Combination of the treatment stages drying and conversion Use of sludges from industrial processes Making of industially reusable products Use of oil and coke as high-energy recources in industrial processes Sludge –Recycling - Process

Process Design

 Petroleum production-, oil refining-, and coal conversion waste  Waste chemical sludge for example oil refining sludge  Sludgy tank cleaning residues, Tank cleaning waste, Oil separator contents  Oil and tar disposal sites / dangerous waste from the past treatment of municipal sewage sludges  Tars,  Acid resins, acid tars Feed material

 making of usable products: oil and coke  Possibility of adaptation to variable tasks  Use of standardised apparatus sizes Advantages of this method

Bulding of plant:  1998 – 1999 Start up:  1999 Shutdown:  Juli 2003 Throughput:  t/a depending on composition of feed material Special featurs:  Double strand plant  Multistase predewatering / dehydration  Production of thermal heat energy for the process out of obtained products Treatment plant

 Dewatering Static -Three lying 100 m³ containers Mechanical -2 decanter, Flottweg, Gemany typ Z4D -10 m³/h per decanter / hydraulic performanie  Conversion -4 converters / type Aicher 9000 / 49 -Efficiency / output 1,1 t/h per converter  Drying -2 vacuum knead dryer type B Evaporating efficiency 660 KW/h per decanter  Product separation / treatment of oil -2 tricanter centrifuges,Flottweg, German type Z4D - 4 m³/h per tricanter/ hydraulic performance Plant components

 Making of the hot water -2 boilers / fired by natural gas or oil (each 2,2 MW fireing heat flow)  Storage and loading of products -Oil – lying tanks, tank trucks -Coke – silo truck / big bags optionaly  Hot gas production (HGP) -2 fireing boxes (each 1,8 MW) -1 emergency firering boxes  Transformer -Output 2 MW Plant components  Cooling plantpart -Cooling down by air-cooled heat exchanger

Specification Pocess control Siemens S 7 (400), visualisation WinCC / measurement technology mainly Endress & Hauser Protection against explosion N2-shielding in relevant plant parts, cooled coke discharge protection against detonation in exhaustair pipeline HGP, production against flareback in converter residual gas pipeline HGP, non – return valve at vacuumpumps of the steam gas pipeline / HGP = hot gas production Supply points Electrical energy: 2 x kVA (= 2 x kW) Emergency power generator:750 kVA (= 600 kW) Water:DN 65 / 5 bar Gas:DN 100 / 800 mbar Safety check boiler system until 12 /2005, last check 02 / 2005, overhauling 05/2003

Plant map

Mechanical dewatering Specifications  Hydraulically powered sedimentation centrifuge  Continuing separation of two liquids and one sedimentable solid phase  Adding of oil- and solid phase (special separate extensions stage of the plant Rositz)  Infinitely variable setting of centrifuge speed  N 2 - shielding (optionaly) Main treatment stages

Drying Specifications  Indirectly heated knead dryer  Heated through double jacket, knead shaft and disk segments  Heated through hot water or steam (16 bar, 176 °C)  Vacuum drying at about mbar absolut, 130°C  Vapour condensation in injection condenser Main treatment stages

Process diagram drying Main treatment stages

conversion Specifications  Conversion aggregate -Tubular reactor: lying, indirectly heated, rotating internals -Patented make -Conversion under exclusion of oxygen ( temp. range °C) -Indirect heating via doublejacket through hot air (temp. range °C)  Condensation of carbonization gas in injection condenser  Thermocatalytic conversion reaction: oil and coke Main treatment stages

Process diagram conversion Main treatment stage

Auxiliary agents and waste products Aux. Agents Natural gas: starting up of firing boxes, operating safety torch  Propan: igniter firing boxes  Aux agens for the breaking of emulsions (as for needed)  Nitrogene: inertiring of plant parts Waste products  Carbonisation water: water from steam condensationof the conversion  Waste water