Easy Guide to Oily Water
Oil Water Separator Selection – made simple
Never dealt with oily water treatment before? Maybe you’ve seen it go wrong and want to make sure you don’t waste money on the wrong system.
We replace dozens of broken, high maintenance, under-performing and non-compliant oily water separators every year. So we though we would share some information on oily water treatment so that you can get it right the first time.
1: Oily Water Basics
The start point is making sure you understand the oily water that needs to be treated, what it looks like and how it is made up.
Obviously we cannot short list oil water separator types till we fully understand the oily water we need to treat.
Many oil water separator types will be ruled out because they simply cannot treat your particular oily water mix / type.
It surprises many to learn that oil pollution in water can take several very different forms. Understanding the different types of contamination is vital in order to determine what methodology of oil water interceptor will be effective.
An oily water problem will be made up of a mix of four main types of oil pollution.
- Free floating and often on the surface
- Large oil droplets typically more than 150 micron.
- Can be removed via gravity given enough time
- Easy to remove – lots of treatment options
- The subject of European EN-858-1 ‘5 mg/l ‘ oil water test standard
- Oil droplets between 2 and 150 micron in size
- Dispersed throughout the water
- Require a powerful oil water separator to remove smaller oil droplets
- Includes oil with small solids particles attached
- The subject of more comprehensive USA oil water test standard
- Oil droplets less than 2 microns
- Cannot be seen by the naked eye, in fact the water may appear to be ‘clean’
- Includes detergents and cleaners dissolved in the water
- Soluble hydrocarbons like benzene and toluene
- Biological degradation of ‘insoluble’ oil like diesel cause dissolved oils
- Cannot be removed with gravity or plate packs; in fact they may make the problem worse!
- Can be over 2000 mg/l oil and grease
- Oil with a density greater than 1000 kg/m3 (e.g. Bunker ‘C’ fuel oil)
- Oil that sticks to heavy solids
Not sure what mix of the 4 types of oil contamination you have? Let us help
Give us a call or send an email. Using our extensive data base of customers oil water pollution types we can put you in the picture in no time!
In addition you can take advantage of our extensive in-house oily water test facilities and laboratory. We are are able to analyse and characterise your oily water problem and give you a full report. In many cases we can do this for free!
2: Characterising Your Oily Water
Why is Oil Droplet Size so important?
All oily water separators are designed to treat a particular range of micron size of oil droplets – this is called the micron rating of the separator – or micron separator range. Some oil separators wont be able to treat oil droplets that are small (eg Gravity, Coalescing Plate Packs, VGS, European EN-858 Tanks) and some oil water interceptors are not able to treat large oil droplets (e.g. Media filters, DAF and Chemical Treatment systems).
A 150 micron rated separator will separate oil droplets 150 micron and larger, but not separate 25 micron droplets – those oil droplets will still be in the water and get discharged with your “treated” water.
A 25 micron rated separator is more powerful and will separate 25 micron droplets as well as larger oil droplets
This is why oil droplet size, and oil droplet size distribution, is one of the most important factors in determining the oil water separation performance of all mechanical separators. Oil droplets in water are never one size, but present in a size distribution, with some smaller and some larger. For the more technically inclined we find in most applications the oil droplet size distribution is a log / normal shape distribution.
Measuring Oil droplet size
Oil droplet size and the oil droplet size distributions must be measured on site with ‘live’ flowing water. You cannot sample your water and send it to a laboratory because the oil droplet size will change very quickly after sampling and the results from the laboratory will be meaningless.
Oil droplet size can be measured on site by a skilled technician with the required equipment. Its is not difficult when you know how but it is a highly specialised area of water analysis; so don’t expect a ‘normal’ laboratory to have the required expertise or equipment. We have many years experience and have the expertise and calibrated equipment, so if you need help let us know.
Ultraspin has several oil droplet particle size measuring tools. The most accurate technology available for measuring droplet size is a video particle analyser. Ultraspin has a portable video particle analyser and skilled operators who can bring it to site to measure your oil droplet size and distribution.
It is vital to have both an accurate oil droplet measuring tool capable of telling the difference between oil droplets, air bubbles and suspended solids AND a skilled operator experienced in oily water analysis. Ultraspin has the best of both! So if you would like our help please let us know. There is no more guesswork required.
Estimating Oil Droplet Size: Similar Applications
There are a couple of ways to estimate your oil droplet size. They are not as accurate as direct measurement described above but should give you a rough idea.
The Ultraspin table below can give you a guide based on “typical” oily water situations. The presence of suspended solids, additives, detergents or surfactants will change your droplet size to be larger or smaller, so you should account for this if they’re in your water.
Estimating Oil Droplet Size: Visually Compare Water Samples
You can also get a rough idea of your oil droplet size with a visual inspection of your sample. In general, if you can see the droplets with the naked eye, they are large, say 150 micron plus. If the water looks hazy, white or milky, the droplets are very small (less than 25 microns, often less than 10 micron). We have a data base of sample photos from thousands of applications with matching droplet sizes to give you a visual guide. Look for a sample that has similar characteristics to yours. If you need help, email us a photo of your sample and our oily water engineers will help you.
3: Comparing Oil Water Separators
Now that you understand the 4 types of oil contamination; the particular mix of these type you have, and the importance of oil droplet size:
– you can begin to short list types of oil separator that might work for you
A good place to start is oil droplet sizes. You can narrow down your choice of oil separator technologies that suit your application based on what droplet size each separator technology is designed to treat.
|Separator Technology Type||300 micron||150 micron||60 micron||25 micron||15 micron|
|Gas flotation with chemicals|
|Gas flotation without chemicals|
|Coalescing Plate Packs - VGS|
|API gravity separator|
|European tanks / SPEL|
|Basic tanks, double or triple interceptors|
Oil Water Separator Performance Curves
Now that you understand the importance of oil droplet size you will now be able to understand Oil Separator Performance Curves. Many factors affect the performance of an oily water separator system installation. For most customers a primary consideration is oily water separation ability because this defines final discharge water quality or oil recovery rates. Oil Separation efficiency can be expressed as follows:
Oil Separator Efficiency (%) = 100 x ( Cin – Cout/ Cin)
- Cin = feed inlet concentration (mg/l)
- Cout = discharge outlet concentration (mg/l)
More powerful separators have a number of advantages including obtaining better quality discharge water, meet or exceed Local and National Trade Waste discharge standards, meet or exceed future discharge standards, deal with accidental oil spills, tolerate higher strength non-“quick-break” detergents and cleaners.
Oil Water separation efficiency can be objectively accessed by examining the separator oil droplet size vs. separation efficiency curves. For higher quality separators these curves should be readily available from manufacturers. Manufacturers should also be able to confirm performance to these curves by independent testing. The purpose of oily water separators is to obtain clean water. However, claims of a separator being able to achieve less than 10 mg/l discharge are meaningless and deceptive without recourse to oil droplet size performance curves.
Caution: There are oily water vendors who can’t measure the oil droplet size as they don’t own the specialised equipment required. You should not trust vendors who can’t measure oil droplet size. They can only guess how their equipment will work in your application.
It’s like a pressure vessel manufacturer not being able to measure pressure, or an oven manufacturer not being able to measure temperature. It’s ridiculous – but it happens!
Always ask your supplier for an objective oil droplet based performance curve like the one shown here. Make sure its one they have generated by measuring oil droplet size on their equipment, and not copied from another vendor like Ultraspin. Compare the curve to the oil droplet size you have or need. If a supplier can’t or won’t send you their own performance curve – be very wary!
4: Other Oily Water Fluid properties
Mean oil droplets size is the single most important factor for defining the dirty oil water, but there are several other factors that are also important.
The viscosity of the water falls as the water temperature rises. This allows oil droplets to move more easily through the water phase, thereby producing better oil separation with many oil water separators (but not all). Therefore, increased temperature improves separation efficiency for most oily water separators. The Ultraspin separator can be supplied to operate within the temperature range 0 to 120°C (32 to 248°F), at higher temperatures special materials may be required.
Oil Water Separators that work better at higher temperatures include:
- Coalescing plate packs (5 to 80 oC)
- Ultraspin Separators (5 to 120 oC)
- Gravity tanks and vessels (5 to 90 oC)
- Centrifuges (5 to 90 oC)
Oil water separators that may not separate as effectively at higher temperatures include:
- Air flotation devices (DAF, CAL, IGF) (5 to 30 oC)
- Media filters (5 to 45 oC)
- Membranes (5 to 65 oC)
- These types of separator may require water coolers to work effectively.
For many oil water separators the oil removal efficiency is dependent on the difference in density between the contaminant and the water. The separation efficiency increases as the difference in density increases. The density difference can increase if you have lighter oils or your water is salty, or both. Typical densities for Oil are 950 to 750 kg/m3 (0.034 to 0.027 lb/in3) and water : 1050 to 995 kg/m3.(0.038 to 0.036 lb/in3).
For these types of oily water separator performance improves as the density difference increases, and generally the density difference must generally be more than 25 kg/m3
- Coalescing plate packs
- Gravity tanks / SPEL / Triple and double interceptors
- Ultraspin Separators
For these types of oil water separators are not greatly effected by small density differences (say less than 25 kg/m3):
- Media filters
- Air flotation (DAF, IAF, CAF)
Some types of oil water separator are NOT well suited to high oil feed concentrations and high feed oil concentrations overload or block the systems. For these types of system careful pre-treatment to remove oil will be required.
- Coalescing plate packs (max 1% oil or 10,000 mg/l).
- With high oil concentration for this type of separator the plates become coated in oil and sludge. This requires the plates to be removed and cleaning to restore oil removal efficiency.
- Air flotation systems (DAF, IAF, CAF) (max 1% oil or 10,000 mg/l)
- Media filters (typical max 100 mg/l oil )
- Membranes (typical max 300 mg/l)
Other types of system can accommodate 100% oil concentration for a period of time:
- Ultraspin systems
- Gravity tanks / SPEL / Triple and double interceptors