Bilge Water Treatment Systems

A SHIPBOARD ZERO LIQUID DISCHARGE

BILGE WATER TREATMENT SYSTEM

Principal InvestigatorRobert J. Simon, Allen Filters, Inc.

522 N. Fremont AvenueSpringfield, Missouri 65802, USA

[email protected]

Co-InvestigatorCurt Elmore, Ph.D. P.E.

Associate ProfessorMissouri University of Science & Technology

1400 N. Bishop Ave. Rolla, MO 65409, [email protected]

573-341-6784Administrative Contact

Katherine Simon, CEO Allen Filters, Inc.522 N. Fremont Avenue

Springfield, Missouri 65802, [email protected]

417-865-2844

mailto:[email protected]



I. OVERVIEW

This White Paper proposes a ship-board Zero Liquid Discharge Bilge Water Treatment System (ZLD-BWTS), which is a compact marine pollution control device (MPCD) that is specifically designed for ship-board installations. It can be installed on ships under construction, as well as, retro-fitted into existing vessels. It can be designed for varying capacities and different ships. It most important feature is the fact that NO LIQUID is discharged into surface waters. The oil-free water phase is vaporized into the atmosphere, while the waste oil phase is stored until discharge at dock-side. Significant advantages include:

the bilge water is continually treated while the ship is on station at sea. the amount of liquid remaining in the bilge compartment after evaporation is greatly

reduced from the volume that normally accumulates during a voyage. the contaminants remain in the waste oil and are disposed of onshore.

II. NATURE OF THE PROBLEM

Bilge water is a mixture of water, oily fluids, lubricants, cleaning fluids and other similar wastes that accumulate in the lowest part of a vessel. Bilge water originates from a variety of different sources, including the engines and other parts of the propulsion system, piping and other mechanical and operational sources. Along with on-board spills, wash water and waste water from operational sources (e.g. water lubricated shaft seals, propulsion system cooling) collect in the bilge. In addition to oil and grease, bilge water may contain solid wastes such as rags, metal shavings, paint, glass and a wide variety of chemical substances such as volatile organic compounds (VOCs), inorganic salts, soaps, degreasers, detergents and dispersants. These cleaning agents form an emulsion, which inhibits the separation of water and oil. The composition of bilge water varies between vessels; however, the common factor is that the majority of the bilge is water.

Allen Filters, Inc. (AFI) is an Environmental Technology Company founded in 1948. It is a woman-owned and operated Small Business located in Springfield, Missouri. AFI designs, engineers, manufactures and support Fluid Filtration and Purification Equipment, Engineered Pump and Control Systems and Pollution Control Systems for customers world-wide. Customers include the U.S. Armed Services, foreign and domestic refineries and power plants, multi-national oil & gas and other industrial companies. In 1990, AFI was awarded SBA’s Exporter of the Year for the State of Missouri. AFI currently manufactures proprietary system components that will be incorporated in the proposed Ballast Water Treatment System (ZLD-BWTS)

III. REGULATORY BACKGROUND

The International Maritime Organization (IMO) has developed regulations governing the discharge of oily water from ships. The International Convention for Prevention of Pollution from Ships (MARPOL) has set the standards for ship-generated pollution.

The National Defense Authorization Act of 1996 amended Section 312 of the Federal Water Pollution Control Act (also known as the Clean Water Act) (CWA) to require that the Secretary of Defense and the Administrator of the Environmental Protection Agency (EPA) develop uniform national discharge standards (UNDS) for vessels of the Armed Forces. Coast Guard regulations (33 CFR 151.10) as amended by the Oil Pollution Act (OPA) and the CWA require oily wastes discharged within the 12 mile zone from the coast to have an oil content of less than 15 ppm.

Enforcement of regulations remains a problem in that most illegal discharges occur at night. The Coast Guard is the primary federal agency responsible for monitoring ships discharges. It has a rigorous enforcement regime involving all vessels regarding violations of MARPOL Annex 1. The Coast Guard conducts inspection of pollution prevention equipment and a review of records. The most common violations of bilge water quality and treatment requirements include intentional falsification of Oil Record Books to conceal deliberate discharges of oily wastes.

Another problem is that most traditional on-board treatment facilities have a liquid discharge and unless the effluent from the on-board marine sanitation device (MSD) is within the 15 ppm oil-in-water level, the quality of the effluent in terms of oil content may vary considerably. In order to maintain vessel stability and eliminate possible hazardous conditions from the accumulation of bilge water, it is necessary to periodically pump out the bilge compartments into a holding tank. The bilge water is then managed in two ways: (1) retained onboard in holding tanks and later discharged on shore; or (2) treated onboard with an Oily Water Separator (OWS). All ships over 400 gross tons are required to have equipment installed onboard that limits the discharge of oil into the oceans to 15 ppm. OWS equipment often cannot produce a consistent effluent quality due to the sloshing of its contents when the ship is in the open ocean. That means that often, the total production of bilge water exceeds the onboard storage capacity, necessitating a necessary but illegal dumping of oily wastes.

IV. HISTORICAL DATA

The following quantities of bilge water were taken from a report by the U.S Navy Station at Pearl Harbor. It gives an indication of annual quantities of bilge water generated by two types of vessels.Vessel type 1 31,500 gallons to on shore facilities

0 gallons discharged while transiting within 12 nm from shore300,000 gallons discharge outside the 12 nm zone

Total generated 331,500 gallons per vessel per year or 38 gallons per hour.

Vessel type 2 331,500 gallons to on shore facilities80,540 gallons discharged while transiting the 12 nm zone400,200 gallons discharge outside the 12 nm zone

Total generated 534,740 gallons per vessel per year or 61 gallons per hour

The total bilge water quantity discharge by two Navy vessels within the 12nm zone was 80,540 gallons or 304,870 liters. Assuming that this discharge had an oil concentration of 15 ppm (mg/l) (the maximum allowable), then the total amount of oil discharge into the 12 nm zone was 304,870 liters x 15 mg/liters = 4,573,045 mg or 4,573 kg of oil. Assuming approximately 3 kg/gal and 42 gallons/barrel or 129 kg/barrel, the amount discharged annually into the ocean is equivalent to 109 barrels of oil.Assuming that the amount of bilge water discharge outside the 12 nm zone was 800,200 gallons or 3,029,013 liters with an oil concentration of 100 mg/l (allowable), then the total amount of oil discharged annually was 3,029,013 liters x 100 mg/l = 302,901,300 mg or 302,901 kg or approximately 2,404 barrels of oil.Therefore, just two Navy vessels discharged a total of 2,513 barrels of oil annually.

With regards to the commercial applicability, the cruise ship industry has reported that cruise ships can produce 1300 to 5300 gallons of oily bilge every 24 hours which equals 54 to 220 gallons per hour. While some cruises are of a short duration, others can last up to one or two months.

V. PROCESS

Bilge water consists mostly of water (sea, fresh or brackish), an emulsion layer, which consists of a tight mixture of oil, water and solids as well as free floating oil. The Allen Bilge Water Treatment System (ZLD-BWTS) separates the water phase from the oil phase. Solids are shredded, strained, dewatered and compacted. The oil phase which contains the shredded detritus can be disposed of in an on shore facility. The water phase is evaporated into the atmosphere, or is condensed (in submarines) for ocean disposal because it is oil-free. This results in a zero liquid discharge for surface vessels and an oil-free liquid discharge for submarines. Figure 1 shows a schematic flow diagram of the ZLD-BWTS.

Compressed Solids OIL-FREE LIQUID DISCHARGE

Liquid Return Solids (FOR SUBMARINES) Press

STRAINER

BILGE WATER TANK ZLD-

BWTS

VAPORCONDENSER

SHREDDER

Waste Oil return

FIGURE 1- FLOW DIAGRAM OF THE ALLEN BILGE WATER TREATMENT SYSTEM (Patent Pending)

The entire process is controlled by a Programmable Logic Controller with 100% redundancy.

The advantage is that this process continues 24/7 while the vessel travels at sea and the amount of bilge water generated is continuously reduced. This allows for longer intervals between the necessity for on shore discharging of oily bilge water. Once onshore, only the oil phase needs disposal.

The entire system consisting of the ZLD-BWTS can be sized for ship board quarters, whether surface vessels or submarines.Surface vessels need only to vent the oil-free water vapor to the atmosphere, while submarines can condense the oil-free vapor and pump it overboard. The minor heat signature of the ZLD-BWTS can be masked to where it does not reveal the submarine’s position. The solids trapped in the strainer are dewatered, dried and compressed. The liquid is returned to the bilge compartment.

VI. PROJECT PROPOSAL

The project will have the following milestones all of which will be accomplished in Springfield, Missouri.

1. Receipt of Notice to Proceed (NTP),2. System design and component specification,3. Fabrication of the BWTS including proprietary AFI systems,4. Final assembly of prototype,5. Performance testing,6. Development of deployment operations and maintenance manual,7. Submission for U.S. Coast Guard certification,8. Final report.

AFI has a complete manufacturing facility that is capable of performing all aspects of the project. No special machinery, equipment or methods of manufacturing are involved or required. For over sixty years AFI has engineered, designed and manufactured sophisticated Vacuum Distillation Systems for fluid purification as well as intricate pump systems with state-of-the-art electronic controls.

VII. ESTIMATED PROJECT DEVELOPMENT COST

TASK DURATION PROJECTED COST

Phase 0 File for an International Patent

$ 50,000.-

System Design and Component Specifications

3 Months $ 75,000.-

Fabrication of BWST including AFI proprietary

System

6 Months $ 300,000.-

Final Assembly of Prototype 5 Months $ 200,000.-

Performance Testing and Fine Tuning

6 Months $ 75,000.-

Submission for U.S. Coast Guard Certification

3 Months $ 100,000.-

Contingencies $ 50,000.-

Total Development Cost $ 800,000.-

VIII. RETURN ON INVESTMENT (ROI)

To date, the Department of Defense (DOD) has spent millions of dollars in development costs for bilge water treatments systems of various types, ALL of which have a liquid discharge of some sort, which contains variable amounts of oil, which invariably enters the surface waters.

The U.S. Navy could be in the forefront of nations to equip our warships with a system for treating oily waste waters that produces NO LIQUID DISCHARGE into surface waters.

The system is self-contained and requires a minimum of operator attention, saving considerable manpower. It is economical to operate, with a minimum of moving parts or rotating equipment. Spare parts are American-made and readily available.

Since bilge water consists of 90 percent water, the bilge compartment can be made considerably smaller, thereby saving precious space for more essential operational equipment.

Bilge water will no longer accumulate during the voyage, but will mostly be eliminated during the voyage. This will contribute to the ships load and power consumption as well as stability.

In commercial applications such as cruise ships, it will prevent illegal discharges which currently generate millions of dollars in fines as a consequence of illegal discharges into surface waters.

IX. BENEFIT TO SHIPPING INDUSTRY

The importance of the ZLD-BWTS to the shipping industry is as follows:

1. No liquid discharge to surface waters. The oil-free liquid phase of the bilge water is evaporated to the atmosphere,

2. For submarines, the oil-free vapor can be condensed and the liquid can be pumped out to the sea,

3. The water phase is continuously reduced while the ship is underway,4. The oil phase is recycled for on shore disposal,5. The solid phase of the bilge water is dewatered and compressed for on shore disposal,6. The ZLD-BWTS system can be adapted to ship-board space constraints,7. The system is designed to operate continuously as long as there is water in the bilge

compartment,8. The ZLD-BWTS is designed to operate automatically, controlled by a Programmable

Logic Controller with a minimum of operator attention.

VIII. CONCLUSION

Discharge into the ocean of oily waste, no matter how small the oil content, is harmful to the oceans and the creatures that live in it. The cumulative effect of even the 15 ppm oil concentration, multiplied by thousand of ships and countless years constitutes an enormous and ultimately unacceptable waste load on the oceans that is now PREVENTABLE.

The proposed system will not create a negative legacy of the U.S. Navy in terms of environmental stewardship. The proposed system is scalable for widespread applicability and it will be constructed of U.S.-made components by an experienced American workforce employed by a Missouri, woman-owned, small business.

IX. TYPICAL ALLEN FILTERS OIL TREATMENT EQUIPMENT

A

HYDROSCAV™

OIL TREATMENT

SYSTEM

AN ALLEN VACUUM DISTILLATION OIL TREATMENT SYSTEM

A PROGRAMMABLE LOGIC CONTROLLER

A LARGE CAPACITY OIL TREATMENT SYSTEM

X. ABBREVIATED CUSTOMER LIST

U.S. Air Force American Israeli Paper Co. Allied Signal Co.U.S. Army Ashland Oil Co. BASF Co.U.S. Navy Saudi Aramco Oil Co. Bechtel CoU.S. Army Corps of Engineers

Calpine ExxonMobil

U.S. Coast Guard Chevron DuPont Naval warfare Center Bethesda MD.

Hoechst Celanese Marathon Oil Co.

US Air Force Wright Patterson AFB

PEMEX Pharmacia Upjohn

Phillips Petroleum Quantum Chemical Co. Rohm & HaasRio Bravo Co. Shell Oil Co. SiemensTexaco Oil Co. Trane Co. Caltex Services Co.Coastal Refining Co. Stone & Webster Co Dept. of DefenseArco Products Co. Caltex Sumatra Frontier Oil RefineryMonsanto City Utilities Co. Consolidated EdisonDow Chemical Exxon Singapore Florida Power & Light Co.Kennecott Copper Co. Mississippi Power Co. Sho-Me Power Co.Puerto Rica Power Co Sperry Rand Co. Tucson Gas & Electric Co.Black & Veatch Co. Saudi Consolidated Electric

Co.Western Light & Electric

West Texas Utilities Co. Northwest Electric Co. Abu Dhabi National Oil CoAC Compressor Co. Alcoa Aluminum Co. `BP Oil Co.Caltex Pacific Indonesia Campbell Soup Co. Caterpillar CoChamplin Refining Co. GMC Chevrolet Div. Ford Motor Co.Chrysler Citgo Refining Co. Amoco Oil Co.Kuwait National Oil Co. Dresser Rand Co. Elliott Compressor Co.Exxon Chemicals Co. General Electric Co. Ingalls Ship Building Co.Ingersoll Rand Co. Lithcon Petroleum Co. National Methanol CoMobil North Sea Ltd. Saudi Aramco Mobil

Refinery Co.Thu Duc Electric Co.

Terra International Co. Texas Gas Transmission Co. Qatar Petroleum Co.Thermodyne France Siemens Germany Nuovo Pignony ItalyWestinghouse Electric Co. Worthington Compressor

Co.Parke Davis

Yanbu Petrochemical Co Refineria Isla Curacao Sulzer UK Co.Stillwater Electric Co. VICO Indonesia refinery Suralaya Electric IndonesiaPetrokimia Gresik Indonesia Amereya refining Co. Egypt Statoil Northsea Ltd.Shell Congo Dakota Gasification Co. Soc. Nat. Electrique Zaire

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