D-KVADRAT.RU: END-TO-END SOLUTION OF ECOLOGICAL PROBLEMS
The increase of oil production, processing and transportation is invariably accompanied with environmental pollution. That problem is urgent almost in each oil-producing region and Urmurtia is not an exception. The problems of waste oil disposal and recycling rank first in the “blacklist” of environmental threats. At present there are lots and lots of oil-slimes in Russia, tens millions of tons. The hydrocarbons content in them is about 30%. These are, in a literal sense, buried millions of dollars. That is why the upper-division oil companies try to find the most efficient ways of recycling oil waste, which, first, guarantees additional profit; second, allows the company to reduce ecological risks; and third, helps to boost the company’s morale. These efficient ways of recycling oil waste exist. The “Neft” company comes up with its own original solution which is a complex system for disposal and recycling of oil-slimes.
“During the past year the enterprise, in cooperation with other manufacturers and designers of engineering equipment, set up production of two types of new equipment intended to solve ecological problems in the oilfield, in case of the accidental release of oil to the environment, and at oil recycling locations,” said the head of innovative projects of OOO “Neft”, Honoured Inventor of the Russian Federation, Doctor of Engineering professor Sergei Pushkarev. “The equipment supplied is of the modular type and is meant for the receipt and storage of drilling cuttings, and for preliminary preparation of drilling cutting for fractionation.
At the end of the last year the company was selected, on a tender basis, as a manufacturer and a supplier of the complex system for recycling of oil-slimes (the KESH project), the tender was put out by TNK-BP (Tyumenskaya Neftyanaya Kompaniya, Tyumen Oil Company). At present the complex is being used as pilot testing equipment for disposal of drilling cuttings by means of deep layer injection. This way of disposal is widely used abroad but it is one-of-a-kind in Russia. The output of the complex is 10 tons an hour.
The technical characteristics of the system speak for themselves: the size is 18,4 х 14,3 х 3,8 meters, the total load is 75 tons, there are more than 10 slurry pumps, hundreds of selectors and valves.
The complex includes a receiving hopper for drilling cuttings supplied with a pumping module, a rig waste sump, a water tank with pumping modules, a line of hydraulic giants, a fluid cut line, and the corresponding hydro-transport and electro-technical equipment.
Last year the company also carried out the development and delivery of another complex intended for the disposal of oil-contaminated soils (the NZG project – on oil-contaminated soils). That project is now being tested in one of the oil companies of the Republic Tatarstan. It is for recycling of any solid oil sludge. The complex complies with all up-to-date technical and technological requirements. The modular principle of the complete unit makes the complex transportable. It can be moved to any distance and its installation is easy.
“The necessity to design the equipment for the disposal and recycling of oil-contaminated soils and oil-based drill cuttings has been dictated by many years’ experience of the company’s work in the market of oil and gas equipment. This is far from the first experience of marketing of ecological plants engineered in OOO “Neft,” declared Vladlena Zakharova, head of sales at OOO “Neft”.
“In advancing new projects the company is guided not only by the commercially-rated intuition but also by a scientific approach. Thus, in the realization of the NZG project under the guidance of Sergei Pushkarev, we have developed a techno-economic project. The result of that techno-economic projecting is the development of the basic version of the NZG complex which is offered for realization and which insures that the engineering and economic-organizing solutions will correspond to the predicted investment.
According to what the designers say, the ecological efficiency from using the KESH complexes and the NZG complexes is rather high; it is especially high in recycling solid oil sludge. Sergei Pushkarev comments this thesis, “In the ideal technological process of oil refining recycling of solid oil sludge should result in obtaining clean oil, clean solid soil, clean water and chemically inactive ingredients or disintegration products which are used or obtained as a result of recycling. But it is not an easy task to obtain such purification efficiency.
There exist many techniques and types of equipment applied for the purpose of the final recycling of solid oil sludge; and each type of equipment or technique has its own advantages and drawbacks. All the techniques have one common primary operation which is to mechanically separate coarse particles and conglomerates of oil sludge. It is desirable even to grind them up to dimensions not more than 1.5-2.0 mm when oil sludge can be considered as conditionally liquid. After obtaining such consistency of the ingoing material the further issue of oil separation can be solved with any of the existing techniques which are, as a rule, engineering secrets of the processors. As for the process of recycling of oil obtained, it is a difficult problem but to solve that problem is a pleasant matter because the solution brings real income.”
Competitiveness and business success of such projects depend on the efficiency of the primary crude oil processing.
In the piloting regime
The ecological equipment was manufactured at the production areas of OOO “Constructional ironworks “INKOR” (Izhevsk) which is a 100% subsidiary production unit of OOO “Neft”. The specialists of the enterprise carried out a comprehensive range of adjustment and supervision works. The specialists’ qualification never gave rise to any criticism on the part of the customers. We never failed to meet the deadline and carried out all the works at a top professional level.
“The company is going to work upon the geographical diversity of application of its equipment,” said Vladlena Zakharova. “As we accumulate the manufacturing experience we are going to market the equipment to a range of oil producing and processing companies, establish closer contacts with regional investors and ecological departments of problem regions. Specialists in many regions of Russia have already grown interest in our development work.
Great future of ecological development work
Creative plans of the development team of OOO “Neft” working under the guidance of the General Director, Ruslan Akhmadullin, are not less ambitious, “We plan to develop the equipment for mechanization of the intake of oil-contaminated soils, pipe-container systems for delivering oil sludge from the place of its intake to the place of its processing, and start other ambitious projects.”
The engineer-development team combines young specialists which are graduates of Izhevsk State Technical University (IzhGTU), Kamsky Institute of Humanitarian and Engineering Technologies (KIGIT), Udmurt State University (UdGU). The average age of the specialists is 30 years old. But the scientific head of the project Sergei Pushkarev highly appreciates the engineering-technical potential of the team in spite of young age of its participants. He thinks that the ambitions of the developers are well-grounded and finds the further development of ecological projects very perspective.
“The experience obtained and studying of the developments of other organizations allowed us to make conclusions and establish the technical policy of development of these projects,” explains Sergei Pushkarev. “First, we supply the complexes with the existing reliable equipment. Second, we stake on the development of our own highly efficient processing equipment, for example, rotary dispergators and hydroseparators of the projectile type. Third, we pursue a policy of adoption of modern information technologies when human factor is excluded at once after the ingoing material has been supplied to the automated store of oil sludge and “switched on” again only in the stores (storages) of the finished product.
The research constructing carried out by the creative team allowed us to develop the perspective concept of the development for modular oil-sludge processing equipment (the working name of the project was Oil-Sludge Complexes (OSC)). To install the OSC plant we form a dimension-type capability series (5, 10, 20 tons/hour), functionality series (starting from unitary operations of the receipt-storage of the ingoing material to the fully functional production), and degree of automation series (from a manual control to the industrial control). All the equipment will have the analytic software, self-diagnosis means and facilities for monitoring of engineering-and-economical performance. I am sure that the ecological developments of OOO “Neft” will open a new page in ensuring ecological safety of industrial projects and become an efficient solution in the field of oil sludge processing.