US20230235232A1

US20230235232A1 - Multistage oil reclamation system

Info

Publication number: US20230235232A1
Application number: US17/998,830
Authority: US
Inventors: Gary L. Stevenson; Jose L. Hernandez
Original assignee: Individual
Current assignee: Texas Oil Recovery Science LLC
Priority date: 2020-05-15
Filing date: 2021-05-17
Publication date: 2023-07-27
Also published as: WO2021232009A1

Abstract

A method of hydrocarbon reclamation utilizing an automated, closed-loop hydrocarbon reclamation system controlled by an operating system. Hydrocarbon is removed from hydrocarbon-fouled substrate by flowing a slurry through a series of chemical and mechanical processes and selectively recycling fluid throughout the system for continuous operation.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 63/025,526, filed May 15, 2020, which is incorporated herein by reference in its entirety.

FIELD

The present invention relates to a method and apparatus for recovery of hydrocarbons found in mud, dirt, or tar sands; more specifically, for a method of treating hydrocarbon contaminated particles for recovery of the hydrocarbons and the environmentally acceptable disposal of the particulate matter utilizing a recirculating water stream.

BACKGROUND

Hydrocarbon-coated substrates pose major environmental problems around the world. The disposal and recovery of hydrocarbons found in oils, pit bottoms, pit sludge, foul sand, dirt around plants, drill cuttings, naturally occurring tar sands, or bitumen seams are problematic in the industry because of the potential for contamination of water bodies and the waste of hydrocarbon bound up with the sand or drill cuttings.
Many reclamation and disposal practices can lead to severe environmental pollution through the contamination of petroleum hydrocarbons to surface, ground, and coastal waterways. Thus, there is a strong desire in the field to adopt greener technology approaches in hydrocarbon reclamation technologies.
Other prior forms of reclamation of these materials depend on heating or incineration, or use abundant quantities of water or other dangerous chemicals. It is generally understood that to maximize the reclamation of substrates coated with hydrocarbon, a combined system is beneficial to overcome existing problems with reclamation technologies and processes while still maximizing the advantages of each technology and process.
However, the use of a combined system increases the amount of management and monitoring within the system. This leads to higher cost of labor needed at each jobsite, and also amplifies the risk that human error will lead to inefficiencies or accidents. Thus, there is a need for a system that allows for the combination of several different reclamation techniques that can be automatically monitored and controlled.

SUMMARY

Devices and methods to separate hydrocarbon-fouled particulate matter are described herein. Embodiments generally include providing an operating system for receiving information feedback from and being communicably connected with a closed loop hydrocarbon reclamation system, wherein the operating system includes at least one computer having a processor, a memory, a graphical user interface, and a plurality of input mechanisms; feeding hydrocarbon-fouled substrate into the closed loop hydrocarbon reclamation system to promote the separation of hydrocarbon from substrate through chemical and physical separation processes to produce a desired final product, wherein a plurality of sensors within the closed loop hydrocarbon reclamation system are communicably connected to the operating system through feedback mechanisms; and selectively recycling a portion of the fluid within the closed loop hydrocarbon reclamation system.
One or more embodiments include the method of the preceding paragraph, wherein the closed loop hydrocarbon reclamation system has a plurality of eductors capable of subjecting the hydrocarbon-fouled substrate to severe shearing forces; a plurality of separation tanks capable of promoting the separation of hydrocarbons from the substrate by allowing overflow of separated hydrocarbons progressively through a weir to a collection tank and the removal of substrate to at least one secondary separation device; and at least one removal device capable of removing substrate from the system after separation from the hydrocarbon.
One or more embodiments may include the method of any preceding paragraph, wherein at least one secondary separation device is a multi-phase centrifuge.
One or more embodiments may include the method of any preceding paragraph, wherein the operating system can be controlled onsite or remotely.
One or more embodiments may include the method of any preceding paragraph, wherein the input mechanisms of the operating system control the flow of hydrocarbon-fouled substrate through the reclamation system with a plurality of valves.
Methods and devices for a closed loop system for hydrocarbon reclamation are described generally herein. Embodiments generally include an input stream assembly for the deposit of hydrocarbon-fouled substrate into the closed loop system; a plurality of eductors capable of subjecting the hydrocarbon-fouled substrate to severe shearing forces to form a slurry; a hydrocyclone retention tank connected to at least one eductor for complete mixing of the water and chemical mixture and hydrocarbon-fouled substrate; a plurality of separation tanks connected to shale shakers and centrifuges for the removal of hydrocarbon from substrate, the separation tanks being connected by a weir to allow for the flow of separated hydrocarbon to a collection tank; and a surge treatment tank operably connected to the collection tank.
One or more embodiments may include the closed loop system of any preceding paragraph, wherein the closed loop system is communicably connected to an operating system capable of receiving information feedback from the system, the operating system including at least one computer having a processor, a memory, a graphical user interface, and a plurality of input mechanisms.
One or more embodiments may include the closed loop system of any preceding paragraph, further including a plurality of sensors and valves communicably connected to the operating system.
One or more embodiments may include the closed loop system of any preceding paragraph, wherein the feedback data triggers notifications and alarms within the operating system when the feedback data is outside of predefined operating limits.
One or more embodiments may include the closed loop system of any preceding paragraph, wherein the operating system opens or closes valves based on feedback data received from the closed loop system.
One or more embodiments may include the closed loop system of any preceding paragraph, wherein the centrifuges are multi-phase centrifuges.
One or more embodiments may include the closed loop system of any preceding paragraph, wherein the closed loop system can be controlled onsite or remotely.
One or more embodiments include the closed loop system of any preceding paragraph, further including a plurality of sensors that provide feedback data to the operating system.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a schematic process flow diagram of the apparatus depicting recovery of hydrocarbons from particulate materials and water, in accordance with one or more embodiments of the present disclosure.

FIG. 2 is a schematic process flow diagram of an isolated first portion of the hydrocarbon reclamation method, in accordance with one or more embodiments disclosed herein.

FIG. 3 is a schematic process flow diagram of an isolated second portion of the hydrocarbon reclamation method, in accordance with one or more embodiments disclosed herein.

FIG. 4 is a schematic process flow diagram of an isolated third portion of the hydrocarbon reclamation method, in accordance with one or more embodiments disclosed herein.

FIG. 5 is a schematic process flow diagram of an isolated fourth portion of the hydrocarbon reclamation method, in accordance with one or more embodiments disclosed herein.

FIGS. 6A through 6C illustrate various perspective views of the hydrocarbon reclamation apparatus, in accordance with one or more embodiments disclosed herein.

DETAILED DESCRIPTION

A detailed description will now be provided. Each of the appended claims defines a separate embodiment, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the “disclosure” may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the “disclosure” will refer to subject matter recited in one or more, but not necessarily all, of the claims. Each of the disclosures will now be described in greater detail below, including specific embodiments, versions and examples, but the disclosures are not limited to these embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the disclosure when the information in this patent is combined with available information and technology.
Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition skilled persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
Further, various ranges and/or numerical limitations may be expressly stated below. It should be recognized that unless stated otherwise, it is intended that endpoints are to be interchangeable. Any ranges include iterative ranges of like magnitude falling within the expressly stated ranges or limitations.
“Substrate” will be used herein to describe the underlying material, or the constituent particles which are carried by or coated with the hydrocarbon. All forms of hydrocarbon-coated substrates could undergo reclamation using this method.
The present disclosure refers to a hydrocarbon reclamation system and method that uses combined reclamation techniques to separate hydrocarbon from substrate. It also selectively recirculates the fluid used for reclamation of the hydrocarbons from the substrate to allow for continuous operation. Further, the present disclosure has a closed system design, thus allowing for the safe and environmentally friendly extraction of volatile gases. The recovered liquid hydrocarbons and volatile gases are prevented from release into the atmosphere due to the closed nature of the apparatus as a whole.
The reclamation process is controlled by an operating system that allows for automation of many of the processes and manual input from a user to control the process. The reclamation process can also be monitored via a graphical user interface that can be mounted directly on the reclamation system or remotely installed. The operating system also provides both remote and onsite access to all operating data and is accessible by phone, laptop, tablet, or other digital means.
The conditions within the reclamation system are monitored and displayed on the graphical user interface. The conditions that may be monitored include, but are not limited to, set points, levels, temperature, saturation, flow, pH, solids content, hydrocarbon viscosity, bottom sediment and fluid level, electrical distribution, rpm, and process tonnage rates.
Various feedback mechanisms are built into the hydrocarbon reclamation system, including but not limited to sensors within separation tanks at various levels to monitor flow within the system. Level sensors can indicate water level hydrocarbon level and solids within a tank and can communicate with the operating system to display the data on the graphical user interface. Various input mechanisms can then be used to adjust the flow throughout the system, either through manual entry or predefined operations.
Sensors for hydrogen sulfide monitoring are also mounted at various points in the hydrocarbon reclamation process. If hydrogen sulfide is detected, the hydrocarbon reclamation system will automatically shut down and isolate the various subsystems, with the exception of the vapor recovery system.
Further, the operating system allows for input data, either from present controls or from manual entry by a user, that can control various stages of the hydrocarbon reclamation process. Valves, pumps, instrumentation, and operational actions can be controlled via various input mechanisms, either manually by a user or through predefined operations. The input mechanisms can be present on the graphical user interface, or can be controlled remotely by phone, laptop, tablet, or other digital means.
Valves required to operate or isolate the hydrocarbon reclamation system are typically automated pneumatic valves designed to fail shut during emergency shutdowns to prevent or minimize the spillage of liquid within the closed loop piping valves, tanks, or storage facility. Any discharge out of predefined operating limits will trigger an alarm locally and to all connected devices indicating the problem and solution to correct the out-of-limit operation. Input mechanisms may then be used to control various processes to resolve the problem or shut down the unit if necessary.
The cause of any system failures and the steps taken to correct any operating issues can be input to memory and recalled at the graphical user interface. The operating system may also provide suggestions to improve the operation and maintenance of the hydrocarbon reclamation system. Users can also upload helpful pictures, either manually or through a predefined operation, that can be seen in real time or stored in memory for further review.
FIG. 1 is a schematic process flow diagram of the apparatus to recover hydrocarbons from particulate materials and water, in accordance with one or more embodiments of the present disclosure. The present disclosure uses fluid to wash and strip hydrocarbons from sand or particulate matter through a combined weir and shaker system, assisted by a chemical bath to break the adhesion of the hydrocarbons to the particles. The fluid can be a mixture of water and various chemicals selected to aid the separation of hydrocarbons from substrate. The amount of fluid loaded into the system from tank 06 through line 11 is controlled by a valve 12 that is communicably connected to the operating system to maintain the proper level of saturation within the system.
Input stream 01 feeds the hydrocarbon-fouled substrate, such as tar sands, bitumen, or contaminated soils or clay, into a macerator tank 02 driven by motor 03 to break the larger pieces of material into a smaller grained material. The broken-down hydrocarbon-fouled substrate is then fed into a hopper 04 by a variable speed belt, front-end loader, augur delivery system, or any other device capable of moving the hydrocarbon-coated substrate into the hopper 04. Pressurized fluid is pumped through pump 31, which can be provided from water source 05 through pump 32 and chemical tank 06, is circulated through the primed system to hopper 04 to an eductor 07, where extraordinary forces of velocity flow and vacuum saturate the hydrocarbon-fouled substrate, subjecting it to severe shearing forces to mix the substrate with the fluid to create a slurry.
The wetted slurry is then moved to hydrocyclone 08, which serves as an agitation retention tank for continued wetting and mixing of the slurry. The hydrocyclone 08 could also be a mixer or agitator tank.
After leaving the hydrocyclone 08, the slurry is moved through line 09 to the first separation tank 10. In the first separation tank 10, hydrocarbon and substrate begin to separate through specific gravity, with the separated hydrocarbon going to the free surface of the liquid in tank 10 and the solids settling to the bottom of tank 10. The separated hydrocarbon flows progressively through weir 60 unobstructed to collection tank 34.
The settled solids in tank 10 are passed through eductor 13 and carried through line 14 to shale shaker 15. The shale shaker 15 separates out larger substrate, which is then moved through conveyor line 16 to conveyor belt 17 for disposal.
If the automatic sensors detect excessive hydrocarbon coating of the particulate matter moving through the discharge on conveyor belt 17, a second chemical tank 18 is activated to coat the material prior to disposal. This chemical treatment helps assure complete removal of residual hydrocarbons on the substrate prior to disposal or recycling. Cleaned solids can be sent from each of the shale shakers 15, 19, 20 to the solids collection facility where they can be either disposed of safely or, if useable as aggregate, can be recycled.
The remaining solids that passed through the screen of shale shaker 15 is then returned through tank 10 through gravity flow line 62. An underflow line 21 then carries substrate that did not pass through the screen of shale shaker 15 to tank 22.
The finer particles that did not pass through the screen of shale shaker 15 move progressively through underflow line 21, which allows solids to flow by molecular weight to continue flowing in solution or dropping to the tank floor of tank 22. The smaller solids that fall to the bottom of tank 22 are removed through eductor 27 through line 28, and then pumped to either shale shaker 19 or shale shaker 20, which have air sparging and tighter screen mesh to remove smaller substrate that is then discharged through conveyor line 16 to conveyor belt 17.
The underflow of solids from tank 22 to tank 23 through underflow line 21 accumulate at the bottom of tank 23, where they are removed through flow line 57 to a pump 25. This pump may be a positive displacement pump or a centrifugal pump. The solids from pump 25 are discharged to a two-phase centrifuge 26 for further separation. The substrate is then discharged to a catch container, and liquid is returned through line 33 to tank 10. The closed loop capacity of the two-phase centrifuge 26 is determined by the design maximum tonnage to be processed by the system and particle size of the substrate.
The hydrocarbon overflow into collection tank 34 accumulates and is withdrawn by an eductor 35 driven by motive flow pump 38 through line 36 to the top of surge treatment tank 37. The surge treatment tank 37 acts as a retention and treatment tank utilizing diluent, heat, and de-emulsion chemical to separate solids from the hydrocarbon. The tank 37 is allowed to overflow continuously into the flow line 39 to pump 40 to a three-phase centrifuge 41. Solids are then discharged by the three-phase centrifuge 41 to a catch container. Remaining water is returned to tank 24 through line 50. Recovered hydrocarbon is discharged to tanks 42, 43, 44. A closed loop is provided in tank 44 by means of a centrifugal pump 46 discharging oil through line 47 into an electrocoagulation treatment device 45. After treatment in the electrocoagulation treatment device 45, the hydrocarbon flows to sales tank 48 through line 49 or optionally into tanks 42, 43, 44 through a branch connection on line 49 to accommodate breaking emulsion in the product oil.
A vacuum flow line 51 is connected to each tank and leads to a knockout tank 52 and condenser 53. A vacuum blower 54 pulls the vapor through the condenser 53, thus condensing the vapor to a liquid and allowing it to be recovered in line 55 to a progressive cavity positive displacement pump 40, which discharges to the three-phase centrifuge 41.
FIG. 2 is a schematic process flow diagram of a first portion of the hydrocarbon reclamation method to show further detail of the reclamation system. Automation of the system begins at the loading and weighing of the substrate that will be processed through the system. Raw materials are loaded into macerator tank 02. This tank may be equipped with a macerator, grinder or delumper, to crush the hydrocarbon-fouled substrate to a smaller size. In certain embodiments, the hydrocarbon-fouled substrate can be crushed to a nominal ¼ inch particle size. However, the hydrocarbon-fouled substrate can be smaller or larger after this stage, depending on the particular hydrocarbon-fouled substrate and the desired final product.
After crushing the particles are fed to hopper 04 by a variable speed belt or auger controlling the tonnage thru-put of the system. The feed system from macerator tank 02 to hopper 04 can be a standalone weight loss measuring and control system, or it may also be incorporated into the operational controls of the operating system. Substrate is fed into tank 04 at a controlled rate and fills by gravity into the shaped tank bottom. The substrate then enters eductor 07 through valve 58. Valve 58 may be controlled by the operating system and selectively opened or closed to control the feed rate from hopper 04. The feed rate to hopper 04 is always slightly less than the eductor 07 capacity. This ensures the eductor 07 capacity is not exceeded, thus allowing for continuous processing of the hydrocarbon-fouled substrate without interdiction or concern for substrate amount.
The feedback mechanisms at the weight loss system at macerator tank 02 provide feedback to the operating system when eductor 07 is not operating at full capacity. The operating system can then utilize an input mechanism, either predefined operational instructions or manual input, to regulate the substrate feed rate into hopper 04, thus matching the adjusted changed capacity of the eductor 07. Substrate is discharged continuously from eductor 07 and is balanced to the substrate feed rate at hopper 04. The hydrocarbon-fouled substrate then passes through hydrocyclone 08 into tank 10, where solids and hydrocarbon are separated by gravity.
Separated solids and hydrocarbon in tank 10 move to the top or bottom of the tank based on weight difference. Hydrocarbon floats to the top of tank 10 and flows progressively through weir 60 unobstructed to collection tank 34. Solids drop to the bottom of tank 10 into eductor 13 through valve 61. Solids from Eductor 13 flow to shale shaker 15 through line 14. Particles larger than the screen mesh size are removed from the flow stream through conveyor line 16 to conveyor belt 17. All other liquid and smaller particles flow through the screen, returning to the tank 10 by gravity flow line 62. From tank 10 an underflow line 21 allows flow from tank 10 to enter tank 22. In certain embodiments, this underflow line 21 is 8 inches in diameter, thus allowing particles that passed through the screen on shale shaker 15 to flow into tank 22. However, this underflow line 21 may be larger or smaller depending on the particular needs and goals of a job. The overflow from tank 10 to 22 through underflow line 21 is a mixture of lighter solids that passed through the shale shaker screens in shale shaker 15, water, chemicals, and some hydrocarbon.
Referring now to FIG. 3 , the hydrocarbon that flows into tank 22 floats to the top, while the solids drop to the bottom of tank 22. The solids are then removed by eductor 27 through line 28 and pumped to shale shakers 19 and 20, which have air sparging and tighter screen mesh to remove the smaller substrate particles. The smaller substrates are then discharged through line 16 to the conveyor belt 17.
The secondary separation devices, including shale shakers 18, 19, 20, may be customized depending on the particular needs of a job. In certain embodiments, the mesh filters may be tighter or larger to selectively allow different sizes of substrate to flow through. In certain other embodiments, the secondary separation devices of multi-phase centrifuges 26, 41 may have more or less stages, or be single-phase centrifuges.
Accumulation amounts of solids in tanks 10, 22, 23 and tank 24 (not presently shown) are measured by contact sensors in each tank. These sensors are communicably connected to the operating system for monitoring and regulation of the system.
Referring now to FIG. 4 , under flow from tank 23 to tank 24 can be controlled through a valve that automatically increases or decreases flow rate in flow line 21. This can be done to vary the retention and settling time in tank 23, thus forcing differing amounts of flow from tank 23 to pass through weir 60 to tank 24. The liquid flowing into tank 24 is substantially clean of solids, and hydrocarbon is floating on the free surface of the liquid through weir 60 to the collection tank 34.
Water is removed at a controlled rate from tank 24 through suction line 64 to pump 29 as motive flow to eductors 13, 27 through line 30. The motive flow liquid then combines with the liquid and solids from tank 10 and tank 22 as eductors 13, 27 draw in solids and liquid under vacuum. Solids are then discharged through flow line 14, 28 to Shale shakers 15, 19, 20. In certain embodiments, eductors may be replaced by slurry pumps in tanks interchangeably without changing the operation or function of the tanks.
A suction head connected to collection tank 34 discharges to pump 38 through line 36 into surge treatment tank 37. Surge treatment tank 37 provides the retention area for the hydrocarbon and remaining solids to separate. Diluent and heat can be used in surge treatment tank 37 to adjust the specific gravity of the hydrocarbon. Product oil accumulates at the free surface of the liquid in tank 37, which overflows through line 39 to pump 40. In certain embodiments, pump 40 is a variable speed positive displacement pump. Pump 40 provides a constant suction head to three-phase centrifuge 41, where solids are discharged to a container for reuse as aggregate or disposal, water and chemical flows back to tank 24 through flow line 50, and product oil flows through line 65 to tank 42.
Referring now to FIG. 5 , shown is a vapor recovery system. Vacuum flow line 51 is connected to tanks 10, 22, 23, 24, 37 by a header arrangement connected to knockout tank 52, condenser 53, and vacuum blower 54. Vacuum flow line 51 pulls a constant slight under pressure to tank 52 and condenser 53, causing condensed vapor and non-condensed gases to flow from either or all of tanks 10, 22, 23, 24, 37 across the knockout tank 52 and condenser 53. Condensed volatile liquids fall to the bottom of knockout tank 52, and an automated control valve opens only when liquid is present delivering said volatiles through flow line 55 to the centrifuge suction line 39.
The three-phase centrifuge 41 discharges solids to a container for discharge or use as an aggregate. Water and chemical is returned to tank 24 through flow line 50. Hydrocarbon condensate, oil and diluent through line 65 flow to treatment tanks 42, 43, 44, which may optionally have inclined plates, 50 kW submerged heaters, and chemical injection mechanisms for enhanced oil emulsion. Pump 46 then takes a suction from tanks 42, 43, 44 individually and discharges the treated liquid through line 47 to an electrocoagulation treatment device 45. The liquid may then be discharged into flow line 49 to recirculate to tanks 42, 43, 44 for oil polishing, or it may be discharged to sales tank 48 as final product.
FIGS. 6A through 6C illustrate various perspective views of a preferred embodiment of the hydrocarbon reclamation apparatus. Specifically, a top perspective view is shown in FIG. 6A, a side perspective view is shown in FIG. 6B, and a front perspective view is shown in FIG. 6C. Each tank 10, 22, 23, 24 is closed and the internal components are not exposed to the atmosphere during circulation.
The present disclosure has been discussed in terms of four separation tanks, it should be noted that more or less separation tanks may be utilized, depending on the particular needs of a job site, the amount of hydrocarbon in the hydrocarbon-fouled particulate, and the desired final product. For instance, certain applications may only require two or three separation tanks if they have less hydrocarbon, as they require less stages to reach a desired final product.
While various methods have been described above in connection with several illustrative embodiments, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiments for performing the same function disclosed herein without deviating therefrom. Further, all embodiments disclosed are not necessarily in the alternative, as various embodiments may be combined or subtracted to provide the desired characteristics. Variations can be made by one having ordinary skill in the art without departing from the spirit and scope hereof. The scope of the present disclosure is determined by the claims that follow.

Claims

1. A method for hydrocarbon claim comprising:

providing an operating system for receiving information feedback from and being communicably connected with a closed loop hydrocarbon reclamation system, wherein the operating system includes at least one computer having a processor, a memory, a graphical user interface, and a variety of input mechanisms;

hydrocarbon-fouled substrate into the closed loop hydrocarbon reclamation system to promote separation of hydrocarbon from substrate through chemical and physical separation feeding processes to produce a desired final product, wherein a plurality of sensors within the closed loop hydrocarbon reclamation system are communicably connected to the operating system through feedback mechanisms; and

selectively recycling a portion of fluid within the closed loop hydrocarbon reclamation system.

2. The method of claim 1, wherein the closed loop hydrocarbon reclamation system includes: a plurality of eductors capable of subjecting the hydrocarbon-fouled substrate to severe shearing forces;

a plurality of separation tanks capable of promoting separation of hydrocarbons from the substrate by allowing overflow of separated hydrocarbons gradually through a weir to a collection tank and removal of substrate to at least one secondary separation device; and at least one removal device capable of removing substrate from the closed loop hydrocarbon reclamation system after separation from the hydrocarbon.

3. The method of claim 2, wherein the at least one secondary separation device is a centrifugal multi-phase.

4. The method of claim 1, wherein the operating system can be controlled onsite or remotely.

5. The method of claim 1, wherein the input mechanisms of the operating system control flow of hydrocarbon-fouled substrate through the reclamation system with a plurality of valves.

6. A closed loop system for hydrocarbon reclamation comprising:

an input stream assembly for depositing hydrocarbon-fouled substrate into the system;

a plurality of educators capable of subjecting the hydrocarbon-fouled substrate to severe shearing forces to form a slurry;

a hydrocyclone retention tank connected to at least one eductor for mixing of a water and chemical mixture and hydrocarbon-fouled substrate;

a plurality of separation tanks connected to shale shakers and centrifugals for removal of hydrocarbon from substrate, the separation tanks being connected by a weir to allow for flow of separated hydrocarbon to a collection tank; and

a surge treatment tank operably connected to the collection tank.

7. The closed loop system of claim 6, wherein the system is communicably connected to an operating system capable of receiving feedback data from the system, the operating system comprising at least one computer having a processor, a memory, a graphical user interface, and a plurality of input mechanisms.

8. The closed loop system of claim 7, further comprising a plurality of sensors and valves communicably connected to the operating system.

9. The closed loop system of claim 7, wherein the feedback data triggers notifications and alarms within the operating system when the feedback data is outside of predefined operating limits.

10. The closed loop system of claim 7, wherein the operating system opens or closes valves based on feedback data received from the closed loop system.

11. The closed loop system of claim 6, wherein the centrifugals are multi-phase centrifugals.

12. The closed loop system of claim 6, further comprising a plurality of sensors that provide feedback data to an operating system.

13. The closed loop system of claim 6, therein the closed loop system can be controlled onsite or remotely.