Plasma hydrocracking units for crude oil, heavy oil residues (fuel oil, sludge, bitumen) and used motor oils
PLAZARIUM PCS
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Description
PLAZARIUM PCS mobile plasma cracking units are intended for the implementation of technological process of plasma cracking (destruction) of heavy hydrocarbon fractions (Heavy fuel oil) by means of plasma jet factors to produce hydrocarbon gas and a liquid mixture of motor fuels’ light fractions.
The raw material for processing is heavy hydrocarbon residues (heavy oils and oil residues such as fuel oil, bitumen, sludge, etc.), used motor oils, industrial oils and hydraulic fluids, gas turbine oils, instrument oils, transformer oils, compressor oils, turbine oils, and mixtures of used oil products.
The mobility of plasma cracking unit for HFO (Heavy fuel oil, also known as heavy oil, marine fuel or furnace oil, is a fraction obtained from petroleum distillation, either as a distillate or a residue) provides convenient transportation, allows to place the unit on car chassis, ensures minimum installation work on the site, the possibility of flexible regulation of technological parameters of the unit with minimal costs for adapting the unit to the conditions of a particular enterprise – by composition and volume of processed waste.
Along with mobility, plasma cracking unit assumes its modular design, both of the whole technological scheme, and individual elements. This allows to compile various versions of the technological scheme for processing a wide range of heavy oil residues on a single fundamental basis, which uses a 20/30/40-ft transport container.
In case of autonomous application, plasma cracking unit is equipped with a rectification column built into the reactor to distill the resulting mixture into separate gasoline and diesel fractions.
The main advantages of PLAZARIUM PCS plasma cracking unit:- Mobility and modularity of the construction;
- Simplicity and safety during installation and operation, absence of contact between the unit personnel and waste;
- Absence of ballast nitrogen and nitrogen dioxide (NO2) and nitrogen oxides (NOx) formation;
- Simplicity and automation of unit control system and waste cracking process management;
- Ability to work in the open and under a wide range of ambient temperatures (from -60°С to +50°С), as well as at high humidity (environmental parameters are determined by the terms of reference for the development of plasma cracking units);
- Full ecological compatibility of the processing of heavy oil residues (fuel oil, sludge, and bitumen) and waste motor oils, industrial oils and hydraulic fluids for hydraulic systems, gas turbine oils, instrument oils, transformer oils, compressor oils, turbine oils and mixtures of used oil products. Absence of resins, dioxins and furans;
- Obtaining a clean fuel fraction or a mixture of fuel fractions at the outlet from plasma cracking units;
- Possibility of operation directly in the place of assembly and accumulation of heavy oil residues;
- Maximum permissible emissions (MPE) comply with the EC directive.
The technical result of work of the plasma cracking unit (PCS) plasma reactor is the change in the fractional and chemical composition of the raw materials (heavy hydrocarbon fraction) due to cracking in the presence of factors of the electric arc plasma torch steam-water plasma jet in such a way that the content of condensable (liquid) fractions is mainly gasoline and diesel fractions, and the decomposition process takes place with a minimum formation of decomposition gases and without the release of hydrocarbon fractions heavier than the raw material. This is achieved due to a high degree of automation, simultaneous control of all parameters of plasma cracking process, at various points of the plasma reactor design, and together with power control of industrial steam plasma torches.
The technical result of work of the plasma cracking unit (PCS) plasma reactor is the change in the fractional and chemical composition of the raw materials (heavy hydrocarbon fraction) due to cracking in the presence of factors of the electric arc plasma torch steam-water plasma jet in such a way that the content of condensable (liquid) fractions is mainly gasoline and diesel fractions, and the decomposition process takes place with a minimum formation of decomposition gases and without the release of hydrocarbon fractions heavier than the raw material. This is achieved due to a high degree of automation, simultaneous control of all parameters of plasma cracking process, at various points of the plasma reactor design, and together with power control of industrial steam plasma torches. Plasma cracking unit is equipped with the most modern set of gas analyzing equipment, designed to control the composition of gas, the concentration of harmful substances, and the mass concentration of dust in the process gas after the plasma-chemical cracking reactor and the condensation process of gas purification systems and a system for the distillation of the resulting mixture into individual gasoline and diesel fractions (optional). 
Plasma cracking unit is equipped with the most modern set of gas analyzing equipment, designed to control the composition of gas, the concentration of harmful substances, and the mass concentration of dust in the process gas after the plasma-chemical cracking reactor and the condensation process of gas purification systems and a system for the distillation of the resulting mixture into individual gasoline and diesel fractions (optional).
Power supply of the plasma cracking unit for heavy hydrocarbon residues (heavy oil and oil residues such as fuel oil, sludge, and bitumen), waste motor oils, industrial oils and hydraulic fluids for hydraulic systems, gas turbine oils, instrument oils, transformer oils, compressor oils, turbine oils and mixtures of used oil products is provided by the external power supply system (industrial three-phase network of alternating electric current, 380/400 V and 50/60 Hz).
The control room equipment includes a special kit for monitoring the quality of network power and interruptions in the supply network, as well as a special uninterruptible power supply kit for all major control systems.
In case of detection of poor-quality power supply or malfunctions in the external electric network, the tracking kit will be able to fix the problem and turn off all loaded equipment, and the uninterruptible power supply kit will be able to maintain the operation of the main control circuit in case of power loss or disconnection of the heavy oil residues plasma cracking unit.Heavy fuel oil plasma cracking unit (HFO plasma cracking unit) is equipped with devices and instruments that allow to regulate all operating parameters of the plasma cracking process, the cooling and condensation of gas, as well as the distillation of the resulting mixture into separate gasoline and diesel fractions in manual and automatic mode.
Explosion and fire safety of the unit is ensured by compliance with the rules and regulations of the operating manual, the availability of explosion-proof valves and automatic nitrogen supply systems with the possibility of manual control, the continuous monitoring of the cracking process, the exclusion of the formation of explosive environments and the choice of components located directly in potentially hazardous areas, and those with the explosion-proof design, as well as the choice of structural, sealing, and thermal insulation materials used for the unit manufacture, based on the conditions of their explosion-fireproof operation under normal and emergency operating conditions.
Heavy fuel oil plasma cracking unit (HFO plasma cracking unit) is equipped with devices and instruments that allow to regulate all operating parameters of the plasma cracking process, the cooling and condensation of gas, as well as the distillation of the resulting mixture into separate gasoline and diesel fractions in manual and automatic mode.
Explosion and fire safety of the unit is ensured by compliance with the rules and regulations of the operating manual, the availability of explosion-proof valves and automatic nitrogen supply systems with the possibility of manual control, the continuous monitoring of the cracking process, the exclusion of the formation of explosive environments and the choice of components located directly in potentially hazardous areas, and those with the explosion-proof design, as well as the choice of structural, sealing, and thermal insulation materials used for the unit manufacture, based on the conditions of their explosion-fireproof operation under normal and emergency operating conditions. -
Application
The processing of heavy hydrocarbon fractions
- Fuel oils are the residue after the separation of secondary processing of gasoline, kerosene, and gas oil fractions boiling up to 350 - 360 °C from oil;
- Viscose and acid sludge are the residue formed as a result of stripping the fractions that boil up to 450 - 600 °C (depending on the nature of oil) from oil at atmospheric pressure and under vacuum, as well as the residue formed during the purification of certain oil products (for example, lubricating oils) with concentrated sulfuric acid;
- Natural and artificial (process) bitumen are the useful minerals of organic origin with a primary hydrocarbon base (natural derivatives of oil, formed when the conservation of its deposits is violated as a result of chemical and biochemical oxidation) and the residual products of oil, coal, and shale processing, similar in composition to natural bitumen.
High-temperature thermal impact inside thePLAZARIUM PCS unit plasma reactor allows to process any heavy hydrocarbon fractions into light products, suitable for the production of motor fuels. The working process is based on the impact of factors of the electric arc plasma torch steam-water plasma jet on raw materials without air oxygen access. More...
The processing of heavy hydrocarbon fractions
- Fuel oils are the residue after the separation of secondary processing of gasoline, kerosene, and gas oil fractions boiling up to 350 - 360 °C from oil;
- Viscose and acid sludge are the residue formed as a result of stripping the fractions that boil up to 450 - 600 °C (depending on the nature of oil) from oil at atmospheric pressure and under vacuum, as well as the residue formed during the purification of certain oil products (for example, lubricating oils) with concentrated sulfuric acid;
- Natural and artificial (process) bitumen are the useful minerals of organic origin with a primary hydrocarbon base (natural derivatives of oil, formed when the conservation of its deposits is violated as a result of chemical and biochemical oxidation) and the residual products of oil, coal, and shale processing, similar in composition to natural bitumen.
High-temperature thermal impact inside thePLAZARIUM PCS unit plasma reactor allows to process any heavy hydrocarbon fractions into light products, suitable for the production of motor fuels. The working process is based on the impact of factors of the electric arc plasma torch steam-water plasma jet on raw materials without air oxygen access. More...The processing of used motor oils
PLAZARIUM PCS plasma cracking units are intended for processing of used motor oils into light products suitable for the production of motor fuels.
More...
The processing of used motor oils
PLAZARIUM PCS plasma cracking units are intended for processing of used motor oils into light products suitable for the production of motor fuels.
More...
The processing of used industrial oils
PLAZARIUM PCS plasma cracking units are designed for the processing of used industrial oils and hydraulic fluids for hydraulic systems, gas turbine oils, instrument oils, transformer oils, compressor oils, and turbine oils into light products suitable for the production of motor fuels.
More...
The processing of used industrial oils
PLAZARIUM PCS plasma cracking units are designed for the processing of used industrial oils and hydraulic fluids for hydraulic systems, gas turbine oils, instrument oils, transformer oils, compressor oils, and turbine oils into light products suitable for the production of motor fuels.
More...The processing of a mixture of used oil products
PLAZARIUM PCS plasma cracking units are designed for the processing a mixture of waste oil products that have lost their consumer properties, including oil flushing fluids, oils recovered from waste oil emulsions, a mixture of oil and oil products collected during the cleaning of storage facilities and transportation, as well as those recovered from treatment facilities and oily waters, into light products suitable for the production of motor fuels.
More...
The processing of a mixture of used oil products
PLAZARIUM PCS plasma cracking units are designed for the processing a mixture of waste oil products that have lost their consumer properties, including oil flushing fluids, oils recovered from waste oil emulsions, a mixture of oil and oil products collected during the cleaning of storage facilities and transportation, as well as those recovered from treatment facilities and oily waters, into light products suitable for the production of motor fuels.
More...
The processing of cooling mixtures
PLAZARIUM PCS plasma cracking units are intended for the processing of cooling mixtures – complex multicomponent oil-emulsion systems, used in virtually all metalworking processes, rolled stock, and the production of reinforced concrete products – into light products suitable for the production of motor fuels.
More...
The processing of cooling mixtures
PLAZARIUM PCS plasma cracking units are intended for the processing of cooling mixtures – complex multicomponent oil-emulsion systems, used in virtually all metalworking processes, rolled stock, and the production of reinforced concrete products – into light products suitable for the production of motor fuels.
More... -
SpecificationPlasma cracking unit:
Specifications Value Plasma cracking unit performance (Note 1) from 50 to 1,000 kg per hour (from 1 to 25 tons per day) Raw materials feeding Fixed / continuous Voltage of alternating current network, V 3 phases, 380±10% (Note 2) Frequency of supply voltage, Hz 50/60 Power consumption of the main process equipment, kW corresponds to 10% of the plasma system power Plasma system power, kW of 50 or more (depending on unit performance) Fuel condensing system cooling Water, closed (Note 4) Operating ambient temperature range, °С from - 60 to + 50 Overall dimensions, L × W × H, m correspond to the size of 20/30/40-ft shipping containersNumber of containers from 1 to 2 and more (Note 5) Total unit weight, tons from 5 to 30 (depending on performance) Operating mode (duty cycle factor) Continuous, constant (DC=100%)
Fuel storage unit:Specifications Value The volume of fuel for storage and exchange between units (Note 1) corresponds to double unit performance Types of fuel to be stored any liquid fuel, heavy hydrocarbon fraction or waste oil, gasoline and diesel fractions Voltage of alternating current network, V 3 phases, 380±10% (Note 2) Frequency of supply voltage, Hz 50/60 Power consumption of the main process equipment, kW 2 Operating ambient temperature range, °С from - 60 to + 50 Overall dimensions, L × W × H, m correspond to the size of 20/30/40-ft shipping containersNumber of containers from 1 to 2 and more (Note 5) Total unit weight, tons from 3 to 40 (depending on performance) Operating mode (duty cycle factor) Continuous, constant (DC=100%)
Notes:
1 - Custom manufacturing of plasma cracking units with a capacity of up to 80 tons per day (HGP-3000) and up to 100 tons per day (HGP-5000) is possible.
2 - Power supply provides automatic adaptation to any input voltage in the range 380 - 450 V for three phases.
3 - Plasma cracking units are developed for a specific type of heavy oil in accordance with the specifications of the customer’s specifications and viscosity of raw materials.
4 - The choice of cooling type depends on the terms of reference for plasma cracking units.
5 - Plasma cracking unit is based in 20/30/40-ft containers, the number of containers from 1 to 6 and more (depends on the required
cracking parameters, the number and productivity of the main blocks, the type and viscosity of heavy oil, and the customer’s specifications).
6 - All parameters of plasma cracking units are manufactured in accordance with the customer’s specification. -
List of EquipmentPlasma cracking unit:
Position Quantity, pcs. Fully equipped PLAZARIUM TPS plasma system1 Plasma cracking reactor 1 System for viscous heavy residue heating and its supply to the plasma cracking reactor 1 Heat exchanger 1 Gas separator 1 Hydrocarbon gas cooling and condensation system 1 Fuel storage and pumping system 1 Control system for plasma cracking unit 1 System of smoke removal or transmission of hydrocarbon gas to plasma gasification unit 1 Manual and complete design and technical documentation for operation 1
Notes:
1 - The unit is based in 20/30/40-ft containers, the number of containers from 1 to 2 per each unit (depends on the performance of each unit, the type of raw materials, and the customer’s specifications).
2 - The complete set and parameters of plasma cracking units are manufactured in accordance with the customer’s specification. -
Software
Fully digital central control of all devices and processes of PLAZARIUM PCS plasma cracking unit for heavy oil (fuel oil) and used oils with a fully analog copy is located on the central front of the system.
The touch panel has modern software with programming and customization options for individual customer requirements.
Digital control of all parameters ofPLAZARIUM PCS plasma cracking unit for heavy oil (fuel oil) and used oils allows to move to full digital synthesis of technological processes using steam-water plasma and cracking process.
The availability of a multilingual interface makes it easy for operators from different countries to configure and manage the main processes and each plasma cracking unit for heavy oil.
The software ofPLAZARIUM PCS fuel oil plasma cracking unit has manual digital control of each individual unit, and also has fully automatic control over preprogrammed algorithms with the possibility of changing them for a specific technological process.
The software includes a 3-level user interface:
- Operator,
- Enterprise technologist,
- Engineer (researcher) – developer of technologies (change of output static and dynamic volt-ampere characteristics and other parameters).
The first two levels are implemented in the operator panel via a graphic screen, the third level is realized by connecting a personal computer via LAN.
