Status and prospect of oil recovery from oily sludge:A review

Energy recoveries and heavy metal migration behaviors of different oily sludges treated by pyrolysis versus solvent extraction

The pyrolysis and trace element mitigation characteristics are investigated by contrast to solvent extraction for four oily sludges, including storage tank bottom sediment (OS-1), scum from a wastewater separator (OS-2), white-clay-adsorbed waste oil (OS-3), and settlings from wastewater treatment (OS-4). Slow pyrolysis at 700 °C generated a single oil phase for OS-1 and separate oil and aqueous phases for OS-2, OS-3 and OS-4. Up to 73.0-88.3 % of the total energy were recovered from OS-1, OS-2 and OS-3 in the oil phase with 19.9-77.1 % oil yield; however, the oil phase from OS-4 accounted for only 13.3 % of the total energy, while the aqueous product accounted for 68.0 % of the total energy. Quantification of 16 trace elements revealed that OS-2 and OS-4 had much higher contents of Cu/Zn/As/Se/Cd/Pb and Ni/Cu/Zn/Se/Cd contents than the average crustal abundances, respectively. Correlations between evaporation and extraction rates indicated that the mitigation behaviors of trace elements were related to their occurrence modes in different oily sludges. Except for Cd, As and Se, all other trace elements were enriched in the pyrolysis residues of the oily sludges. Ni in the pyrolysis residue of OS-4 posed a moderate potential ecological risk.

Carbonaceous materials from a petrol primary oily sludge: Synthesis and catalytic performance in the wet air oxidation of a spent caustic effluent

Oil refineries produce annually large quantities of oily sludge and non-biodegradable wastewater during petroleum refining that require adequate management to minimize its environmental impact. The fraction solid of the oily sludge accounts for 25 wt% and without treatment for their valorization. This work is focused on the valorization of these solid particles through their transformation into porous materials with enhanced properties and with potential application in the catalytic wet air oxidation (CWAO) of a non-biodegradable spent caustic refinery wastewater. Hence, dealing with the valorization and treatment of both refinery wastes in a circular approach aligned with the petrol refinery transformations by 2050. The obtained oily sludge carbonaceous materials showed improved surface area (260-762 m2/g) and a high Fe content. The good catalytic performance of these materials in CWAO processes has been attributed to the simultaneous presence of surface basic sites and iron species. Those materials with higher content of Fe and basic sites yielded the highest degradation of organic compounds present in the spent caustic refinery wastewater. In particular, the best-performing material ACT-NP 1.1 (non-preoxidated and thermically treated with 1:1 mass ratio KOH:solid) showed a chemical oxygen demand (COD) removal of 60 % after 3 h of reaction and with a higher degradation rate than that achieved with thermal oxidation without catalyst (WAO) and that using an iron-free commercial activated carbon. Moreover, the biodegradability of the treated wastewater increased up to 80% (from ca. 31% initially of the untreated effluent). Finally, this material was reused up to three catalytic cycles without losing metal species and keeping the catalytic performance.

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.

Pyrolysis characteristics and product distribution of oil sludge based on radiant heating

It needs to be improved the conversion efficiency and stable operation of conventional pyrolysis with high-temperature flue gas heating (HFH). Herein, a new radiative heating (RH) pyrolysis method is proposed. Experimental studies are carried out on a self-made radiation pyrolysis pilot plant to investigate the effects of different factors (pyrolysis final temperature, residence time, and carrier gas volume) on product distribution. The results show that with the increase of pyrolysis temperature, the yield of the gas phase consistently increases, and the proportion of CH4 and H2 in the pyrolysis gas reaches 62.31% at 700 °C. The yield of the liquid phase increases and then decreases. The recovery rate of pyrolysis oil achieves 68.07% when the pyrolysis temperature is 600 °C with main components of ketones and unsaturated hydrocarbon compounds. The yield of the solid phase consistently decreases. The RH in this work generates more pyrolysis gas in the pyrolysis process and alleviates the effects of fouling layers on the continuous operation of the equipment which has guiding significance for the efficient resource utilization of oil 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.

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.

Homogenizing microwave pyrolysis of oily sludge using nano-Fe3O4: volatile gas product analysis

To improve the homogeneity of heating, the magnetic absorbing material Fe3O4 is considered to use in microwave pyrolysis of oily sludge. Therefore, the effect of Fe3O4 on the microwave pyrolysis of oily sludge is investigated based on gas volatile products. Thermogravimetric mass spectrometry result certifies that Fe3O4 will increase the weight-loss ratio from 13.0% to 14.1%. Also, the characteristic peak intensity of CO in gas products decreases from 5.41 × 10-10 A/g to 1.95 × 10-10 A/g, while H2O increases from 3.57 × 10-10 A/g to 7.32 × 10-10 A/g and CO2 increases from 6.87 × 10-10 A/g to 8.92 × 10-10 A/g. This is caused by the esterification of alcohols and esters and the reduction of Fe3O4 by CO. Based on the decrease in activation energy and enthalpy values of Stage II and IV, it infers that Fe3O4 catalyzes the pyrolysis process of oily sludge to some extent. Similarly, gas chromatography-mass spectrometry results show that Fe3O4 can make the types of gas products increase. Especially, the number of molecular species increases from 5 to 46 under 200-300 °C. Finally, a simple molecular dynamics simulation model is conducted, and the results are in agreement with the experimental results. This study shows that Fe3O4 improves the pyrolysis homogeneity and the pyrolysis efficiency also improves.

Ultrasonication-flotation-advanced oxidation tertiary treatment of oil-based drilling cuttings

The treatment of oil-based drilling cuttings (OBDCs) with high oil content is difficult. In this study, a tertiary treatment of ultrasonication-flotation-advanced oxidation for treating OBDCs with a high oil content of 20.10 wt% was proposed for the first time. All stages of the treatment processes were optimised. The recommended parameters for ultrasonication at room temperature were a mass ratio of OBDCs to the degreaser of 1:8, an ultrasonication power of 600 W and treatment time of 30 min. After the ultrasonication treatment, the oil content of the OBDCs decreased from 20.10 wt% to 5.00 wt%. Flotation was performed at room temperature with a mass ratio of OBDCs to the degreaser of 1:10, a stirring speed of 400 rpm, an aeration head aperture of 3 μm and airflow rate of 400 mL/min under N2 injection for 60 min. After the flotation treatment, the oil content of the OBDCs decreased from 5.00 wt% to 2.01 wt%. Advanced oxidation was performed at room temperature with a mass ratio of OBDCs to water of 1:10, 3.57 wt% sodium persulphate in water, 4.17 wt% ferrous sulphate heptahydrate in water and ultrasonication power of 1000 W for 100 min. Following the advanced oxidation treatment, the oil content of the OBDCs decreased from 2.01 wt% to 0.58 wt%. The results of this study provide a new method and idea for treating OBDCs with high oil content.

Recovery of fuel from real waste oily sludge via a new eco-friendly surfactant material used in a digital baffle batch extraction unit

This study focused on developing a new cocktail extraction agent (CEA) composed of solvent and a new surfactant material (SM) for enhancing the efficiency of fuel recovery from real waste oil sludge (WSO). The effects of different solvents (e.g. methyl ethyl ketone (MEK), naphtha, petrol and kerosene), SMs (Dowfax and sodium thiosulfate), extraction time (10-20 min), extraction temperatures (20-60 °C) and CEA/sludge ratios (1-4) on the extraction performance were investigated. SMs and DBBE design enhanced the extraction efficiency by increasing the dispersion of solvent in WSO and enhancing the mixing and mass transfer rates. Results proved that Dowfax was the best SM for oil recovery under various conditions. The best CEA (e.g. MEK and Dowfax) provides the maximum fuel recovery rate of 97% at a period of 20 min, temperature of 60 °C and 4:1 CEA/sludge ratio. The produced fuel was analysed and fed to the distillation process to produce diesel oil. The characteristics of diesel oil were measured, and findings showed that it needs treatment processes prior its use as a finished fuel.

Assessment of oily sludge biodegradation in lab scale composting and slurry bioreactor by bacterial consortium

The present study aimed to investigate biodegradability of oily sludge in lab scale composting and slurry bioreactor using a potential bacterial consortium isolated from petroleum-contaminated sites. The consortium used in the study consisted of bacterial genera, including Enterobacter, Bacillus, Microbacterium, Alcaligenes Pseudomonas, Ochrobactrum, Micrococcus, and Shinella which were obtained after rigorous screening using different hydrocarbons. The meticulously designed lab scale composting experiments were carried out and showed that the combination of 10% oily sludge (A1) exhibited the highest total carbon (TC) removal, which was 40.33% within 90 days. To assess the composting experiments' efficiency, the first (k₁) and second (k₂) order rate constants were evaluated and was found to be 0.0004-0.0067 per day and second (k₂) 0.0000008-0.00005 g/kg. day respectively. To further enhance the biodegradation rate of A1 combination, a slurry bioreactor was used. The maximum total petroleum hydrocarbon (TPH) removals in a slurry bioreactor for cycle-I and -II were 48.8% and 46.5%, respectively, on the 78th and 140th days of the treatment. The results obtained in the study will be a technological platform for the development of slurry phase treatment of petroleum waste in a sustainable and eco-friendly manner.

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.

Contribution of Bayesian networks as a robust tool in risk assessment under sustainability considerations, a case study of Bandarabbas refinery

Background and purpose

Refineries are among the industrial centers that supply the energy and raw materials to downstream industries. To achieve sustainable development goals, creating appropriate balance between economical and environmental goals has always been the focus of managers and policy makers in the societies. Bayesian Network model has become a robust tool in the field of risk assessment and uncertainty management in refineries. The focus of this research is to prioritizing different units from the point of view of social and ecological aspects for facilitating the decision making process in the context of waste material treatment in Bandarabbas refinery in line with the sustainable development goals.

Materials and methods

The methodology of this research is based on risk assessment with the aid of Bayesian Networks. To this end, first material flow analysis of the processes procured risk identification, subsequently influence diagram and Bayesian Network structure were designed. After completing conditional probability tables, finally risk factors were prioritized. What is more, sensitivity analysis of the model performed by applying three approaches namely predictive, diagnostic, and considering only one risk.

Conclusion

According to the risk assessment results, Amine treatment and Fuel units were classified as the most significant risk factors, whereas Pipelines and Plant air & instrument air system were identified as the most environmental friendly units. In addition, sensitivity analysis of the model provided appropriate framework to shed some light on the circumstances of determining dominant risk factors whether only one or concurrently all of the endpoints are evaluated.

Environmental Risk Analysis Based on Characterization of Ground Oily Sludge

Oily sludge is recognized as hazardous waste. To reduce the potential danger and harmful factors of oily sludge, it is very important to analyze its environmental risk. In this paper, the characterization of oily sludge from Shengli Oilfield in China was tested experimentally, including the composition content, particle size, microscopic morphology, heavy metal content, organic composition, inorganic composition, and thermogravimetric analysis, which were used to analyze environmental risks. The results show that the oil content of oily sludge is as high as 10.3%, which will cause serious pollution. It is calculated that China can recover 772.5 million liters of oil and reduce 553.9 million kg of carbon emissions compared with incineration in one year, if the oily sludge can be managed effectively. The content of heavy metals such as Ba, Zn, Cr, As, Ni, Se, Be, and Hg in oily sludge exceeds the standard. It will restrain the self-healing ability of soil, pollute groundwater, and endanger animals and plants. The organic matter of oily sludge is concentrated in C₁₁ to C₂₉. It contains a large amount of benzene series and polycyclic benzene hydrocarbons, which can lead to cancer in the human body. Inorganic substances in oily sludge are mixed with some additives, which can not only reduce the toxicity of heavy metals, but also be used as building materials. The median particle size D₅₀ of oily sludge is 0.91 μm, and it spreads all over the narrow pores. Generally, it needs to be treated under high temperature conditions, which will cause secondary pollution to the environment. The research content of this paper provides a theoretical reference for the management of oily sludge.

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.

Iron Compounds in Anaerobic Degradation of Petroleum Hydrocarbons: A Review

Waste and wastewater containing hydrocarbons are produced worldwide by various oil-based industries, whose activities also contribute to the occurrence of oil spills throughout the globe, causing severe environmental contamination. Anaerobic microorganisms with the ability to biodegrade petroleum hydrocarbons are important in the treatment of contaminated matrices, both in situ in deep subsurfaces, or ex situ in bioreactors. In the latter, part of the energetic value of these compounds can be recovered in the form of biogas. Anaerobic degradation of petroleum hydrocarbons can be improved by various iron compounds, but different iron species exert distinct effects. For example, Fe(III) can be used as an electron acceptor in microbial hydrocarbon degradation, zero-valent iron can donate electrons for enhanced methanogenesis, and conductive iron oxides may facilitate electron transfers in methanogenic processes. Iron compounds can also act as hydrocarbon adsorbents, or be involved in secondary abiotic reactions, overall promoting hydrocarbon biodegradation. These multiple roles of iron are comprehensively reviewed in this paper and linked to key functional microorganisms involved in these processes, to the underlying mechanisms, and to the main influential factors. Recent research progress, future perspectives, and remaining challenges on the application of iron-assisted anaerobic hydrocarbon degradation are highlighted.

Production of Mesoporous Magnetic Carbon Materials from Oily Sludge by Combining Thermal Activation and Post-Washing

In this work, the oily sludge (OS) from a local waste oil recycling plant was reused as a precursor for producing porous magnetic carbon composites (CC) by pyrolysis, followed by carbon dioxide activation. Based on the thermogravimetric analysis (TGA) of the OS feedstock, the preparation experiments were performed at 800−900 °C. From the pore analysis of the CC products, it indicated an increasing trend, as the BET surface area greatly increased from about 1.0 to 44.30 m2/g. In addition, the enhancement effect on the pore properties can be consistently obtained from the acid-washed CC products because the existing and new pores were reformed due to the leaching-out of inorganic minerals. It showed an increase from 32.27 to 94.45 m2/g and 44.30 to 94.52 m2/g at 850 and 900 °C, respectively, showing their mesoporous features. These porous and iron-containing features were also observed by the scanning electron microscopy-energy dispersive X-ray spectroscopy (SEM-EDS). In addition, the adsorption removal of total organic carbon (TOC) in the raw wastewater, by the CC product, showed its high performance (>80%).

Analysis of Pyrolysis Characteristics of Oily Sludge in Different Regions and Environmental Risk Assessment of Heavy Metals in Pyrolysis Residue

As a resource treatment method, pyrolysis realizes the recovery of oil and immobilization of heavy metals in oily sludge (OS). The results showed that the composition of OS had little effect on the trend of the whole pyrolysis process, but it had different effects on the mass loss and maximum weight loss rate at each pyrolysis stage. SEM-EDS results showed that the pyrolysis residue had a porous internal structure, which was similar to that of activated carbon. The elements S, Ca, O, Fe, Al, and Si were embedded in the carbon skeleton. After OS pyrolysis, the oil content of the solid residue was far less than 2%, which met the pollution control requirements for comprehensive utilization specified in China's oil and gas industry standard. At the same time, the ratio of exchangeable fraction decreased and the ratio of residual fraction increased after OS pyrolysis. The potential ecological hazard coefficient (E _r) of Cd in OS2, OS2-500, and OS2-600 was greater than 40, which were strong and medium hazards. The E _r values of OS2-700 and other metals were far lower than 40, which were low hazards. With the increase of pyrolysis temperature, the comprehensive ecological hazard index (RI) of heavy metals in the residue gradually decreased and the RI value of OS2-700 decreased to 28.01. Therefore, the pyrolysis residue had an internal porous structure and controllable environmental risk. It could be used as an adsorption material for heavy metals to realize the comprehensive utilization of OS.

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.

Characterization and biodegradability assessment of water-soluble fraction of oily sludge using stir bar sorptive extraction and GCxGC-TOF MS

Percolation of water through oily sludge during storage and handling of the sludge can cause soil and groundwater contamination. In this study, oily sludge from a refinery was equilibrated with water to obtain the water-soluble fraction (WSF) of oily sludge. The WSF had dissolved organic carbon (DOC) of 166 mg/L. Human cell line-based toxicity assay revealed IC₅₀ of 41 mg/L indicating its toxic nature. The predominant compounds in WSF of oily sludge included isomers of methyl, dimethyl and trimethyl quinolines and naphthalenes along with phenol derivatives and other polynuclear aromatic hydrocarbons (PAHs). Biodegradation of WSF of oily sludge was studied using a consortium of Rhodococcus ruber, Bacillus sp. and Bacillus cereus isolated from the refinery sludge. The consortium of the three strains resulted in 70% degradation over 15 days with a first-order degradation rate of 0.161 day^-1. Further analysis of the WSF was performed using the stir-bar sorptive extraction (SBSE) followed by GCxGC-TOF MS employing a PDMS Twister. The GCxGC analysis showed that Bacillus cereus was capable of degrading the quinoline, phenol and naphthalene derivatives in WSF of oily sludge at a faster rate compared to pyridine and benzoquinoline derivatives. Quinoline, phenol, biphenyl, naphthalene, pyridine and benzoquinolines derivatives in the WSF of oily sludge were reduced by 87%, 92%, 88%, 77%, 40% and 62%, respectively with respect to the controls. The WSF of oily sludge contained, n-alkanes, ranging from n-C12 to n-C18 which were removed within 2 days of biodegradation.

Removal of Cr(VI) by biochar derived via co-pyrolysis of oily sludge and corn stalks

The co-pyrolysis of oily sludge with biomass to prepare carbon materials is not only an effective way to mitigate oily sludge pollution, but it is also a method of obtaining carbon materials. In this study, a carbon material (OS-CS AC) was obtained by the direct co-pyrolysis of oily sludge (OS) and corn stalks (CS) and then applied to Cr(VI) removal. According to the hydroxy and carboxy masking experiments and the characterization of OS-CS AC by FT-IR, SEM, XPS, XRD, and N₂ physical adsorption–desorption, Cr(VI) can be adsorbed efficiently through pore filling, the surface oxygen-containing functional groups can promote the reduction of Cr(VI) to Cr(III) through electron donors, and the greater the electrostatic attraction between the electron-donating functional groups of OS-CS AC and the Cr(VI) is, the stronger the ability to remove Cr(VI). In addition, the removal process was discussed, and the results indicated that the McKay kinetic model, Langmuir isotherm model and Van't Hoff thermodynamic model were the most suitable models for removal. The main factors affecting the removal of Cr(VI) were discussed, and the removal of Cr(VI) reached 99.14%, which gives a comprehensive utilization way of oily sludge and corn stalks.

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.

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).

Products distribution and hazardous elements migration during pyrolysis of oily sludge from the oil refining process

Oily sludge is a hazardous waste due to the enrichment of nitrogen, sulfur, PAHs, and heavy metals. In this work, an oily sludge from oil refining factory was pyrolyzed at various temperatures of 250-850 °C in a fixed bed reactor focusing on product distribution and migration of hazardous compounds of PAHs, sulfur, nitrogen-containing compounds, and heavy metals. The mechanism of PAHs formation and migration of nitrogen, sulfur, heavy metals were elucidated by comprehensive analysis of the solid, liquid, and gas products. The distribution and risk analysis of heavy metals were also conducted. The pyrolytic products distribution was markedly affected by pyrolysis temperatures. A maximum oil yield was observed at 500 °C, which can further crack into gas due to secondary reaction. The pyrolytic gas was enriched in the order of CO₂ > CO > CH₄ > H₂. At lower temperatures, CO₂ was largely generated due to the elimination of oxygen-containing functional groups, while H₂ was mainly formed above 450 °C due to the recombination reaction. Higher temperatures promoted more N-/S-containing compounds into tar and gas phases. The N-/S-containing compounds mainly included NH₃, HCN, H₂S, SO₂, COS in the gas phase and amines, indoles, pyridines, nitriles, thiophenes in liquid phase. PAHs with 2-ring to 5-ring were mainly generated due to the secondary reaction at higher temperatures. Moreover, Pyrolysis caused the accumulation of heavy metals in chars. Cd presented a high potential risk while the other heavy metals in chars presented a low risk.

Petroleum Hydrocarbon Composition of Oily Sludge and Contaminated Soils in a Decommissioned Oilfield Waste Pit under Desert Conditions

Field and laboratory investigations were conducted to characterize the composition of petroleum hydrocarbons in oily sludge and the underlying contaminated soils in a decommissioned oilfield waste pit in Kuwait. The results show that the petroleum hydrocarbon composition in the oily sludge and contaminated soils was spatially variable. Highly toxic petroleum hydrocarbon species such as BTEX and PAHs were generally lacking, and both sludge- and soil-borne hydrocarbons were dominated by long-chain petroleum hydrocarbons. The soil contamination depth was generally very shallow although localized deep profiles (>0.5 m) were found. A loose relationship was established between TPH in the sludge and that in the underlying soil. On average, the soil had a greater percentage of shorter-chain hydrocarbon fractions (either aliphatics or aromatics), as compared to the sludge. The environmental risk from the oily sludge and contaminated soils is considered to be relatively low. For cost-effective management of the environmental risk of decommissioning an oilfield waste pit, containment of the sludge and contaminated soils using a soil-capping approach may be sufficient to minimize the possible adverse environmental impacts from the decommissioned waste pit, and this may represent an option that is superior to other costly remediation strategies.

Supercritical Fluid Application in the Oil and Gas Industry: A Comprehensive Review

The unique properties of supercritical fluid technology have found wide application in various industry sectors. Supercritical fluids allow for the obtainment of new types of products with special characteristics, or development and design of technological processes that are cost-effective and friendly to the environment. One of the promising areas where supercritical fluids, especially carbon dioxide, can be used is the oil industry. In this regard, the present review article summarizes the results of theoretical and experimental studies of the use of supercritical fluids in the oil and gas industry for supercritical extraction in the course of oil refining, increasing oil recovery in the production of heavy oil, hydraulic fracturing, as well as processing and disposal of oil sludge and asphaltenes. At the end of the present review, the issue of the impact of supercritical fluid on the corrosion of oil and gas equipment is considered. It is found that supercritical fluid technologies are very promising for the oil industry, but supercritical fluids also have disadvantages, such as expansion or incompatibility with materials (for example, rubber).

Bioprospecting of indigenous biosurfactant-producing oleophilic bacteria for green remediation: an eco-sustainable approach for the management of petroleum contaminated soil

In the present study, the efficiency of four different strains of Pseudomonas aeruginosa and their biosurfactants in the bioremediation process were investigated. The strains were found to be capable of metabolizing a wide range of hydrocarbons (HCs) with preference for high molecular weight aliphatic (ALP) over aromatic (ARO) compounds. After treating with individual bacteria and 11 different consortia, the residual crude oils were quantified and qualitatively analyzed. The bacterial strains degraded ALP, ARO, and nitrogen, sulphur, oxygen (NSO) containing fractions of the crude oil by 73-67.5, 31.8-12.3 and 14.7-7.3%, respectively. Additionally, the viscosity of the residual crude oil reduced from 48.7 to 34.6-39 mPa s. Further, consortium designated as 7 and 11 improved the degradation of ALP, ARO, and NSO HCs portions by 80.4-78.6, 42.7-42.4 and 21.6-19.2%, respectively. Moreover, addition of biosurfactant further increased the degradation performance of consortia by 81.6-80.7, 43.8-42.6 and 22.5-20.7%, respectively. Gas chromatographic analysis confirmed the ability of the individual strains and their consortium to degrade various fractions of crude oil. Experiments with biosurfactants revealed that polyaromatic hydrocarbons (PAHs) are more soluble in the presence of biosurfactants. Phenanthrene had the highest solubility among the tested PAHs, which further increased as biosurfactant doses raised above their respective critical micelle concentrations (CMC). Furthermore, biosurfactants were able to recover 73.5-63.4% of residual oil from the sludge within their respective CMCs. Hence, selected surfactant-producing bacteria and their consortium could be useful in developing a greener and eco-sustainable way for removing crude oil pollutants from soil.

Compound Cleaning Agent for Oily Sludge from Experiments and Molecular Simulations

This paper reported a new oily sludge compound cleaning agent formula, which used a combination of molecular simulation and experimental methods to study its interfacial formation energy (IFE), and exciting results were obtained. From a total of 24 surfactants in five categories, sodium silicate (Na₂SiO₃), sodium dodecylbenzene sulfonate, and fatty alcohol polyoxyethylene polyoxypropylene ether (JFC-SF) were screened out because of their excellent washing oil effect. Under a reasonable orthogonal system, when the mass ratio of the three surfactants was 3:1:1, the oil desorption effect was the best, the oil residual rate could reach 2.13%, and the oil removal efficiency could reach 93.53%. Verified by the molecular dynamics simulation module, the absolute value of the interface binding energy was the largest at this compound ratio, which was 465.71 kcal/mol. More importantly, we have discussed in depth the mechanism of adsorption and permeation of oily sludge by cleaning agents. Through single-factor influence experiments, the following optimized working condition parameters of the cleaning agent were determined: cleaning conditions with an agent content of 4%, a temperature of 70 °C, a stirring speed of 400 rpm, a cleaning time of 30 min, and a liquid-solid ratio (L/S) of 4:1. The research results laid the foundation for resource utilization, harmlessness, and reduction of oily sludge in the Liaohe oilfield.

Enhanced Separation of Oil and Solids in Oily Sludge by Froth Flotation at Normal Temperature

Oily sludge (OS) contains a large number of hazardous materials, and froth flotation can achieve oil recovery and non-hazardous disposal of OS simultaneously. The influence of flotation parameters on OS treatment and the flotation mechanism were studied. OS samples were taken from Shengli Oilfield in May 2017 (OSS) and May 2020 (OST), respectively. Results showed that Na2SiO3 was the suitable flotation reagent treating OSS and OST, which could reduce the viscosity between oil and solids. Increasing flotation time, impeller speed and the ratio of liquid to OS could enhance the pulp shear effect, facilitate the formation of bubble and reduce pulp viscosity, respectively. Under the optimized parameters, the oil content of OST residue could be reduced to 1.2%, and that of OSS could be reduced to 0.6% because of OSS with low heavy oil components and wide solid particle size distribution. Orthogonal experimental results showed that the impeller speed was the most significant factor of all parameters for OSS and OST, and it could produce shear force to decrease the intensity of C-H bonds and destabilize the OS. The oil content of residue could be reduced effectively in the temperature range of 24–45 °C under the action of high impeller speed.

Effect of Oily Sludge Treatment with Molten Blast Furnace Slag on the Mineral Phase Reconstruction of Water-Quenched Slag Properties

Blast furnace slag, which is the main by-product of the ironmaking process discharged at 1450 °C, contains high-quality sensible heat, while oily sludge is the main solid waste produced in the process of gas exploration, storage, and transportation. The energy and resource utilization of blast furnace slag is complementary to the environmentally friendly treatment of oily sludge, which has provided a new idea for the multi-factor synergistic cycle and energy transformation of the two wastes. The pyrolysis of the oily sludge with the molten blast furnace slag was conducted in the current paper. Results showed that the oily sludge was rapidly pyrolyzed, and the heavy metal elements in the oily sludge were solidified. The solidification rate of the heavy metals exceeds 90%, except for vanadium. The reconstituted water-quenched blast furnace slag still has good activity, and it will not affect the further use of the slag after pyrolysis (BFS-P).

Sludge Formation Analysis in Hydraulic Oil of Load Haul Dumper 811MK V Machine Running at Elevated Temperatures for Bioenergy Applications

Hydraulic oil degrades expediently during operating at elevated temperatures, and due to oil degradation, malfunction of all hydraulic components starts that hampers the hydraulic functioning of the machine. An inefficient component of the hydraulic system converts useful energy into heat. Overheating starts when the rate of heat energy escaping from the system overcomes the rate of heat dissipation. Viscosity, total acidic number (TAN), rheology, and FTIR analyses were carried out on the oil samples collected chronically, and the reasons for degradation and sludge formation were evaluated; the results showed that thermal cracking resistance capacity of the oil was low due to the imbalance percentage of additives in the base oil. Sludge impaired the system efficiency and prejudicially creates repercussions on power consumption. Sludge can be recycled for biofuel and to avoid imbalance in the ecosystem. The test result is plotted in a 3D view graph using the MATLAB R 2019 software for a better explanation. Variation in the behaviour of the hydraulic fluid with respect to time, temperature, shear stress, and shear rate was studied, and the result is validated with correlation and regression analyses.

Hazardous elements flow during pyrolysis of oily sludge

Oily sludge (OS) is a hazardous waste and pyrolysis is a promising technology to achieve energy recovery and non-hazardous disposal simultaneously. However, the distribution of hazardous elements, including N/S/Cl and heavy metals, in pyrolytic products possibly causes secondary pollution. This study conducted a systematic research on hazardous elements flow during OS pyrolysis under variant temperature. Results showed that N/S/Cl in OS were distributed 44.77-15.51 wt%, 83.29-80.22 wt%, and 78.59-73.41 wt% into the solid residues after pyrolysis, respectively. Elevating pyrolysis temperature facilitated more N/S/Cl flowing into pyrolytic oil and gas. The macromolecular N-/S-/Cl-containing compounds, including amides, amines, nitriles, sulfonates, chloroalkanes, etc., were widely distributed in pyrolytic oil and gas products. The micromolecular N-/S-/Cl-containing pollutants released between 200 and 400 °C included HCN, NH₃, NO_x, H₂S, CH₄S, CS₂, SO₂, and HCl, which originated from the decomposition of the amine N, organic sulfide and sulfone-S, and inorganic Cl, respectively. The main pollutants released at above 400 °C included NH₃, HCN, NO_x, CS₂, and SO₂, which were derived from the decomposition of heterocyclic N and inorganic pyritic-S and sulfate-S. Moreover, the solid residues intercepted more than 60.0 wt% of total heavy metals, which should be concerned in the future.

Oily Wastewater Treatment: Overview of Conventional and Modern Methods, Challenges, and Future Opportunities

Industrial developments in the oil and gas, petrochemical, pharmaceutical and food sector have contributed to the large production of oily wastewater worldwide. Oily wastewater pollution affects drinking water and groundwater resources, endangers aquatic life and human health, causes atmospheric pollution, and affects crop production. Several traditional and conventional methods were widely reported, and the advantages and limitations were discussed. However, with the technology innovation, new trends of coupling between techniques, use of new materials, optimization of the cleaning process, and multiphysical approach present new paths for improvement. Despite these trends of improvement and the encouraging laboratory results of modern and green methods, many challenges remain to be raised, particularly the commercialization and the global aspect of these solutions and the reliability to reduce the system’s maintenance and operational cost. In this review, the well-known oily wastewater cleaning methods and approaches are being highlighted, and the obstacles faced in the practical use of these technologies are discussed. A critical review on the technologies and future direction as the road to commercialization is also presented to persevere water resources for the benefit of mankind and all living things.

A critical review on energy recovery and non-hazardous disposal of oily sludge from petroleum industry by pyrolysis

This review systematically reports the pyrolysis of oily sludge (OS) from petroleum industry in regards to its dual features of the energy recovery potential and the environmental risks. The petroleum hydrocarbons are the nonbiodegradable fractions in OS that possess hazardous properties, i.e. ignitability and toxicity. Besides, complicated hazardous elements (i.e. N, S and Cl) and heavy metals inherently existing in OS further aggravate the environmental risks. However, the high oil content and heating value of OS contribute to its huge energy resource potential. Considering the energy demand and the environmental pressure, the ultimate purposes of the OS management are to enhance the oil recovery efficiency to minimize the oil content as well as to stabilize the hazardous elements and heavy metals into the solid residue. Among various OS management technologies, pyrolysis is the most suitable approach to reach both targets. In this review paper, the pyrolysis principle, the kinetics and the product distribution in three-phases are discussed firstly. Then the effects of operating parameters of the pyrolysis process on the quality and the application potential of the three-phase products, as well as the hazardous element distribution are discussed. To further solve the dominant concerns, such as the oil content in the solid residue, the pyrolytic oil quality and the migration of hazardous elements and heavy metals, the potentials of the catalytic pyrolysis and the co-pyrolysis with additives are also summarized. Also, the typical pyrolysis reactors are then presented. From the perspective of the energy efficiency and the non-hazardous disposal, the integrated technology combining the pyrolysis and the combustion for the OS management is recommended. Finally, the remaining challenges of OS pyrolysis encountered in the research and the industrial application are discussed and the related outlooks are itemized.

Recent advances in applications of power ultrasound for petroleum industry

Power ultrasound, as an emerging green technology has received increasing attention of the petroleum industry. The physical and chemical effects of the periodic oscillation and implosion of acoustic cavitation bubbles can be employed to perform a variety of functions. Herein, the mechanisms and effects of acoustic cavitation are presented. In addition, the applications of power ultrasound in the petroleum industry are discussed in detail, including enhanced oil recovery, oil sand extraction, demulsification, viscosity reduction, oily wastewater treatment and oily sludge treatment. From the perspective of industrial background, key issue and resolution mechanism, current applications and future development of power ultrasound are discussed. In addition, the effects of acoustic parameters on treatment efficiency, such as frequency, acoustic intensity and treatment time are analyzed. Finally, the challenges and outlook for industrial application of power ultrasound are discussed.