System for treating petroleum and petrochemical slop oil and sludge wastes

This application is a continuation-in-part of Ser. No. 09/317,669 filed May 24, 1999, which is being issued as U.S. Pat. No. 6,322,621 on Nov. 27, 2001, the disclosure of which is incorporated herein by reference.

1. Field of Invention

The present invention relates generally to converting crystalline wax, as, for example, exists in slop oil, to an amorphous form of wax, causing it to be dissolvable in, for example, crude oil at, for example, ambient temperature and maintained in a dissolved state for a prolonged period of time at ambient temperature, and more particularly, in its preferred, exemplary embodiment, to the use preferably of a chemical composition of surfactants, polymeric dispersants and corrosion & scale formation inhibitors that can, for example, recover waste hydrocarbon products (paraffin waxes, asphaltenes, and coke) from both naturally-occurring and synthetic sources, and more particularly to recover these waste hydrocarbon products for use as energy sources and to reduce environmental pollution. A number of other applications is also disclosed and claimed.

Also, since the advent of new environmental laws for the disposal of hydrocarbon based sludge, the petrochemical industries have implemented the use of various types of cleanup systems. The most commonly used methods have been mechanical systems such as centrifuges, decanters, tricanters and various types and designs of liquid-solid separators. Most mechanical separation systems are limited by temperature and volume constraints.

Using mechanical systems alone, solid-liquid separations are never complete. In order to obtain a complete separation with a minimum of residual emulsion rag (BS&W) remaining, chemicals are added to enhance the efficiency of the separation. Since refinery and petrochemical sludge oil residues are listed by the E.P.A. as toxic and hazardous wastes, they must be disposed of at a regulated special waste dump. Because of the limited amount of sites available for disposing such toxic and hazardous wastes, the disposal costs are extremely high.

In the year 2000 the average worldwide cost for disposal of these wastes ranged from 350 to 500 dollars/metric ton (52 to 75 dollars per barrel) of sludge oil waste. Oilfield production slop oil and sludge wastes are also a problem and are normally treated with the same methods used by refineries.

2. Prior Art

For general background, “prior art” information pertinent to the invention, reference is had to:

• The Chemistry and Technology of Waxes by Albin H. Warth, published by Reinhold Publishing Corp. (New York, 1947), p. 239 et al;
• Petroleum Refinery Engineering by W. L. Nelson, published by McGraw-Hill Book Co. (New York, 4^th Ed., 1958), particularly Chapter 12 “DeWaxing” (pp. 374-75 et seq.);
• Physical Chemistry by Walter J. Moore, published by Prentice-Hall, Inc. (New York, 1955), particularly Chapter 16 “Surface Chemistry” (p. 498 et seq.); and
• chemical and process technology encyclopedia edited by Douglas M. Considine, published by McGraw-Hill Co. (New York, 1974), particularly its sub-section on “Waxes” (p. 1167 et seq.).

Also some patents cited in the parent application hereof include the following—

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