MegaMacs process description
The cleaning process in general is the same for tank bottoms, processing drummed sludge or cleaning up a lagoon or separator pond. Idea is to liquefy sludge by washing/diluting agent, extract it from reservoir and bring to MegaMacs.
MegaMacs main process tank is filled to 80% capacity with water, which is circulated through the heat exchanger and returned to the tank using the wash pump. This re-circulation continues until solution temperature reach approximately 180° F (82° C) then wash pump is switched to cleaning mode and delivers cleaning solution to reservoir to be cleaned. Heated, by on board heat exchanger, water cuts and dilutes sludge to the ratio 4:1 creating mix of oil, water and solids. This mix is then pumped back to MegaMacs up to 500' (150 m) away.
As the mix enters the machine it goes trough the vibrating separator where solids larger than 1/4" (6 mm) are removed and conveyed to the debris box where they are collected for further disposal. Remaining mix of oil, water and fine solids delivered to main tank where next step of separation takes place. Majority of solids is settling to the bottom of the tank and water/oil mix (60% oil and 40% water) rise to surface. Floating skimmer pump removes this lighter fraction and evacuates it for further handling. The rest of the liquid is reheated and re-circulated back to reservoir closing the loop.
There are two ways to handle this 60% oil and 40% water mix. It could be sold as a final product or directed to Tri-Phase centrifuge for further separation, to remove fine solids and separate oil and water. As the feed material enters the unit three separated phases come out from centrifuge.
^ TopTank and lagoon cleaning process diagram
The oil phase containing at least 95% of oil is a sellable product and brings substantial profit.
Depending on peripheral equipment and configuration system can process up to 15 tons of sludge per hour.
Different oil products may require specific cleaning solution (water or cutter stock) which will slightly alter described above process and create different sellable byproduct. Decision which solution or equipment to use should be made based on your specific conditions and environment.
Using MegaMacs you will save time, money and minimize environmental impact of oil tanks and reservoirs cleaning. Which is a win-win situation for your operations bottom line and environment!
First stage of tank cleaning while sludge level higher manhole.
Conducting the initial stage of the process of removing the sludge from the tank if sludge level is higher than manhole. Special bin is installed under the manhole with booster pump placed inside. Manhole bolts are replaced with the telescopic bolts and than they are slowly unscrewed, allowing to gradually release sludge from the tank. Booster pump is moving the sludge to the MegaMacs Main unit. Then hatch is removed and sludge is liquefied with pressure handgun. When space is sufficient, booster pump moved inside the reservoir and pressure cannon is installed on the manhole flange. Once there is enough space inside the tank, robotic Cannon is installed and further operations done remotely.
(Download MegaMacs video - First stage of tank cleaning while sludge level higher manhole.)
Sludge Extractor in operation.
The Extractor is a small collapsible scraper used to extract and liquefy sludge from big tanks (over 50,000 m3). It is carried into the tank through manhole (500 mm) as several light and easy to assemble pieces. The heaviest part is 30 kg. Extractor re-assembled inside the tank (2 hrs.) and hydraulically powered by MegaMacs’ unit.
Two independently powered track drives are used to propel and maneuver the unit around the tanks interior. A powerful hydraulically driven scraper arm excavates the sludge and draws it into the machine intake; helical screw moves it to the build in screw pump where it is slurried with water prior to being pumped from the tank.
When properly operated, unit can excavate, slurry, and pump up to 500’ (150 m) approximately 15 tons of heaviest sludge per hour. Just one driver/operator required inside the tank to operate extractor limiting liability exposure to the minimum.
(Download MegaMacs video - Sludge Extractor in operation.)