2. Bootstrap System: 400 b/d*
Start by filling the 210 bbl
mixing tank halfway with
sludge, then cover with diesel
Diesel
Pump Ionizer**
Sludge (circulate 3
times) Generator
2x 210 bbl tanks Sit for
4-6 hours
Sludge-
Diesel ‡ This
crude oil should be saleable, but
*The system should safely operate one Mixture
**Ionizer & pump sit on may incur a slight discount for falling
cycles per day at 400b/d each. With
a trailer and services outside the tight contract specification.
experience a second cycle may be
charged in the evening and sit both tanks. Circulating
overnight for 800 b/d. the tank 3x takes ~45
minutes. Repositioning
takes 15-30 minutes
2
3. Bootstrap System: 400-800 b/d
Project
Bootstrap System Spec Unit Cost No. Cost Comments
Diesel Trucks Pump directly from delivery truck; no capex
Mixing Tanks 210 bbl $15.0k 2 $30.0k API, 12 guage, galvinized, hatch, manhole, mangate, steps, etc.
Moveable built tank snaps into place in 2hrs. Cheaper tanks
may be sourced locally or, say, Romania
Tank valves & fittings $1.0k 2 $2.0k Welding on pipe work to aid circulating the sludge-diesel mix
Stinger $0.5k 1 $0.5k Manually operated; used for first circulation when required
Generator diesel $5.0k 1 $5.0k Check local pricing
Ionizer + pump + trailer $25.0k 1 $25.0k
TAN control mixer $1.0k 1 $1.0k For Nalco dry base chemical
Field laboratory $3.0k 1 $3.0k
Sub-Total 1 $66.5k
Transport & contingency 30% 1 $20.0k
Total Bootstrap System 1 $86.5k 400-800 bbls/day
3
4. Basic System: 800 b/d* *The system should safely
operate 2 cycles at 400b/d each.
With experience a third cycle
may be charged in the evening
Start by filling the 210 bbl and sit overnight for 1200 b/d
mixing tank halfway with
sludge, then cover with diesel
Diesel Off Gases
Generator Pump Ionizer**
Sludge (circulate 3
times)
2x 210 bbl tanks Sit for
4-6 hours
Diesel
Storage Heater
Treater Finished
Sludge- Product
Diesel Storage
210 bbl Mixture
**Ionizer & pump sit on
tank
a trailer and services
both tanks. Circulating Trace Water
the tank 3x takes ~45 1500 bbl
minutes. Repositioning tank
takes 15-30 minutes
4
5. Basic System: 800-1200 b/d
Project
Basic System Spec Unit Cost No. Comments
Cost
Bootstrapping by loading from tanker trucks directly may be
Diesel Storage Tank 210 bbl $15.0k 1 $15.0k
possible, but risks production delays
Diesel pump & hose $0.5k 1 $0.5k
API, 12 guage, galvinized, hatch, manhole, mangate, steps, etc.
Mixing Tanks 210 bbl $15.0k 2 $30.0k Moveable built tank snaps into place in 2hrs. Cheaper tanks
may be sourced locally or, say, Romania
Tank valves & fittings $1.0k 4 $4.0k Welding on pipe work to aid circulating the sludge-diesel mix
Stinger $0.5k 1 $0.5k Manually operated; used for first circulation when required
Simple boiler attached to loop of piping at the bottom of
Tank Heaters steam $3.0k 2 $6.0k
mixing tanks. Can probably fitted in locally
Generator diesel $5.0k 1 $5.0k Check local pricing
Ionizer + pump + trailer $25.0k 1 $25.0k
This is for a high quality unit from the USA; local ones with
Heater Treater $25.0k 1 $25.0k
simple controls should be cheaper w/ the usual caveats
H-Treat pump & hose $0.5k 1 $0.5k
Bootstrapping by using a smaller, cheaper tank may be
Finished Product Tank 1500 bbl $25.0k 1 $25.0k
possible, but risk disrupting production.
TAN control mixer $1.0k 1 $1.0k For Nalco dry base chemical
Field laboratory $3.0k 1 $3.0k
Sub-Total $137.5k
Transport & contingency 30% 1 $41.3k
Basic System $178.8k 800 bbls/day; with experience might push to 1200 b/d
Finished Product Tank 1500 bbl $32.5k 1 $32.5k Additional tankage (including 30% contingency)
Tank valves & fittings $1.3k 1 $1.3k Welding on pipe work to aid circulating the sludge-diesel mix
Basic w/ xtra Storage $212.6k
5
6. System Details
Tank Stinger Tank Dry Ice
Heating Cleaning
Heater
Treater
210 bbl mixing tanks Substantially all water and solids
have piping welded When the sludge is very thick a will fall from solution in normal
into the base for “Stinger” can be used to jet ionized operation, so the tank will not be
steam from a boiler diesel from the 3” outlet pipe into a drawn all the way to the bottom. If dry Ice (frozen CO2) is
to heat the sludge. 1” pipe onto shear the surface of the Periodically solids built up on the available locally, then it can
sludge. This should only be necessary bottom will need to be raked out be to finish de-watering the
to start the tank circulating. via a “Man Gate” at the base of crude and avoid buying a
the tank Heater Treater
TAN Reduction Storage Capacity
The Ionized diesel will already have reduced TAN to While it’s possible to bootstrap operations with less
a degree. But after de-watering the crude, it’s storage, in order to keep transportation disruptions
preferred to use a chemical additive from Nalco to Finished from shutting down the process, the site should build
adjust TAN Product up to having storage = 3x daily production
Storage
6
7. *The system should safely operate 2
shifts at 800b/d each. With
experience a third cycle may be
Expansion to 1600 b/d* charged in the evening and sit over
night for 2400 b/d
Diesel Off Gases Finished
Ionizer
Product
Pump (circulate 3
Storage #2
Sludge times)
Diesel
Sludge-
Storage Heater
Diesel
Mixture Treater Finished
Product
Storage
Trace Water
Mixing
Tank #3
*Both the Ionizer / Pump
trailer and the Heater-
Treater can service multiple Finished
Mixing tanks Product
Tank #4 Finished
Product Storage #4
Storage #3
7
8. Expansion System: 1600-2400 b/d
Project
Basic System Spec Unit Cost No. Cost Comments
Basic w/ xtra Storage 1 $212.6k
Mixing Tanks 210 bbl $15.0k 2 $30.0k
API, 12 guage, galvinized, hatch, manhole, mangate, steps, etc.
Tank valves & fittings $1.0k 6 $6.0k Welding on pipe work to aid circulating the sludge-diesel mix
Simple boiler attached to loop of piping at the bottom of
Tank Heaters steam $3.0k 2 $6.0k
mixing tanks. Can probably fitted in locally
Bootstrapping by using a smaller, cheaper tank may be
Finished Product Tank 1500 bbl $25.0k 2 $50.0k
possible, but risk disrupting production.
Sub-Total 1 $92.0k
Transport & contingency 30% 1 $27.6k
Total Expansion System 1 $119.6k 1600 bbls/day; with experience might push to 2400 b/d
Simple + Expansion 1 $332.2k
8
