Tank recovery 5
- 1. Ionizer Sludge Recovery System April 6, 2010
- 2. Bootstrap System: 400 b/d* Start by filling the 210 bbl mixing tank halfway with sludge, then cover with diesel Diesel Pump Ionizer** Sludge (circulate 3 times) Generator 2x 210 bbl tanks Sit for 4-6 hours Sludge- Diesel This crude oil should be saleable, but *The system should safely operate one Mixture **Ionizer & pump sit on may incur a slight discount for falling cycles per day at 400b/d each. With a trailer and services outside the tight contract specification. experience a second cycle may be charged in the evening and sit both tanks. Circulating overnight for 800 b/d. the tank 3x takes ~45 minutes. Repositioning takes 15-30 minutes 2
- 3. Bootstrap System: 400-800 b/d Project Bootstrap System Spec Unit Cost No. Cost Comments Diesel Trucks Pump directly from delivery truck; no capex Mixing Tanks 210 bbl $15.0k 2 $30.0k API, 12 guage, galvinized, hatch, manhole, mangate, steps, etc. Moveable built tank snaps into place in 2hrs. Cheaper tanks may be sourced locally or, say, Romania Tank valves & fittings $1.0k 2 $2.0k Welding on pipe work to aid circulating the sludge-diesel mix Stinger $0.5k 1 $0.5k Manually operated; used for first circulation when required Generator diesel $5.0k 1 $5.0k Check local pricing Ionizer + pump + trailer $25.0k 1 $25.0k TAN control mixer $1.0k 1 $1.0k For Nalco dry base chemical Field laboratory $3.0k 1 $3.0k Sub-Total 1 $66.5k Transport & contingency 30% 1 $20.0k Total Bootstrap System 1 $86.5k 400-800 bbls/day 3
- 4. Basic System: 800 b/d* *The system should safely operate 2 cycles at 400b/d each. With experience a third cycle may be charged in the evening Start by filling the 210 bbl and sit overnight for 1200 b/d mixing tank halfway with sludge, then cover with diesel Diesel Off Gases Generator Pump Ionizer** Sludge (circulate 3 times) 2x 210 bbl tanks Sit for 4-6 hours Diesel Storage Heater Treater Finished Sludge- Product Diesel Storage 210 bbl Mixture **Ionizer & pump sit on tank a trailer and services both tanks. Circulating Trace Water the tank 3x takes ~45 1500 bbl minutes. Repositioning tank takes 15-30 minutes 4
- 5. Basic System: 800-1200 b/d Project Basic System Spec Unit Cost No. Comments Cost Bootstrapping by loading from tanker trucks directly may be Diesel Storage Tank 210 bbl $15.0k 1 $15.0k possible, but risks production delays Diesel pump & hose $0.5k 1 $0.5k API, 12 guage, galvinized, hatch, manhole, mangate, steps, etc. Mixing Tanks 210 bbl $15.0k 2 $30.0k Moveable built tank snaps into place in 2hrs. Cheaper tanks may be sourced locally or, say, Romania Tank valves & fittings $1.0k 4 $4.0k Welding on pipe work to aid circulating the sludge-diesel mix Stinger $0.5k 1 $0.5k Manually operated; used for first circulation when required Simple boiler attached to loop of piping at the bottom of Tank Heaters steam $3.0k 2 $6.0k mixing tanks. Can probably fitted in locally Generator diesel $5.0k 1 $5.0k Check local pricing Ionizer + pump + trailer $25.0k 1 $25.0k This is for a high quality unit from the USA; local ones with Heater Treater $25.0k 1 $25.0k simple controls should be cheaper w/ the usual caveats H-Treat pump & hose $0.5k 1 $0.5k Bootstrapping by using a smaller, cheaper tank may be Finished Product Tank 1500 bbl $25.0k 1 $25.0k possible, but risk disrupting production. TAN control mixer $1.0k 1 $1.0k For Nalco dry base chemical Field laboratory $3.0k 1 $3.0k Sub-Total $137.5k Transport & contingency 30% 1 $41.3k Basic System $178.8k 800 bbls/day; with experience might push to 1200 b/d Finished Product Tank 1500 bbl $32.5k 1 $32.5k Additional tankage (including 30% contingency) Tank valves & fittings $1.3k 1 $1.3k Welding on pipe work to aid circulating the sludge-diesel mix Basic w/ xtra Storage $212.6k 5
- 6. System Details Tank Stinger Tank Dry Ice Heating Cleaning Heater Treater 210 bbl mixing tanks Substantially all water and solids have piping welded When the sludge is very thick a will fall from solution in normal into the base for Stinger can be used to jet ionized operation, so the tank will not be steam from a boiler diesel from the 3 outlet pipe into a drawn all the way to the bottom. If dry Ice (frozen CO2) is to heat the sludge. 1 pipe onto shear the surface of the Periodically solids built up on the available locally, then it can sludge. This should only be necessary bottom will need to be raked out be to finish de-watering the to start the tank circulating. via a Man Gate at the base of crude and avoid buying a the tank Heater Treater TAN Reduction Storage Capacity The Ionized diesel will already have reduced TAN to While its possible to bootstrap operations with less a degree. But after de-watering the crude, its storage, in order to keep transportation disruptions preferred to use a chemical additive from Nalco to Finished from shutting down the process, the site should build adjust TAN Product up to having storage = 3x daily production Storage 6
- 7. *The system should safely operate 2 shifts at 800b/d each. With experience a third cycle may be Expansion to 1600 b/d* charged in the evening and sit over night for 2400 b/d Diesel Off Gases Finished Ionizer Product Pump (circulate 3 Storage #2 Sludge times) Diesel Sludge- Storage Heater Diesel Mixture Treater Finished Product Storage Trace Water Mixing Tank #3 *Both the Ionizer / Pump trailer and the Heater- Treater can service multiple Finished Mixing tanks Product Tank #4 Finished Product Storage #4 Storage #3 7
- 8. Expansion System: 1600-2400 b/d Project Basic System Spec Unit Cost No. Cost Comments Basic w/ xtra Storage 1 $212.6k Mixing Tanks 210 bbl $15.0k 2 $30.0k API, 12 guage, galvinized, hatch, manhole, mangate, steps, etc. Tank valves & fittings $1.0k 6 $6.0k Welding on pipe work to aid circulating the sludge-diesel mix Simple boiler attached to loop of piping at the bottom of Tank Heaters steam $3.0k 2 $6.0k mixing tanks. Can probably fitted in locally Bootstrapping by using a smaller, cheaper tank may be Finished Product Tank 1500 bbl $25.0k 2 $50.0k possible, but risk disrupting production. Sub-Total 1 $92.0k Transport & contingency 30% 1 $27.6k Total Expansion System 1 $119.6k 1600 bbls/day; with experience might push to 2400 b/d Simple + Expansion 1 $332.2k 8