Design and Analysis of a Removable Sludge Making Coal Machine

Abstract

This paper designs an operational workflow, and key performance metrics of a novel removable sludge making coal machine, with parameters for the moisture content of 84.27%, at the rate of 10.08% of oil as the design object. The machine can be moved to the stacking site for treatment, recovering oil and making low oil content sludge to coal. The separated water will be used for oilfield injection, and can be processed for reuse. It not only access to the environmental benefits, it will also produce the enormous economic benefits. It designed for flexible, on-site deployment in oilfields and refineries, this integrated unit eliminates the need for costly and risky off-site transportation of hazardous oily sludge. The system, which is 1.8 meters in height and diameter, integrates a mechanical clarification tank, an automatic continuous discharge centrifuge, and a coal mixer. The operational workflow involves chemical pre-treatment and clarification at 500C, followed by centrifugal dewatering, and then blending the resulting solid cake with pulverized coal. Based on the design, the system achieves a high 98.89% oil removal rate and a 90% solid recovery rate, successfully transforming tank bottom mud with 10.08% oil content into a valorized sludge-coal mixture suitable for use as a solid fuel. The machine was successfully designed with the turbine as power with molding briquette, to convey solid-liquid separation in separation chamber to sludge for automatic continuous centrifuge, then to mud discharging pipe, and into the coal mixing machine. The device has the advantages of simple operation, good effect of processing factors and small human influence.

Introduction

Oily sludge, a hazardous byproduct of petroleum extraction, refining, transportation, and storage, contains toxic pollutants like heavy metals and hydrocarbons, posing serious environmental and health risks. Its complex composition and volume necessitate efficient treatment methods that enable resource recovery, such as oil recycling and solid fuel production.

To address this, a Movable Sludge Making Coal Machine was designed at Liaoning Shihua University. The device is a mobile, integrated system that can be transported to sludge storage sites for on-site treatment. It processes oily sludge into reusable oil, water for reinjection, and briquetted solid fuel by combining several key components:

• Mechanical Clarification Tank (for heating, mixing, and flocculation),

• Centrifuge (for dewatering sludge),

• Coal Mixer (for blending sludge with pulverized coal),

• Control panel and pump systems.

Key Results:

• Oil Recovery Rate: 98.89%

• Solid Recovery Rate: 90%

• Final Product: Sludge-coal briquettes for use as solid fuel

• Processing Capacity: Handles 0.42 m³/h of oily sludge

Design Advantages:

• Mobility: Enables in-situ sludge treatment

• Compact Integration: Combines separation, dewatering, and mixing in one unit

• Economic and Environmental Benefits: Reduces pollution and creates valuable fuel

The machine addresses China's growing oily sludge problem by offering a sustainable, cost-effective solution that transforms hazardous waste into usable resources while minimizing environmental impact.

Conclusion

This study successfully designed a removable sludge making coal machine which offers a practical and efficient solution for the resource recovery and harmless treatment of oily sludge. By integrating mechanical clarification, centrifugation, and coal mixing, the device achieves high oil recovery and produces usable coal briquettes. The design addresses the environmental challenge of oily sludge disposal while offering an economically attractive solution through resource recovery. Its mobile nature makes it particularly suitable for decentralized application in oilfields, contributing to cleaner production and circular economy principles in the petroleum industry.

References

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Copyright

Copyright © 2025 Dede Lawan Dahiru, Zhaouxuan Li, Abdulsalam Muhammad. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.