Operating principle

Principle of Operations

The feedstock is picked up by the MDL-VI plant-installed pumps (either from the clients tanks or open dump site) for feeding into the plant process. Process heat is provided by GFSE through our provision of a Hot Water Boiler, or clients steam via our Site Steam Converter (clients choice of options) and by way of the MDL-VI installed Heat Exchangers whereby hot water is utilized to heat the oily waste to the required range of 95°C by the time it is fed to the 6000-g 3-phase Oil Purifying Centrifuge. To begin the process the waste oil feed is first pumped across the screen separator and then into the 2-phase decanter. The primary application of the decanter is to remove 97% to 99 % of the solids. After the solids are removed the decanted effluent is ready for treatment in the 6000-g 3-phase disc stack centrifuge. Depending on the contamination volume of water contained in the oil phase, the oil-water droplet sizes and the volume of particle sizes in the range of 5 mµ to 10 mµ determines if Treating Chemicals are required in the separation process. Normally at 6000-g treatment of oily waste can be accomplished without the use of Treating Chemicals thereby significantly reducing cost. However in most cases treating chemicals are required to improve the capacity flow and separation performance of the plant. Therefore the MDL-VI is delivered with a vibrating screen effluent tank where chemical is injected to mix with the contaminated oil to insure the treating chemicals come into direct contact with the water phase droplets and the sediment particles so as to de-emulsify or coalesce them for separation. From the vibrating screen effluent tank the treated oil/water mixture is pumped to the 6000-g High Speed 3-phase disc stack centrifuges where oil and water, along with the remaining sediments are separated. The separated oil is immediately transferred to the clean oil export tank and ready to be returned to the client or sold into the market place. The separated water discharged from the 6000-g centrifuge contains oil-in-water in a range of 500 ppm to 2% oil. In many cases this water specification is acceptable for delivery or pumping to the client’s wastewater treatment facility (WWTF). Most refineries for example have their own WWTF systems. However if required, GFSE can include its Water Concentration Centrifuge (WCC) to treat the water separated from the 6,000-g 3-phase Oil Purifying Centrifuge so that it meets the disposal regulation for land or sea. Water is normally dispatched from the WCC in the range of 5 ppm to 20 ppm oil-in-water. Solids separated from the 3-phase centrifuges represent a minor portion of the solids as the majority of solids are separated up-stream at the screen separator and decanter. These minor portions of solids discharged from the 6000-g centrifuge are pumped into a GFSE designed thickener.

The solids removed from the 3-phase centrifuges are dispatched through side ports by means of a self cleaning mechanism using a water operated hydraulic bowl where a small ~10 liter water cushion leaves with the solids during each ejections interval. Solids are ejected from the bowl approximately each 10 minutes and this time interval is set according to the solids content in the feed to the centrifuge. The ejected solids, along with the water cushion, are deposited into a sludge tank and pumped into the Sludge Thickener where the solids are thickened (dried) and conveyed into a waste skip for final disposal and the free water is collected and returned to the process. Finally the total of solids separated from the screen separator, the decanter and the centrifuges are directly conveyed into waste skips for final disposal and declassification. Finally the MDL-VI Plant as shown in the photos represents one of several plant designs standard to our product line. If required GFSE specializes in the design and manufacture of custom plants to meet any defined capacities specific to the needs of our customers. This is achieved by the simple addition of multiples of the main components to either achieve a greater capacity or performance specification.

Installation & Serviceability

GFSE plants are supplied with one-year of spares and come with a recommended maintenance schedule based on each 2000 hours of operations (4 times per year). All primary equipment is supplied as a complete package including special tools and is ready for installation on a level concrete pad. Further to our service a team of GFSE engineers supervise the plant installation and commissioning on site, which normally takes ~14-days. The client is expected to provide a level plant installation concrete pad a 15 ton forklift to unstuff the shipping containers, and a 50 ton crane to lift and place all the plant module into place on the concrete pad. Installation tools and special equipment servicing tools are also provided with the delivery of the plant. Immediately following plant commissioning the actual operations are ready to commence. No other requirements for installation are needed except for the client to bring service points (electricity, water, waste feed and clean oil-water take off pipes) to the concrete pad for hook up purposes. GFSE provides all utility details and placement. Following plant-commissioning GFSE will provide on-site training to the clients assigned Plant Operator to insure a smooth handover. This is done by arranging training contracts with clients whereby our operations engineer remains at the clients site for as long as necessary to train the local staff up to operational competence and full take-over. In our experience we have commissioned plants where the clients engineers took over immediately after commissioning, this we consider exceptional. Normally training requires an additional 30 to 90 days period after commissioning for the local engineers to reach operational competency.

Dimensions & Utilities

Basically, if the client orders a plant with a heat supply from GFSE, the only utility requirements are electrical power, internet connection, fresh water diesel for the Hot Water Boiler. The power and water requirement depend on plant size and options chosen, details of which are provided with our full quotations. For the MDL-VI plant shown in the photo the electrical requirement is 120 kW of installed power and the footprint is ~L20m x ~W15m (includes walkways).

Delivery timeframe, plant certification & equipment warrantees

Delivery, from the time of approved order placement up to ex-works, requires GFSE 16 weeks to construct the plant shown in the photos. BUT delivery is mainly dependent upon the delivery timeframe of the major components. Therefore in most circumstances we advise clients to plan for a delivery period of 22 to 26 weeks up to our Ex-works. It is the policy of GFSE that before shipment the plant is fully assembled at the factory so that it undergoes a complete Factory Mechanical Completion Certification. The buyer is asked to attend this certification. During the last 14-day period of plant fabrication GFSE invites two of the Buyers assigned engineers to our manufacturing facility in Holland for schooling and hands on training. GFSE provides the Buyer a Mechanical Warranty to certify that the plant delivered is under warranty for 100% of the supply against any defects for the first year of operations, starting from the date of commissioning, or for a period of 14 months from the date of ex-works delivery, whichever comes first. We have experiences with delivery and installation all over the world.