A review of the application of different treatment processes for oily sludge

Green transformation of oily sludge through geopolymer: Material properties and hydration mechanisms

Oily sludge (OS) is a kind of hazardous waste generated from the petrochemical industry. Currently, pyrolysis has been widely applied for OS disposal, while low-oil content (<5 wt%) OS still lacks novel technology to achieve efficient resource utilization and harmful substances immobilization. In this study, a kind of OS-based geopolymer was developed by OS and ground granulated blast furnace slag (GGBS). The results showed that in geopolymer with 30 wt% OS, the content of total petroleum hydrocarbons (TPHs) decreased by 82%, Zn achieved 100% stabilization, and the 28 d compressive strength could still reach 32.8 MPa. The appropriate oil content filled the pores and cracks in geopolymer matrix. The constructed model compounds further elucidated the hydration mechanisms of OS-geopolymer. The nucleation effect of crude oil and micro-aggregate effect of minerals jointly improved the polymerization degree of C-(A)-S-H gels. OS promoted the transformation of [SiO4]4- monomers into C-(A)-S-H unbranched middle groups and three-dimensional networks, thereby efficiently stabilizing harmful substances. Sustainability analysis showed that OS-based geopolymer had good environmental and economic benefits. Overall, this work provides theoretical guidance for the green transformation of OS in the construction field.

Ecological and human health risk associated with heavy metals (HMs) contaminant sourced from petroleum refinery oily sludge

The environmental and human health risk of heavy metals (HMs) in petroleum based oily sludge (OS) varies depending upon the source of origin of the crude oil and treatment processes practiced at the refineries. Consequently, the present study explores the potential risk associated with HMs of OS obtained from different refinery sites to the environment and human health. The results showed that HMs (Cu, Ni, Zn, Mn) present in OS surpasses the permissible limit of WHO guidelines except for Cr. Additionally, the Igeo value (grade 3-6), Ef (2.48-121.4), PLI (5.12-22.65), Cd (32.48-204.76) and PERI (grade 1-5) confirmed the high level of HMs contamination into the OS and its risk to the environment. Besides, the hazard index (HI) and the total carcinogenic risk (TCR) for HMs show substantial risk to both adult and children health. Likewise, the G-mean enzyme index and potential soil enzyme risk index (PSERI) of the OS showed a high risk to soil biological properties. Furthermore, statistical analysis confirmed the heterogeneity in properties of the OS and its potential impact on the soil ecosystem arising from different sites. Finally, the study unveils a novel perspective on the environmental and human health consequences associated with the OS.

The methods for improving the biodegradability of oily sludge: a critical review

Biological degradation method, as an environmentally friendly, low-carbon, and clean pollution treatment technology, is widely used for the harmless disposal of oily sludge. The biodegradability of oily sludge with stable emulsification system, high oil, and water content is poor. Therefore, it is necessary to pre-treat the oily sludge to improve its biodegradability, including recover the petroleum resources and remove heavy metals and bio-toxic organic matters. This review systematically summarizes five oily sludge treatment methods and their influences on sludge biodegradability, including pyrolysis, chemical hot washing, solvent extraction, chemical oxidation, and hydrothermal. Pyrolysis at temperatures above 750 °C produces high molecular weight polycyclic aromatic hydrocarbons, chemical hot washing and chemical oxidation would cause secondary pollution, solvent extraction method could not be applied due to the high cost and high toxicity of the extractant, and the oil removal of hydrothermal method is inefficient. Additionally, the principles, advantages, and disadvantages of those treatments and the factors affecting microbial degradation were analyzed, which provide the development direction of pretreatment technology to improve the biodegradability of oily sludge.

Characterization and treatment of oily sludge: A systematic review

Oily sludge is a prevalent hazardous waste generated in the petroleum industry, and effectively treating it remains a key challenge for the petroleum and petrochemical sectors. This paper provides an introduction to the origin, properties, and hazards of oil sludge while summarizing various treatment methods focused on reduction, recycling, and harmlessness. These methods include combustion, stabilization/solidification, oxidation and biodegradation techniques, solvent extraction, centrifugation, surfactant-enhanced oil recovery processes as well as freezing-thawing procedures. Additionally discussed are pyrolysis, microwave radiation applications along with electrokinetic method utilization for oily sludge treatment. Furthermore explored are ultrasonic radiation techniques and froth flotation approaches. These technologies have been thoroughly examined through discussions that analyze their process principles while considering influencing factors as well as advantages and disadvantages associated with each method. Based on the characteristics of oily sludge properties and treatment requirements, a selection methodology for choosing appropriate oily sludge treatment technology is proposed in this study. The development direction of processing technology has also been explored to provide guidance aimed at improving efficiency by optimizing existing processing technologies. The paper presents a comprehensive treatment method for oily sludge, ensuring that all the parameters meet the standard requirements.

Advances in ultrasonic treatment of oily sludge: mechanisms, industrial applications, and integration with combined treatment technologies

In the petroleum sector, the generation of oily sludge is an unavoidable byproduct, necessitating the development of efficient treatment strategies for both economic gain and the mitigation of negative environmental impacts. The intricate composition of oily sludge poses a formidable challenge, as existing treatment methodologies frequently fall short of achieving baseline disposal criteria. The processes of demulsification and dehydration are integral to diminishing the oil content and reclaiming valuable crude oil, thereby playing a critical role in the management of oily sludge. Among the myriad of treatment solutions, ultrasonic technology has emerged as a particularly effective physical method, celebrated for its diverse applications and lack of resultant secondary pollution. This comprehensive review delves into the underlying mechanisms and recent progress in the ultrasonic treatment of oily sludge, with a specific focus on its industrial implementations within China. Both isolated ultrasonic treatment and its combination with other technological approaches have proven successful in addressing oily sludge challenges. The adoption of industrial-scale systems that amalgamate ultrasound with multi-technological processes has shown marked enhancements in treatment efficacy. The fusion of ultrasonic technology with other cutting-edge methods holds considerable potential across a spectrum of applications. To fulfill the goals of resource recovery, reduction, and neutralization in oily sludge management, the industrial adoption and adept application of a variety of treatment technologies are imperative.

Petroleum sludge formation and its treatment methodologies: a review

Different petroleum operations produce huge amount of oil sludge annually. For instance, US EPA estimates the annual sludge production of each US refinery of 30,000 tons, while the average oily sludge produced from petrochemical industries in China is estimated about 3 million tons per year. In the last year, our center could recover about 30,206 barrels of raw oil from 32,786 barrels of tank bottom sludge (TBS) for different petroleum companies. This sludge causes huge economic losses besides its negative environmental impacts. The accumulation of sludge in the tanks results in reducing the tanks' capacity for storing liquid crude, accelerating the corrosion of the tanks, delay in the production schedule, and disturbing the whole production operation. There are diverse treatment methodologies such as solvent treatment, addition of certain chemicals, and centrifuging. Of course, the environmental regulations and the overall cost limitations are very important in deciding the preferred applicable method(s). Although several works handled the problem of sludge deposition and treatment from different aspects, we intend to introduce a different work. First, composition, formation, types, and properties of TBS were reviewed. Then, environmental and economic problems caused by TBS were revised. At last, different methodologies applied for treatment of oily TBS to recover oil and safe disposal of hazardous remains were investigated focusing on the most straightforward and environmentally friendly protocols. It is expected that this review attracts the experts in petroleum chemistry, and other relevant fields and provides a comprehensive understanding of current sludge control and treatment research.

Activation of peroxymonosulfate by biochar-supported Fe3O4 derived from oily sludge to enhance the oxidative degradation of tetracycline hydrochloride

Carbon materials used for catalysis in advanced oxidation processes tend to be obtained from cheap and readily available raw materials. We constructed a carbon material, OSC@Fe3O4, by loading Fe3O4 onto the pyrolyzed hazardous waste oily sludge. OSC@Fe3O4 was then used to activate peroxymonosulfate (PMS) for the removal of tetracycline hydrochloride (TTCH) from water. At 298 K, 0.2 g⋅L-1 of catalyst and 0.3 g⋅L-1 of PMS, the reaction rate constant of the OSC@I-2/PMS system reached 0.079 min-1, with a TTCH removal efficiency of 92.6%. The degradation efficiency of TTCH remained at 81% after five cycles. The specific surface area and pore volume of OSC@I-2 were 263.9 m2⋅g-1 and 0.42 cm3⋅g-1, respectively, which improved the porous structure of the carbon material and provided more active points, thus improving the catalytic performance. N and S were doped into the oily sludge carbon due to the presence of N- and S-containing compounds in the raw oily sludge. N and S doping led to more electron-rich sites with higher negative charges in OSC@I-2 and gave the oily sludge carbon a higher affinity to PMS, thereby promoting its ability to activate PMS. Sulfate radicals (SO4•‾) played a dominant role in the degradation of TTCH, with demethylation and the breaking of double bonds being a possible degradation pathway. A biotoxicity test showed that the microbial toxicity of the degradation intermediates was significantly reduced. This work provides a strategy for the application of PMS-based catalysts derived from waste carbon resources.

Deep dewatering of refinery oily sludge by Fenton oxidation and its potential influence on the upgrading of oil phase

Highly efficient dewatering is essential to the reduction and reclamation disposal of oily sludge, which is a waste from the extraction, transportation, and refining of crude oil. How to effectively break the water/oil emulsion is a paramount challenge for dewatering of oily sludge. In this work, a Fenton oxidation approach was adopted for the dewatering of oily sludge. The results show that the oxidizing free radicals originated from Fenton agent effectively tailored the native petroleum hydrocarbon compounds into smaller organic molecules, hence destructing the colloidal structure of oily sludge and decreasing the viscosity as well. Meanwhile, the zeta potential of oily sludge was increased, implying the decrease of repulsive electrostatic force to realize easy coalescence of water droplets. Thus, the steric and electrostatic barriers which restrained the coalescence of dispersed water droplets in water/oil emulsion were removed. With these advantages, the Fenton oxidation approach derived the significant decrease of water content, in which 0.294 kg water was removed from per kilogram oily sludge under the optimal operation condition (i.e., pH value of 3, solid-liquid ratio of 1:10, Fe²⁺ concentration of 0.4 g/L and H₂O₂/Fe²⁺ ratio of 10:1, and reaction temperature of 50 °C). In addition, the quality of oil phase was upgraded after Fenton oxidation treatment accompanying with the degradation of native organic substances in oily sludge, and the heating value of oily sludge was increased from 8680 to 9260 kJ·kg^-1, which would facilitate to the subsequent thermal conversion like pyrolysis or incineration. Such results demonstrate that the Fenton oxidation approach is efficient for the dewatering as well as the upgrading of oily sludge.

Efficient Treatment of Oily Sludge via Fast Microwave-Assisted Pyrolysis, Followed by Thermal Plasma Vitrification

Oily sludge, as a critical hazardous waste, requires appropriate treatment for resource recovery and harmfulness reduction. Here, fast microwave-assisted pyrolysis (MAP) of oily sludge was conducted for oil removal and fuel production. The results indicated the priority of the fast MAP compared with the MAP under premixing mode, with the oil content in solid residues after pyrolysis reaching below 0.2%. The effects of pyrolysis temperature and time on product distribution and compositions were examined. In addition, pyrolysis kinetics can be well described using the Kissinger-Akahira-Sunose (KAS) and the Flynn-Wall-Ozawa (FWO) methods, with the activation energy being 169.7-319.1 kJ/mol in the feedstock conversional fraction range of 0.2-0.7. Subsequently, the pyrolysis residues were further treated by thermal plasma vitrification to immobilize the existing heavy metals. The amorphous phase and the glassy matrix were formed in the molten slags, resulting in bonding and, hence, immobilization of heavy metals. Operating parameters, including working current and melting time, were optimized to reduce the leaching concentrations of heavy metals, as well as to decrease their volatilization during vitrification.

Trend in Research on Characterization, Environmental Impacts and Treatment of Oily Sludge: A Systematic Review

Oily sludge is a hazardous material generated from the petroleum industry that has attracted increasing research interest. Although several review articles have dealt with specific subtopics focusing on the treatment of oily sludge based on selected references, no attempt has been made to demonstrate the research trend of oily sludge comprehensively and quantitatively. This study conducted a systematic review to analyze and evaluate all oily sludge-related journal articles retrieved from the Web of Science database. The results show that an increase in oily sludge-related research did not take place until recent years and the distribution of the researchers is geographically out of balance. Most oily sludge-related articles focused on treatment for harmfulness reduction or valorization with limited coverage of formation, characterization, and environmental impact assessment of oily sludge. Pyrolytic treatment has attracted increasing research attention in recent years. So far, the research findings have been largely based on laboratory-scale experiments with insufficient consideration of the cost-effectiveness of the proposed treatment methods. Although many methods have been proposed, few alone could satisfactorily achieve cost-effective treatment goals. To enable sustainable management of oily sludge on a global scale, efforts need to be made to fund more research projects, especially in the major oil-producing countries. Pilot-scale experiments using readily available and affordable materials should be encouraged for practical purposes. This will allow a sensible cost-benefit analysis of a proposed method/procedure for oily sludge treatment. To improve the treatment performance, combined methods are more desirable. To inform the smart selection of methods for the treatment of different oily sludge types, it is suggested to develop universally accepted evaluation systems for characterization and environmental risk of oily sludge.

Efficient Separation and Recovery of Petroleum Hydrocarbon from Oily Sludge by a Combination of Adsorption and Demulsification

The treatment of oily sludge (OS) can not only effectively solve environmental pollution but also contribute to the efficient use of energy. In this study, the separation effect of OS was analyzed through sodium lignosulfonate (SL)-assisted sodium persulfate (S/D) treatment. The effects of SL concentration, pH, temperature, solid-liquid ratio, revolving speed, and time on SL adsorption solubilization were analyzed. The effects of sodium persulfate dosage, demulsification temperature, and demulsification time on sodium persulfate oxidative demulsification were analyzed. The oil removal efficiency was as high as 91.28%. The results showed that the sediment was uniformly and finely distributed in the S/D-treated OS. The contact angle of the sediment surface was 40°, and the initial apparent viscosity of the OS was 56 Pa·s. First, the saturated hydrocarbons and aromatic hydrocarbons on the sediment surface were adsorbed by the monolayer adsorption on SL. Stubborn, cohesive oil agglomerates were dissociated. Sulfate radical anion (SO4-·) with a high oxidation potential, was formed from sodium persulfate. The oxidation reaction occurred between SO4-· and polycyclic aromatic hydrocarbons. A good three-phase separation effect was attained. The oil recovery reached 89.65%. This provides theoretical support for the efficient clean separation of oily sludge.

Oily sludge treatment in subcritical and supercritical water: A review

Oily sludge, an inherent byproduct of the petroleum industry, presents dual characteristics of petroleum resources and hazardous waste. Owing to the unique physicochemical properties of sub-/supercritical water, hydrothermal technologies have been increasingly used for oily sludge treatment. This review is the first to focus on oily sludge treatment using sub-/supercritical water. Eight hydrothermal technologies used for different purposes are summarized herein: pressurized hot water extraction (PHWE) for hydrocarbon separation, thermal hydrolysis (TH) for dewaterability improvement, hydrothermal carbonization (HTC) for hydrochar production, wet air oxidation (WAO) for biodegradability improvement, hydrothermal liquefaction (HTL) for bio-oil production, supercritical water upgrading (SCWU) for light oil production, supercritical water oxidation (SCWO) for complete degradation, and supercritical water gasification (SCWG) for H₂-rich syngas production. Moreover, a general reaction pathway for sub-/supercritical water treatment of oily sludge is presented, with a particular focus on the chemical mechanism at temperatures above 350 °C. Lastly, two reaction maps are included to illustrate the reaction pathways of two groups of identifiable model compounds in oily sludge: aliphatic and aromatic hydrocarbons. This review provides detailed information that can promote a better understanding of various hydrothermal technologies, a guideline for selecting the suitable hydrothermal process for a particular oily sludge, and recommendations for further researches.

Preparation and Characterization of Insulating Panels from Recycled Polylaminate (Tetra Pak) Materials

Eco-sustainability and the reuse of materials are highly topical issues. In fact, in recent years, much study and research has been developed on this aspect, making the eco-sustainability of materials a real need. Polylaminate containers, more commonly called Tetra Pak containers, represent the most used packaging in the world. This work proposes a new strategy for the reuse of discarded polylaminate containers in order to create panels that can be used in construction and in particular as insulating panels. The proposed thermal method has been optimized in terms of operating variables such as time, temperature, pressure, number of polylaminate sheets. The results obtained show that the proposed thermal method is suitable for obtaining panels with characteristics suitable for use in green building. The advantage of the thermal method is that it does not use chemical or other binders and moreover uses only and exclusively sheets of recycled polylaminate.

Petroleum sludge treatment and disposal techniques: a review

Petroleum sludge is a solid emulsified waste and contaminant commonly produced in the petroleum industry. In the recent past, there has been increased business growth in the oil sector, resulting in increased volumes of oily sludge characterized by high viscosity and toxicity. Therefore, sludge treatment before discarding is extremely necessary. This review seeks to highlight various conventional and evolving approaches in the treatment, recovery, and disposal of petroleum sludge and assess their suitability under various conditions.

Removal of Methylene Blue by Metal Oxides Supported by Oily Sludge Pyrolysis Residues

As a typical pollutant, methylene blue poses a serious threat to the environment and human health. Oily sludge pyrolysis residue loaded with metal oxides could be used to prepare composite materials, which is not only an effective way to treat oily sludge, but also a possible method to treat methylene blue pollutants. In this paper, composite materials (AC-CuO, AC-ZnO, and AC-TiO2) were prepared by oily sludge pyrolysis residue-loaded CuO, ZnO, and TiO2 directly, and characterized by XRD, SEM, EDS, BET, FT-IR, and XPS, and it was shown that the metal oxides were successfully supported on the pyrolysis residue. Then, the composite materials were applied to the removal of methylene blue solution. The removal effect of composite materials on methylene blue with respect to the impregnation time, impregnation ratio and dosage, and the contact time and number of regenerations were investigated, and the removal parameters were optimized by response surface methodology. The removal process for methylene blue was described by applying Lagergren, McKay, Langmuir isotherm, Freundlish isotherm and intraparticle diffusion models. According to the response surface methodology and the main factors affecting the removal effect of methylene blue, the results indicate that the removal effect of 5 mg/L methylene blue could reach 95.28%, 94.95%, and 96.96%, respectively, and the corresponding removal capacities were 4.76, 4.75, and 4.85 mg/g. In addition, kinetic studies showed that the removal process of methylene blue was mainly constituted by chemical adsorption. The intraparticle diffusion showed that the removal of methylene blue may be controlled by both liquid film diffusion and intraparticle diffusion. The isotherms showed that the adsorption sites of composites for methylene blue were uniformly distributed and had the same affinity. Furthermore, regeneration experiments showed that the composite materials were stable and had relatively reusability.

Preparation and Characterization of Porous Carbon Composites from Oil-Containing Sludge by a Pyrolysis-Activation Process

Large amounts of oil-containing sludge (OS) are produced in the energy, industry and services sectors. It is mainly composed of residual oil and particulate matter, thus posing an environmental threat and leading to resource depletion if it is improperly handled. In this work, the OS feedstock was thermally treated to produce porously magnetic carbon composites (CC) using a pyrolysis-activation process. Using the data on the thermogravimetric analysis (TGA) of the OS feedstock, the thermal activation experiments were performed at 850 °C as a function of residence time (30, 60 and 90 min). The results of pore analysis for the resulting CC products showed that the Brunauer–Emmett–Teller (BET) surface area greatly decreased from 21.59 to 0.56 m2/g with increasing residence time from 30 to 90 min. This decline could be associated with continuous gasification by CO2, thus causing the removal of limited carbon on the surface of CC for a longer reaction time. Furthermore, the physical properties of the resulting CC products can be enhanced by post acid-washing due to the development of new pores from the leaching-out of inorganic minerals. The BET surface area increased from 21.59 to 40.53 m2/g at the residence time of 30 min. Obviously, the resulting CC products were porous materials with mesopores and macropores that were concurrently formed from the thermal activation treatment. These porous features were also observed by scanning electron microscopy (SEM).

Pyrolysis and Volatile Evolution Behaviors of Cold-Rolling Oily Sludge

Cold-rolling oily sludge contains high amounts of oil and iron resources that can be recycled by pyrolysis. We investigated the pyrolysis behavior and volatile products of oily sludge by thermogravimetric analysis (TG) coupled with Fourier transform infrared spectroscopy (FTIR) and a pyrolyzer (PY) coupled with gas chromatography/mass spectrometry (GC/MS). The pyrolysis process was divided into three stages: H2O drying and CO2 desorption at low temperatures (below 393 K); the volatilization of low-molecular-weight organics and the covalent bond cleavage of C=C, C-O, and C-H in the medium-molecular-weight organics at medium temperatures (393–844 K); and chain scission of the high-molecular-weight organics and reduction of iron oxides by CO at high temperatures (above 844 K). The weight losses of oily sludge in the three stages were 0.4 wt %, 47.9 wt %, and 14.7 wt %, respectively. According to the kinetic models, stage 2 and stage 3 could be described with the second-order and third-order reaction models, and their activation energies were 40.22 kJ/mol and 214.99 kJ/mol, respectively. The compounds in the volatile products were identified by FTIR and GC/MS. The organics in the volatile products from stage 2 pyrolysis mainly consisted of aliphatic hydrocarbons, fatty acids, esters, ketones, and nitrogen compounds, while the volatile products from stage 3 predominantly contained aliphatic hydrocarbons, mononuclear aromatic hydrocarbons, and small amounts of nitrogen compounds and CO, suggesting the occurrence of chain scission of heavy organics.