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Crude oil storage tanks are long-term static systems where natural separation processes such as sludge formation, wax deposition, temperature stratification, and water-oil separation continuously occur.
Without effective mixing, these phenomena gradually reduce usable storage volume, increase pumping instability, and lead to higher maintenance costs and operational downtime.
KEHENG side entry mixers are engineered to solve these challenges through continuous low-energy axial circulation flow, ensuring stable crude oil quality and improved tank operational efficiency.
With over 30 years of industrial mixing experience, KEHENG provides engineered side entry mixing systems for large-scale crude oil storage and refinery applications worldwide.
Crude oil is a multi-phase fluid system containing hydrocarbons, water, solids, and paraffinic components. During static storage, gravity separation and thermal gradients naturally occur.
Density-driven phase separation
Paraffin crystallization and settling
Bottom sludge accumulation
Thermal stratification across tank height
Reduced flowability in heavy crude oils
These mechanisms directly affect tank performance and downstream processing stability.
Heavy hydrocarbons, sand, corrosion particles, and asphaltic residues gradually settle and form compact sludge layers.
Reduced effective storage capacity
Higher cleaning cost and shutdown frequency
Pump suction instability
In medium and heavy crude oils, paraffin crystals form at lower temperatures and settle without circulation.
Flow obstruction in pipelines
Increased heating energy demand
Reduced pumpability
Large storage tanks develop vertical temperature gradients due to poor mixing.
Viscosity inconsistency
Poor blending performance
Uneven product quality
Water and fine solids separate and accumulate at the tank bottom over time.
Lower crude oil quality
Higher downstream separation cost
Increased corrosion risk
KEHENG side entry mixers are designed to generate continuous horizontal axial circulation loops that cover the entire tank bottom area.
High-efficiency axial flow impeller generates directional momentum
Flow spreads horizontally along tank bottom
Circulation loop continuously lifts and redistributes sediments
Full tank homogenization achieved over time
This prevents sediment accumulation and stabilizes crude oil properties.
Designed for maximum hydraulic efficiency with minimum energy loss.
High thrust generation efficiency
Low shear stress on fluid
Optimized for large tank circulation
Reduced energy consumption per mixing volume
Each mixer is positioned based on tank diameter, fluid viscosity, and required circulation pattern.
Improves bottom sweeping efficiency
Eliminates stagnant zones
Enhances tank-wide flow distribution
Built for continuous refinery and storage terminal operation.
Industrial gearbox system for high torque loads
Long-life bearing assembly
Corrosion-resistant material options
24/7 continuous operation design
Compared with top-entry or mechanical agitation systems:
Lower installed motor power
Higher circulation efficiency per kW
Reduced lifecycle energy cost
Lower maintenance frequency
The tank suffered from severe sludge accumulation and inconsistent temperature distribution, resulting in:
Frequent cleaning shutdowns every 12 months
High BS&W levels in pumped crude oil
Unstable pumping performance during winter conditions
Installed dual side entry hydrofoil mixers with optimized installation angles and low-speed axial circulation design.
Sludge accumulation reduced by ~65%
Tank cleaning interval extended from 12 months → 24 months
Temperature uniformity significantly improved across tank height
Pumping energy consumption reduced by ~18–22%
Improved crude oil stability and downstream processing efficiency
| Item | Specification Range |
|---|---|
| Motor Power | 1.5 – 110 kW |
| Impeller Type | Hydrofoil axial flow |
| Shaft Length | Customized per tank |
| Speed Range | Low-speed high-flow design |
| Tank Size | Small tanks to ultra-large storage tanks |
| Material Options | Carbon Steel / SS304 / SS316L / Duplex Steel |
Each system is designed based on:
Crude oil viscosity and density
Wax and paraffin content
Tank diameter and height
Storage temperature range
Sludge composition
Required circulation intensity
| Operational Metric | Improvement |
|---|---|
| Sludge accumulation | ↓ 60–70% |
| Tank cleaning frequency | ↓ 30–50% |
| Temperature uniformity | ↑ significantly improved |
| Pump stability | ↑ improved flow consistency |
| Energy consumption | ↓ 15–25% |
| Parameter | Conventional System | KEHENG Side Entry Mixer |
|---|---|---|
| Flow Pattern | Local turbulence | Full axial circulation |
| Sludge control | Limited | Highly effective |
| Energy efficiency | Moderate | Optimized |
| Large tank performance | Weak | Strong |
| Maintenance demand | High | Low |
| Operational stability | Variable | Stable |
Side entry mixers generate continuous axial circulation along the tank bottom, preventing sludge formation and improving oil homogenization.
By maintaining constant horizontal flow that keeps heavy particles suspended and prevents sedimentation.
Temperature drops and insufficient flow allow wax crystals to form and settle at the tank bottom.
Yes, they are specifically designed for large-diameter tanks where full-volume circulation is required.
They achieve high circulation efficiency at low rotational speed, reducing power consumption compared to conventional mixing systems.
Every crude oil storage system requires tailored engineering design based on real operating conditions.
KEHENG provides:
Tank flow analysis
Mixing pattern simulation
Impeller and gearbox selection
Energy optimization design
Installation engineering support
Contact us with your tank parameters to receive a customized side entry mixing solution for your crude oil storage application.
