Chapter-2

Literature Review

2.1 Oily Water Separation System

The OWS systems are used for the removal of fine suspended oily
material from aqueous solutions. OWS systems are used on the process and
wastewater streams for oil particles that freely float and can be collected on
the surface of the liquid in the vessel. The OWS can be used for the removal
of oils for both municipal and industrial applications. The OWS maximizes
FOG removal while minimizing chemistry and utility usage. The OWS floats
the material to be removed by providing for the maximum effective separation
area in the form of coalescing plastic media which oil droplets come into
contact with as they traverse the vessel. The contact of oil with the media
accumulates them and increases their size. This results in increased oil
buoyancy. The collected oil is then drained into a collection basin Generally,
chemical pre-treatment is not required for the removal of most “free” oils.
However, chemistry may be found in some instances to assist in the collection
of the oil droplets. The addition of chemical(s) may also increase the
agglomeration of the droplets.
Due to large sea bottom pressure, vertical height is low, so the device is
mainly placed on the horizontal. Well, production flows into the gas-solid
separation equipment through the liquid pipe. And gas and a small residual
solid phase will be separated from the production liquid. When the separated
oil-water mixture flows into the period separating device in the period
separating device, the oil-water mixture is evenly divided into two periods to
inject into the adsorption device for oil-water separation. In the adsorption
process of the device, water, through the adsorption device and liquid
separating device, is re-injected by the pump. In the desorption process, oil is
fed into the platform through the liquid-separating device through a pump.
fig (2.1)-Simple sketch of oily water separator

Separating oil from the water allows to refuse both fluids in varying capacities.
Waste edible oil can be extracted from wastewater using the OWS system method.
This waste edible oil is ideal for use as raw materials in the biofuels and tire
manufacturing industries. Efficient oily separators lead to significant cost savings.
They enable clean water discharge, meet environmental regulations, and reduce
disposal and water treatment costs. Improved equipment efficiency also reduces
downtime and increases productivity, which adds to overall cost efficiency. If normal
oil pollutants are present in wastewater, 50-90% yield can be realized. The yield is
greatly determined by the flow profile in the oil/water separator and the
physical/chemical properties of present oil-like components, e.g. density and
solubility.
 Primarily OWS is used to remove oil from water/wastewater. Based on the
wastewater inlet parameters and site conditions & requirements a well-
designed OWS can reap many benefits, which are:
 Improved Process Efficiency: Effective oil removal from wastewater enhances
process efficiency. For example, when an OWS is installed in a wastewater
reuse treatment plant the chemical treatment, and filtration process is more
effective due to the absence of oils. Also, the filtration performance is
facilitated.
 Reduced Maintenance: A well-designed oil-water separator considers the
application's challenges and efficiently separates oil from water, thereby
enabling the efficient performance of downstream equipment ensuring low
maintenance requirements.
  Green Solution: OWS does not use any chemicals to separate oil and water.
Thus, it is an environmentally friendly method of oil removal.
 Improved Savings: The reclaimed oil can be reused in the processes thereby
reducing expenditure. No chemicals or consumables are required to separate
oil and water thus substantially saving on recurring costs.
An OWS is an integral part of industrial processes, a cost-effective green solution
to separate oil and water. ASTM method can be used to test oil grease in wastewater
to design an efficient OWS. Based on on-site conditions and discharge parameters
customization of OWS may be required. Also, in some cases, a mobile oil water
separator can be deployed.

2.2 Technical specification

This specification relates primarily to separators and filters of low to medium
capacity. Separating equipment should be capable of giving an effluent containing
not more than 100 ppm of oil irrespective of the oil content (from 100 percent) of
the feed supplied to it. Filtering equipment should reduce the effluent's oil content
to not more than 1 5 ppm.

2.2.1 The equipment should be strongly constructed and suitable for shipboard use,
bearing in mind its intended location on the ship.

2.2.2 The satisfactory functioning of the equipment should not be affected by the
movements and vibrations experienced on board the ship. In particular, electrical
and electronic alarm and control arrangements should be tested to show that they
are at least capable of continued operation under vibration conditions as follows: (i)
from 2 Hz-13.2 Hz with an amplitude of ±1 mm, and (ii) from 13.2 Hz-80 Hz with an
acceleration amplitude of ±0.7 g. Additionally, the equipment should be capable of
reliable operation at angles up to 22.5° in any plane from the normal operational
position.

2.2.3 It should comply with the relevant safety regulations for such spaces if it is
intended to be fitted in locations where flammable atmospheres may be present.
Any electrical equipment that is part of the equipment should be placed in a non-
hazardous area or should be certified by the Administration as safe for use in a
hazardous area. Any moving parts fitted in hazardous areas should be arranged to
avoid the formation of static electricity.

2.2.4 The equipment should be so designed that it functions automatically.

However, provision should be made for emergency manual control.

2.2.5 Changing the feed to the separating equipment from oily water to oil. or from
oil and/or water to air should not result in the discharge overboard of any mixture
containing more than 100 ppm of oil. In the case of filtering equipment, the oil
content in the discharge overboard should not be more than 15 ppm under the
same circumstances.

2.2.6 The system should require a minimum of attention to bring it into operation. In
the case of equipment used for engine room bilges, there should be no need for any
adjustment to valves and other equipment to bring the system into operation and,
when fitted in unattended machinery spaces, the system should be capable of
operating for at least 24 hours of normal duty without attention.
2.2.7 All working parts of the equipment which are liable to wear or to damage
should be easily accessible for maintenance.

2.3 Test Specification

These test standards refer to separating or filtering equipment of low or medium
capacity.

2.3.1 The oil/water mixture, with which the system has in practice to deal, depends
on:
(i) the position of the oil/water interface, concerning the suction point. in the
space being pumped;
(ii) the type of pump used;
(iii) the type and degree of closure of any control valve in the circuit; and
(iv) the general size and configuration of the system
It is therefore desirable that the test rig be so constructed as to include not only the
separating and filtering equipment but also the pump and most importantly the
valves, pipes, etc. The pipework should be designed for a maximum liquid velocity of
3 m/s.

2.3.2 The tests should be carried out with a supply rate equal to the full throughput
for which the equipment is designed.

2.3.3 Tests should be performed using two grades of oil. All the tests should be
carried out using a fuel oil of a relative density of about 0.94 at 15°C and of a
viscosity not less than 220 centistokes (about 900 seconds Redwood No.1) at 37.8°C
(100°F). In addition, the tests described in 2.2.10 and 2.2.11 should be carried out
using a light distillate fuel oil having a relative density of about 0.83 at 15°C.

2.3.4 f the equipment includes an integrated feed pump fitted before or after the
separator, this equipment should be tested with that pump supplying the required
quantity of oil and water to the equipment at its rated capacity. If the equipment is
to be fed by the ship's bilge pumps, then the unit will be tested by supplying the
required quantity of oil and water mixture to the inlet of a centrifugal pump
operating at not less than 1,000 rpm. This pump should have a delivery capacity of
not less than 1.5 times the rated capacity of the equipment at the delivery pressure
required for the test. The variation in oil/ water ratio will be obtained by valves on
the oil and water suction pipes adjacent to the pump suction, and the flow rate of oil
and water or the oil content of the supply to the equipment should be monitored. If
a centrifugal pump is used, the excess pump capacity should be dissipated by either
a by-pass to the suction side, or by a throttle valve or standard orifice plate on the
discharge side. In all cases. to ensure uniform conditions. the piping arrangements
immediately prior to the equipment should be such that the influent to the
equipment should have a Reynolds Number of not less than 10,000 as calculated in
fresh water, a liquid velocity of not less than 1 m/s, and the length of the supply pipe
from the point of oil injection to the equipment should have a length not less than
20 times its diameter. A mixture inlet sampling point and a thermometer pocket
should be provided near the equipment inlet and an outlet sampling point and
observation window should be provided on the discharge pipe. Figure 1 gives
diagrammatic representations of two possible test rigs, though it should be noted
that the water and oil from the equipment need not be led back to the supply tanks.
Where the water and oil are re-circulated during the test, additional sampling points
should be fitted in the water and oil lines to the mixture pump to check the quality
of the water and oil is being supplied to the pump. To approach isokinetic sampling,
i.e. the sample enters the sampling pipe at stream velocity, the sampling
arrangement should be as shown in Figure 2 and, if a cock is fitted, free flow should
be effected for at least 1 minute before any sample is taken. The sampling points
should be in pipes running vertically.

2.3.5 The tests should be carried out with clean water having a relative density at
15°C not more than 0.085 greater than the relative density of the heavier fuel oil
detailed.
2.3.6 In the case of equipment depending essentially on gravity, the feed to the
system should be maintained at a temperature not greater than 25°C, and heating
and cooling coils should be provided where necessary. In other forms of separation
where the dependence of separation efficiency on temperature is not established.
tests should be carried out over a range of temperatures representing the normal
shipboard operating range of 10°C to 30°C or should be taken at a temperature in
this range where the separation efficiency is known to be worst.
2.3.7 In those cases where. for the equipment, it is necessary to heat water to a
given temperature and to supply heat to maintain that temperature, the tests
should be carried out at the given temperature.

2.3.8 To ensure that the equipment commences the test with the oil section full of
oil and with the supply line impregnated with oil. the equipment should, after filling
with water and while in the operating condition, be fed with pure oil for not less
than five minutes.

2.3.9 A test lasting a minimum of three hours should be carried out to check that the
equipment will operate continuously and automatically. This trial should use a cycle
varying progressively from water to oily mixture with approximately 25 percent oil
content and back to water every 1 5 minutes. and should test adequately any
automatic device that is fitted. The whole test sequence should be performed as a
continuous program. At the end of the test. while the equipment is being fed with
25 percent oil, a water effluent sample should be taken for analysis.
2.3.10 In the presentation of the results, the following data should be reported in
the International Metric System of Units:
(i) Properties of the oil:
relative density at 1 5°C
-viscosity (centistokes at 37 .8°C)
-flashpoint
-ash
-water content(total)
(ii) Properties of the water:
-relative density at 15°C with details of any
solid matter percent;
(iii) Temperature at the inlet to the
equipment;
(iv) The method used in the analysis of all
samples taken and the results thereof together with meter readings where
appropriate.

2.4 Working Principle of Oily Water Separator

The fundamental principle of separation by which oil/water separators work is the
difference in gravity between oil and water. The fundamental principle of separation
by which oil/water separators work is the difference of gravity between oil and water.
The oil exists in oily water mixtures as a collection of globules of various sizes. The
force acting on such a globule which causes it to move in the water is proportional to
the difference in weight between the oil particle and an equal volume water particle.
The resistance to movement of the globule depends on its size and the fluid viscosity.
In the case of small particles moving under streamlined flow conditions, the
relationship between these properties can be expressed in Stoke’s Law.

2.4.1 Stoke’s Law

Stokes law states that force that returns a sphere moving through a viscous fluid
under streamlined flow or laminar flow is directly proportional to the velocity of the
sphere diameter of the sphere viscosity of the fluid, it is expressed as,
Fr=3πvud
Fr=resistance to movement
v= terminal velocity of particle
u= viscosity of road
d=diameter of particle
The separation of oil from oil/ water mixture only when separating force and terminal
force equal. In general, a high separation rate is encouraged by the large size of the oil
globule, the elevated system temperature (which increases the specific gravity
differential of oil and water and reduces the viscosity of the oil), and the use of
seawater.
Turbulence or agitation should be avoided as it causes the oil to be mixed and re-
entrained. Laminar or streamlined flow is beneficial for the good operation of OWS.
In addition, the heating coils are provided to improve separation.
There are several other means used for improving and speeding up the operation.
The oil/water separator entrance area is large so that the flow is slow and large oil
slugs can move quickly to the surface.

2.4.2 Oily Water Separator Working

The complete unit is filled with clean water and after that, the oil/water is
pumped to the first stage of the coarse separating compartment. Here, oil with a lower
density than water will rise to the surface with the aid of heating coils in this process.
It’s known as a collection space. A sensor then senses the oil level and the oil is then
dumped (according to ppm ) to the dirty oil tank via an oil valve. The remaining oil-
water mixture moves down to the fine separation compartment and moves slowly
between the catch plates. On the underside of these plates, more oil will separate and
move outwards until it is free to rise to the collection space. And then, almost oil-free
water passes on to the second stage of the unit. In the second stage, two coalesce filters
are situated. The first filter removes any physical impurities present and promotes
some filtration, the 2nd filter uses coalesce filter elements to achieve final filtration.
Clean water then leaves the 2nd stage onto a clean water holding tank or via a 15ppm
monitor with audible and visual alarms overboard. Coalescence:- Breakdown of
surface tension between the oil droplets in an oil-water mixture which causes them to
join and increase in size.

2.4.3 Working and Construction

 It is the operation of an oily water separator with a fifteen ppm monitor. The
separation of fine water in the separated fixed place in two stages, in the first stage
of separation is by gravity whereas in the second stage, the separation is by
coalescing filter.

2.4.4 Components of OWS

Oily water separator mainly consists of 3 units
1. Separator Unit
2. Filter Unit
3. Control Unit (oil content monitor)

A. Separator Unit
This unit consists of catch plates which are inside a coarse separating compartment
and an oil collecting chamber. The boost pump delivers clean seawater to the first
stage of the separation through the inlet valve. The vent is kept open till all the air is
removed from the separator; the oily water mixture is then pumped through the
separator inlet pipe into the course separating compartment. Here, because of its
lower density, some oil can separate and rise into the oil collection spaces. The
remaining oil-water mixture now flows down into the fine separating compartment
and passes gradually between the catch plates. More oil can separate on the
underside of these plates and travel out until the oil-collecting space is free to rise.
Almost oil-free water passes through the central pipe and leaves the separator unit.
The purity at this point will be a hundred parts per million or less. An automatically
operated valve releases the oil into a storage tank. (The oil drain valve from the top
of the first stage separated is a diaphragm-controlled piston valve that controls air
and supplied to the diaphragm through the solenoid-operated pilot valve, the
capacitance probe senses oil quantity in the collection space and energizes the form
allied to the control switch, was a passive downwards from the first to the second
phase coalesce the two central pipe). Air is released from the Unit By A Vent valve.
Steam or electric heating coils are provided in the upper and sometimes the lower
part of the separator, depending upon the type of oil to be separated. (heating
reduces the viscous drag of oil and thus makes separation of oil and water Easier)
where greater purity is required the almost oil-free water passes to a filter unit, the
water flows in turn through two filter stages and the oil removed passes to oil
collecting spaces. The first stage filter removes physical impurities present and
promotes some points of fine separation.

2. The Filter Unit

● This is a separate unit whose input comes from the discharge of the first unit.
● The unit consists of three stages — the filter stage, the coalescer stage, and the
collection chamber.
● The impurities and the particles are separated by a filter and settled down to the
bottom for removal. The second stage filter uses coalescer inserts for final de-oiling.
Coalescence is the breakdown of surface tension between oil droplets in an oil-
water mixture which causes them to join and increase in size.
Coalescer filter
The oil content of the final discharge is the last thing ppm, in case the discharge of
water after the second stage is more than fifteen ppm. The monitor synthesizes and
gives an audible and visual alarm in the engine room, at the same time the monitor
and the signal to a three-way valve on the overboard discharge line which closes the
overboard and opens those tanks. The sensor reports the normal operation, once
the oil content drops below fifteen between the test cocks can be used to ascertain
the levels of oil and water manually. The oil from the collecting spaces is drained
manually, as is usually required, about once a week. Filter inserts will require a
change in the period of useful life, depending on the operating conditions.

3. Oil Content Monitoring Unit

Regulations on the discharge of oily water, set a concentration limit of, up to 15
parts per million. A monitor is required to measure these values and to provide both
continuous recordings and alarms where the level allowed is exceeded. The principle
used is that of ultra-violet fluorescence. This is the emission of light by a light-
absorbing molecule. Energy is lost during the short time between absorption and
emission, and light of a longer wavelength is emitted. Oil fluoresces more readily
than water, so this provides the means to detect it. A sample is drawn off from the
overboard discharge and passes through the sample cell (Figure). The ultraviolet
light is directed to the sample and the fluorescence is monitored by a photoelectric
cell. The measured value is compared to that of the maximum desired value in the
controller/recorder. When an excessive level of contamination is detected, the
alarm is sounded and the diverting valve is operated. The discharging liquid is then
passed to a slop Vault.
2.5 Stage of Operation
Figure shows a typical separation train might have a well producing into an HP
separator at 1100psig, with the oil to an IP separator at 450psig, and an LP separator
at 150 psi. If the production is high pressure and if the oil from the separator is put
directly in the pipeline, gas will flash as the pressure decreases due to friction losses
in the pipeline.
Gas takes up a much larger volume than its equivalent mass of oil, so a pipeline sized
for liquid flow will be undersized if some of the liquid flashes into gas resulting in
excessive velocities and pressure drop [3]. For this reason, oil pipeline owners
generally specify a maximum vapor pressure allowed to prevent the lighter
components in the oil from flashing into gas. Separator pressure is chosen so that
the flash gas from each separation stage feeds into a stage of compression with
reasonable compression ratios for each compressor stage.

2.6 Flash Calculation

The amount of hydrocarbon fluid that exists in the gaseous phase or the liquid
phase at any point in the process is determined by a flash calculation, for a given
pressure and temperature each component in the gas phase will depend not only on
pressure and temperature, but also on the partial pressure of the element [16,17].
Therefore the amount of gas depends upon the total composition of the fluids as the
mole fraction of any one element in the gas phase is the function of the mole
fraction of every other element in this phase. This is best understood by assigning an
equilibrium “K” value to each component. The K value is a strong function of
temperature and pressure and the composition of the vapor and liquid phases. It is
defined as
KN = VN/V / LN/L
Where, KN =Constant for component N at a given T and P
VN = Moles of component N in the vapor phase
V = Total moles in the vapor phase
LN =Moles of component N in the liquid phase
L =Total mole on the liquid phase
If KN for each component and the ratio of total moles of vapor to total moles of
liquid
(V/L) are known, then the moles of the component N in the vapor phase (VN) and
the
moles in the liquid phase (LN) can be calculated from
KN FN
V N= 1
V
L

where FN = total moles of component N in the fluid.

2.7 Flow rate
a. Gas Flow Rate
If the flow rate of the inlet stream is known in moles per day, then the
number of moles per day of gas flow is
V = F./ 1+ 1/(V/L)
Where V = gas flow rate (moles/day)
b. The flow rate in standard cubic feet can be determined by:
Q g = 380V/1000000
Where Q g = Gas Flow Rate, MMscfd
c. Liquid Flow Rate
Q l = L x (MW) / 350 (SG) (2.20)

where QL = Liquid Flow Rate, bpd

2.8 Optimization Model

Algorithm mathematical optimization techniques have been used widely in the
design
optimization. Mathematical programming formulas are used for the design units,
systems and are even used at the conceptual level. To cast the separator problem
into a mathematical program it must be formulated in the
general form:
max or min z = f (x1, x2, …………., x n)
subject to g1 (x1, x2……x n) (≤, =, ≥) b1
 gm (x1, x2……x n) (≤, =, ≥) bm
The objective function (z), which is a function of the design variables (xi) is to be
maximized or minimized subject to a set of constraints (gI). The constraints are
functions of the design variables and describe physical design relationships
expressed as inequalities or equalities. A feasible solution of a mathematical
program satisfies all the constraints. A subset of the inequality constraints will be
active, which is satisfied at equality. The active constraint will inform which physical
relationships are constraining the design. The status of the inactive constraints can
be used to quantify the flexibility of the design. An optimal design is one for which
no other design has a higher or lower objective function value.
Many algorithms exist to solve mathematical programs. Because of nonlinearity in
the separator design problem both in objective function and in constraints, the
Generalized Reduce Gradient (GRG2) to find the optimal separator design.