Product Recovery System

A national engineering firm needed a product recovery system for remediation at a former manufactured gas plant site. MGP sites present particularly complex remediation challenges due to the presence of coal tar and other dense non-aqueous phase liquids (DNAPLs) that settle below the water table and resist conventional extraction methods.

The system required chemical injection capabilities to enhance product mobility and recovery rates, multi-phase pumping to extract both liquid product and groundwater, and oil-water separation to segregate recovered product from the extracted water stream. All equipment needed to be containerized for efficient transportation from Fliteway's Wisconsin manufacturing facility to the remote California project site.

The design had to accommodate the specific subsurface conditions and product characteristics at the MGP site, including variable product viscosity, fluctuating groundwater levels, and the need for precise chemical injection metering to optimize recovery without exceeding reagent dosing limits.

Fliteway provided a complete product recovery system engineered for the site-specific conditions at the MGP location. The system was built around several integrated subsystems: extraction well controls, chemical injection and metering, multi-phase pumping, oil-water separation, and a centralized control system to coordinate all operations.

The extraction well controls managed the operation of downhole pumps in the recovery wells, including pump cycling, level-based operation, and flow monitoring. Each well was equipped with instrumentation to track water levels, pumping rates, and product recovery volumes.

The chemical injection system used precision metering pumps to deliver treatment reagents at controlled dosing rates. Chemical storage, containment, and injection plumbing were all integrated into the containerized system.

Containerized pumping skids housed the transfer pumps, piping manifolds, and associated controls needed to move recovered fluids from the extraction wells to the separation and treatment components. The entire system was deployed via trailer to the California project site after factory assembly and testing in Wisconsin.

The product recovery system was fabricated at Fliteway's Cudahy, Wisconsin facility, thoroughly tested, and delivered to the California project site for commissioning. The containerized design allowed for efficient cross-country transportation and rapid on-site setup, minimizing the mobilization timeline.

The integrated chemical injection, multi-phase pumping, and oil-water separation systems worked in concert to achieve the product recovery objectives defined by the remediation program. The precision metering and well-level controls provided the operational flexibility needed to adapt to changing subsurface conditions throughout the recovery campaign.