Choosing the right oil water separator can seem daunting. Just as not all applications are alike, not all separators are made alike. Customers should understand a few important points to make sure they’re getting what they pay for.
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The HD Q-PAC media has vastly superior properties compared to the traditional media used in oil-water separators. These properties result in a more efficient and effective separation than that attained by traditional coalescing media, for a variety of reasons.
In a typical oil-water separator with traditional media, incoming oily water slowly flows from the inlet through a media comprised of a series of parallel, inclined plates. As the oil droplets in the water coalesce with other oil droplets on the media surface, the oil droplets grow in size and travel up the plates to the water surface. This design, however, allows some water droplets to by-pass the plates and flow through the separator, requiring secondary polishing filters to achieve the required effluent characteristics. The shapes and configurations of tradition coalescing media also traps particles and sludge on the media itself, resulting in a sludge build-up and a reduction of effective flow through the separator.
The HD Q-PAC media provides improved performance in oil-water separators over traditional media due to the following properties:
– A larger amount of surface area per cubic foot of media allows for greater oil drop coalescence. HD Q-PAC media has 132 ft2/ft3 surface area for oil droplets to contact. Other typical coalescing media have about 48 ft2/ft3 to 68 ft2/ft3.
– A more efficient first step separation reduces the need for a second polishing step. HD Q-PAC media removes 99.9% of oil droplets 20 microns in size and larger. This meets EPA Method 1664 Revision A and European Standard EN 858-1.
– An open design eliminates trapping of particles and subsequent clogging of water channels. Oil water separators with HD Q-PAC media require fewer maintenance shut-downs and separates oil and water faster.
– Where higher-than-normal operating temperatures are required, HD Q-PAC media outperforms its competitors. HD Q-PAC media works effectively in temperatures up to 212°F, versus a maximum temperature of about 120°F for competing media.
Oil Water Separators are designed to effectively remove floating solids and non-emulsified oil from an oil and water mixture on a beginning to end flow process through the separator. The mixture of oil and water enters one end of the separator and slowly flows toward the other end. If oil and water are mixed and not emulsified, the oil originally exits the water in different sizes of droplets. When the drops of oil are large enough and the flow is laminar, or moving in a smooth and gentle flow with no turbulence, the oil droplets will separate before reaching the end of the separator tank.
Since the calculations of Stokes’ Law are supported on a zero velocity flow, a Reynolds number lower than 500 guarantees optimal separation. The majority of oil water separators commonly use the parallel corrugated plate design which causes oil droplets to enlarge in size and ascend to the surface of the water. Flow of oil and water through the oil water separator follows several main steps after entering the separator:
- Mixture particulates, heavier sludge drops from liquid and is confined in sludge hopper.
- Lighter weight particles from mixture travel up inclined plates.
- Inclined plates begin separating the mixture.
- Some oil will rise to the top of the separator.
- Particulates drop down into sludge hopper.
- Remaining mixture travels on through coalescing media packs.
- Most remaining small oil particles attach to media and coalesce with retained droplets.
- Retained droplets form larger oil droplets.
- Larger oil droplets float, rising to top of separator.
- Oil volume reaches a certain level and is pumped or drained to a storage tank.
- Clean water travels on to a chamber and goes through a final polishing pack.
- Clean water is discharged from the separator.
It is especially essential for the flow of the liquid through the oil water separator to be laminar to act in accordance with Stokes Law. To achieve this type of flow, a design that is cross-fluted and having an internal structure of connecting channels between adjoining plates can be used. With this design and the enlarged surface area, the effectiveness of the oil water separation process is greatly enhanced.
An oil water separator needs to be properly and regularly maintained to stay in good working order. When these devices are not drained and cleaned out religiously, oils and other debris will stop them up and make them useless. This can cause the levels of oil in the released water to go beyond the effluency limits indicated.
Models of oil water separators that sit above the ground are somewhat easier to keep clean since everything is easy to get to. This is because there are no tight spaces and plates can be easily taken out, cleaned and replaced. All above-ground types can be maintained from the ground level. Also, solid waste can easily be removed via a large opening at the ground level.
If using a below ground oil water separator, it is particularly essential that you follow a strict schedule of maintenance. Because the unit is underground where it can’t be seen, it is far more likely that you will forget to clean it. Here are the maintenance procedures to follow for this type of oil water separator.
After one month of use, make sure you inspect and clean the inlet area in the following way:
- Turn off the influent water to the unit.
- Open the unit cover.
- Remove any oil and dispose of it in a way that complies with company and legal procedures.
- Drain the water from the separator.
- Measure the depth of the leftover solids and write it down. This will serve as a framework for scheduling future maintenance and cleaning.
- If necessary, dispose of the solids.
After doing all of this, you will need to clean the media plates. They can be cleaned while still in the unit or removed for cleaning. To clean them without removal, stick a low pressure hose in between the plate spaces on the plate packs. Any dirt flushed from the plates should be removed through the drain on the hopper outlet.
For cleaning the plates outside of the oil water separator, rinse them down with a low pressure hose while taking extreme care to avoid getting the discharge on the ground where it has access to groundwater. All that needs to be removed is the sludge and oil buildup.
When this is done, check the tank for damage and repair the internal coating if needed. To start the separator again, just place the plate packs back into the unit as they were before. Ensure that they are securely installed to prevent them from floating when the unit resumes functioning. Maintenance should be carried out regularly by a qualified professional, depending upon the unit’s application and the amount of oil and other debris accumulated.
To receive a quote on a separator for your particular needs, call us today at 800-453-8639.
It is a well known fact that oil and water do not mix. But separating the two before releasing the wastewater into sewers or open water areas is no easy feat. Because millions of gallons of oil wastewater have the potential to get into our water supply , wetlands and environment each year, the EPA and state agencies have implemented guidelines for keeping our environment free of oil contaminated wastewater. While the process of separating oil and dirt from wastewater is not simple or inexpensive, it guarantees all of us will have uncontaminated water supply and wetlands for decades to come.
How Problems Occur
Operating and washing heavy machinery will combine water with oil, grease and grime. Without treatment, this wastewater would release harmful contaminants into the environment.
Solutions
Case studies conducted by Wash Bay Solutions prove that much of the oils and dirt from contaminated wastewater can be removed before it is discharged to the sewer. One way this is done is by putting the wastewater through a specially-designed clarifier separator equipped with inclined plates to drop out the solids and advanced coalescing media to remove the oils. If the water needs to be re-used, it can be put through more filtration.
Result
Water without oil and dirt contamination can be reused or safely discharged. By using oil water separators on wastewater, we are using good “Green” business practices to both save money and be good stewards of the environment.
Recent media coverage has increased focus on oil and gas drilling operations and ways to prevent contamination from harming groundwater, wetlands and waterways. Wash Bay Solutions provides the Best Available Technology (BAT) for oil water separation systems and equipment cleaning systems. Wash Bay Solutions helps the oil and gas drilling industry establish positive environmental stewardship by recycling, reusing and reducing wastewater.
“Solids & Oil Water Separation System”
Waste Bay Solutions has developed the Solids & Oil Water Separation System (SOWS) using horizontal gravity flow treatment. This Green system removes oil and solids from produced and flow-back oil-contaminated water using a five-stage process of separation:
Stage 1: Remove free oil particles larger than 150 microns
Stage 1: Intercept and collect settleable solids
Stage 3: Capture suspended solids and dispersed oil
Stage 4: Collect remaining suspended solids and remove free oil droplets 30 microns or larger
Stage 5: Trap any trace oils before water is discharged
The SOWS System has many key features including no moving parts, low maintenance and solid heavy-duty construction. Reusing water from oil-contaminated wastewater is an environmentally-conscious practice to protect waterways and protected wild life reserves. It also saves money.
“Responsible Corporate Citizen”
Whenever there is an oil spill or groundwater intrusion, the oil and gas drilling industry receives negative press. Communities are more willing to support oil and gas drilling operations when they know that these companies minimize their negative impact on the environment. Washbaysolutions.com helps businesses become responsible corporate citizens.
Most mining activities rely heavily on water. They use large volumes of water for everything from processing and transporting minerals to washing equipment and vehicles.
Mining and Heavy Dump Trucks
The efficient use, reclamation and reuse of water on-site are important considerations at every mining operation. Developing and implementing programs that both maintain both water quality and quantity will provide mining companies critical long-term access to water as well as ensure that their company grows and thrives.
We believe it is possible for both mining companies and their neighbors to have enough clean water for their needs. We at WashBaySolutions.com have the knowledge, experience and equipment to help mining companies maintain their water quality and minimize water usage.
Typical solutions include completely self-contained water recycling systems and separation systems.
We offer the following units for your mining operation:
Economic and environmental sustainability is often sited as an integral part of oil and gas companies’ business activities. They strive to conduct operations that are not only profitable and safe, but also have minimum impact on environmental resources. One of the main resources that they concentrate on is water.
Water is used in association with many oil and gas activities. Large volumes of water are used during the drilling and completion of oil and gas wells. Water is used during drilling for drilling fluid preparation, make-up water and completion fluids. In enhanced recovery and well stimulation procedures such as “fracing”, water is used as a supplemental fluid.
In smaller volumes, water is used for cooling water in gas plants and boilers; as hydrostatic test water for pipelines and tanks; and as wash water for rigs, trucks, heavy vehicles and other equipment. Equipment washing in oil and gas drilling applications is an essential part of keeping the drilling operation running 24/7.
In order to maintain good environmental stewardship and increase profitability, many oil and gas drilling operators are looking at ways they can “reduce, reuse, and reclaim” the large volumes of water they use on a daily basis.
At WashBaySolutions.com our engineered solutions to “reducing, reusing, and reclaiming” include completely self-contained water recycling systems, solids and oil separation systems and high pressure washing systems.
Please see our units available for the oil and gas drilling industry:
Oil and water separator systems and water reclaim systems are generally used in commercial settings to remove oil and solids from wastewater effluents. Electrical substations, chemical plants, and oil refineries utilize this technology every day. There are two main types of systems, sewer pre-treat systems and closed-loop systems. Sewer pre-treat systems will treat and clean the water so that it can be discharged into the local sewer system. A closed loop system will treat the water so that it can be reused onsite.
In an oil water separator, the corrugated plates intercept oil droplets as the wastewater travels through the separator. New droplets coalesce (combine) with retained droplets, and the droplets become larger. Enlarged droplets are released from the water and rise to the surface where they are decanted into a storage tank, and then properly disposed of with any local or government waste management facility.
Washbay Solutions offers a complete line of the best oil water separators and water reclaim systems on the market today. Whether above or belowground, a closed-loop or sewer pre-treat system, Washbay Solutions has the right system to fit the needs of your company.
A case study was conducted of our sewer pre-treat system at one of our customers located in one of the strictest sewer authorities in North Carolina. After assisting our customer with obtaining a permit, we also helped save them thousands of dollars on a water meter required by the permit. Our client was very pleased with the system, and we returned quarterly to assist with and coordinate water analyses required by their permit. As the water analyses results kept proving our system was cleaning the water remarkably well, the permit requirements kept decreasing which saved our client thousands of dollars in analyses costs.
Another case study was conducted of our closed-loop system at a trucking company. Since they were located outside of the local sewer limits, they needed to be able to clean and recycle their own wastewater. In May of 2007, we assisted the trucking company with the installation of a closed-loop water reclaim and separation system that is used on a daily basis today. We still provide quarterly inspections to ensure the closed loop system is working as designed.
Whether your company is looking for a closed-loop or a pre-sewer treatment system, Washbay Solutions can help design the system that is right for you.
All businesses that wash vehicles are required to separate the oil from the waste water they create before discharging it into the municipal sewer system. This is not only the legal thing to do, but the right thing to do. Water is a valuable resource and we need to do all we can to conserve it and keep it clean.
Oil water separators work on the principal of water and oil not mixing and their property of natural separation. With this principal, an oil water separator enhances the separation. This is usually done with coalescing media that intercepts the oil droplets and cause them to move together and increase in size. The larger droplets then rise to the surface and are captured in a storage area. There are above ground systems and below ground systems. They should be as compact as possible, sized to the job. In most cases, they require no moving parts, power consumption, chemicals or cartridge use of any kind.
When looking for an oil and water separator, it is necessary to know the water flow rates and the requirements of the particular municipality involved. Many times, it is wise to deal with a company that knows the local requirements and codes so that the system being installed meets those requirements.
Depending on the type of machinery that is being cleaned, more equipment may be needed. For large vehicles covered with a lot of dirt and debris, a demucking unit may be your most effective way to clean. If you can not discharge the water to a sewer, a closed loop recycle system will be required.
When getting into a business that will involve oily water that requires separation, it is best to look for a company that will be sure to outfit the business with equipment that meets the requirements of the municipality. If possible, look at a company’s case studies of some of its most challenging installations, and consider that when making a decision in the oil water separator that will be purchased or leased.
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At WashBaySolutions.com, we have been specializing in high tech, custom-engineered solutions to complex washing and wastewater issues since 1991.
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