IKEM Technologies develops and implements advanced technology in Kazakhstan, consisting of special equipment and its own catalytic system. We designed concept and introduced a contemporary method for hydrocarbon waste beneficiation into high value commercial products (Euro-5) without fugitive emissions and solid formation. We are willing to transfor waste into a renewable economy. The technology is aimed, first of all, at solving an urgent environmental problem - the safe disposal of hazardous and toxic hydrocarbon wastes that are generated as a result of the activities of various sectors of the economy: electric power, oil and gas, mining, metallurgical, chemical and manufacturing industries.
According to official reports on the inventory of industrial waste, Kazakhstan has accumulated 639 million tons of oily waste of the amber list.
Hazardous hydrocarbon wastes include:
- used oils (automobile, aviation, transformer, industrial)
- oil sludge and oil waste mixtures, pit oil
- oil sludge, coal tar
The concept of turning waste into a commercial product has been successfully tested on an industrial scale at two plants.
The technology is based on the method of processing raw materials, which refers to thermal conversion and thermal catalytic destruction in the presence of an oil-soluble catalyst. The process uses a block for the preparation of mechanochemical activation of raw materials - where shear destruction occurs with the participation of asphaltene nanoparticle atoms in the dispersed phase of the colloidal system, caused by the destruction of the stabilizing resin shells.
In the catalyst input unit, hydrodynamic effects of supersonic vapor-liquid flows occur, as well as out-cavitation processes characterized by the presence of high stresses, shear rates and high-frequency flow pulsations. Also, flow reactors with a pressure of 0.1-2 MPa are used with the formation of hydrogen and a cocatalyst in the reaction zone. Further, the raw material is heated in a furnace at a temperature of 350-420 degrees and fed into the separation column.
The result of applying the technology is an increase in the depth of processing of raw materials with an increase in the yield of distillate fractions to the maximum acceptable values, depending on the physical and chemical composition of the raw materials. VAT residue - tar, passing through the oxidation unit, turns into high quality modified road/construction bitumen and is packed in big bags or in metal euro-barrels.
All this allows processing without generating waste, as well as fugitive emissions due to filtration and combustion catalysts. It should be noted that the technology eliminates fire and explosion situations, emissions of harmful substances and gases into the atmosphere, and also eliminates the negative impact on the environment, greatly facilitating the working conditions of maintenance personnel.
We have been able to develop reliable, scalable, modular and environmentally friendly micro-refineries
in rough the implementation of innovations. The circular economy is a renewable resource derived from
recycled waste. This is the most efficient and safest way to deal with the growing natural resources deficit
and rising cost of raw materials. We can produce marketable petroleum products from recycled hazardous waste,
corresponding to Euro-5 quality.
The second part of the modular technology is a raw hydrocarbon portable micro-refinery unit.
With a production rate of up to 30 tons per day. The smooth refining process is based upon a
universal multi-purpose evaporation column (UPRA) to fractionate even an extra-heavy oil with a higher viscosity by integration of the whole processing systems with a PLC/PAC computer based control system allows for production on a 24/7 basis.
Turning waste
To eliminate this problem we can offer a desulfurization unit based on alumina catalysts filtration in various combinations with low operational costs and high-quality output
The final part of the modular micro-refinery is a tar residues oxidation unit to produce a modified high quality road and construction bitumen packed in big bags or metal euro barrels. The oxidizing modular unit is an important economic and environmental solution for waste-free recycling.
About technology
into generating income
Transforming Waste into a Renewable Economy
Versatility and ability to process various types of raw materials: from commercial sour to heavy paraffinic and bituminous oils, including toxic hydrocarbon waste from various industries
Maximum recovery of marketable petroleum products (at the level of modern American refineries)
Compliance of petroleum products with Euro-5 quality
The possibility of autonomous operation of units on cargo platforms for carrying out activities in hard-to-reach areas and near sources of waste: deposits, landfills, chemical dumps
Demand and prospect for joint activities with oil companies in order to meet internal production needs: processing of hard-to-recover heavy oil from the wellhead.
High gross margin of production (from 45%) and fast payback period (from 1.5 years)
Possibility of additional waste processing units integration from SW, SR, PP to obtain pyrolytic liquid with the production of Euro-5 jet fuel, gasoline, diesel.
The main advantages of technology:
