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Technologies |
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THE GENOIL CRYSTAL OIL AND WATER SEPARATION SYSTEM |
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DESCRIPTION |
| The Genoil Crystal 2-phase oily water separation system was developed to clean a water
stream to discharge specifications. At present, refiners use API ponds where the first section
utilizes gravitational separation aided by floating oil skimmers to recover oil that is sent to a slop
oil tank. This slop oil is then reprocessed in the refinery as a slipstream. The second section of
the API pond is primarily a biological process made up of one or two ponds where air is added
by either perforated piping or aerators for the bacteria. The HRT is typically anywhere from 30
to 45 days. In this application there would be potential for the Crystal system in order to
substantially improve the overall efficiencies of this process, especially when real estate is at a
premium. |
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3D DRAWINGS |
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The Crystal 2-phase oily water treatment units are designed to separate the liquid phases in six
stages located within a single vessel. Each stage is devised to remove oil particles of a certain
size and renders the liquid cleaner for the next stage. This ensures greater effectiveness and
manageable loads for each stage. Furthermore, it also precludes undue contamination and
clogging of various stages by oil, resulting in trouble free-operation.
Minute gas bubbles resulting from controlled vacuum conditions enhance the removal of oil
droplets from the water stream. Vacuum is created in stages operating prior to the circulation
pump. Oil is retained at the upper portion of the stages and is gradually accumulated in collection
zones.
Downstream from the pump the stages are slightly pressurized. Oil extracted in these stages is
transferred continually into the collection zones through specially designed conduits. The
transfer of oil occurs due to the pressure differential existing between the stages located upstream
and downstream from the pump respectively. Continual oil extraction ensures outstanding
cleanliness of the polishing stages and prevents accidental contamination of the effluent.
Oil accumulation in the collection zones is monitored by a probe that initiates periodic oil
discharge sequences. The separator is isolated from the discharge line and connected to a
pressurized line. Clean water back-flushes the stages and displaces the oil from the collection
zones. The oil probe resumes the separation process after a preset amount of oil is evacuated.
The first stage achieves oil-water separation through gravity enhanced by a flotation effect of
minute gas bubbles. Most of the oil droplets are removed in this stage. The flow is reversed prior
to the liquid entering the second stage. This assists in leaving the oil behind in the primary
collection zone. Sludge and other contaminants denser than water are deposited at the lower
portion of the first stage.
The second stage achieves oil-water separation by coalescence. A perforated chamber
accommodates suitably sized oleophilic beads. An arrangement designed to agitate the liquid and
allow free movement of the beads enhances the coalescing effect and also a self-cleaning
process. As a result, oil droplets adhering to adjacent beads are readily brought together. Larger
drops formed in this fashion overcome the force of attraction exerted by the beads. As a result
they leave the beads and migrate toward the oil collection area. The rubbing action occurring
between the beads in motion releases solid contaminants, thus cleansing the beads.
An oil layer formed within the chamber absorbs small hydrocarbon particles in order to break
down emulsified oil. The thickness of the oil layer is self-regulating. As the liquid enters the
third stage the coalescing process is resumed. Smaller oil particles reaching this stage are dealt
with in a similar fashion by optimally sized beads.
A pump draws the liquid from the third stage and pumps it into the fourth stage for further
separation by means of a vortex-generating device. Centripetal forces within the vortex
agglomerate the oil particles and force them to coalesce in order to form larger globules.
Furthermore, an effect similar to one created by a cyclone also agglomerates the oil particles thus
enhancing the coalescing process. A perforated pipe retrieves the globules that migrate toward
the eye of the vortex and directs them to a dispersion plate placed above the vortex generator. Oil
particles then travel through suitably sized perforations in the dispersion plate, gather around a
funnel and migrate toward the oil collector of the second stage.
Spinning liquid rapidly exits the vortex generator, being deflected downwards by the dispersion
plate for separation by gravity. Further separation of minute oil particles occurs in the fifth stage
by means of an electro-static field. Thus the oil particles are forced to form clusters of larger
globules, which are readily left behind as the flow is reversed and reaches the fifth stage
polishing. In most cases the separation is completed prior to this stage. However, for oils of very
high density the sixth stage retains the remaining particles by means of filters. The filter media
are designed to coalesce minute particles of oil on their surface. Enhanced buoyancy by
coalescence and the sweeping effect of the liquid take away the oil particles from the filter
media. Thus filter media lifespan can be prolonged to significant periods of time. This is due to
minimizing the amount of oil particles reaching the media and effective oil removal from the
surface of the media.
When continual operation is required a positive displacement pump evacuates the oil while the
separation process is taking place. An oil content meter may monitor the quality of the effluent.
In the unlikely event the oil content exceeds 15 mg/l, a re-circulation valve isolates the unit from
the discharge line. The effluent is then re-circulated to the inlet line and reprocessed in the
separator until it meets the requirements.
The main advantage of a Crystal is the nesting design. The four separation principles (gravity,
coalescing beads, vortex, filter) employed in this design are simple, and have no moving parts.
With the nesting design, Crystal is a very compact unit that is ideal for tight quarters. It was
originally designed for the bilge area of a ship. The order used in the separation principles is key
to reduced maintenance and effectiveness. The bulk of the oil is removed in the stages prior to
filtration. A pump is located between the third and forth stage, and since the bulk of the oil has
been removed, emulsions are much less of a problem than if a pump was placed up front of the
unit. The filter is the last stage. Of course the filter has to be changed when it is clogged.
However by having five stages in front of it, the filter does not receive a lot of oil and therefore
would not require frequent changes. The unit can also be run without the filter, virtually
eliminating maintenance. |
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PROCESS FLOW DIAGRAM |
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MAIN FEATURES AND APPLICATIONS |
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- Oily-water inlet
- Oil outlet
- Effluent outlet
- Back flushing line
- Pump
- Drain
- Control panel
- Oil content meter
- Oil probe, 1st stage
- Oil probe, 2nd stage
- Lid
- 3-way valve
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| Electrical supply : |
380 VAC / 3 phase / 50Hz
440 VAC / 3 phase / 60 Hz
220 VAC / 1 phase / 50 Hz
115 VAC / 1 phase / 60 Hz |
Compressed air supply: 600-800 KPa
Back flushing water pressure: 100-200 KPa |
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Main Features |
- Unique six-stage design for enhanced efficiency and performance
- No limitations on oil particle size
- Handles emulsions and oils with very high densities
- Low downtime, maintenance and operating costs
- Compact design for portability and applications where space is at a premium
- Simple and reliable operation
- Versatility for a wide range of applications
- Quality service and assistance for specific applications
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Applications: |
- Sand-washing plants, recycling of condensed steam in oil batteries, refineries
- Oil platforms
- Thermal power stations
- Wastewater treatment plants
- Reclaiming emulsified oil in steel mills
- Bilge water separation aboard sea-going vessels
- Gasoline/Diesel service stations
- Cement factories
- Salt mines
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Genoil Crystal oily-water separators utilize a patented, unique process for multi-stage
separation of immiscible phases with different densities such as mineral or vegetal oils and
water, animal fat and water etc. An innovative separation process combines gravitational and
centrifugal forces with surface tension and vortex effects prior to the polishing stage. A highly
effective polishing stage enhances performance and minimizes maintenance costs and downtime.
There are no limitations on oil particle size, and Crystal separators feature a method for
braking down emulsions. Thus emulsified oil utilized in steel mill processes is reclaimed and
recycled with considerable savings. Sludge and solids are collected at the bottom of the first
stage, which, in some applications can be fitted with Genoil patented fluidizing devices to
facilitate disposal.
Through superior efficiency and engineering the separators are compact and easy to install
wherever space is at a premium. The tank module is precision built, meeting or exceeding the
rigorous specifications of classification societies. Separators installed aboard ships have been
certified by Germanischer Lloyds and Registrul Naval Roman (Certificate Nos.
32451BUC/27.06.96 and 17/I/3425-DR, respectively). Each unit is tested prior to delivery for
complete customer satisfaction and all tests are conducted in accordance with I.M.0. Resolution
A.393 (X) / MEPC 60(33).
The automation system ensures unattended operation and features PLC units, self-cleaning oil
sensors, and other fail-safe components. The automation is also user-friendly for convenient
operation and includes carefully selected components. In custom-built units Crystal can be
integrated into complex automation systems being operated and monitored from a central
location.
Explosion-proof automation (Class I Div. I) for the oil industry is available upon request.
Our team provides technical assistance in special applications, guarantees quality service and
helps clients with the installation of larger units. The separators can be custom engineered to suit
specific requirements from 600 to 50,000 liters/hour capacities.
Crystal separators typically achieve effluent purities of less than 5 mg/l for 0-100% oil in
water mixtures and relative oil densities of up to 0.97. In some applications oil content in the
effluent is consistently below 2 mg/l at ambient temperature. In very demanding situations with
hydrocarbon densities as high as 0.985 the purity can be reduced to 8 mg/l.
In some US navy and army bases Crystal separators operate in conjunction with Anjan
filtering units devised to remove dissolved contaminants. When used in conjunction with Anjan,
the effluent purity was below 0.1 mg/l, which is virtually undetectable. |
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SPECIFICATIONS |
Model |
Capacity
[liters
per
hour] |
A
Height
[mm] |
B
Length
[mm] |
C
Depth
[mm] |
Inlet
Line
[inch] |
Effluent
Line
[inch] |
Oil
Outlet
[inch] |
Power
[kw] |
Weight
[kg] |
IU 0.6
MU
0.6 |
600 |
1300 |
950 |
450 |
3/4 |
3/4 |
3/4 |
0.75 |
250
265 |
IU
1.25
MU
1.25 |
1250 |
1450 |
1160 |
500 |
1 |
1 |
1 |
1 |
450
475 |
IU 2.5
MU
2.5 |
2500 |
1600 |
1400 |
750 |
1 1/4 |
1 |
1 |
1.5 |
900
950 |
IU 5
MU5 |
5000 |
1900 |
1900 |
900 |
2 |
1 |
1 |
3 |
1450
1530 |
IU 10 |
10000 |
1900 |
2100 |
1200 |
4 |
1 1/2 |
1 1/2 |
5 |
2900 |
IU 20 |
20000 |
1900 |
2200 |
1600 |
6 |
3 |
2 |
7.5 |
4800 |
IU 50 |
50000 |
2200 |
2400 |
1900 |
8 |
4 |
2 |
15 |
9600 |
IU-industrial use. MU- marine use Specifications subject to change without notice
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PARTIAL LISTING OF INSTALLATIONS AND TESTIMONIALS |
Several Crystal units were installed in different locations around the world before Genoil
acquired the technology.
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OWNER |
APPLICATION |
CAPACITY
[LITERS/HOUR] |
QUANTITY |
INSTALLATION
DATE |
Boyd T. Keogh &
Associates
Manley, Australia |
Units are operated in
conjunction with Anjan
filtering equipment for
processing industrial
wastewater.
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5000
600 |
2
1 |
1995
1995 |
Enviremedial
Services Inc.
Vista, California
U.S.A. |
Separators operate
upstream Anjan
filtration units for
processing wastewater
at the U.S. Army base
of Camp Pendleton.
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600
1250
5000
1250
2500
5000 |
1
1
1
1
1 |
1995
1996
1996
1998
1998
1998 |
Hydroxyl Inc.
Sidney, B.C.
Canada |
Unit installed upstream
oxygen-based
decontamination plant.
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1.250 |
1 |
1996 |
Oil Terminal S.A.
Constanta,
Romania |
Unit processes ballast
oily-water from tankers
for disposal to sewer.
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50000 |
1 |
1997 |
Administratia
Cailor Navigabile
S.A.
Constanta,
Romania
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Bilge separators
installed aboard ships. |
600
600 |
1
2 |
1997
1998 |
Santierul Naval
Oltenita S.A.
Oltenita, Romania
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Unit processes storm
water for disposal to
sewer. |
1250 |
1 |
1998 |
U.S. Navy
Coronado,
California, U.S.A |
In conjunction with
Anjan filtering
equipment Crystal
processes
contaminated water in
a car wash station.
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1250 |
1 |
1999 |
CE3 Technologies
Inc.
Edmonton,
Alberta Canada |
Units installed in a
water treatment plant
in conjunction with
Anjan and Alfa Laval
distillation plants
designed to process
produced water into
pure distilled water.
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20000 |
4 |
2000 |
Centrala Electro
Termica Progresul
S.A.
Bucharest,
Romania |
Owned by the
Romanian
Government, the
power plants employ
Crystal units for
processing water
contaminated with
heavy fuels and
bottoms for disposal
to sewer.
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20000 |
3 |
2003 |
Ispat Sidex S.A.
Galati, Romania |
Units reclaim
emulsified oil
resulted from steel
mill
cooling/quenching
processes and recyle
the oil with important
savings.
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10000 |
2 |
2003 |
Centrala Electro
Termica Iasi S.A.
Iasi, Romania
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Application similar to
the one at Bucharest
power plant. |
10000 |
2 |
2003 |
Centrala Electro
Termica Sud S.A.
Bucharest,
Romania
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Application similar to
Bucharest power
plant. |
20000 |
2 |
2003-2004 |
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TESTIMONIALS |
“As the wastewater manager for Fort Bliss I encountered extraordinary water management
issues that seemed to defy any easy solution. Your plant was placed in operation within 30
minutes and was able to treat the worst oil-water sludge from our oil-water separator processes
to below EPA effluent discharge standards. I know for a fact that all military representatives
who were present at your demonstrations were highly impressed. In my opinion, there are
several important reasons why your technology represents a breakthrough and, therefore,
represents great value to the Federal Government, particularly for military bases facing closure:
1) speed of set-up and case of performance; 2) ESI’s offer to provide a service-based contract to
get the job done on a guaranteed basis; and 3) high performance at an extremely competitive
cost. We were so impressed with ESI’s performance that I will make it a point to relay
information about your technology to my counterparts at other military bases. You can expect a
list of these contacts at the first of the year. What you have done is of outstanding value to the
Government and to our country in general. Let me know if there is anything I can do to help.”
Michael Landis
Wastewater Manager
Fort Bliss, Texas
“Our company was interested in operating mobile water treatment systems and an intricate part
of that was the removal of oil from water down to very low parts per million in the effluent.
Crystal was the only system we found that could give us the desired results and be suitable to be
moved about in a vehicle. We first used this system in two plants, sold to the Royal Thai
Government. We have since purchased other units and have been very satisfied ever since. Our
satisfaction not only came from the quality of the product but the level of service and
commitment from Mr. Costinel. His first thought was always the satisfaction of the customer and
how well his separators service the customer needs.”
Chris Keogh,
CEO Enviremedial Services Inc.
“Mr. Costinel’s unique invention is complementary to my company’s patented equipment, and
we have imported his Crystal Oil/Water Separator as an integral part of our plants, for use both
in Australia and overseas. Mr. Costinel’s attention to detail and insistence on a high and
reliable level of service plus the quality of his product make it a pleasure to deal with him.”
Boyd T. Keogh,
President Boyd T. Keogh and Associates. |
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