Experimental study on catalytic pyrolysis of oil sludge under mild temperature

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.

Role of municipal solid waste incineration fly ash components in co-pyrolysis of oily sludge: Pyrolysis products and catalytic mechanism

The co-pyrolysis of oily sludge (OS) and municipal solid waste incineration fly ash (IFA) is a promising strategy for sustainable waste management. This study delves into the distinct catalytic roles of individual IFA components during co-pyrolysis and assesses their impact on the inherent Fe species in OS, highlighting their contributions to overall catalytic activity. Notably, in comparison to IFA, CaCl2 and KCl significantly enhance pyrolysis oil upcycling, while IFA components collectively exhibit a positive catalytic effect on pyrolysis gas and coke production. Ca(OH)2 notably boosts H2 yield by 137.16 %. Alkali chlorides facilitate gaseous hydrocarbon formation and convert oxygen-containing compounds to CO and CO2 which are subsequently consumed and absorbed by CaO and Ca(OH)2. CaCl2 and KCl promote heavy compound decomposition and alkane aromatization, reducing coke formation and increasing light aromatic production. Conversely, NaCl increases alkane proportions. However, CaSO4 and CaCO3 hinder catalytic reactions, promoting carbon conversion to coke. Importantly, IFA compounds aid the dispersion of inherent Fe-based species from OS on char surface, enhancing in-situ catalytic pyrolysis. Additionally, the augmented H2 production accelerates the reduction of Fe-based species. The findings expand waste utilization possibilities and provide insights for co-processing solid wastes.

Selective stepwise adsorption for enhanced removal of multi-component dissolved organic chemicals from petrochemical wastewater

The coexistence of multi-component dissolved organic chemicals causes tremendous challenge in purifying petrochemical wastewater, and stepwise selective adsorption holds the most promise for enhanced treatments. This study is designed to enhance the removal of multiple dissolved organic chemicals by stepwise adsorption. Special attention is given to the selective removal mechanisms for the major pollutant N,N-dimethylformamide (DMF), the sensitive pollutant fluorescent dissolved organic matter (FDOM) and other components. The results indicated that the combination of coal activated carbon and aluminum silica gel produced a synergistic effect and broke the limitation of removing only certain pollutants. Combined removal rates of 80.5 % for the dissolved organic carbon and 86.7 % for the biotoxicity in petrochemical wastewater were obtained with the enhanced two-step adsorption. The adsorption performance of both adsorbents remained stable even after five cycles. The selective adsorption mechanism revealed that hydrophobic organics such as DMF was adsorbed by the macropores of coal activated carbon, while the FDOM was eliminated by π-π stacking, electrostatic interaction and hydrophobic interaction. The hydrophilic organics were removed by the mesopores of aluminum silica gel, the silica hydroxyl groups and hydrophilic interaction. This study provides a comprehensive understanding of the selective adsorption mechanism and enhanced stepwise removal of multiple pollutants in petrochemical wastewater, which will guide the deep treatment of complex wastewater.

Enhancement of H2 and light oil production and CO2 emission mitigation during co-pyrolysis of oily sludge and incineration fly ash

The proper treatment and utilization of oily sludge (OS) and incineration fly ash (IFA) remains a significant challenge due to their hazardous nature. To attain effective recovery of petroleum hydrocarbons and synergistic disposal, this study investigated the co-pyrolysis of OS and IFA, resulting in successful energy recovery, CO2 mitigation, and heavy metal immobilization. Results revealed that the peak ratio of light oil to heavy oil fractions reached 179.42% with 20 wt% IFA addition, accompanied by the highest aromatic hydrocarbons selectivity of 30.72% and the lowest coke yield of 106.13 mg/g OS under the optimal temperature of 600 °C. In-depth analysis indicated that IFA inhibited the poly-condensation of macromolecular PAHs and promoted their cracking into light aromatic hydrocarbons. The addition of 50 wt% IFA significantly increased H2 yield (21.02 L/kg OS to 60.95 L/kg OS) and facilitated CO2 sequestration due to its higher content of Ca-bearing minerals. Moreover, high IFA ratios promoted the reduction of Fe species in OS to a low-valence state. Heavy metals in co-pyrolysis char were well immobilized into stable fractions with lower environmental risks. This work highlights the potential of co-pyrolysis as a viable approach for simultaneous disposal of multiple hazardous wastes and offers new insights for their utilization.

Biochar-Assisted Catalytic Pyrolysis of Oily Sludge to Attain Harmless Disposal and Residue Utilization for Soil Reclamation

Pyrolysis of oily sludge (OS) is a feasible technology to match the principle of reduction and recycling; however, it is difficult to confirm the feasible environmental destination and meet the corresponding requirements. Therefore, an integrated strategy of biochar-assisted catalytic pyrolysis (BCP) of OS and residue utilization for soil reclamation is investigated in this study. During the catalytic pyrolysis process, biochar as a catalyst intensifies the removal of recalcitrant petroleum hydrocarbons at the expense of liquid product yield. Concurrently, biochar as an adsorbent can inhibit the release of micromolecular gaseous pollutants (e.g. HCN, H₂S, and HCl) and stabilize heavy metals. Due to the assistance of biochar, pyrolysis reactions of OS are more likely to occur and require a lower temperature to achieve the same situation. During the soil reclamation process, the obtained residue as a soil amendment can not only provide a carbon source and mineral nutrients but can also improve the abundance and diversity of microbial communities. Thus, it facilitates the plant germination and the secondary removal of petroleum hydrocarbons. The integrated strategy of BCP of OS and residue utilization for soil reclamation is a promising management strategy, which is expected to realize the coordinated and benign disposal of more than one waste.

Progress in thermochemical co-processing of biomass and sludge for sustainable energy, value-added products and circular economy

To achieve the main goal of net zero carbon emission, the shift from conventional fossil-based energy/products to renewable and low carbon-based energy/products is necessary. Biomass has been perceived as a carbon-neutral source from which energy and value-added products can be derived, while sludge is a slurry waste that inherently contains high amount of minerals and organic matters. Hence, thermochemical co-processing of biomass wastes and sludge could create positive synergistic effects, resulting in enhanced performance of the process (higher conversion or yield) and improved qualities or characteristics of the products as compared to that of mono-processing. This review presents the current progress and development for various thermochemical techniques of biomass-sludge co-conversion to energy and high-value products, and the potential applications of these products from circular economy's point of view. Also, these technologies are discussed from economic and environmental standpoints, and the outlook towards technology maturation and successful commercialization is laid out.

Self-circulation of oily spent hydrodesulphurization (HDS) catalyst by catalytic pyrolysis for high quality oil recovery

In this study, roasted spent HDS ash (sHDSc-A) was used for the first time to catalytically pyrolyze oily spent HDS catalysts (sHDSc) to improve the yield and quality of pyrolysis oil. The results showed that sHDSc-A promoted the decomposition of coke in oily sHDSc, resulting in the recovery of more oil and gas. Meanwhile, sHDSc-A significantly improved the quality of the pyrolysis oil. They inhibited the aromatization of alkanes to increase the saturation of the pyrolysis oil from 59.39% to 74.25% and the H/C radio from 1.62 to 1.72; promoted the decomposition of long-chain alkanes to increase the content of C11-C22 from 41.97% to 61.99%; enhanced the conversion of carboxylic acids to ketones led to the reduction of heteroatomic compounds such as N (56.10%-45.39%), S (66.95%-56.59%), and O (45.26%-26.70%) in the pyrolysis oil. The promotion of sHDSc-A in the pyrolysis process is attributed to the catalytic effect of the metal oxides in sHDSc-A. Among them, Al₂O₃ and Fe₂O₃ can promote decarboxylation of carboxylic acids and reduce O mobility, while MoO₃ and Fe₂O₃ play a significant role in reducing coke and increasing pyrolysis oil. NiO can also promote methane vapor reforming, and thus increase the production of H₂ in non-condensable gas. This study achieves self-circulation of oily sHDSc with a "waste-treatment-waste" strategy that presents the advantage of value-added energy recovery and waste reuse.

Rapid effective treatment of waxy oily sludge using a method of dispersion combined with biodegradation in a semi-fluid state

Waxy oily sludge (WOS) from petrochemical enterprises has complex components and difficult treatment. Long-term large-scale stacking has seriously threatened human health and the ecological environment. In this paper, a new rapid and effective treatment method combining dispersion and biodegradation in a semi-fluid state was developed for the WOS. The degradation mechanism of the WOS in the bioreactor was preliminarily discussed. The component analysis results showed that the compounds with large molecular weight (M ≥ 282) in the WOS accounted for more than 50%. Among all microbial consortiums, the treatment effect of the consortium FF: NY3 = 9: 1 was the best for treating the crude oil in WOS, which was significantly different from that of a single strain (p < 0.05). Under the optimal nitrogen source NH₄NO₃ and the concentration of rhamnolipid, the developed high-efficiency microbial consortium (FF: NY3 = 9:1) could remove 85% of the total hydrocarbon pollutants in the 20 L semi-fluid bioreactor within 9 days. The degradation characteristics of WOS components in the bioreactor showed that the developed consortium has good degradation ability for n-alkanes (about 90%), middle- (77.35%)/long-chain (72.66%) isomeric alkanes, alkenes (79.12%), alicyclic hydrocarbons (78.9%) and aromatic hydrocarbons (62.78%). The kinetic analysis results indicated that, in comparison, the middle-chain n-alkanes, middle-chain isomeric saturated alkanes, alkenes, and alicyclic hydrocarbons were most easily removed. The removal rates of long-chain n-alkanes, long-chain isomeric saturated alkanes, and aromatic hydrocarbons were relatively low. The biological toxicity test showed that the germination rate of wheat seeds in treated waxy sludge was Significantly higher than that in untreated waxy sludge (p < 0.01). These results suggest that the new method developed in this paper can treat refractory WOS quickly and effectively. This method lays the foundation for the pilot-scale treatment of the semi-fluid bioreactor.

Treatment of DEHP-rich PVC waste in subcritical urine wastewater: Efficient dechlorination, denitrification, plasticizer decomposition, and preparation of high-purity phthalic acid crystals

It is difficult to dispose diethylhexyl phthalate-rich polyvinyl chloride (DEHP-rich PVC) waste due to the high level of chlorine and plasticizer. On the other hand, the denitrification of urine wastewater with high nitrogen content also faces great challenges. In this study, a synergistic treatment strategy was developed for the DEHP-rich PVC waste and urine wastewater by a subcritical water process. Subcritical urine wastewater (SUW) was used as a reaction medium in the synergistic treatment. PVC dechlorination, DEHP decomposition, and denitrification of urine wastewater were synchronously achieved in the one pot SUW. Under the optimal conditions (300 °C, 15 min, 1:5 g/mL), the PVC dechlorination ratio, urine wastewater denitrification ratio and DEHP decomposition ratio could reach 98.4%, 64.9%, and 99.2%, respectively. The decomposition of DEHP mainly included hydrolysis, nucleophilic substitution, and acylation. DEHP could be converted into phthalic acid crystal at 220 °C with a yield of 66.25% due to the efficient hydrolysis action of SUW. All the removed Cl was transferred from PVC matrix to aqueous phase. Hydroxyl nucleophilic substitution is the principal dechlorination path of PVC. The reactions between N-containing species and DEHP in SUW resulted in the high-efficiency denitrification of urine wastewater, and the N element was fixed in solid residue or transferred to oil phase as amides compounds. It is believed that the proposed SUW process is a promising technology for the synergistic treatment of DEHP-rich PVC waste and urine wastewater.

Synthesis of nano-β-CD@Fe3O4 magnetic material and its application in ultrasonic treatment of oily sludge

The extraction process of Tarim oil field in Xinjiang is accompanied by a large amount of oily sludge generation, which seriously restricts the progress of oil and gas development and causes serious pollution to the environment due to its large production, complex composition, and difficult treatment. Nanomaterials combined with ultrasound have been demonstrated to be a promising method for the disposal of hazardous oily sludge. In this paper, a magnetic material Nano-β-CD@Fe₃O₄ was prepared by hydrothermal method and surface modification method. Nano-β-CD@Fe₃O₄ can be intelligently enriched at the oil-water interface and oil-solid interface, and it can be stably dispersed to form nanofluid under the action of ultrasound. Nano-β-CD@Fe₃O₄ can cause changes in oil composition when it is exposed to ultrasound, resulting in the decrease of viscosity and increase of fluidity. The experimental results of treating oily sludge in Xinjiang Tarim showed that the best treatment effect was achieved when the concentration of Nano-β-CD@Fe₃O₄ was 0.5 %, the ultrasonic frequency was 60 Hz and the temperature was 60℃. This solution can reach 90.17 % oil removal efficiency within 45 min, and the secondary oil removal efficiency of Nano-β-CD@Fe₃O₄ recovered by magnetic separation could still reach 85.65 %. This efficient oily sludge treatment method proposed in our study provides valuable information for the development of oily sludge treatment technology.

Production of valuable chemicals through the catalytic pyrolysis of harmful oil sludge over metal-loaded HZSM-5 catalysts

This research studied the catalytic pyrolysis of oil sludge (OS) over metal-loaded HZSM-5 catalysts, an eco-friendly and cost-effective technology to produce value-added aromatics such as benzene, toluene, ethylbenzene, and xylene (BTEXs). In particular, it evaluated the respective effects of the experimental parameters: the type and amount of the metal loaded, the reaction temperature, and the OS/catalyst ratio, on the BTEXs yield sequentially to achieve optimum conditions. This evaluation showed that the highest yields of the BTEXs (6.61 wt%) and other aromatics were achieved when Ni was incorporated into the HZSM-5 (Ni/HZSM-5) followed by the corresponding yields of Ga/HZSM-5 and Fe/HZSM-5, due to a better distribution of Ni on the support surface and an enhanced acidity strength of this catalyst. Further, increase in Ni loading (up to 10 wt% Ni/HZSM-5) increased the BTEXs yield to 13.48 wt%. However, the excessive Ni loading (15 wt% Ni/HZSM-5) resulted in a reduced BTEXs yield due to the blockage of the zeolite channels. Next, an increase in the reaction temperature from 500 °C to 600 °C increased the yield of the BTEXs and other aromatics. However, a further increase in the reaction temperature to 650 °C decreased slightly their yield because of the stimulating secondary reactions at high temperatures. The increase of catalyst amount (OS/catalyst of 1/3) also maximized the BTEXs yield (30.50 wt%).

Enhancing low-temperature thermal remediation of petroleum sludge by solvent deasphalting

Thermal treatment is a promising technique for treating petroleum sludge (PS). However, asphaltenes as a recalcitrant fraction of PS induce strong bounding between petroleum and minerals, and therefore lead to the need for high temperature and hence high energy consumption in thermal treatment of PS. In this study, a novel method combining a deasphalting pretreatment of PS with low-temperature thermal desorption (LTTD) was developed. The efficiency of deasphalting was found to be positively correlated to the ability of n-alkanes and asphaltene dispersants in dispersing asphaltenes. In treating six different kinds of PS, the residual oil contents were all below 2.5% after the deasphalting alone. Compared with direct thermal desorption at 600 °C for 1 h, dodecyl benzene sulfonic acid (DBSA)-assisted heptane deasphalting made thermal desorption at 350 °C for 1 h sufficient to treat these APS. The residual oil content of sludge after LTTD is lower than 0.45%. FT-IR, Raman spectra and XPS analysis confirmed that the carbon residue in APS after LTTD is primarily graphite state, which is extremely stable and does not migrate to the surrounding environment as compared with the crude oil in the APS. Hence, solvent deasphalting results in effective treatment of PS by LTTD, while the solvent can be recycled by distillation and crude oil recovered as value-added petroleum resource. The LTTD represents therefore a novel green strategy for treating PS and resource utilization.

Simulation study on comprehensive thermal treatment of oil sludge based on Aspen plus

This article proposed an original comprehensive thermal treatment coupled with gasification and combustion (CGC) of oil sludge (OS), which was designed to produce hydrogen-rich syngas. Based on the experimental results of OS gasification with steam, the combustion characteristics of char from OS gasification were analyzed by thermogravimetric experiments under different heating rates of 10, 20 and 30 °C/min. The combustion process of OS gasification char can be divided into three stages, including water evaporation, volatile combustion and heavy component combustion. The average values of activation energy (E) obtained by Friedman, FWO and Starink methods were 89.98 kJ/mol, 147.61 kJ/mol and 143.09 kJ/mol, respectively. According to OS gasification and OS gasification char combustion experiments, the comprehensive thermal treatment process CGC of OS was simulated by Aspen Plus. The simulation results showed that increasing both gasification temperature and the mass ratio of steam to OS (SOS) could promote the hydrogen production. Considering energy consumption, the recommended OS gasification temperature, SOS and char combustion temperature were 800 ∼ 900 °C, 0.3 ∼ 0.5, and 900 ∼ 1000 °C, respectively, which could ensure full burning of char and reduce the generation of pollutants. The CGC process could reduce CO₂ emissions by 44.2% from carbon flow analysis.

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.

A review of application and development of combustion technology for oil sludge

Oil sludge is a typical hazardous waste in the petrochemical and electric power industry. It has complex components and special properties, and has serious hazards to humans, plants, water, and soil. Therefore, how to realize the effective disposal of oil sludge has become an urgent issue to be solved worldwide. Among the existing oil sludge treatment approaches, combustion has been considered to be a promising technology to realize the large-scale industrial application. In the present work, the characteristics of oil sludge were described in detail. The application and development of oil sludge combustion technology were critically summarized and discussed, including factors affecting combustion, drying process, combustion characteristics, synergistic treatment technology, and formation and control of secondary pollution. Besides, the development of combustion equipment, and integrated thermal treatment technology for oil sludge were prospected. This work can be used for guiding the industrial disposal of oil sludge.

Propositure of maximum permissible limits for environmental assessment and classification of materials stabilized by solidification incorporated with oil waste

In the present work, oil sludge was subjected to the process of stabilization by solidification, the objective was to indicate maximum permissible limits of chemical demand for oxygen and oils and greases to evaluate the resulting material. A factorial design was used with the addition of three repetitions at the central point, to evaluate the performance of different percentage of residue and different curing times. The factors adopted were the percentage of oil sludge and the curing time. This material was evaluated using contaminants immobilization tests. From the leached and solubilized liquid, the concentration of the contaminants was determined and the environmental assessment was also carried out through the analysis of chemical demand for oxygen and oils and greases. One of the contributions of this work was to propose the maximum allowable limit for chemical oxygen demand, which is 1,000 (one thousand) milligrams per litre and, for oil and grease content, 100 (one hundred) milligrams per litre, both for the leaching test. For the solubilization test, 10 (ten) milligrams per litre were proposed for chemical oxygen demand and 1 (one) milligrams per litre for the oil and grease content. It was observed that the best results are obtained, when lower values of percentage of oil sludge were used and longer cure time. This work allows to affirm that the proposal of limits of environmental evaluation contributes to assure an adequate disposition and use of the cement matrix, that is the final product of the oily residue stabilized by solidification.

Catalytic co-pyrolysis of oil sludge and biomass over ZSM-5 for production of aromatic platform chemicals

Hazardous oil sludge (OS) poses a great challenge to the environment, whereas conventional treatment methods (i.e., incineration or pyrolysis-incineration) are relatively less value-added and will bring about air pollution problems. To realize the high-value utilization of OS, catalytic co-pyrolysis with waste biomass to produce platform chemicals was studied using TG-FTIR and Py (pyrolyzer)-GC/MS methods. Results showed that for the non-catalytic co-pyrolysis of RH (rice husk) and OS, the main synergy on weight loss was the greatly lowered initial pyrolysis temperature of RH (for ∼55 °C) at the lower temperatures and the reduced weight loss ratio of OS (∼10-18 wt%) within the higher temperature range. ZSM-5 catalyst promoted the degradation of OS and RH mixtures at < 150 °C, yet showed minor effects on their weight loss at higher temperatures. The oxygenated and aliphatic compounds from non-catalytic co-pyrolysis were efficiently converted, resulting in an increased relative yield of aromatics to the highest of 46% and an elevated selectivity to BTX (as high as 60%). Despite the relatively short carbon chain length of OS components, ZSM-5 was proved effective to activate the OS pyrolysis products, thus enhancing the further aromatization reactions with biomass pyrolysis intermediates. This study provides a novel method for value-added co-utilization of hazardous OS waste and abundant biomass waste, and thus is beneficial to producing renewable chemicals while reducing the environment pollutant.

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 oil and products recovery from oily sludge: Characterization and analysis of pyrolysis products

Oily sludge (OS) has attracted special interest because of its hazardous nature and high potential as an energy resource. This study investigated the oil recovery from OS by thermal cracking and catalytic pyrolysis. The oil yield increased when the temperature exceeded 450 °C and reached a maximum (76.84 wt%) at 750 °C. Catalysts significantly improved the quality of oil produced during catalytic pyrolysis. Aromatic hydrocarbons were dominant (10.01-52.69%) in pyrolysis oil (PO) from OS catalytic pyrolysis, and the catalysts significantly reduced the presence of oxygen heterocycles. In addition, KOH and CaO reduced the I_D (D-band peak intensity)/I_G (G-band peak intensity) of OS char (OC) and increased the degree of graphitization. Owing to its higher iodine adsorption value and methylene blue (MB) adsorption value, OC exhibits potential as an adsorbent. The environmental assessment and potential applications of OC, along with possible reaction mechanisms and kinetic characteristics, are also discussed.

Functional Group Characteristics and Pyrolysis/Combustion Performance of Karamay OS Based on FT-IR and TG-DTG Analyses

Proximate analysis, ultimate analysis, Fourier-transform infrared spectroscopy (FT-IR), and thermogravimetry-differential thermal analysis characterization were carried out on oily sludge (OS) samples OS1-OS5, from Karamay, Xinjiang, China. The Coast-Redfern model (CRm) was used to simulate the pyrolysis and combustion kinetics of oily samples. The results showed that the peak area percentage of benzene ring trisubstitution of OS5, in the range of 700-900 cm^-1, is close to 75%, corresponding to its high volatile content. Based on the kinetic analysis by the CRm, it is found that the fitting degree of the five samples is better when the reaction order is selected as n = 2, with R ² close to 1.00 and 2RT/E to 0. Among them, the S _N and D _W of OS5 are 17.8 × 10^-10%² min^-2 °C^-3 and 0.10899 × 10^-5% min^-1 °C^-2, respectively, higher than those of other samples, indicating a good combustion performance.

Experimental study on gasification of oil sludge with steam and its char characteristic

Hydrogen can be prepared by oil sludge (OS) gasification with steam, which is of great significance for industrial hazardous waste treatment and resource conservation. The gasification performance was studied by a tube furnace reactor. The OS gasification was carried out at different temperatures (600, 700, 800 and 900 °C) and with different steam to OS ratio (SOS) (0.1:1, 0.3:1, 0.5:1). During the gasification process, hydrogen production first increased and then decreased, and hydrogen production was faster in 5-15 min. The yield of hydrogen of OS gasification reached the maximum when the SOS was 0.3:1 at 800 °C. The highest hydrogen yield per unit mass OS was 48.50 mL min^-1 g^-1. After gasification, the char yield was high, generally more than 50%. It was necessary to treat the char and incineration was an effective solution for low carbon fuels. Thus particle size distribution, incineration thermogravimetric analysis and heavy metal leaching concentrations analysis were carried out. The results showed that the average particle size of char ranged from 85 to 120 µm. The char incineration process could be divided into three stages: water evaporation, the precipitation and combustion of volatiles, and the combustion of fixed carbon and heavy components. After OS gasification at 800 °C, the leaching concentrations of typical heavy metals (As, Cr, Cu, Ni, Pb and Zn) were all up to the standard. Therefore, OS gasification combined with char incineration was an effective approach for the utilization of solid waste, which can recover hydrogen energy and reduce environmental risks.

Hierarchical Porous Catalytic Pyrolysis Char Derived from Oily Sludge for Enhanced Adsorption

A novel pyrolysis char (PC), prepared by H3PO4 catalytic pyrolysis of oily sludge (OS), was presented to remove methylene blue (MB) dye from aqueous solution for the first time. The optimal preparation conditions (catalytic pyrolysis temperature of 411 °C, H3PO4 impregnation ratio of 2.44, and catalytic pyrolysis time of 59 min) were predicted by the response surface methodology. The optimal PC exhibited favorable hierarchical porous properties, which brought a large adsorption capability (322.89 mg/g). The adsorption process fitted well with the Langmuir model and pseudo-second order model. In addition, thermodynamic parameters showed that the adsorption process was endothermic (ΔH 0 > 0) and spontaneous (ΔG 0 < 0). The adsorption capability was strongly influenced by coexisting metal ions due to the competitive adsorption effect. The inhibition for MB adsorption was arranged in the following order: Al3+ > Fe3+ > Mg2+ > Ca2+ > K+ > Na+. The adsorption mechanism of MB onto the OS-derived PC includes pore filling, π-π interactions, and electrostatic interactions. The as-obtained PC adsorbent exhibited good reusability performance, which leads to great potential in practical application for wastewater treatment.

Combustion characteristics and kinetic analysis of oil sludge with CaO additive

Combustion of High-sulfur oil sludge (OS) blended with CaO can significantly reduce the emission of sulfur gas pollutants, but its combustion and kinetic characteristics need to be further studied. TGA experiments showed the combustion characteristics of OS were significantly changed after adding CaO. As reflected by comprehensive combustion index (S), the combustion performance of OS decreased after adding CaO, and significantly improved with the increase of heating rate. The kinetic parameters of the main combustion process of OS with CaO were calculated by the iso-conversion methods of Friedman, FWO, and Starink, respectively. Kinetic analysis results indicated the energy required for OS combustion with CaO first increased and then decreased with deepening of reaction degree. The thermodynamic parameters of ΔH, ΔG and ΔS were determined on the basis of kinetics. The negative ΔH, positive ΔG, and negative ΔS validated the combustion of OS with CaO was an exothermic and nonspontaneous process.

Pyrolysis characteristics and kinetics analysis of oil sludge with CaO additive

In the process of exploitation, transportation and refining of high-sulfur crude oil, a large number of oil sludge (OS) with high sulfur content is produced. Pyrolysis has been proved to be an effective method for OS disposal, but for solid waste with high sulfur content, lots of sulfur-containing gases will be released during thermal disposal. The addition of calcium oxide in pyrolysis process is an economical and effective way to capture sulfur-containing gases. In order to understand the pyrolysis process of OS with CaO, a thermogravimetric analyser was used to conduct pyrolysis experiments of OS with different Ca/S molar ratios (0, 1, 2 and 3) at different heating rates (10°C/min, 20°C/min, 30°C/min and 40°C/min). The results showed that with the increase of CaO addition the derivative thermogravimetric curves showed a gentle trend. In addition, new weight loss peaks were occurred at 700-900°C and after 1100°C, which were the decomposition of calcium carbonate and calcium sulfate, respectively. The kinetic parameters were solved by Friedman, FWO, and Starink methods, and the results were similar, with an average activation energies (E) value of 214 kJ/mol. The change trend of the activation energy was followed by an increase and then a decrease corresponding to the change of energy demand for the reaction. The calculated average values of ΔH, ΔG and ΔS were about 207, 447 and -0.3250 kJ/mol, respectively. When the conversion rate was 0.5, the thermodynamic parameters reached their maximum values.

Inexact inventory-theory-based optimization of oily waste management system in shoreline spill response

The oily waste generated from the cleanup operations during shoreline spill response can result in challenging environmental and socioeconomic problems. In this study, an inexact inventory-theory-based optimization model (ITOM) for oily waste management during shoreline spill response was developed to support the spill management team. The most appropriate facilities and optimal waste allocation scheme under uncertainty can be selected to achieve minimum total system cost. To satisfy the demand of oily waste treatment, these oily waste management facilities can be selectively opened depending on the situation. In the combination with the economic order quantity model of inventory theory, the developed model can provide the optimal solutions of batch size and order cycle for treatment facilities to minimize the inventory cost. A case study was used to demonstrate the application of ITOM. The obtained solutions include the facilities selection and waste allocation for waste collection and destocking stages under different risk levels. These solutions can provide a good guideline with managers to analyze the trade-offs between system cost and constraint-violation risks. The developed model has high application potential as a job-aid tool to manage the oily waste generated from oiled shoreline cleanup operations.

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.

Effects of added calcium-based additives on swine manure derived biochar characteristics and heavy metals immobilization

Although pyrolysis is a promising way for treating animal manure, the application is restricted with some limitations of biochar. To improve the quality of biochar derived from swine manure and enhance the immobilization of heavy metals (Cu and Zn) in it, swine manure was mixed with four types of Ca-based additives (CaO, CaCO₃, Ca(OH)₂, and Ca(H₂PO₄)₂) prior to pyrolysis at 300-700 °C. The thermogravimetric characteristics of swine manure were obviously influenced The addition of CaO, CaCO₃, and Ca(OH)₂ during the whole decomposition process. Furthermore, with the addition of CaO and Ca(OH)₂, the emission of CO₂ and CO was substantially decreased at 200-500 °C, whereas the formation of CO, H₂, CO₂, and CH₄ was drastically increased at 600-800 °C. The biochar produced with CaO addition had the highest pH, surface area and carbon content. Moreover, by addition of Ca-based additives, except for Ca(H₂PO₄)₂, the transformation of labile Cu and Zn to the stable fraction was promoted, and the leachability and environmental risk of them were simultaneously reduced. In contrast, CaO and Ca(OH)₂ were more favorable for the immobilization of Cu and Zn than CaCO₃. Our study indicated that the catalytic pyrolysis using CaO was an effective and valuable method of animal manure treatment.

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.