Crystal Separator

Running 24/7 for 10 years

Designed for the rigors of the oil field, the Genoil Crystal 2-phase oily water separation system was developed to clean a water stream to discharge specifications. At present, refiners use API ponds where the first section utilizes gravitational separation aided by floating oil skimmers to recover oil that is sent to a slop oil tank. This slop oil is then reprocessed in the refinery as a slipstream. The second section of the API pond is primarily a biological process made up of one or two ponds where air is added by either perforated piping or aerators for the bacteria. The HRT is typically anywhere from 30 to 45 days. In this application there would be potential for the Crystal oily water separator in order to substantially improve the overall efficiencies of this process, especially when real estate is at a premium.

The Crystal 2-phase oily water treatment units are designed to separate the liquid phases in six stages located within a single vessel. The Crystal with no internal moving parts is designed to run 24 hours and can keep up with the most aggressive production and drilling quotas. Our Crystal can't break down. We have systems in the field running continuous for decades, 24/7/3650. No environment is too demanding for our units. Our Crystal can handle anything you bring at it. We Guarantee it!

Each stage is devised to remove oil particles of a certain size and renders the liquid cleaner for the next stage. This ensures greater effectiveness and manageable loads for each stage. Furthermore, it also precludes undue contamination and clogging of various stages by oil, resulting in trouble free-operation.

Minute gas bubbles resulting from controlled vacuum conditions enhance the removal of oil droplets from the water stream. Vacuum is created in stages operating prior to the circulation pump. Oil is retained at the upper portion of the stages and is gradually accumulated in collection zones.

Downstream from the pump the stages are slightly pressurized. Oil extracted in these stages is transferred continually into the collection zones through specially designed conduits. The transfer of oil occurs due to the pressure differential existing between the stages located upstream and downstream from the pump respectively. Continual oil extraction ensures outstanding cleanliness of the polishing stages and prevents accidental contamination of the effluent.

Oil accumulation in the collection zones is monitored by a probe that initiates periodic oil discharge sequences. The oily water separator is isolated from the discharge line and connected to a pressurized line. Clean water back-flushes the stages and displaces the oil from the collection zones. The oil probe resumes the separation process after a preset amount of oil is evacuated.

The first stage achieves oily water separation through gravity enhanced by a flotation effect of minute gas bubbles. Most of the oil droplets are removed in this stage. The flow is reversed prior to the liquid entering the second stage. This assists in leaving the oil behind in the primary collection zone. Sludge and other contaminants denser than water are deposited at the lower portion of the first stage.

The second stage achieves oily water separation by coalescence. A perforated chamber accommodates suitably sized oleophilic beads. An arrangement designed to agitate the liquid and allow free movement of the beads enhances the coalescing effect and also a self-cleaning process. As a result, oil droplets adhering to adjacent beads are readily brought together. Larger drops formed in this fashion overcome the force of attraction exerted by the beads. As a result they leave the beads and migrate toward the oil collection area. The rubbing action occurring between the beads in motion releases solid contaminants, thus cleansing the beads.

An oil layer formed within the chamber absorbs small hydrocarbon particles in order to break down emulsified oil. The thickness of the oil layer is self-regulating. As the liquid enters the third stage the coalescing process is resumed. Smaller oil particles reaching this stage are dealt with in a similar fashion by optimally sized beads.

A pump draws the liquid from the third stage and pumps it into the fourth stage for further separation by means of a vortex-generating device. Centripetal forces within the vortex agglomerate the oil particles and force them to coalesce in order to form larger globules. Furthermore, an effect similar to one created by a cyclone also agglomerates the oil particles thus enhancing the coalescing process. A perforated pipe retrieves the globules that migrate toward the eye of the vortex and directs them to a dispersion plate placed above the vortex generator. Oil particles then travel through suitably sized perforations in the dispersion plate, gather around a funnel and migrate toward the oil collector of the second stage.

Spinning liquid rapidly exits the vortex generator, being deflected downwards by the dispersion plate for separation by gravity. Further separation of minute oil particles occurs in the fifth stage by means of an electro-static field. Thus the oil particles are forced to form clusters of larger globules, which are readily left behind as the flow is reversed and reaches the fifth stage polishing. In most cases the separation is completed prior to this stage. However, for oils of very high density the sixth stage retains the remaining particles by means of filters. The filter media are designed to coalesce minute particles of oil on their surface. Enhanced buoyancy by coalescence and the sweeping effect of the liquid take away the oil particles from the filter media. Thus filter media lifespan can be prolonged to significant periods of time. This is due to minimizing the amount of oil particles reaching the media and effective oil removal from the surface of the media.

When continual operation is required a positive displacement pump evacuates the oil while the separation process is taking place. An oil content meter may monitor the quality of the effluent. In the unlikely event the oil content exceeds 15 mg/l, a re-circulation valve isolates the unit from the discharge line. The effluent is then re-circulated to the inlet line and reprocessed in the oily water separator until it meets the requirements.

The main advantage of a Crystal oily water separator is the nesting design. The four separation principles (gravity, coalescing beads, vortex, filter) employed in this design are simple, and have no moving parts. With the nesting design, Crystal oily water separator is a very compact unit that is ideal for tight quarters. It was originally designed for the bilge area of a ship. The order used in the separation principles is key to reduced maintenance and effectiveness. The bulk of the oil is removed in the stages prior to filtration. A pump is located between the third and forth stage, and since the bulk of the oil has been removed, emulsions are much less of a problem than if a pump was placed up front of the unit. The filter is the last stage. Of course the filter has to be changed when it is clogged. However by having five stages in front of it, the filter does not receive a lot of oil and therefore would not require frequent changes. The unit can also be run without the filter, virtually eliminating maintenance.