Therma-Flite
Indirect Thermal Desorption System Cutting-Edge Innovation in Thermal Processing
Tank Bottom Sludge
Drilling Mud
Separation and Collection of Hydrocarbons from solids
Therma-Flite, Inc P.O. Box 847, 849 Jackson Street Benicia, CA 94510 877-DRY-SLDS 707-747-5951 fax info@Therma-Flite.com www.Therma-Flite.com
Soil Remediation
Hazardous Waste
Therma-Flite screw processors: high-efficiency, low profile
Drill Cuttings Dryers
With a state-of-the-art screwconfiguration, our processors deliver greater heat transfer surface per cubic foot of equipment than other thermal processor technology. This efficient design means an extremely powerful unit that packs high-impact processing in a compact footprint.
PROCESS 1.5 TO 500 TONS PER DAY WITH 99.5% HYDROCARBON RECOVERY Therma-Flite Holo-Scru® thermal desorption systems volatilize and recover 99.5% of hydrocarbons from drilling mud. Oil, diesel and other synthetics are often used as lubricants in drilling for natural gas. After this mud is recovered and centrifuged, the slurry typically contains high levels of water, diesel, even crude oil.
The way it works is simple. Feed stock is treated through controlled heat (or cold) conduction, so it is never degraded or contaminated by interacting with material necessary to operate the unit (water, steam, oil or gas). Feed stock flows like clockwork through the ThermaFlite screw processor, and is exposed only to a consistent, pre-set temperature for accurate thermal processing.
Holo-Scru® processes can accept feed stock with hydrocarbon percentages greater than 70%, effectively collecting and condensing water, diesel and other hydrocarbon vapors. In applications such as natural gas drilling where diesel and water constitute the liquid phase, diesel is typically filtered, then resold or reused as a lubricant for future drilling. Therma-Flite units in operation in the U.S. process drill cuttings from shale drilling; This feed stock is generally 10% to 30% diesel, and 20% water. Recovery rates for diesel typically range from 97% to 99.5%.
Decades of reliable performance and innovation
In 1939, Therma-Flite (then Christian Engineering) designed, built and sold the first Holo-Scru® heat exchanger for the food business. After World War II, Holo-Scru also became widely-used in the chemical and construction industries. Therma-Flite sets the world standard in screw conveyor technology and auger design, as well as manufacturing equipment for the chemical and processing industries. Our processors last longer, and process a larger quantity and variety of material than any other manufacturer, bar none. The Therma-Flite difference is that we don’t simply sell equipment, we deliver solutions. Every order begins by taking into account the specific objectives and specifications of our customer. We then take great care in engineering flight designs, rotor configurations, heat-transfer mediums, and making proper material selection for a processor that will stand the test of time, and exceed your expectations.
Need portability? Mobile units are now available for field testing.
Tank Bottom Sludge and Soil Remediation CONDENSE AND RECOVER HYDROCARBONS IN ONE EASY STEP If storage tanks storing crude oil are not cleaned regularly, dirt, water and oily sediment at the bottom of the tank can be disturbed, and contaminate the contents. Therma-Flite Holo-Scru® desorption units heat residual material to 1,000-plus-degrees Fahrenheit, so that hydrocarbons and water vapor are condensed and recovered. These tank bottoms may also be discarded after they have been thermally treated to recover hydrocarbons. Multi-stage systems make the process even simpler by removing water in one unit, while removing hydrocarbons in a second. • There are Therma-Flite Holo-Scru® installations that have been in operation for more than 20 years processing tank bottom sludges and other feed stocks such as soil and catalyst fines.
Hazardous Waste Processing DELISTING RESOURCE CONSERVATION AND RECOVERY ACT (“RCRA”) WASTE Therma-Flite Holo-Scru® desorption units are excellent for delisting RCRA waste. Drums, cans, glass and plastic containers are just some of the items that carry hydrocarbon-laden materials such as paint, perfume, degreaser, oil, resins, and hair spray. Such feed stock is typically shredded to 2-inch minus in order to add easily to the desorption unit. Holo-Scru handles the shredded metal and glass quickly and efficiently. Sticky materials are also handily-processed by virtue of the system’s self-cleaning, rotor design. Process temperatures between 850 and 1,200-degrees Fahrenheit (depending on feed stock requirements) volatilize all hydrocarbons.
Truly Ingenious Technology YOUR CHOICE OF HEAT TRANSFER MEDIUMS: THERMAL OIL, STEAM, LIQUID SALTS, AND WATER Therma-Flite Holo-Scru® thermal desorption systems are turn-key, and include all necessary components to: • Hold and meter feed stock into the desorption chamber • Provide an airlock to the inlet and discharge of the unit • Cool the material exiting the desorption chamber • Condense volatiles for collection The feed system may be customized, but the standard system includes a feed screw with loading trough, or for applications when feed storage is required, a feed hopper with integrated live bottom. For low viscosity sludges, such as drill cuttings containing diesel and water, a positive displacement pump is used to feed the unit. Feed stock is discharged from the feed screw into a double knife-gate airlock. The airlock cycles to allow feed to enter the airlock chamber while maintaining a seal to the desorption chamber. For added safety, the airlock includes optional fittings for a nitrogen or CO2 purge which can be used to insure any air remaining in the airlock is displaced prior to the airlock cycling, and discharging the feedstock into the desorption chamber. The heart of the system, the desorption unit, includes intermeshed Holo-Scru® rotors. In this chamber, feed stock is heated under a slight negative pressure in a sealed, anaerobic environment; heating is indirect. Thermal fluid is circulated throughout the Holo-Scru® rotors and outer jacket of the desorption chamber. The proprietary Holo-Scru® dual rotor design is self-clearing and feed stock which might otherwise bake on to the rotors, is easily removed. Different mixing programs may be set in the Programmable Logic Controller (PLC) which will increase the heat transfer into the feed stock. A variety of heat transfer fluids may be used to heat product up to 850-degrees Fahrenheit. A second stage system can be incorporate to heat the product to above 1200-degrees Fahrenheit. Most feed stocks may be de-volatilized to less than .05% remaining hydrocarbons. As the heated solids exit the desorption chamber, they pass through a second airlock and into a cooling screw conveyor. In the cooling screw, solids are indirectly cooled by circulating water through the jacketed wall of the screw. The temperature is further reduced by direct-contact quench cooling via atomizing sprays along the top of the cooling screw housing. The vapors exit the unit into a Venturi-effect, multi-stage condenser. Cooled and filtered condensate is used as the condensing fluid. The Venturi-effect condenser is highly-efficient with less than .01% hydrocarbons remaining in the noncondensable stream. The non-condensable stream is released through a duct to the air intake on the diesel generator providing the unit’s electrical power. • Maximum product temperature: 900-degrees Fahrenheit • Maximum operating pressure: 350 psi • Maximum operating vacuum: 50 millitorr
Single-stage desorption unit SCRUBBER / CONDENSER INLET AIRLOCK FEED HOPPER
Recovered hydrocarbons
THERMAL FLUID SUPPLY THERMAL FLUID RETURN DESORPTION CHAMBER DISCHARGE AIR LOCK
ROTARY AIR LOCK
PRODUCT COOLER
Partial Customer List Air Products Alcoa Allen-Sherman-H Allen Bradley Company Allis Chalmers Alstom Power Amax Amoco Arizona Public Service AT&T Babcock & Wilcox Bechtel Petroleum Bethlehem Corporation Boise Cascade Box USA Bussman Corporation C&H Sugar Cabot Corporation Chemical Waste Management Chevron Research Company Climax Molybdenum Company Coal Technology Corporation Combustion Engineering Compania Minera El Indio Conoco Phillips Dedert Corp Thermal Processing Denver Equipment Company Detroit Stoker Company Diamond Shamrock Corp. Dow Chemical Energy Factors Energy Products of Idaho Exxon Research & Engineering Fluor Daniel Corporation Fluor Engineering Corporation Foster Wheeler Boiler Corp. Foster Wheeler Energy Corp. General Mills Environmental Gulf Chemical Gulf Coast Transit Gulf Oil Guntert & Zimmerman Hershey Chocolate Hewlett Packard Intenco Incorporated International Titanium Kaiser Aluminum Kellogg Salada Canada M&M Mars Candy Mearl Corporation Nabisco Nassau Metals Nichols Engineering Owens Corning Fiberglass Patterson Equipment Peterson Manufacturing Corporation Phelps-Dodge Phoenix Metals Procedyne Proctor & Gamble Pyropower Corp. Rineco Chemicals Rollins Environmental RTI International Shaklee Corporation Solar Turbines South Lake Utility District er Chemical Company S Tenneco Oil Exploration Thermal Processes Timet Metal Corp. Union Carbide Agriculture Union Oil US Bureau of Mines Utility Engineers Wausau Paper Mills Westinghouse – Haztech Westward Seafood Wyoming Mineral Corp. Xerox Corporation
PROCESS TECHNOLOGY Calcining Cooking Cooling Crystallizing Drying Heating Pyrolizing Thermal desorption INDUSTRIES SERVED Chemical Food Processing Mining Petro-Chemical Power Generation Environmental Municipal Solid Waste and Hazardous Waste Treatment Sludge and Wastewater Wastewater Treatment Paper and Pulp SERVICES OFFERED Engineering and Design Equipment Manufacturing and Repair Fabrication and Welding Field Service Machine Work Technical Support
P.O. Box 847, 849 Jackson Street Benicia, CA 94510 P: 707-747-5949 F: 707-747-5951 info@Therma-Flite.com www.Therma-Fite.com
Publication TF-IDTDS 053012