MyCelx Technologies Corporation

Transcription

1 MyCelx Technologies Corporation Maximising consumable media filtration efficiency Produced Water Club meeting, Aberdeen Copyright 2013 MyCelx Technologies Corporation. 1

2 MyCelx Technologies Corporation Company overview Specialist industrial water treatment technology & engineering company US-based (Atlanta / Houston); offices in Saudi Arabia & London Global clients in the upstream & downstream oil & gas industry first systems installed in 2004 Patented polymer removes droplets & solids down to 2 microns high efficiency, low cost filtration Produced Water capabilities: specialise in upset conditions / WSOs / heavy oil / EOR Selected oil & gas clients 2

3 MyCelx Systems Full range of produced water / process water treatment capabilities FWKO / Surge Tank MyCelx Advanced Separator / Coalescer MyCelx RE-GEN MyCelx Polisher Oil in Water content >1% Enhanced gravity separation Removes up to 10,000ppm oil to ~100ppm Permanent media Backwashable bulk media: contact filtration Removes solids >2 microns oil to ~50ppm Permanent media Tertiary treatment stage - removes oil to <1ppm Failsafe / permanent operation Consumable filter media 3

4 Patented technology + proprietary engineering MyCelx polymer enables permanent oil removal in real time Media are housed within MyCelxdesigned & engineered vessels Technology MyCelx s patented polymer Polymer is infused onto standard filtration media MYCELX Discharge Oil Free Water Applicable to wide range of water problems free & dispersed oil, emulsions, WSO 99.9% oil removal up to 8x weight of filters, no water retention Media, vessels and polymer all customised to specific PW needs 4

5 5 Bridging the Technology Gap Where does MyCelx fit in?

6 Deepwater Gulf of Mexico Small footprint vs previous treatment systems (90% space saving) 15,000 bpd, 3-element polisher installed as sidestream for failsafe WSO removal on 40,000 bpd platform Failsafe required to handle upset conditions downstream of the IGF system already in place Successfully reduced WSO levels from 14ppm-30ppm range to 5ppm-10ppm range 6

7 Anadarko Installation of MyCelx four-stage polisher to guarantee oil sheen-free water and discharge < 10ppm into local evaporation pond Inlet fluctuations not previously controlled by upstream equipment (walnut shell filter)(10ppm-150ppm) Continuous operation to <5ppm since 2006 treating 30,000 bpd Low operating costs, small footprint and simple operation and maintenance Led to offshore trial for Anadarko WSO treatment

8 Consumable filtration media the challenge High flow-rates / oil loading = fast consumption & change-out Rate of filter consumption determined by weight of oil captured, ie flow-rate x oil & solids loading Most Polisher installations handle 15,000 30,000 bwpd, downstream of existing equipment; manageable change-out, small footprint, low opex, low operator intervention Higher flow-rates / oil loading = more frequent change-out Solutions / process improvements: 1. Install additional upstream equipment 2. Ensure flow through Polishers only occurs when IGF / hydrocyclone outlet > 30ppm 3. Control flow through Polishers to remove only as much oil as is necessary to achieve overall discharge objectives 8

9 Case study deepwater GoM Failsafe Polisher usage Deepwater Gulf of Mexico 22,500 bwpd polisher unit at outlet of IGF Twin train, one operational / one standby, manual operation Dec 2011 Jan 2013 performance report, 1,950 grab samples: 16% usage Average inlet 32ppm, outlet 3.8ppm Operating cost $0.07/bbl (zero when not in use) Operating cost plus optimisation $0.03/bbl 14ft x 10ft x 12ft skid existing space Zero discharge in breach of Clean Water Act limits even in highly upset / high turndown conditions Total maintenance time 32 hours in 12 months (manual operation, no automation)

10 Case study deepwater GoM Failsafe Polisher usage 1,959 data points through grab samples over 413 day period Average overboard flowrate 6,050 bwpd Polisher manually deployed 453 times (16%), average 18.5 hr duration BUT usage not necessary on 67.5% of those occasions due to time lag / conservative use 10

11 Case study deepwater GoM Failsafe Polisher usage Zero average daily discharge > 29 ppm Operating cost $0.07 per barrel, 32 man-hours Significant optimisation potential (usage & proportion) to reduce cost to $0.03 per barrel Performance data Vessel Change Outs (MyCelx Filters) 35 MyCelx Filters Used 2,275 Vessel Change Outs (Solids Filters) 29 Solids Filters Used 1,885 Total Cost of Filters Used $9,425 Duration Inside Period (hours) 7,915 Volume of water discharged (bbl) 1,995,492 Average cost to treat ($/bbl) 0.07 Total yearly maintenance time (hrs) 32 System Footprint (ft 2 ) 140 Discharge > EPA limit 0 Optimised cost to treat ($/bbl) 0.03 Example data-set Time and Date Float Cell outlet ppm O&G 7/29/12 8:00 AM /29/12 9:30 AM /29/12 11:00 AM /29/12 12:30 PM /29/12 3:00 PM /29/12 6:15 PM /29/12 7:30 PM /29/12 10:30 PM /30/12 1:00 AM /30/12 3:30 AM /30/12 11:00 AM MyCelx outlet ppm O&G 11

12 Case study Houston Fuel Oil Terminal Automated flow controls Run-off / storm water treatment + condensate / boiler feed water MyCelx Advanced Separator plus Polisher 480 gpm contact water to <15ppm 360 gpm process water at 190 to 1ppm Oil: fuel & bunker oil Complete system fully automated Intelligent by-pass through proprietary technology 12

13 Case study Houston oil terminal (2) Automated flow controls 480 gpm stormwater treatment plant currently being installed Multiple units, all fully automated: Advanced Separator, Solids Settling Tank, Chemical Injection pump for ph control, Pumps, Polisher Train and Carbon Filter (to guarantee COD levels) Advances on HFOTC: Multiple units, fully automated SA100 self-cleaning, lower maintenance Different size bypass line to equalise pressure drop Networked controls enable remote operation Summary of automated flow control advantages 13 Minimised operating cost; filters used to maximum capacity Lower maintenance, longer filter lifecycle Immediate response to upset conditions Guaranteed failsafe discharge compliance Adjustable target effluent concentration Dual train polishers allow for automated switching to fresh train and filter media type based on oil droplet size Remote troubleshoot capability

14 Fabricator Shop visit Feb 2013 carbon vessel Fabricator Shop visit Mar 2013 Advanced Separator Control panel Bag Filter unit Polisher vessels 14

15 MyCelx Technologies Corporation 470 Woods Mill Road, Gainesville, GA Park Row, Suite 190, Houston, TX 17 Dartmouth St, London SW1H 9BL Copyright 2013 MyCelx Technologies Corporation. 15