Oil Water Separators

EC – Emulsion Cracking

Emulsion Cracking System

Emulsion Cracking System - Efficient Oil-Water Separation for Industrial Wastewater

Break Emulsions. Recover Value. Meet Compliance.

Our advanced Emulsion Breaking System delivers reliable, cost-effective separation of stable oil-in-water and water-in-oil emulsions. Designed for demanding industrial applications, it combines chemical demulsification with mechanical separation for superior results — even with challenging emulsions from manufacturing, oil & gas, food processing, and metalworking.

Achieve >95% oil removal • Reduce disposal costs • Enable water reuse

Product Overview

Emulsions form when oils, greases, surfactants, or other emulsifiers stabilize mixtures that resist natural separation. Our Emulsion Cracking System destabilizes these emulsions through targeted pH adjustment, chemical dosing, and advanced coalescing technology.

The result is clean water discharge or reuse, recovered oil for recycling, and reduced sludge volumes.

Whether you process produced water, coolant waste, wash water, or refinery effluents, the EC provides a complete, automated solution that lowers operating costs while ensuring regulatory compliance.

Key Features of the EC

• Dual pH Reaction Tanks: Precise acidification (typically pH 2-4) to crack emulsions, followed by neutralization for safe discharge.
• High-Efficiency Coalescing Media: Removable PVC or enhanced packs with optimized spacing for rapid oil droplet coalescence.
• Automated Chemical Dosing: Integrated controls for demulsifiers, coagulants, flocculants, and pH adjusters.
• Robust Construction: Heavy-duty carbon steel with corrosion-resistant coatings (interior coal tar/epoxy, exterior polyurethane enamel).
• Integrated Oil-Water Separator: Removes free-floating oils and settleable solids post-demulsification.
• Level Controls & Sensors: PLC-based automation with alarms, flow monitoring, and adjustable weirs.
• Pre-Assembled & Skid-Mounted: Minimizes on-site installation time and costs.
• Modular & Scalable: Available in various capacities to match your flow rates (e.g., 10–1000+ GPM).

Emulsion Cracking Benefits

• Superior Separation Efficiency — Breaks even stable emulsions that gravity or standard separators cannot handle.
• Cost Savings — Lower chemical usage, reduced sludge hauling, recovered oil value, and extended equipment life.
• Environmental Compliance — Produces high-clarity effluent meeting discharge limits; supports water recycling.
• Low Maintenance — Easy-access media packs, durable design, and automated operation.
• Improved Downstream Performance — Protects biological treatment systems, DAF units, and membranes.
• Fast ROI — Many customers see payback within 12–18 months through reduced disposal fees and resource recovery.

How It Works

1. Influent Collection — Wastewater enters the system.
2. Chemical Demulsification — pH adjustment and/or demulsifier dosing destabilizes the emulsion interface, allowing droplets to coalesce.
3. Coalescence & Separation — Media packs and gravity separation divide oil, water, and solids.
4. Neutralization & Polishing — pH is adjusted to discharge specifications; optional filtration or flotation for ultra-clear effluent.
5. Oil Recovery & Sludge Removal — Separated oil is skimmed for reuse; solids are concentrated for easy handling.

The entire process is continuous or batch-capable with real-time monitoring.

Technical Specifications (Example Model: EC-100)

• Flow Rate: Up to 1000 GPM (custom sizes available)
• Material: 3/16”+ carbon steel / 304 SS construction
• Media: Removable PVC coalescing packs (¾” spacing standard)
• Power: 230/460V 3-phase (customizable)
• Controls: PLC with HMI touchscreen
• Options: Heated tanks, explosion-proof design, remote monitoring, integrated DAF

Contact us for detailed specs tailored to your site.

Why Choose Our Emulsion Breaking System?

Proven performance in real-world conditions with minimal operator intervention. Backed by engineering expertise and ongoing support.

Ready to Simplify Your Emulsion Challenges?

Custom configurations available. Jar testing services offered to ensure optimal chemistry and performance.

Industrial Applications

Ideal For:

• Oil & Gas / Produced Water
• Metalworking & Coolant Wastewater
• Truck & Vehicle Wash Stations
• Food Processing (FOG removal)
• Refineries & Petrochemical Plants (refinery wastewater, stripped sour water)
• Natural Gas Processing, Coke-Making & Gasification Plants
• Manufacturing & Industrial Laundries
• Wastewater Treatment Plants