Tank Profiling Assessment Retains $6.4M in Value
A tank profiling assessment performed by TankScope at Flint Hills Resources’ Pine Bend Refinery revealed that sludge levels inside a large crude/slop crude tank were far lower than historical estimates. Verified tank data allowed the refinery to reduce cleaning scope and identify and characterize hydrocarbons present within the sludge layer. The revised plan delivered $2.6M in direct cleaning cost savings and recovered approximately 55,000 barrels of oil, for total retained value of $6.4M USD.
$6.4M USD Retained Through Verified Sludge Assessment and Hydrocarbon Recovery Planning
Flint Hills Resources planned a cleaning project for a 280-foot diameter crude/slop crude storage tank at their Pine Bend Refinery. The initial cleaning budget of $6.0M USD was based on historical estimates suggesting sludge accumulation of more than six feet.
TankScope’s tank profiling assessment revealed actual sludge levels of less than twelve inches.
With verified sludge depth, distribution, and material characterization data, Flint Hills revised the cleaning scope and implemented a strategy to recover hydrocarbons contained within the sludge layer.
The revised plan delivered $2.6M in direct cleaning cost savings and recovered approximately 55,000 barrels of oil worth $3.8M, resulting in $6.4M USD in retained value from a single tank.
Project Details
Tank Type
280-foot diameter tank storing crude oil and slop crude
Location
Pine Bend Refinery, Rosemount, Minnesota, USA
Challenge
Cleaning budget of $6.0M USD based on estimated sludge accumulation of ≥6 ft
Number of Tanks
1
Estimated Sludge Volume
≥6 ft
Actual Sludge Level
≤12 in
The Problem
Historical Sludge Estimates Created Major Budget Risk
Flint Hills Resources planned a large cleaning campaign based on the assumption that more than six feet of sludge had accumulated in a crude/slop crude tank.
Without verified measurement, the refinery was preparing for a major operation involving:
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Extended tank outage duration
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Large disposal volumes
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Significant contractor mobilization and equipment requirements
When sludge depth is unknown, planning relies on conservative assumptions. These assumptions often lead to inflated cleaning budgets or unexpected scope changes during execution.
A refinery tank assessment was required to verify sludge depth, distribution, and hydrocarbon content before committing to the full cleaning scope.
TankScope Approach
Tank Profiling Assessment and Sludge Depth Verification
TankScope conducted a tank profiling assessment to verify sludge depth, distribution, and composition before cleaning began.
The assessment included:
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Infrared thermography to detect sludge boundaries through tank shell temperature differentials
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Sludge topography measurements to verify depth and distribution across the tank floor
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Material characterization sampling to analyze sludge composition
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Chemical assessment testing to identify potential safety hazards
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Hydrocarbon analysis to quantify hydrocarbon content within the sludge layer
The verified data allowed Flint Hills Resources to revise the cleaning scope and optimize the recovery strategy.
$6.0M Budget Estimate
TankScope Assessment
Verified Tank Data
Revised Cleaning Scope
Optimized Execution
$6.4M Retained Value
Results
Tank Cleaning Cost Reduction and Hydrocarbon Recovery
The tank profiling assessment confirmed that sludge depth was dramatically lower than historical estimates.
With verified sludge data, Flint Hills Resources revised the cleaning scope and implemented a recovery strategy for hydrocarbons contained within the sludge.
Total Retained Value
$6.4M USD
Direct Cleaning Cost Savings
$2.6M (single tank)
Incremental Oil Recovered
Approximately 55,000 barrels worth $3.8M
Sludge Variance
Estimated ≥6 ft vs Actual ≤12 in (over 80% lower than expected)
Outcome
Revised cleaning plan successfully implemented using verified tank assessment data
[PLACEHOLDER – Client Testimonial]
Questions We Get Often
What is a tank profiling assessment?
A tank profiling assessment verifies sludge depth, distribution, and composition before cleaning begins. TankScope combines thermography, sludge topography measurement, sampling, and laboratory analysis to provide verified tank condition data.
Why were sludge levels overestimated in this case?
Historical sludge estimates often rely on conservative assumptions or outdated records. Direct sludge measurement revealed that actual accumulation was far lower than expected.
How did this project recover hydrocarbons from tank sludge?
Material characterization and hydrocarbon analysis identified hydrocarbons present within the sludge layer. With this information, the cleaning strategy could be revised to enable recovery during the cleaning process.
Are similar results common for crude storage tanks?
Every tank is different. However, historical estimates frequently overstate sludge accumulation. A refinery tank assessment often reveals opportunities to reduce cleaning scope or recover hydrocarbons.
What technologies were used in this assessment?
TankScope used FLIR infrared thermography to detect sludge boundaries, proprietary sludge topography tools to measure depth at multiple locations, and laboratory analysis to characterize sludge composition and potential hazards.
How were safety hazards evaluated?
Samples collected during the assessment were tested for safety-critical properties including Hâ‚‚S concentration, flash point, explosive gas presence, and other hazardous characteristics. This data informed safety planning for the cleaning operation.
When should a tank profiling assessment be performed?
The assessment is typically conducted before cleaning planning or tank outages so teams can understand actual tank conditions and plan scope, safety controls, and recovery opportunities accordingly.
Stop paying to dispose of product that could be recovered.
Use verified tank data to understand sludge conditions, identify hydrocarbons within the sludge layer, and plan cleaning operations with confidence.
1-888-417-0155 | info@tankscope.com