With the rapid development of global economy and the deterioration of crude oil, the amount of oily sludge with high water content (OS) is ascending year by year, and processing difficulty also increases (Ren et al., 2020). OS is composed of water, organic matter and solid residue, which forms a multiphase mixed system. Due to the difference of production area and refining method of crude oil, the water content, oil content and solid content of OS are generally 80 ~ 99%, 0.5 ~ 50% and 0.2 ~ 40%, respectively (Ningbo et al., 2021). The water in OS does not exist alone, and most of that is combined with other ingredients (e.g., petroleum substances) to form a fairly stable emulsified structure such as oil-in-water and water-in-oil. Organics in OS includes crude oil, asphalt, alkanes and some benzene series. Thus, OS has the characteristics of serious emulsification, high viscosity and difficulty in sedimentation and dewaterability (Zhang and Liu, 2013). Additionally, OS also contains toxic, harmful and refractory organics such as benzene, phenols and anthracene, as well as heavy metal salts (copper, chromium, mercury, etc). It will endanger ecological environment and human health if directly stacked or improperly handled (AL-Doury, 2019). According to the "Solid Waste Environmental Pollution Prevention Law" and the "Hazardous Waste List", OS needs to be harmlessly treated and used as resource.
At present, the main treatment methods of OS include conditioning-mechanical separation (Hou et al., 2013), solvent extraction (Mohit et al., 2020), freezing/thawing (Ju et al., 2012), pyrolysis (Liu et al., 2021), incineration (Dal Mas et al., 2021), solidification method (Hu et al., 2020), etc. Among them, incineration method is to treat OS with the characteristics of low oil content, a certain calorific value (Tunçal and Uslu, 2014). The technical advantages of incineration are rapid operation, thorough treatment, high sterilization rate and great reduction effect. After treatment, the reduction rate of OS can reach ~ 95%. In this case, the organics in OS will be completely oxidized and then completely decomposed, discharged in the form of fly ash, flue gas, slag, etc, which solves the foul smell of OS (Xiehong et al., 2017). However, there exists problems such as secondary pollution, high cost and energy consumption. In particular, the leaching amount of heavy metals and the produced dioxins are relatively high after incineration (Hu et al., 2013). Hence, it is urgent to transform OS into solid fuel by conditioning. Briefly, OS is firstly dehydrated and modified, and then converted into solid fuel. In this way, the harmless treatment of OS can be reached, and the residual value of OS can be recycled to realize resource utilization to the greatest extent.
Based on this, we developed a novel OS conditioner (OSO-101). On one hand, the reduction, harmlessness and stabilization of OS processing were realized. On the other hand, the resource utilization of OS was completed. Free radical reaction, polar reaction and redox reaction with were possibly involved between OSO-101 and petroleum hydrocarbons, thereby OS could be polymerized and converted into condensed solid structures. Moreover, the mixed solid was stable, irreversible and would not cause secondary sludge (Qinghua et al., 2021). Simultaneously, OSO-101 made long-chain non-flammable components (e.g., asphaltenes and gums) polymerize, and the water adsorbed in OS was converted into free water and released (Zhang et al., 2014). Under normal temperature and pressure, OS was finally transformed into solid fuel after curing in natural conditions for 3–5 days or reacting by mechanical drying for 1 h, which had great incineration performance. The whole treatment process would not produce wastewater and exhaust gas, and is safe, harmless and simple to operate. Automatic production could be realized in this treatment process, in which small space occupation, short investment cycle and quick effect could also be reached.
Herein, X-Ray fluorescence (XRF) and other methods were utilized to analyze the physicochemical properties of OS, and the effect of OSO-101 dosage on the dewaterability of OS were studied. Then, the effects of conditioning and incinerating on the solid-phase morphology, element composition and surface functional groups of OS were analyzed by scanning electron microscopy (SEM), X-ray diffraction (XRD) and some other characterization methods. Finally, the calorific value change of OS after conditioning, heavy metal content and dioxins content of fly ash leached from incinerated product were measured for resource analysis and environmental assessment.