes: saturated hydrocarbons like paraffins also called by naphthenes.

They are cyclic structure one ring at least. Some examples for naphthenes structure:

1.2.4- Aromatics: unsaturated cyclic hydrocarbons which are based on the benzene
rings. Therefore, an aromatic compound has one or more benzene rings. Some examples for
aromatic structure [1].
Benzene ring are very stable according to an electron arrangement and three double bonds
of carbons in the benzene ring; therefore, benzene ring doesn’t crack into smaller compounds.
This stability makes aromatics compounds have the highest octane number between the crude
oil compounds [7].
1.2.5- Sulphur Compounds: are found in the crude oil in inorganic forms like (hydrogen
sulphide H2S, carbonyl sulphide COS) also, in organic forms like (mercaptans, sulphides,
polycyclic sulphides and thiophenes). Some examples for sulphur compounds [1]:
Sweet crude oil with less than 1 wt. % sulphur and sour crude oil that with more than 1
wt. % sulphur [1].

1.2.6- Oxygen Compounds: the crude oil when exposure to the atmosphere that result to
create the oxygen compounds in the crude oil. The percent of the oxygen content is less than
2% wt. the oxygen compounds are alcohols, ethers, carboxylic acids, phenolic compounds,
ketones, esters and anhydrides. Some examples for oxygen compounds [1]:
1.2.7- Nitrogen Compounds: are classified as basic and non-basic. Basic nitrogen
compounds consist of pyridines and non-basic nitrogen compounds are generally of pyrrole
types [1].
1.2.8- Metallic Compounds: the metallic components in the crude oil is found as
inorganic water-soluble salts, oil-soluble organometallic compounds, organometallic soaps and
some metallic appear as oil-soluble compounds. The common metallic components in the crude
oil are sodium, potassium, magnesium, calcium, vanadium, nickel, copper and iron [1].
1.2.9- Asphaltenes and Resins: Asphaltenes are dark brown friable solids that have no
definite melting point represented by polynuclear aromatic [1] and the components consist
asphaltenes are carbon, hydrogen, nitrogen, oxygen, sulphur and metals. Asphaltenes have
complex structure difficult to specific chemical formula [3].
Resins are organic compounds which has molecular weight range between 500-1000.
Some theories believe that resins responsible to dissolve and stabilize the solid asphaltenes
molecules in the liquid oil by surrounded and suspended them [1].

1.3- Oily Sludge
Storage tanks for crude oils and their products in a refinery through the operation, residual
deposits accumulate in the bottom of storage tanks to depths of one meter or more in the large
tanks according to many conditions. These residual deposits are called by oily sludge [10,19].
There are other sources for oily sludge in a refinery like the API separator and tilted plate
interceptor (TPI) unit [20]. Oily sludge is semi solid or solid material and has a black color [19].
Also, oily sludge called petroleum sludge [26,27].
1.3.1- Oily Sludge Compounds & Elements
Compounds and compositions for each samples of oily sludge are different between them
according to a crude oil source, processes flow and an equipment [21]. Generally, oily sludge
comprises of water in oil emulsion, and suspended solids [19,26,27].
Table 1.1 shows possible ranges of compounds for oily sludge which is from crude oil origin
[22].
Compounds Wt. % of oily sludge

wax 10-40%
Asphaltenes 1-10%
Water 0-10%
Inorganic solids 0-05%
Light hydrocarbons 40-80%
nitrogen sulphur and oxygen components are found in hydrocarbons compounds or in

inorganic solids such as (naphthenic acids, mercaptans and pyridines) or (iron sulphuide and
iron oxide) [21]. Inorganic solid elements are aluminum, calcium, chlorine, iron, magnesium,
potassium, silicon and sodium [23].
1.3.2- The Formation of Oily Sludge in The Bottom Storage Tank
There are main reasons behind accumulate oily sludge in the bottom storage tanks [19]:

▪ A gravity difference between the crude oil compounds is separated the light compounds
and heavy compounds where the heavy compounds will be settled in the bottom of
storage tanks to create residual deposited.
▪ Induced dipole force is produced by paraffins which will be tend to flocculate and then
accumulate in the bottom of storage tanks as wax.
▪ Asphaltenes and resins tend to create colloidal materials which are electrically charged.
The neutralization of this charge can result in precipitation of the material [19].
1-3-3- Problems Cause by Oily Sludge
Oily sludge leads to many problems through refineries when accumulate in bottom of
storage tanks [10]:
▪ Decrease the capacity of the storage tanks.
▪ Oily sludge leads to fail pumps, filters and other equipment.
▪ Close the suction of the storage tanks by oily sludge, therefore pumps can't withdraw
crude oil from the storage tanks.
▪ Oily sludge makes clogs in the pipes.
These problems create the necessity to remove oily sludge from the storage tanks. In the
past even now, some countries remove oily sludge and then directly disposal it to the
environment in the specific area without treatment [chapter 2,3]. Oily sludge contains several
toxic compounds, therefore considered as hazardous waste [21]. That creates many problems
which effect on different sides of the environment like the atmosphere, soil and groundwater
and also leads to problems which impact on the health [18]. Now, the big challenge between
companies to build up process to remove and treat the oily sludge in a way that safes the
environment, consumes less energy and cost.

1.4- Objective of The Study
The aim of this study to design a process to remove oily sludge from a crude oil tank.
After eliminate oily sludge from the crude oil tank, oily sludge goes to further processes to treat
oily sludge and recover valuable materials from oily sludge. Therefore, the process targets to:
1. Removal sludge from the crude oil storage tank to save the operation system.
2. Recover hydrocarbons from oily sludge to reduce the pollution in the environment and
also the recovery hydrocarbons provide valuable product which backs to the refinery.

15 | Chapter Two: Sludge Treatment Methods
Chapter Two: Sludge Treatment Methods
Sludge treatment methods are an interesting topic for many researchers in oil industry
field. The sludge accumulates in crude oil storage tanks and is formed for many reasons such
as high density and viscosity of crude oil. This sludge causes many problems like reducing the
storage capacity for the tanks and failing to equipment if the sludge crosses the suction line for
the tank. Therefore, the sludge should be removed to maintain the operation processes in
refineries [18]. According to the literature, the sludge treatment methods can be classified to
three types:
1. Mechanical Methods
2. Chemical Methods
3. Hybrid Methods
In this chapter, common sludge treatment methods will be discussed.
2.1- Manual Cleaning
Manual cleaning is a primary method for cleaning tanks. It is a simple and easy way to
clean the storage tanks that have few amounts of sludge. It represents the most common and the
cheapest method for tank cleaning. The method is achieved by leaving only the sludge in the
tank and then staff (workers) enters inside the tank to remove the sludge from the tank by using
manual equipment to move the sludge out the manway [17].
The advantages of this method do not need to use large and expensive equipment, easy
and very low operating cost. Therefore, all this makes the method is the cheapest method.
The disadvantages of this method, the materials (mixtures of hydrocarbons and heavy
metals such as cobalt, lead and vanadium) inside tank is toxic [21] and mostly flammable and
harmful to environment and not safe for human. They harm the atmosphere by releasing toxic
gases and vapors when they expose to high temperature. They may be dumped into disposal
lands and end in ground waters. This process spends a long time to be achieved and leading to
lose storage capacity during the process [17].

2.2- Steam Cleaning
The method depends on a high-pressure steam (H.P.S) and black oil. The method is
developed and applied by Aldawra refinery-Bagdad. The equipment used in the process are
filters, pumps, spray nozzles, nozzle distributors and rubber hoses. Figure 2.1 shows the block
flow diagram of sludge removal by steam [24].
Figure 2.1 block flow diagram of sludge removal by steam.
Process Steps:
Firstly, the tank should be as empty as possible or just contains sludge, that means all that
the storage tanks should not contain any hydrocarbons materials. But if the hydrocarbons are
presented, black oil is added to the sludge tank and black oil should cover the sludge and be
higher than the sludge by 15 cm. The major function for black oil is extracted light
hydrocarbons exist in the sludge to prevent these components to be volatile in the tank at a
high temperature to keep the process safety [24].

The high-pressure steam is provided from the refinery utilities, high-pressure steam
(H.P.S) line is connected to nozzle distributors by rubber hoses which have the ability to resist
the high temperature and high pressure (270 oC, 33 bar). Nozzle distributors are installed above
the tank connected to spray nozzles inside the tank by rubber hoses (flexible hoses) [24].
The spray nozzles extent through the sludge in the tank as Figure 2.2. The numbers of
spray nozzles depend on the amount of sludge, the sludge components and the tank volume.
Sludge
Figure 2.2 the distribution spray nozzles in the tank.

The steam flows through spray nozzles at (17 bar, 2500C) and can be adjustfy if need, to
melt the sludge. At the same time, black oil stays at a temperature 60 0C to lower the density of
melted sludge. The mixture of black oil and sludge in the tank is recirculated to keep the mixture
in homogenous [24].
The mixture pumped from the tank to the filters (an intermedia tank) to separate solid
particles. The mixture is stored in a black oil storage tank. After that, raise the temperature in
the tank between the range (70-80) 0C to complete melt sludge. But the temperature should not
exceed the range to ensure the water in the sludge do not change to the vapor state. After
complete melt the sludge as possible, also should be pumped to the black oil storage tank across
the filters. This method has been applied in different oil locations in Iraq [24].

2.3- Dispersion Method
This method combines two methods; chemical and mechanical. Chemicals called sludge
dispersant is used in this method. The sludge dispersant disperses accumulated sludge in oil
storage tanks to breakout the heavy-viscous molecules such as waxes and asphaltenes.
Dispersant materials surround the hydrocarbon molecules and break down the attraction forces
between the hydrocarbon molecules [13].
High-pressure fluid (mechanical method): Removing sludge depends on dispersed

molecules principle of petroleum sludge by jetting liquids at high pressure through nozzles
connect to pipe [13]. The apparatus assembly and equipment used in the process are shown in
Figure 2.3 and Figure 2.4:
Figure 2.3 apparatus assembly used in the process.
Figure 2.4 apparatus assembly used in the cleaning process.

19 | Chapter Three: Hydrocarbons Recovery from Petroleum Sludge
Chapter Three: Hydrocarbons Recovery from Petroleum Sludge
Petroleum sludge accumulates in large mass in crude oil tanks, refinery tanks, desalters
and elsewhere through petroleum production and processes even in pipelines. In addition, toxic
substances [21] in petroleum sludge make it a major source of environmental pollution.
Therefore, the most desirable environmental choice for handling petroleum sludge is to recover
valuable components. The technology used in treatment of petroleum sludge should be
developed for direct processing in the refinery to high quality petroleum products and safe
environment [11].
3.1- Removing Sludge and Recovering Oil by Atmospheric Residue
The method uses an atmospheric residue as thermal oil which is discharged to the tank
contain sludge to melt sludge and then separating thermal oil and hydrocarbons from inorganic
materials [14]. Figure 3.1 shows process flow diagram for this method.
Figure 3.1 process flow diagram with atmospheric residue.
The atmospheric residue is produced from the atmospheric distillation. It is represented

as thermal oil used through the process. In the south refineries company, the atmospheric
residue or thermal oil is named RCR and it is used because [14]:

▪ High boiling point about (260-550) o C, high flash point and lower vapor pressure
(lower gases and vapors content) all that provide safe handling.
▪ The crude oil contains (30-40) % from atmospheric residue, so that the atmospheric
residue is available in sufficient amount by the refinery process.
▪ The storage temperature of atmospheric residue is about (80-130) oC which means
the process of removing sludge does not require an additional equipment such as a
heat source.
As Figure 3.1 shows the process, where the tank 2 is storage tank contains the sludge,
the tank 2 should be just contains the sludge for safety reasons especially the crude oil storage
tanks. The tank 1 contains the thermal oil. Thermal oil is pumped from the tank 1 to the tank 2
at the temperature ranges between (50-130) o C. If the temperature of thermal oil below the
range, thermal oil should be passed through a heat exchanger to supply the necessary heat to
keep the temperature of thermal oil between the range [14].
In the tank 2, the temperature of thermal oil and melted sludge should stay between (50-
130) 0C in the tank 2. If the temperature becomes lower than 500C in the tank 2 because a fusion
heat to melt the sludge and the heat loss in the system, the mixture of thermal oil and melted
sludge is recirculated by the pump through the heat exchanger back to the tank 2. It is faster to
melt sludge in the tank 2 by using mixers beside the high temperature [14].
In the tank 2, the distribution temperature can be as indicator for knowing complete melt
sludge along the tank level. If the temperature of top level is similar to bottom level, this means
complete melt of sludge. If the temperature of top level is higher than the bottom level, this
means the melting process is not completed and needed more time [14].
After complete melting, the mixture in the tank 2 is transferred to the separation tank. In
the separation tank, the mixture is maintained at temperature of 60 oC or higher, because higher
temperature leads to lower viscosity, causing inorganic materials to settle in the bottom of
separation tank. Then the thermal oil and the recovered oil from the sludge are withdrawn from
the separation tank as marine oil or feed for the secondary treatment process. After that the
inorganic components should be disposed in a landfill [14].

3.2- Centrifugation Treatment
The sludge removal from the tank by washing water should be the first step in the process.
This step is accomplished by jetting water at high pressure to form slurry inside the tank
[chapter 2]. The slurry is discharged to the centrifugation treatment be treated.
The centrifugation treatment depends on a principle of centrifugal force to separate the

solid materials from the liquid. For high efficiency, heat and mixing can be applied for the
treatment to increase the high percent of oil recovery from the sludge [15]. Figure 3.2 shows
flow chart for the process.
As Figure 3.2, the slurry from the first step (sludge removal) becomes feedstock 12 for
the centrifugation treatment. Feedstock 12 is diluted with water to get the slurry of weight
present less than 5% and then passed through screen 14 to remove large particles that have a
diameter larger than 2 mm to be discarded as debris 16 [15].
The slurry is fed to the conditioning vessel 18 where agitated by mixing at high
temperature arrived to 83 oC or higher (if needed) for enough time to ensure that waxy
petroleum solids are melted. The purpose of that process is to reduce the density and the
viscosity as well as to break a surface adhesion (the tendency of similar or identical
particles/surfaces to cling to one another [39]) between petroleum and fine particles. The
concentration of gas formed in conditioning vessel 18 is controlled to ensure the concentration
does not exceed to lower explosive limit. The gas formed goes to steam generator 20 [15].
The slurry becomes ready to go from conditioning vessel 18 to first centrifuge 22. The
centrifuge has the ability to achieve good separation. The first centrifuge 22 has two outlets that
are a liquid effluent that contains most petroleum fractions which go back to refinery 24. The
residual cake is not ready to be disposed. Therefore, the residual cake goes into reactor tank 26
where agitated and diluted with the hot water 28 at the temperature 83 o C to create a second
slurry to be treated with a hydrogen peroxide 30. Hydrogen peroxide oxidizes toxic polycyclic
aromatic hydrocarbons to non-toxic derivatives. For example, the reaction of naphthalene with
hydrogen-peroxide as shown below [15].

12 gas 20 steam
feedstock steam generator
16 14
debris screen
18 steam
Conditioning vessel
First effluent 30 28
22
H2O2 source Hot water
first centrifuge
Residual cake
12
Waste feed
Second
effluent 32
Second centrifuge
24 Residual cake
36 34
To refinery Dewatering Solids disposal
Figure 3.2 flow chart for centrifugation treatment [15].

The gas formed in the reactor tank 26 is controlled to not be exceeded a limit
concentration to prevent an explosive. Therefore, the formed gas is taken to the steam generator
20. The second slurry becomes ready to the second centrifuge 32 which has two outlets. The
second liquid effluent connects with the first liquid effluent from the first centrifuge 22 to back
for the refinery 24 and the second residual cake may contain about 0.5% weight of petroleum
fractions. The second residual cake is disposal 34 directly, or dewatering 36 to be dry to meet
disposal requirement then disposal 34 [15].
3.3- Zaopin Technologies for Crude Oil Tank Cleaning Systems
Tank cleaning system by zaopin technologies is safely removing sludge and recovering
95% of hydrocarbons from the sludge. These technologies are use with crude oil tanks and oil
derivatives [16]. The system consists of two main processes:
1. Zaopin COW system: COW (Crude Oil Washing). The system runs automatic and using
high-pressure, high impact washing cannons to break up the sludge. It contains on
advanced oil sludge separation system which recovers most of the oil from the sludge.
The main system components are [16]:
▪ Nitrogen generation unit
▪ Oil/solids separation module
▪ Oil/water separation module
▪ Washing cannon
▪ Control room
2. Zaopin dozer: special cleaning vehicle removes any inorganic sediments remaining on
the tank floor. The dozer is operated by one man from control room. Figure 3.3 shows
the process.

Figure 3.3 block flow diagram for zaopin process [16].
Process Steps:
1- Preparation
A 15 cm of crude oil should be remained above the sludge to be used as washing medium
during the process. Then washing cannons install in the tank by the manway at the top or bottom
according the kind of tank and sludge height in the tank. The main components of washing
cannon [16]:
▪ Large cleaning nozzle can move with 1800 vertically and horizontally which have
ability to wash the tank with pressure up to 270 kpa at volumetric flow rate 50 m3/h.
▪ A video camera and headlamp are used to monitoring and recording washing
cannons.
The process needs 1-4 washing cannons to achieve high performance. Finally, the
concentration of oxygen and explosive gases in the tank should be limited. Therefore, nitrogen
generation unit fills the tank with nitrogen. The oxygen concentration is controlled
automatically and the concentration of oxygen has to be less than 8% by mol. Oil Wash
(desludging) [16].
The remained crude oil in the storage tank is heated and pumped at high pressure by
washing cannons to break up and liquefying the sludge to be a mixture as a slurry. The slurry

is pumped from the tank to oil/solids separation module and oil/water separation module. The
separated oil from separation units is reheated and recirculated for washing cannons. The
separated water is clean enough to be disposal through waste water area. The separated solids
are suited for directly disposal through specific area. The oil wash step is safe for the
environment and minimizes pollutions because not or less emission and recirculated oil
(washing medium) in closed loop to clean tank [16].
2- Washing water
Now, the washing cannons pump the water as washing medium at high pressure in the
tank to remove remain oil residue from walls and bottom the tank. The mixture in the tank is
pumped to separation units where the water is separated and recirculated to the tank in closed
loop until the tank is completely clean [16].
3- Sediment removal
This step depends on the compositions of the sludge. Some inorganic compositions have
high density which is remain to form thin layer on the tank floor. This sediment is removed by
zaopin extractor (cleaning dozer is small, hydraulically powered and can be assembled inside
the tank in less than 2 hours). Cleaning dozer cannot be used with all type tanks because some
tanks contain a heating coil on the tank floor which makes it difficult for cleaning dozer to move
inside the tank [16].
4- Disassembly
The tank following by inspection and then all equipment is removed from the site [16].

26 | Chapter Four: Selection and Design the Process
Chapter Four: Selection and Design the Process
As shown in previous chapters importance of remove and recover hydrocarbons from

oily sludge, a process design to treat oily sludge is needed.
4.1- Process Description
The process design will be based on a principle of solvent extraction for treatment oily
sludge in the crude oil storage tanks and recovery hydrocarbons from oily sludge [25,10]. The
selection process design depends on:
1. Convenient and suited with requirement of refineries.

2. the refineries provide a sufficient amount from kerosene which is used as the extraction
solvent in the process to cover a ratio (1 kg sludge: 4 liter kerosene) [25].
3. Solvent extraction also called liquid-liquid extraction [28] is high effective to remove
oily sludge and recover hydrocarbons also, reduce in the cost [25,10].

4.1.1- Process Steps
Step One
Determine the characterizations of oily sludge and the best conditions for the process
(solvent-sludge volume ratio, temperature). In this study, two samples from oily sludge for two
tanks (dried solid, semi dry solid) from crude oil of Egypt by Egyptian Petroleum Research
Institute EPRI [25]. Also, a data of sludge is formed at Turkmenbashi Refinery (Turkmenistan)
[26].
Table 4.1.a: Oily (Petroleum) sludge composition. The samples were taken along the depth of
the storage pond so that sample PS1 was taken at the surface and sample [26]:
Sample number
Content in petroleum sludge
PS1 PS2 PS3 PS4 PS5
Water wt% 2.5 38.7 26.9 12.6 6.1
Mechanical impurities wt% 0.3 5.3 12.2 24.9 28.7
Organic matter wt% 97.2 56 60.9 62.5 65.2
Table 4.1.b: Two samples from oily sludge for two tanks (dried solid, semi dry solid) from
crude oil of Egypt [25]:
Volatile
Water matter
Solid Carbon Ash,
content, @105 C0 Nonvolatile
Test Physical Content residue, wt%,
wt% for Hydrocarbons,
Sample properties @550 C0, wt% ASTM
ASTM 24h, wt%
wt% ASTM D189 D482
D95 wt%
Dried solid,
15.63
oil content Nil
TK-C2 0.73 16.73 82.54 29.60
melted@65
C0
Semi dry
solid, oil
TK-C15 content Nil 6.69 2.88 90.43 13.03 2.63
melted@50
C0
Table 4.2: the characterizations of kerosene which is used in the process as solvent [25]:
Density (kg/m3) at 25 oC Heat capacity (kJ / kg oC) at 25 oC Viscosity (cp) 25 oC

789 2.01 1.92
The best condition for hydrocarbons recovery shows by Table 5.3 and Table 5.4:

Table 4.3: hydrocarbons recovery at various (kg sludge: Liter solvent) ratios [25]:
a- dried solid (TK-C2)
Solvent type N- Toluene Methylene Ethylene Diethyl Naphtha Kerosene

Sludge- Heptane dichloride dichloride ether cut Cut
solventration
1-4 45.50 50.20 50.30 51.45 49.60 65.56 63.16
1-7 60.70 68.14 65.54 67.10 65.45 80.54 83.99
1-8 66.89 75.94 72.30 70.05 70.19 80.54 83.99
1-9 72.48 75.94 72.30 70.05 70.19 …. ……
1-10 72.48 …… …… …… ……. … …
b- semi dry solid (TK-C15)
Solvent type
N- Methylene Ethylene Diethyl Naphtha Kerosene
Slugde- Toluene
Heptane dichloride dichloride ether cut cut
solvent ration
1-2 55.59 67.85 69.20 69.68 59.99 78.03 80.97

1-3 65.92 83.00 80.70 87.60 73.77 90.80 92.00
1-4 77.60 91.00 89.60 95.92 83.00 97.09 97.20
1-5 85.20 95.68 95.32 95.92 91.00 97.09 97.20
1-6 90.75 95.68 95.32 …… 95.06 …. …..
1-7 94.26 …… …… .... 95.06 …. …..
1-8 94.26 … … … …. …. …..
Table 4.4: Hydrocarbon recovery at various temp. at ideal (kg sludge: liter solvent) ratio [25]:
a- dried solid (TK-C2)

A-Solvent type N- Toluene Methylene Ethylene Diethyl Naphtha Kerosene
Temperature(C0) Heptane dichloride dichloride ether cut Cut
35.00 48.70 44.14 40.16 45.97 49.54 47.73 48.21
70.00 72.48 75.94 72.30 70.05 70.19 80.54 83.99
80.00 72.48 75.94 72.30 70.05 70.19 80.54 83.99
b- semi dry solid (TK-C15)
Solvent type N- Methylene Ethylene Diethyl Naphtha Kerosene

Toluene
Temperature (C0) Heptane dichloride dichloride ether cut cut
35.00 65.92 67.85 69.20 69.68 59.99 78.03 80.97
70.00 94.26 95.68 95.32 95.92 95.06 97.06 97.20
80.00 94.26 95.68 95.32 95.92 95.06 97.06 97.20

According these data, the best conditions for kerosene to use in the process with semi dry
solid and dried solid are:
1- kg sludge: liter kerosene ratio = 1:4
2- the temperature of kerosene > 80 oC before inter the tank
3- The temperature of the sludge and the solvent in the tank between (70-80) oC
4- the temperature of kerosene and dissolved sludge should be below 80 oC to keep the
process in a limited level of safety.
Step Two
the crude oil storage tank has to contain only oily sludge in the bottom tank. Then, oily
sludge in the tank is treated with kerosene as solvent, Figure 4.1 shows the process flow
diagram.
Figure 4.1 the process flow diagram with kerosene.
Kerosene is pumped at a temperature (40 oC depends on the weather) across a heat

exchanger to raise the kerosene temperature to be 80 oC [25]. Kerosene is pumped in the tank
until became the ratio of the sludge to kerosene ( kg sludge: Liter kerosene) equal to 1:4 for
both dried sludge and semi dry sludge, so it is used the same condition if the tank contains either
dried sludge or semi dry sludge in the tank [25]:

Table 4.5: the process conditions with kerosene.
Conditions Dried solid sludge Semi dry solid sludge
kg sludge: Liter kerosene 1:4 1:4
inlet temperature of Kerosene in the tank 80 oC 80 0C
The Tem. of kerosene and dissolved sludge

70 oC 70 oC
inside the tank should be above
The job of kerosene is dissolved the sludge according to heat transfer from kerosene to
the sludge. The dissolving of the sludge is completed when:
𝑇𝑜𝑡𝑎𝑙 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑓𝑟𝑜𝑚 𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 𝑞𝑡𝑜𝑡𝑎𝑙 = 𝑇𝑜𝑡𝑎𝑙 ℎ𝑒𝑎𝑡 𝑡𝑜 𝑑𝑖𝑠𝑠𝑜𝑙𝑣𝑒 𝑡ℎ𝑒 𝑠𝑙𝑢𝑑𝑔𝑒 𝑞𝑓
As the heat transfer, the kerosene temperature goes down from 80 0C until be 70 0C
therefore, kerosene should be recirculated to the tank across the heat exchanger to rise the
temperature at 80 0C. Through the recirculating, kerosene and the dissolved sludge pass through
a filter to remove solid particles then the filtrate enters to a gravity settling tank (settler) to
separate kerosene from the dissolved sludge [14] where kerosene backs to the tank and
dissolved sludge backs to refinery for further process [14,15].
Step Three
The process continuous until complete the dissolving and this point is determined by
using temperature sensors which are used inside the tank to read the temperature in the top and
the bottom tank [14].
And when the process arrives to complete dissolving the recirculating line is closed and
kerosene with dissolved sludge backs to refinery as products, Figure 4.2 shows the average
properties of the crude oil tank in refineries.

Figure 4.2 properties of the crude oil tank in refineries [14,30].
The amount of kerosene should be used in the process according tank diameter 40 m and
the sludge height in the tank 0.5 m [14] calculated:
The tank contains dry sludge which has a density equals to 1390 kg/ m3 [27] and a density of
organic matter in the sludge equals to 1130 kg / m3 [27]:
The mass of the sludge in the tank:
𝑚 = 𝜌𝑉
𝑚 = (1390)( 𝜋 202 0.5) = 278000𝜋 𝑘𝑔
𝑚 = 873362.758 𝑘𝑔 𝑓𝑟𝑜𝑚 𝑠𝑙𝑢𝑑𝑔𝑒
The ratio [ 1 kg sludge: 4 Liter kerosene] [25], so the kerosene volume in the tank:
4𝐿 𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 1 𝑚3
𝑉 𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 = ∗ ∗ 278000𝜋 𝑘𝑔 𝑠𝑙𝑢𝑑𝑔𝑒 = 3493.451 𝑚3
1𝑘𝑔 𝑠𝑙𝑢𝑑𝑔𝑒 1000 𝐿

The mass (kg) of kerosene in tank (the density of kerosene = 789 kg/m3 [25]):
𝑚 = 𝜌𝑉
= 789 ∗ 3493.451
𝑚 = 2756332.839 𝑘𝑔
The height of kerosene in the tank:
𝑉 = 𝜋𝑟 2 ℎ
3493.451 = 𝜋 202 ℎ
ℎ = 2.78 𝑚
By heat transfer, it is used to calculate rate of dissolved sludge from sludge bulk [30]:
𝑄𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 = 𝑄𝑠𝑙𝑢𝑑𝑔𝑒 + 𝑄𝑙𝑜𝑠𝑠𝑒𝑠
Where:
➢ 𝑄𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 : the heat transfer from kerosene

➢ 𝑄𝑠𝑙𝑢𝑑𝑔𝑒 : heat transfer for sludge
➢ 𝑄𝑙𝑜𝑠𝑠𝑒𝑠: ∶ losses heat by tank wall
𝑄𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 = − 𝑚̇ 𝐶𝑝 𝛥𝑇
the specific heat capacity for kerosene in the rang temperature (40-90) oC equal to 2.01
kJ / kg oC [29], the inlet flow rate of kerosene in the tank equal to 4 L/sec = 0.004 m3/sec
and the change temperature of kerosene in thew tank form 80 oC to 70 oC:

𝑚3 𝑘𝑔
𝑚̇ = (0.004 ) (789 3 ) = 3.156 𝑘𝑔/𝑠𝑒𝑐
sec 𝑚
𝑄𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 = −3.156 ∗ 2.01 ∗ ( 70 − 80) = 63.4356 𝑘𝑊
The heat losses by the tank wall calculated by [30]:
𝛥𝑇 𝑜𝑣𝑒𝑟𝑎𝑙𝑙
𝑄𝑙𝑜𝑠𝑠𝑒𝑠 = 𝑟
ln ( 2 )
𝑟1 1
+
2𝜋𝑘𝐿 ℎ 𝐴2
Where:
➢ r1: inside radius for the tank = 20 m
➢ r2: outside radius for the tank where wall thickness 10 mm = 20+0.01 = 20.01 m
➢ k: thermal conductivity of tank wall = 16.3 W/m2 oC [14,30]
➢ L: the height of kerosene in the equal to 2.78 m
➢ h: thermal coefficient for air with the tank wall
➢ A2: the outside area for the tank (the area which is surrounded the kerosene in the
tank)
1
𝛥𝑇 4
ℎ = 1.42 ( )
𝑑
1⁄
70 − 40 4 𝑤
= 1.42 ( ) = 1.32145
40 𝑚2 ℃
𝐴2 = 𝜋 𝑑 𝐿
= 𝜋 ∗ 40 ∗ 2.78
𝐴2 = 349.345 𝑚2
Sub. all the variable in the eq.

𝛥𝑇 𝑜𝑣𝑒𝑟𝑎𝑙𝑙
𝑄𝑙𝑜𝑠𝑠𝑒𝑠 = 𝑟
ln ( 2 )
𝑟1 1
+
2𝜋𝑘𝐿 ℎ 𝐴2
(70 − 40)
𝑄𝑙𝑜𝑠𝑠𝑒𝑠 = = 13838.047 𝑊𝑎𝑡𝑡
20.01
ln ( ) 1
20
2𝜋 ∗ 16.3 ∗ 2.78 + 1.32145 ∗ 349.345
The heat transfer for the sludge [30]:
70
𝑄𝑠𝑙𝑢𝑑𝑔𝑒 = 𝑚̇ ∫ 𝐶𝑝 𝑑𝑇
40
The Specific heat capacity of the sludge changes with the change of temperature [27]:
Figure 4.3 specific heat capacity of oily sludge at variation of temperature [27].
Table 4.6: specific heat with temperature of oily sludge.
T ( oC) 40 45 50 55 60 65 70
Cp (kJ / kg oC) 1.14 1.16 1.2 1.22 1.26 1.30 1.34

by using 2/3 Simpsons’ rule for integration [31]:
70
3ℎ
∫ 𝐶𝑝 𝑑𝑇 = [𝐶 (𝑇 ) + 3 (𝐶𝑝 (𝑇1 ) + 𝐶𝑝 (𝑇2 )) + 2𝐶𝑝 (𝑇3 ) + 3 (𝐶𝑝 (𝑇4 ) + 𝐶𝑝 (𝑇5 )) + 𝐶𝑝 (𝑇6 )]
40 8 𝑝 0
𝑇𝑓 − 𝑇𝑖 70 − 40
ℎ= = =5
𝑁 6
3∗5
= {1.14 + 3(1.16 + 1.2) + 2 ∗ 1.22 + 3(1.26 + 1.3) + 1.34}
8
70
∫ 𝐶𝑝 𝑑𝑇 = 36.9 𝑘𝑗/𝑘𝑔
40
Sub. in the equation:
𝑄𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 = 𝑄𝑠𝑙𝑢𝑑𝑔𝑒 + 𝑄𝑙𝑜𝑠𝑠𝑒𝑠
63.4356 = 𝑚̇ ∗ 36.9 + 13.838
Kerosene could dissolve the sludge by rate (dissolved sludge rate in the tank):
𝑘𝑔
𝑚̇ = 1.334419
𝑠𝑒𝑐
The time to complete dissolved of the sludge in the tank:
𝑚 278000𝜋
𝑡𝑑𝑎𝑦 = = = 7.5 𝑑𝑎𝑦𝑠
𝑚̇ 1.34419 ∗ 3600 ∗ 24

4.2- Material Balance
For continuous processes at steady-state, the accumulation term in the general balance
equation, Equation [32]:
𝑖𝑛𝑝𝑢𝑡 + 𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑖𝑜𝑛 = 𝑜𝑢𝑡𝑝𝑢𝑡 + 𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛
So, the balance is on a nonreactive species or on total mass, the generation and
consumption terms equal zero and the equation reduces to [32]:
𝑖𝑛𝑝𝑢𝑡 = 𝑜𝑢𝑡𝑝𝑢𝑡
The process is continuous process at steady state. So, the material balance on the following
equipment:
4.2.1- Material Balance of the Tank
Figure 4.4: a-material balance of the tank.
The composition of dissolved sludge [27] from Table 4.1.a:
Sample number
Content in petroleum sludge
PS1 PS2 PS3 PS4 PS5
Water wt% 2.5 38.7 26.9 12.6 6.1
Mechanical impurities wt% 0.3 5.3 12.2 24.9 28.7
Organic matter wt% 97.2 56 60.9 62.5 65.2

2.5 + 38.7 + 26.9 + 12.6 + 6.1

𝑤𝑎𝑡𝑒𝑟 𝑤𝑡% = = 17.36%
5
0.3 + 5.3 + 12.2 + 24.9 + 28.7

𝑀𝑒𝑡𝑎𝑙𝑠 𝑤𝑡% = = 14.28%
5
97.2 + 56 + 61 + 62.5 + 65.2

𝑜𝑟𝑔𝑎𝑛𝑖𝑐 𝑚𝑎𝑡𝑡𝑒𝑟 𝑤𝑡% = = 68.36%
5
The composition of (kerosene and dissolved sludge) stream:
0.1736 ∗ 1.34419
𝑤𝑎𝑡𝑒𝑟 𝑤𝑡% = = 5.2%
4.5
0.1428 ∗ 1.34419
𝑀𝑒𝑡𝑎𝑙𝑠 𝑤𝑡% = = 4.3%
4.5
0.6836 ∗ 1.34419
𝑜𝑟𝑔𝑎𝑛𝑖𝑐 𝑚𝑎𝑡𝑡𝑒𝑟 𝑤𝑡% = = 20.42%
4.5
3.156
𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 𝑤𝑡% = = 70.13%
4.5
The density of (kerosene and dissolved sludge) stream:
𝜌 = 𝑥1 𝜌𝑠𝑙𝑢𝑑𝑔𝑒 + 𝑥2 𝜌𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒
1.3 3.156 𝑘𝑔
𝜌 = ( ) 1390 + ( ) 789 = 968.499 3
45 4.5 𝑚
Table 4.7: inlet and outlet stream of the tank.
Kerosene Dissolved sludge Kerosene and dissolved sludge

3.156 kg / sec 1.34419 kg / sec 3.156+1.34419= 4.5 kg /sec
4 liter/ sec 1 liter/ sec 4+1=5 liter / sec
𝑘𝑔 𝑘𝑔 𝑘𝑔
𝜌 = 789 𝜌 = 1390 𝜌 = 968.499
𝑚3 𝑚3 𝑚3
Water wt% = 0.1736

Metals wt% = 0.1428 Water wt% = 0.052

Organic matter = 0.6836 Metals wt% = 0.043
Organic matter wt% = 0.2042
Kerosene wt% = 0.793
Figure 4.5 b-material balance of the tank with result
4.2.2- Material Balance of Filter
Figure 4.6 a-material balance of filter.
The rotary drum filter used in the process (for continuous operation). So, assume the filter
is ideal and used to remove all solids particles from (kerosene +dissolved sludge) stream:

𝑓𝑖𝑙𝑡𝑒𝑟 𝑐𝑎𝑘𝑒 𝑟𝑎𝑡𝑒 = 𝑚𝑒𝑡𝑎𝑙𝑠 𝑤𝑡% ∗ 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑖𝑛𝑙𝑒𝑡 𝑠𝑡𝑟𝑒𝑎𝑚
𝑘𝑔
𝑓𝑖𝑙𝑡𝑒𝑟 𝑐𝑎𝑘𝑒 𝑟𝑎𝑡𝑒 = 0.043 ∗ 4.5 = 0.1935
𝑠𝑒𝑐
The rate and composition of filtrate stream:
𝑚̇𝑖𝑛𝑙𝑒𝑡 = 𝑚̇𝑓𝑖𝑙𝑡𝑒𝑟 𝑐𝑎𝑘𝑒 + 𝑚̇𝑓𝑖𝑙𝑡𝑟𝑎𝑡𝑒
4.5 = 0.1935 + 𝑚̇𝑓𝑖𝑙𝑡𝑟𝑎𝑡𝑒
𝑚̇𝑓𝑖𝑙𝑡𝑟𝑎𝑡𝑒 = 4.3065 𝑘𝑔/𝑠𝑒𝑐
0.052 ∗ 4.5
𝑤𝑎𝑡𝑒𝑟 𝑤𝑡% = = 0.05434 = 5.434%
4.3065
0.2042 ∗ 4.5
𝑜𝑟𝑔𝑎𝑛𝑖𝑐 𝑚𝑎𝑡𝑡𝑒𝑟 𝑤𝑡% = = 0.2134 = 21.34%
4.3065
0.7013 ∗ 4.5
𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 𝑤𝑡% = = 0.7328 = 73.28%
4.3065
The density of the filtrate stream:
𝜌 = 𝑥1 𝜌𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 + 𝑥2 𝜌𝑤𝑎𝑡𝑒𝑟 + 𝑥3 𝜌𝑜𝑟𝑔𝑎𝑛𝑖𝑐 𝑚𝑎𝑡𝑡𝑒𝑟
Where the density of organic matter = 1130 kg/m3 [27]
𝜌 = 0.7328 ∗ 789 + 0.05434 ∗ 1000 + 0.2134 ∗ 1130
𝜌 = 873.6612 𝑘𝑔/𝑚3

Figure 4.7 b-material balance of filter with result.
4.2.3- Material Balance of Gravity Settling Tank (Settler)
Figure 4.8 a-material balance of gravity settling tank (settler)
The kerosene stream should have flow rate =3.156 kg/sec (4 liter/sec). Then, the flow
rate of dissolved sludge:

𝑚̇𝑖𝑛𝑙𝑒𝑡 = 𝑚̇𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 + 𝑚̇𝑑𝑖𝑠𝑠𝑜𝑙𝑣𝑒𝑑 𝑠𝑙𝑢𝑑𝑔𝑒
4.3065 = 3.156 + 𝑚̇𝑑𝑖𝑠𝑠𝑜𝑙𝑣𝑒𝑑 𝑠𝑙𝑢𝑑𝑔𝑒
𝑚̇𝑑𝑖𝑠𝑠𝑜𝑙𝑣𝑒𝑑 𝑠𝑙𝑢𝑑𝑔𝑒 = 1.1505 𝑘𝑔/𝑠𝑒𝑐
The composition of the dissolved sludge stream:
0.05434 ∗ 4.3065
𝑤𝑎𝑡𝑒𝑟 𝑤𝑡% = = 0.203403 = 20.34%
1.1505
0.2134 ∗ 4.3065
𝑜𝑟𝑔𝑎𝑛𝑖𝑐 𝑚𝑎𝑡𝑡𝑒𝑟 𝑤𝑡% = = 0.79879 = 79.879%
1.1505
The density of the dissolved sludge stream:
𝜌 = 𝑥1 𝜌𝑤𝑎𝑡𝑒𝑟 + 𝑥2 𝜌𝑜𝑟𝑔𝑎𝑛𝑖𝑐 𝑚𝑎𝑡𝑡𝑒𝑟 Type equation here.
𝜌 = 0.2034 ∗ 1000 + 0.79879 ∗ 1130
𝜌 = 1106.033 𝑘𝑔/𝑚3
The volumetric flow rate for dissolved sludge stream:
𝑚̇
𝑉=
𝜌
1.1505
=
1106.033
𝑉 = 1.0004 ∗ 10−3 𝑚3 ⁄𝑠𝑒𝑐
= 1 𝑙𝑖𝑡𝑒𝑟 /𝑠𝑒𝑐

Figure 4.9 b-material balance of gravity settling tank (settler) with result.

4.3- Energy Balance
The first law of thermodynamics for an open system at steady state has the form [32]:
𝑖𝑛𝑝𝑢𝑡 = 𝑜𝑢𝑡𝑝𝑢𝑡
𝑄+𝑊+ ∑ 𝐸𝐽̇ = ∑ 𝐸𝑗̇

𝑖𝑛𝑙𝑒𝑡 𝑠𝑡𝑟𝑒𝑎𝑚𝑠 𝑜𝑢𝑡𝑙𝑒𝑡 𝑠𝑡𝑟𝑒𝑎𝑚𝑠
∑ 𝐸𝑗̇ − ∑ 𝐸𝐽̇ = 𝑄 + 𝑊
𝑜𝑢𝑡𝑙𝑒𝑡 𝑠𝑡𝑟𝑒𝑎𝑚𝑠 𝑖𝑛𝑙𝑒𝑡 𝑠𝑡𝑟𝑒𝑎𝑚𝑠
𝛥𝐻 + 𝛥𝐸𝑘 + 𝛥𝐸𝑝 = 𝑄 + 𝑊
Where:
➢ 𝛥𝐻: change of enthalpy in the system
➢ 𝛥𝐸𝑘 : change of kinetic energy in the system
➢ 𝛥𝐸𝑝 : change the potential energy in the system
➢ Q: heat transfer through the system with surrounding (from or to system)
➢ W: work done (on or from) system
In the process, there are not change in the kinetic and potential energy of system
(process):
𝛥𝐻 = 𝑄 + 𝑊

4.3.1- Energy Balance for Pump P-2
Figure 4.10 a-energy balance for pump p-2.
Assume centrifugal isotropic pump [33]:
∆𝐻 = −𝑊𝑠
𝑤𝑠 = −𝑉(𝑃2 − 𝑃1 )
𝑤ℎ𝑒𝑟𝑒:
𝑚3 1
𝑉( ) =
𝑘𝑔 𝜌
𝑃1 = 𝜌 𝑔ℎ = 968.4989 × 9.81 × 2 = 19001.94 𝑝𝑎 = 19 𝑘𝑝𝑎
Figure 4.11 head pressure is represented by the height of kerosene and dissolved sludge above
suction line 2 m.

1 𝑘𝑗
𝑤𝑠 = − × (5(101.325) − 19) = −0.5034
968.4989 𝑘𝑔
So, the pump power:
𝑚̇ 𝑊𝑠
𝑝𝑜𝑤𝑒𝑟 =
ηpump
ηpump : the efficiency of pump, from Figure 4.3 shows a curve between volumetric flow rate
and pump efficiency [34].
Figure 4.12 the curve between the volumetric flow rate and pump efficiency [34].
So, the pump efficiency ηpump = 0.7
𝑘𝑔 𝑘𝑗
4.5 𝑠 × 0.5034
𝑘𝑔
= = 3.236 𝐾𝑤
0.7
The change in the enthalpy:

∆𝐻 = 3.236 𝑘𝑤

Hence that, to find T2 from the change temperature:
𝑇2
∆𝐻 = 𝑚̇ ∫ 𝐶𝑝 𝑑𝑇 + 𝑉∆𝑃
70
Assume the specific heat capacity for dissolved sludge could be constant at the range
(70 to T2) oC:
𝑘𝐽
𝐶𝑝 𝑑𝑖𝑠𝑠𝑜𝑙𝑣𝑒𝑑 𝑠𝑙𝑢𝑑𝑔𝑒 = 1.34
𝑘𝑔 ℃
∆𝐻 = 𝑚̇ ( 𝑥1 𝐶𝑝 𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒 + 𝑥2 𝐶𝑝 𝑑𝑖𝑠𝑠𝑜𝑙𝑣𝑒𝑑 𝑠𝑙𝑢𝑑𝑔𝑒 )𝛥𝑇 + 𝑉𝛥𝑃
3.236 = 4.5[0.7013(2.01) − 0.2987(1.34)](𝑇2 − 70) + (0.5034 * 4.5)
𝑇2 = 70.214 ℃
Figure 4.13 b-energy balance for pump p-2 with result.

4.3.2- Energy Balance for Pump P-1
Figure 4.14 a-energy balance for pump p-1.
Assume centrifugal isotropic pump [33]:
∆𝐻 = −𝑊𝑠
𝑊𝑠 = −𝑉(𝑃2 − 𝑃1 )
𝑤ℎ𝑒𝑟𝑒:
𝑃1 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑓𝑟𝑜𝑚 𝑝𝑢𝑚𝑝 (𝑃_2) − 𝛥𝑃 𝑡ℎ𝑟𝑜𝑢𝑔ℎ 𝑡ℎ𝑒 𝑓𝑖𝑙𝑡𝑒𝑟
𝑃1 = 5(101.325) − 84.3 = 422.325 𝑘𝑝𝑎
Then, the work of shift:
1 𝑘𝑗
𝑊𝑠 = − × (10(101.325) − 422.325) = −0.7489
789 𝑘𝑔
From Figure 4.3, the pump efficiency ηpump = 0.7
So, the pump power:
𝑚̇ 𝑊𝑠
𝑝𝑜𝑤𝑒𝑟 =
ηpump

𝑘𝑔 𝑘𝑗
3.156 𝑠 × 0.7489
𝑘𝑔
= = 3.3764 𝐾𝑤
0.7
The change in the enthalpy:

∆𝐻 = 3.3764 𝑘𝑤
Hence that, to find T2 from the change temperature:
𝑇2
∆𝐻 = 𝑚̇ ∫ 𝐶𝑝 𝑑𝑇 + 𝑉∆𝑃
70.24
3.3764 = (3.156 ) × (2.01) × (𝑇2 − 70.24) + (0.7489 × 3.156)
𝑇2 = 70.37 ℃
Figure 4.15 b-energy balance for pump p-1 with result.

4.3.3- Energy Balance for Heat Exchanger
Figure 4.16 energy balance for heat exchanger.
𝑄ℎ𝑒𝑎𝑡 𝑓𝑟𝑜𝑚 𝑤𝑎𝑡𝑒𝑟 = 𝑄ℎ𝑒𝑎𝑡 𝑡𝑜 𝑘𝑒𝑟𝑜𝑠𝑒𝑛
How much needed heat from water to rise Temp. of kerosene from 70 to 80 ℃:
𝑄𝑟𝑒𝑞𝑖𝑟𝑒𝑑 𝑓𝑟𝑜𝑚 𝑤𝑎𝑡𝑒𝑟 = (𝑚. 𝐶𝑝 ∆𝑇)𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒
All physical properties of kerosene and water from Table 5.1:

𝑄𝑟𝑒𝑞𝑖𝑟𝑒𝑑 𝑓𝑟𝑜𝑚 𝑤𝑎𝑡𝑒𝑟 = [3.156 × 2.01 × (80 − 70)]
𝑄𝑟𝑒𝑞𝑖𝑟𝑒𝑑 𝑓𝑟𝑜𝑚 𝑤𝑎𝑡𝑒𝑟 = 63.436 Kw
The flowrate of water which needed to accomplish this requirement:
𝑄𝑤𝑎𝑡𝑒𝑟 = [𝑚̇ 𝐶𝑝 ∆𝑇]𝑤𝑎𝑡𝑒𝑟
63.436 = 𝑚̇ × 4.199 × (90 − 85)

𝑘𝑔
𝑚̇. = 3.0215
𝑠𝑒𝑐

50 | Chapter Five: Equipment Design
Chapter Five: Equipment Design
5.1- Gravity Settling Tank (Settler)
Settlers are used to separate liquids where there is a sufficient difference in density
between the liquids for the droplets to settle readily. Settler are essentially tanks which give
sufficient residence time for the droplets of the dispersed phase to rise (or settle) to the interface
between the phases. Settlers are normally designed for continuous operation [28], Figure 5.1
shows a gravity settling tank.
Figure 5.1 shows a gravity settling tank.

(Z1 – Z3) ρ1 g +Z3 ρ2 g = Z2 ρ2 g
(Z1 −Z3 )ρ1

Z2 = ρ2
+ 𝑍3
Where:
➢ ρ1: density of the light liquid (kg/m3)
➢ ρ2: density of the heavy liquid (kg/m3)
➢ Z1: height of light liquid overflow (m)
➢ Z2: height of heavy liquid overflow (m)
➢ Z3: height of interface (m)
The settler is sized on the basis [28, page 442, equation 10.6]:
Velocity of the continues phase ˂ settling velocity of dispersed phase
𝐿𝑐
(𝑢𝑐 = ) ˂ 𝑢𝑑
𝐴𝑖
Where:
➢ ud: settling velocity of the dispersed phase (m/s)
➢ uC: velocity of continues phase (m/s)
➢ LC: continues phase volumetric flow rate (m3/s)
➢ Ai: area of the interface (m2)

Settler streams:
➢ Feed: kerosene and dissolved sludge have 5 liter/sec
➢ Light liquid: kerosene, V= 4 liter/sec, 𝜌 = 789 kg/m3
➢ Heavy liquid: dissolved sludge, V= 1 liter/sec
Stokes law is used to determine the settling velocity of the droplets [28, page 442,
equation 10.7]:
d2d g (𝜌𝑑 − 𝜌𝐶 )
𝑢𝑑 =
18𝜇𝑐
Where:
➢ Kerosene: dispersed phase
➢ Dissolved sludge: continuous phase
➢ ud = settling velocity of dispersed phase, m/s.
➢ ρc = density of the continuous phase, kg/m3.
➢ ρd = density of the dispersed phase, kg/m3.
➢ μc = viscosity of the continuous phase, pa s.
➢ g = gravitational acceleration, 9.81 m/s2.
The density of continuous phase where the composition from material balance:
𝜌𝑐 = 𝑥1 𝜌 𝑤𝑎𝑡𝑒𝑟 + 𝑥2 𝜌 𝑜𝑟𝑔𝑎𝑛𝑖𝑐 𝑚𝑎𝑡𝑡𝑒𝑟
= 0.2034(1000) + 0.79879(1130) = 1106.033 𝑘𝑔/𝑚3
The viscosity of continuous phase where the viscosity of water and organic matter are 1 and
2.8 centi poise respectively [26,27].
𝜇𝑐 = 𝑥1 𝜇 𝑤𝑎𝑡𝑒𝑟 + 𝑥2 𝜇 𝑜𝑟𝑔𝑎𝑛𝑖𝑐 𝑚𝑎𝑡𝑡𝑒𝑟

= 0.2034(1) + 0.79879(2.8) = 2.44 centi poise
Let assume dd = 150 µm
d2d g (𝜌𝑑 − 𝜌𝐶 )
𝑢𝑑 =
18𝜇𝑐
(0.15 × 10−3 )2 (9.81)(789 − 1106.0327)

= = 1.5933 ∗ 10−3 𝑚/𝑠𝑒𝑐
18 × 2.44 × 10−3
Volumetric flow from continuous phase Lc = 1 L/sec = 0.001 m3/sec
𝐿𝐶
𝑈𝐶 =
𝐴𝑖
So, the Ai :
𝐿𝐶
𝐴𝑖 =
𝑈𝐶
0.001
𝐴𝑖 = = 0.6276 m2
1.5933 × 10−3
The radius of settler equal to:
2 𝐴𝑖
𝑟𝑖 = √
π
0.6276
𝑟𝑖 = √ = 0.45 𝑚
𝜋
Then, the diameter of settler 2(0.45) = 0.90 m

The height of settler:
ℎ = 2 (𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟)
ℎ = 2 (0.9) = 1.8 𝑚
the Dispersion Band:
𝐷. 𝐵 = 0.1 ℎ
𝐷. 𝐵 = 0.1 ∗ 1.8 = 0.18 m
Check residence time of the droplets in the dispersion band:
𝐷⋅𝐵
𝑅. 𝑇 =
𝑢𝑑
0.18
=
1.5933 ∗ 10−3
𝑅. 𝑇 = 112.97 𝑠𝑒𝑐
= 1.88 min ≅ 2 𝑚𝑖𝑛
This is satisfactory a time between 2 to 5 min is normally recommended [28, page 444].
Piping arrangement
To minimize entrainment by the jet of liquid entering the vessel, the inlet velocity for
settler should keep below 1 m/s [28, page 444]. Flow rate inters the settler = 5 L/s.
𝑚3
0.005 𝑠𝑒𝑐
2
𝐴𝑟𝑒𝑎 𝑝𝑖𝑝𝑒 = 𝑚 = 0.005 𝑚
1
𝑠𝑒𝑐

Let the position of the interface as half-way up the vessel and the light liquid of take as 90
percent of the vessel, then:
𝑧1 = 0.9 ∗ 1.8 = 1.62 𝑚
𝑧3 = 0.5 ∗ 1.8 = 0.9 𝑚
(Z1 − Z3 )ρ1
Z2 = + 𝑍3
ρ2
[1.62 − 0.9] × 789

𝑍2 = + 0.9 = 1.4136 𝑚
1106.033
Figure 5.2 designed settler with dimension

Mechanical Design of Settler
▪ Thickness of wall 𝑒 [37, 𝑝𝑎𝑔𝑒 815, 𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛 13.40𝑏]:

𝑃𝑖 . 𝐷𝑠𝑒𝑡𝑡𝑙𝑒𝑟
𝑒= +𝐶
(2𝐽. 𝑓 − 𝑃𝑖 )
➢ Max. Working pressure 𝑃𝑖 = 422.325 kpa ∗ 1.2 = 506.79 kpa = 0.50679 Mpa
➢ Max. allowable working stress for stainless steel-321 f =160 Mpa [37, page 812, Table 13.2]
➢ Weld efficiency factor J = 0.8 (Max) [37, page 813, Table 13.3]
➢ Corrosion allowance for stainless steel C = 2 mm [37, page 813]
➢ 𝐷𝑠𝑒𝑡𝑡𝑙𝑒𝑟 = 900 𝑚𝑚
0.50679 ∗ 900
𝑒= + 2 = 3.8 𝑚𝑚
(2 ∗ 160 ∗ 0.8 − 0.50679)
According Minimum practical wall thickness for diameter 900 mm, it is preferred to use
a thickness = 5 mm and neglected the value = 3.8 mm [37, page 814].
▪ Ellipsoidal Head Thickness [37, page 819, equation 13.43]:
𝑃𝑖 . 𝐷𝑠
𝑒ℎ = +𝐶
(2𝐽. 𝑓 − 0.2𝑃𝑖 )
0.50679 ∗ 900
𝑒ℎ = + 2 = 3. 78 𝑚𝑚
(2 ∗ 160 ∗ 0.8 − 0.2 ∗ 0.50679)
According this value, the ellipsoidal Head Thickness = 5 mm

5.2- Design of Rotary Drum Filter
one of the most widely used vacuum filters is the rotary drum filter. Figure 5.2 shows a
rotary drum filter [35, page 415].
Figure 5.3 shows a rotary drum filter.
1-From material balance

V = 5 liter/sec = 0.005 m3/s
t= 7.5 day = 648000 sec
2-Volume of filtrate
𝑚3
𝑉𝑓𝑖𝑙𝑡𝑟𝑎𝑡𝑒 = 𝑥𝑓𝑖𝑙𝑡𝑟𝑎𝑡𝑒 . 𝑉 ( ) . 𝑡(sec)
sec

𝑚3
= (1 − 0.043) × 0.005 ( ) × 648000 (sec)
sec
𝑉𝑓𝑖𝑙𝑡𝑟𝑎𝑡𝑒 = 3100.68 𝑚3
3- From the test of the slurry which have similar properties of sludge [35, page 394]:
𝐿
= 2.19 ∗ 10−3 𝑚−2
𝑣
𝑟𝜇𝑣 = 3.43 ∗ 104
𝛥𝑃 = 84300 𝑝𝑎
4- For constant rate [35, page 380, equation 7.39]:

𝐿 𝐴2 (−∆P)t
𝑉12 + ( ) 𝐴𝑉1 =
𝑣 𝑟𝜇𝑣
𝐴2 (84300) ∗ 698000
(3100.68)2 −3
+ A (2.19 ∗ 10 ∗ 3100.68) =
3.48 ∗ 104
𝐴 = 2.47 𝑚2
5- diameter of drum (𝑑𝑑 ):
𝐴 = 𝜋𝑑𝑑 𝐿𝑑
𝐿𝑑
Normally, = 2.5
𝑑𝑑
2.47 = 𝜋 𝑑𝑑2 2.5
𝑑𝑑 = 0.6 𝑚
Then, the length of the drum
𝐿𝑑 = 1.5 𝑚

5.3- Design of Heat Exchanger
Heat exchanger is used to rise the kerosene temperature from 70 oC to 80 oC by water.

Where kerosene flows through shell-side by one shell pass and water flows through the tubes-
side by two tube passes. The physical properties of two stream in Table 5.1:
Figure 5.4 heat exchanger, where kerosene in shell side and water in tube side
Table 5.1: the physical properties of kerosene stream and water stream [37,30,physical
properties appendix].
Physical properties Cp (kj/kg oC) 𝜌 (kg/m3) 𝜇 (pa sec) K (W/m2 oC)

Kerosene at 75 oC 2.01 789 1.92*10-3 0.145
Water at 87.5 oC 4.199 967 0.327*10-3 0.675
From energy balance:
𝑄 = 63436 𝑊𝑎𝑡𝑡
𝑘𝑔
𝑚̇ = 3.156 𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒
sec
𝑘𝑔
𝑚̇ = 3.0214 𝑤𝑎𝑡𝑒𝑟
𝑠𝑒𝑐
𝐻𝑜𝑡 (𝑤𝑎𝑡𝑒𝑟) 𝑇1 = 90℃ 𝑡𝑜 𝑇2 = 85℃

𝑐𝑜𝑙𝑑 (𝑘𝑒𝑟𝑜𝑠𝑒𝑛𝑒) 𝑡1 = 70℃ 𝑡𝑜 𝑡2 = 80℃
(𝑇1 − 𝑡2 ) − (𝑇2 − 𝑡1 )
𝛥𝑇𝐿𝑚 =
𝑇 − 𝑡2
ln 1
𝑇2 − 𝑡1
(90 − 80) − (85 − 70)

𝛥𝑇𝐿𝑚 =
90 − 80
ln
85 − 70
𝛥𝑇𝐿𝑚 = 12.33℃
▪ First trial, assume the overall heat transfer coefficient is 𝑈0 = 300 𝑊/𝑚2 ℃: [37, page
637]
𝑡2 − 𝑡1 80 − 70
𝑃= = = 0.5
𝑇1 − 𝑡1 90 − 70
𝑇1 − 𝑇2 90 − 85
𝑅= = = 0.5
𝑡2 − 𝑡1 80 − 70
The value of correction factor [36], F=0.95:
𝑄 = 𝐹 𝑈𝑜 𝐴𝑜 𝛥𝑇𝐿𝑚
63436 = 0.95 ∗ 300 ∗ 𝐴0 ∗ 12.33
𝐴𝑜 = 18.05
Assume:
Inside diameter of tubes 𝑑𝑖 = 16 𝑚𝑚
Outside diameter of tubes 𝑑𝑜 = 20 𝑚𝑚
Length of tubes 𝐿 = 2.44 𝑚
Then, the number of tubes N is:
𝐴𝑜 = 𝜋𝑑𝑜 𝐿𝑁
18.05 = 𝜋 ∗ 0.02 ∗ 2.44 ∗ 𝑁
𝑁 = 118 𝑡𝑢𝑏𝑒𝑠

▪ Tube arrangement is triangular pitch, Where the pitch is:

𝑃𝑡 = 1.25 𝑑𝑜
= 1.25 ∗ 20
= 25 𝑚𝑚
▪ Bundle diameter 𝐷𝑏 :
1
𝑁 𝑛1
𝐷𝑏 = do ( )
𝑘1
Where 𝑘1 = 0.249 , 𝑛1 = 2.207 [37, 𝑝𝑎𝑔𝑒 649, 𝑇𝑎𝑏𝑙𝑒 12.4]
1
118 2.207
𝐷𝑏 = 20 ( ) = 326 𝑚𝑚
0.249
▪ Inside diameter of shell 𝐷𝑠 ,where the type of shell is split ring floating head:
𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 = 𝐷𝑠 − 𝐷𝑏
Where, clearance = 55 mm [37, page 646, Figure 12-10]
55 = 𝐷𝑠 − 326
𝐷𝑠 = 381 𝑚𝑚
Calculation total heat transfer coefficient 𝑼𝒐
▪ Tube-side heat transfer coefficient ℎ𝑖 :
𝑚̇ = 𝜌𝑢𝐴𝑥
𝜋 𝑁
𝑚̇ = 𝜌𝑢 ( 𝑑𝑖2 𝑛) , 𝑛=
4 𝑝𝑎𝑠𝑠𝑒𝑠
𝜋 118
3.0214 = 967 ∗ 𝑢 ∗ ( ∗ 0.0162 ∗ )
4 2

𝑢 = 0.2634 𝑚/𝑠𝑒𝑐
𝐶𝑝 𝜇
𝑃𝑟 =
𝑘
4199 ∗ 0.327 ∗ 10−3

= = 2.034
0.675
𝜌𝑢 𝑑𝑖
𝑅𝑒 =
𝜇
967 ∗ 0.2634 ∗ 0.016

= = 12462.76
0.327 ∗ 10−3
ℎ𝑖 . 𝑑𝑖
𝑁𝑢 = = 0.023 𝑅𝑒 0.8 𝑃𝑟 0⋅4
𝑘
ℎ𝑖 (0.016)
= 0.023 ∗ 12462.760.8 ∗ 2.0340.4
0.675
𝑊
ℎ𝑖 = 2436.372
𝑚2 ℃
▪ Shell-side heat transfer coefficient ℎ0 :
𝐿𝐵 = 0.2𝐷𝑠 , 𝐿𝐵 : 𝑏𝑎𝑓𝑓𝑙𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
𝐿𝐵 = 0.2(381) = 76.2 𝑚𝑚
(𝑃𝑡 − 𝑑𝑜 )𝐷𝑠 𝐿𝐵
𝐴𝑠 =
𝑃𝑡
(25 − 20) ∗ 381 ∗ 76.2

= = 5806.44 𝑚𝑚2
25
3.156 𝑘𝑔
𝑚𝑎𝑠𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝐺𝑠 = −6
= 543.534 2
5806.44 ∗ 10 𝑚 sec

1.1 2
𝑑𝑒 = (𝑃 − 0.917𝑑𝑜 2 )
𝑑𝑜 𝑡
1.1
𝑑𝑒 = (252 − 0.917 ∗ 202 ) = 14.2 𝑚𝑚
20
𝐺𝑠 𝑑𝑒
𝑅𝑒 =
𝜇
543.534 ∗ 14.2 ∗ 10−3

= = 4019.88
1.92 ∗ 10−3
𝐶𝑝 𝜇
𝑃𝑟 =
𝑘
2010 ∗ 1.92 ∗ 10−3

= = 26.615
0.145
ℎ𝑜 . 𝑑𝑒 1 𝜇 0.14
𝑁𝑢 = = 𝑗ℎ 𝑅𝑒 𝑃𝑟 ⁄3 ( )
𝑘 𝜇𝑤
Where: 25% baffle cut, heat transfer factor 𝑗 = 8 ∗ 10−3 [38, 𝑝𝑎𝑔𝑒 202, 𝐹𝑖𝑔 1.87] and the
viscosity term is neglected.
ℎ𝑜 ∗ 0.0142 1
= (8 ∗ 10−3 )(4019.88)(26.615)3
0.145
𝑊
ℎ𝑜 = 980.45
𝑚2 ℃
▪ In this design, the cupro-nickel alloys (70 percent Cu) have been selected due to this
material has excellent resistance to corrosion-erosion and is used for heat-exchanger
tubes, mainly where river water is used as heating source and The thermal conductivity
of cupro-nickel alloys 𝑘𝑤𝑎𝑙𝑙 = 50 𝑊/𝑚2 . °𝐶 [37,38].
▪ The fouling coefficients [37, page 640, Table 12.2]:
𝑅𝑖𝑣𝑒𝑟 𝑤𝑎𝑡𝑒𝑟 𝑓𝑖 = 3000

𝐾𝑒𝑟𝑜𝑠𝑒𝑛𝑒 𝑓𝑜 = 5000
Then, the overall heat transfer coefficient 𝑈𝑜 :
𝑑ₒ
1 𝑑ₒ 𝑑ₒ ln ( ) 1 1 𝑑ₒ
𝑑𝑖
=[ + + + + ]
𝑈ₒ ℎ 𝑑𝑖 2 𝑘𝑤𝑎𝑙𝑙 ℎₒ 𝑓ₒ 𝑓𝑖 𝑑𝑖
20
1 20 0.02 ∗ ln ( )
=[ + 16 + 1 + 1 + 20
]
𝑈ₒ 2436.372 ∗ 16 2 ∗ 50 980.45 5000 3000 ∗ 16
𝑊
𝑈ₒ = 455.727
𝑚2 °𝐶
𝑈𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 − 𝑈𝑎𝑠𝑠𝑢𝑚𝑒𝑑
% 𝑒𝑟𝑟𝑜𝑟 = ∗ 100%
𝑈𝑎𝑠𝑠𝑢𝑚𝑒𝑑
455.727 − 300
= ∗ 100% = 52%
300
The error =52% is not acceptable. Therefore, it is needed to change the design by assumed the
baffle spacing is 𝐿𝐵 = 0.7𝐷𝑠 and recalculating the shell-side heat transfer coefficient ℎ0 .
▪ Shell-side heat transfer coefficient ℎ0 :
𝐿𝐵 = 0.7𝐷𝑠 , 𝐿𝐵 : 𝑏𝑎𝑓𝑓𝑙𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
𝐿𝐵 = 0.7(381) = 266.7 𝑚𝑚
(𝑃𝑡 − 𝑑𝑜 )𝐷𝑠 𝐿𝐵
𝐴𝑠 =
𝑃𝑡
(25 − 20) ∗ 381 ∗ 266.7

= = 20322.54 𝑚𝑚2
25
3.156 𝑘𝑔
𝑚𝑎𝑠𝑠 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝐺𝑠 = −6
= 155.3 2
20322.54 ∗ 10 𝑚 sec

1.1 2
𝑑𝑒 = (𝑃 − 0.917𝑑𝑜 2 )
𝑑𝑜 𝑡
1.1
𝑑𝑒 = (252 − 0.917 ∗ 202 ) = 14.2 𝑚𝑚
20
𝐺𝑠 𝑑𝑒
𝑅𝑒 =
𝜇
155.3 ∗ 14.2 ∗ 10−3

= = 1148.57
1.92 ∗ 10−3
𝐶𝑝 𝜇
𝑃𝑟 =
𝑘
2010 ∗ 1.92 ∗ 10−3

= = 26.615
0.145
ℎ𝑜 . 𝑑𝑒 1 𝜇 0.14
𝑁𝑢 = = 𝑗ℎ 𝑅𝑒 𝑃𝑟 ⁄3 ( )
𝑘 𝜇𝑤
Where: 25% baffle cut, heat transfer factor 𝑗 = 1.6 ∗ 10−2 [38, 𝑝𝑎𝑔𝑒 202, 𝐹𝑖𝑔 1.87] and
the viscosity term is neglected.
ℎ𝑜 ∗ 0.0142 1
= (1.6 ∗ 10−2 )(1148.57)(26.615)3
0.145
𝑊
ℎ𝑜 = 560.3
𝑚2 ℃
𝑑ₒ
1 𝑑ₒ 𝑑ₒ ln ( ) 1 1 𝑑ₒ
𝑑𝑖
=[ + + + + ]
𝑈ₒ ℎ 𝑑𝑖 2 𝑘𝑤𝑎𝑙𝑙 ℎₒ 𝑓ₒ 𝑓𝑖 𝑑𝑖
20
1 20 0.02 ∗ ln ( )
=[ + 16 + 1 + 1 + 20
]
𝑈ₒ 2436.372 ∗ 16 2 ∗ 50 560.3 5000 3000 ∗ 16

𝑊
𝑈ₒ = 338
𝑚2 °𝐶
338 − 300
% 𝑒𝑟𝑟𝑜𝑟 = ∗ 100% = 12.6%
300
The error =12.6 % is acceptable.
▪ Pressure drop in tube-side 𝛥𝑃𝑡 :
𝐿 𝜇 −𝑚 𝜌𝑢𝑡 2
𝛥𝑃𝑡 = 𝑃 [8 𝑗𝑓 ( ) ( ) + 2.5]
𝑑𝑖 𝜇𝑤 2
Where, the viscosity term neglected, tube passes 𝑃 = 2 and friction factor 𝑗𝑓 = 4.5 ∗ 10−3 [37,
page 668, Figure 12-24]:
−3 )
2.44 967 ∗ 0.26342
= 2 [8(4.5 ∗ 10 ( ) + 2.5]
0.016 2
𝛥𝑃𝑡 = 536 𝑝𝑎
▪ Pressure drop in shell-side 𝛥𝑃𝑠 :
𝐷𝑠 𝐿 𝜌𝑢𝑠 2 𝜇 −0.14
𝛥𝑃𝑠 = 8𝑗𝑓 ( )( )( )( )
𝑑𝑒 𝐿𝐵 2 𝜇𝑤
Where, the viscosity term neglected and friction factor 25% 𝑏𝑎ff𝑙𝑒 𝑐𝑢𝑡 𝑗𝑓 = 7 ∗ 10−2 [37, page
674, Figure 12-30]:
𝐺𝑠 155.3
𝑢𝑠 = = = 0.1968 𝑚/𝑠𝑒𝑐
𝜌 789
381 2.44 789 ∗ 0.1968262

𝛥𝑃𝑠 = 8(7 ∗ 10−2 ) ( )( )( )
14.2 0.2667 2
𝛥𝑃𝑠 = 2100.34 𝑝𝑎
The pressure drops for 𝛥𝑃𝑠 = 2100.34 𝑝𝑎 𝑎𝑛𝑑 𝛥𝑃𝑡 = 536 𝑝𝑎 are acceptable:
𝛥𝑃𝑡 , 𝛥𝑃𝑠 < 68947 𝑝𝑎

Table 5.2: Summery for design of heat exchanger
Tube-side
Fluid flows through Water

metals cupro-nickel alloys (70 percent Cu)
Passes 2
Outside diameter 20 mm
Inside diameter 16 mm
Length 2.44 m
Number of tubes 118
Bundle diameter 326 mm
Tube Arrangement Triangular 𝑃𝑡 = 25 𝑚𝑚
Heat transfer coefficient 2436.372 W/m2 oC
Pressure drop 536 𝑝𝑎
Fouling factor 𝑓𝑖 3000 W/m2 oC
Shell-side
Fluid flows through Kerosene

Metals Steel (304)
type split ring floating head
Passes 1
Inside diameter 381 mm
Baffle spacing 266.7 𝑚𝑚
Baffle cut % 25%
Clearance 55 mm
Heat transfer coefficient 560.3
Pressure drop 2100.34 pa
Fouling factor 𝑓𝑜 5000 W/m2 oC

Mechanical Design of heat exchanger
▪ Shell Thickness 𝑒 [37, 𝑝𝑎𝑔𝑒 815, 𝑒𝑞𝑢𝑎𝑡𝑖𝑜𝑛 13.40𝑏],:

𝑃𝑖 . 𝐷𝑠
𝑒= +𝐶
(2𝐽. 𝑓 − 𝑃𝑖 )
1 − 𝑀𝑎𝑥. 𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑃𝑖 = 10 𝑏𝑎𝑟 ∗ 1.2 = 12 𝑏𝑎𝑟 = 1.2 𝑀𝑝𝑎
2 − 𝑀𝑎𝑥. 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑤𝑜𝑟𝑘𝑖𝑛𝑔 𝑠𝑡𝑟𝑒𝑠𝑠 𝑓𝑜𝑟 𝑠ℎ𝑒𝑙𝑙 𝑚𝑒𝑡𝑎𝑙𝑠 𝑓 = 150 𝑀𝑝𝑎 [37, 𝑝𝑎𝑔𝑒 812, 𝑇𝑎𝑏𝑙𝑒 13.2 ]
3 − 𝑤𝑒𝑙𝑑 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 𝐽 = 0.8 (𝑀𝑎𝑥) [37, 𝑝𝑎𝑔𝑒 813, 𝑇𝑎𝑏𝑙𝑒 13.3 ]
4 − 𝑐𝑜𝑟𝑟𝑖𝑠𝑜𝑛 𝑎𝑙𝑙𝑜𝑤𝑎𝑛𝑐𝑒 𝑓𝑜𝑟 𝑠ℎ𝑒𝑙𝑙 𝑚𝑎𝑡𝑒𝑙𝑠 𝐶 = 2 𝑚𝑚 [37, 𝑝𝑎𝑔𝑒 813 ]
1.2 ∗ 381
𝑒= + 2 = 4 𝑚𝑚 (satisfied) [37, 𝑝𝑎𝑔𝑒 647]
(2 ∗ 150 ∗ 0.8 − 1.2)
▪ Ellipsoidal Head Thickness [37, page 819, equation 13.43]:
Figure 5.5 heat exchanger with head position
𝑃𝑖 . 𝐷𝑠
𝑒ℎ = +𝐶
(2𝐽. 𝑓 − 0.2𝑃𝑖 )
1.2 ∗ 381
𝑒ℎ = + 2 = 3.91 ≈ 4 𝑚𝑚
(2 ∗ 150 ∗ 0.8 − 0.2 ∗ 1.2)
▪ Weight – Loads total shell weight 𝑊𝑣 [37, page 836, equation 13.76]:

𝑊𝑣 = 240 𝐶𝑣 𝐷𝑚 (𝐻𝑣 + 0.8𝐷𝑚 ). 𝑡
Where:
➢ 𝐶𝑣 = 1.08 factor weight for a few internal fittings [37, page 836]
➢ 𝐻𝑣 ∶ the length of the cylindrical section; m
𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑡𝑢𝑏𝑒 2.44
𝐻𝑣 = = = 1.22 𝑚
𝑡𝑢𝑏𝑒 𝑝𝑎𝑠𝑠𝑒𝑠 2
➢ t = 4 mm wall thickness of shell; mm
➢ 𝐷𝑚 ∶ mean diameter; m
𝐷𝑚 = (𝐷𝑠 + 𝑡) ∗ 10−3
= (381 + 4) ∗ 10−3 = 0.385 𝑚
Then 𝑊𝑣 ,;
𝑊𝑣 = 240 ∗ 1.08 ∗ 0.385 ∗ (1.22 + 0.8 ∗ 0.385) ∗ 4
𝑊𝑣 = 609.928 𝑁
▪ Weight of Material 𝑊𝑓 (fluid):
𝜋 2
𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙𝑠, 𝑉= 𝐷 . 𝐻𝑣
4 𝑠
𝜋
𝑉= ∗ 0.3812 ∗ 1.22 = 0.1391 𝑚3
4
𝑘𝑔
Where, the max. density of water is 𝜌 = 967
𝑚3
𝑚𝑎𝑠𝑠, 𝑚 = 𝜌𝑉
= 967 ∗ 0.1391 = 134.5 𝑘𝑔
The weight of materials 𝑊𝑓 :
𝑊𝑓 = 134.5 ∗ 9.18 = 1319.45 𝑁

▪ Weight of tube 𝑤𝑡 [37, page 836, equation 13.76]:
𝑊𝑡 = 240 𝐶𝑣 𝐷𝑚 (𝐻𝑣 + 0.8𝐷𝑚 ). 𝑡. 𝑁
Where;
➢ t: thickness of tube; mm
𝑑𝑜− 𝑑𝑖 20 − 16
𝑡= = = 2 𝑚𝑚
2 2
➢ mean diameter for tube; m
𝐷𝑚 = (𝑑𝑖 + 𝑡) ∗ 10−3
= (16 + 2) ∗ 10−3 = 0.018
➢ 𝐶𝑣 = 1.08 factor weight for a few internal fittings [37, page 836].
➢ 𝐻𝑣 = 2.44 𝑚 length of tube
➢ 𝑁 = 118 number of tubes
Then the weight of tubes is:
𝑊𝑡 = 240 ∗ 1.08 ∗ 0.018 ∗ (2.44 + 0.8 ∗ 0.018). 2 ∗ 118
= 2702.49 𝑁
▪ Design of Saddles [37, page 847]:
Figure 5.6 Saddles of heat exchanger.

Table 5.3: The dimensions of typical “standard” saddle designs.
Shell Dimensions (m) mm

diameter V Y C E J G t1 t2 Bolt D Bolt holes
0.381 0.48 0.15 0.55 0.24 0.19 0.095 6 5 20 25

72 | References
References
1- Mohamed Fahim, Taher Al-Sahhaf, Amal Elkilani “Fundamental of petroleum refining”
First Edition, Elsevier,page 11, page 12.
2- H. K. Clbdel-Clal and Mohamed eggour, petroleum and gas field processing, page 11,
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3- http://www.oilfieldwiki.com/wiki/Asphaltenes
4- Tissot, B. P., & Welte, D. H. (1978). Composition of Crude Oils. Petroleum Formation
and Occurrence, 333–368.
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6- Petroleum sludge, its treatment and disposal: a review, Faculty of Pharmacy, Omar Al-
Mukhtar University, TOBRUK, LIBYA, 2015.
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8- 14. Robertson SJ, McGill WB, Massicotte HB, Rutherford PM. Petroleum hydrocarbon
contamination in boreal forest soils: A mycorrhizal ecosystems perspective. Biol. Rev.
2007.
9- Fuel Storage Tank Cleaning at Shore Establishment (finished Product Tanks).
10- Meyer DS, Brons GB, Perry R, Wildemeersch SLA, Kennedy RJ. Oil tank sludge removal
method. United States Patent; 2006: US 2006. (ExxonMobil)
11- Taiwo EA, Otolorin JA. Oil recovery from petroleum sludge by solvent extraction. Petrol.
Sci. Technol. 2009.
12- Aerco Inc. and P. S., Solvent Extraction Technology for Used Oil Treatment, Clean
Washington Center, Report 0-95-1 (1995).
13- M. Craig Winslow, method for dispersing and removing sludge contained in a storage
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14- Myung-Jun Kim, method for removing sludge in tank and recovering oil therefrom,2004
July 6.
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17- Greg M. Heath, Robert A. Heath and Zdenek Dundr, Paraffinic sludge reduction in crude
oil storage tanks through the use of shearing and resuspension, 2004.
18- Olufemi Adebayo Johnson, Augustine Chioma Affam, Petroleum sludge treatment and
disposal: A review, 2019.
19- Bipin Kumar, Dr. Raj Mohan B. , Petroleum Oily Sludge and The Prospects of Microwave
for Its Remediation, 2013 Nov.
20- J. K. Bhattacharyya and A. V. Shekdar, Treatment and disposal of refinery sludges: Indian
scenario, 2003.
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Sludge from Petroleum Industry – A Review, 2013-7-29.
22- Paratene™ sludge fluidization and recovery. 6 November 2017.
23- Lima, C. S.;* Lima, R. O.; Silva, E. F. B.,Analysis of Petroleum Oily Sludge Produced
from Oil-Water Separator, 2014-6-5.
24- 2018 ‫ بغداد من قبل قسم الدراسات والتخطيط والمتابعة في مصفى الدورة‬/ ‫ورشة عمل اقيمت في مقر وزارة النفط‬
25- A. Y. El Naggar, E. A. Saad “Petroleum cuts as solvent extractor for oil recovery from
petroleum sludge” 15 February, 2010.
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Plant of a Refinery”, International Journal of Engineering and Technology, Vol. 8, No.2,
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Fourth Edition, Elsevier, page 477.
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30- J.P. Holman “Heat transfer” Tenth Edition, McGraw-Hill, page 6, page 27, page28
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page 615.
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Fourth Edition, Wiley, Chapter 4, Chapter 7.
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McGraw-Hill, Chapter 7.
34- S. Maurice “Surface Production Operations: Volume IV: Pumps and Compressors” First
Edition, Elsevier, page 90.
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Volume 2, Fifth edition, Elsevier, Chapter 7, page 387.
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37- R. K. Sinnott,” Coulson & Richardson’s Chemical Engineering Design”, Volume 6,
Fourth Edition, Elsevier, (page 649, Table 12.4), (page 646, Figure 12-10), (page 640,
Table 12.2), (37, 𝑝𝑎𝑔𝑒 812, 𝑇𝑎𝑏𝑙𝑒 13.2),
38- Raj Chhabra and V. Shanker “Coulson & Richardson’s Chemical Engineering Design”,
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39- https://en.wikipedia.org/wiki/Adhesion

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Ministry of Higher Education and Scientific Research

Basrah University for Oil and Gas (BUOG)

Oil & Gas Engineering College

Chemical Engineering and Oil Refining Department

Sludge Removal of Crude Oil Tanks and Recovery of

Basrah University for Oil and Gas (BUOG) IRAQ

‫بسم هللا الرمحن الرحي‬

‫صدق هللا العيل العظي‬

‫‪Basrah University for Oil and Gas (BUOG) IRAQ‬‬

‫اىل من تتسابق اللكامت لتخرج معربة عن مكنون ذاهتا‬

‫‪Basrah University for Oil and Gas (BUOG) IRAQ‬‬

‫من علينا بنعمة الاميان والعل‬

‫‪Basrah University for Oil and Gas (BUOG) IRAQ‬‬

Chapter One: Introduction …………………………………………………………… 8

Chapter Two: Sludge Treatment Methods…………………………………………. 15

Chapter Three: Hydrocarbons Recovery from Oily Sludge………………………. 19

Chapter Four: Selection and Design the Process…………………………………… 26

Chapter Five: Equipment Design……………………………………………………. 50

Basrah University for Oil and Gas (BUOG) IRAQ

page Figure list

Basrah University for Oil and Gas (BUOG) IRAQ

Page Table list

a: oily (petroleum) sludge composition. the samples were taken

the characterizations of kerosene which is used in the process as

hydrocarbon recovery at various temp. at ideal (kg sludge: liter

30 Table 4.5 the process conditions with kerosene.

34 Table 4.6 specific heat with temperature of oily sludge.

37 Table 4.7 inlet and outlet stream of the tank.

67 Table 5.2 summery for design of heat exchanger.

71 Table 5.3 the dimensions of typical “standard” saddle designs.

Basrah University for Oil and Gas (BUOG) IRAQ

Chapter One: Introduction

1.1- Crude Oil

Aromatic The classes of Saturated

Figure 1.1 the main classes of hydrocarbons [1].

1.2- Crude Oil Compounds

Basrah University for Oil and Gas (BUOG) IRAQ

1.2.3- Cycloalkanes: saturated hydrocarbons like paraffins also called by naphthenes.

Basrah University for Oil and Gas (BUOG) IRAQ

Basrah University for Oil and Gas (BUOG) IRAQ

Basrah University for Oil and Gas (BUOG) IRAQ

1.3- Oily Sludge

1.3.1- Oily Sludge Compounds & Elements

Compounds Wt. % of oily sludge

nitrogen sulphur and oxygen components are found in hydrocarbons compounds or in

1.3.2- The Formation of Oily Sludge in The Bottom Storage Tank

Basrah University for Oil and Gas (BUOG) IRAQ

1-3-3- Problems Cause by Oily Sludge

▪ Decrease the capacity of the storage tanks.

▪ Oily sludge leads to fail pumps, filters and other equipment.

▪ Oily sludge makes clogs in the pipes.

Basrah University for Oil and Gas (BUOG) IRAQ

1.4- Objective of The Study

Basrah University for Oil and Gas (BUOG) IRAQ

Chapter Two: Sludge Treatment Methods

2.1- Manual Cleaning

Basrah University for Oil and Gas (BUOG) IRAQ

2.2- Steam Cleaning

Figure 2.1 block flow diagram of sludge removal by steam.

Basrah University for Oil and Gas (BUOG) IRAQ

Figure 2.2 the distribution spray nozzles in the tank.

Basrah University for Oil and Gas (BUOG) IRAQ