Water Solutions in the Oil & Gas Industry Up-stream Water Treatment

Transcription

1 Water Solutions in the Oil & Gas Industry Up-stream Water Treatment Restricted Siemens AG

2 Water Treatment in the Oil & Gas Industry Up-stream Content Produced Water Treatment Objectives Primary Separation Secondary Separation Tertiary Separation Reference Installations ü acc. RoK Standards ü acc. Intl. Standards Page 2

3 Serving All Sectors of the Oil & Gas Industry Exploration & Production Upstream Transport & Storage Midstream Refining & Processing Downstream Oil production Gas/Oil separation Pipeline Tank farms Refinery Petro chemistry Gas Gas production Gas treatment Liquefaction Pipeline Terminal Gas processing Distribution Page 3

4 Treatment Objectives Page 4

5 Overview Treatment Objectives Up-Stream Produced Water Treatment for Reinjection Removal of Free Oil & Grease Suspended Solids Sea Water Removal Treatment of for Injection Removal of Suspended Solids Oxygen Sulfate Production (Oil Well) Page 5

6 Limitations of Separation Technology Separator Type Technology Oil Droplet Removal Range API Gravity Down to 150 micron CPI Gravity Coalescer Down to 50 micron Flotation IGF Hydraulic IGF Mechanical DGF Brise Pump Sparge Technology Down to 50 Microns Down to 75 Microns Down to 30 micron Down to 75 microns Hydrocyclones Centrifugal Force Down to micron Centrifuge Centrifugal Force Down to 5 20 micron Walnut Shells/Carbon/ Cartridge Filtration/Coalescing Down to 2 micron UF,RO, Micro, Nano Membrane Less than 1 micron Page 6

7 Oil & Gas Production Produced Water Treatment Process Map Produced Water Solids Separation Primary Produced Water Separation Secondary Produced Water Separation Tertiary Produced Water Separation Discharge or Reinjection for Water Flood Page 7

8 Primary Separation Page 8

9 Primary Separation - Hydrocyclones Liquid/liquid, solid/liquid designs Maximum separation in a small footprint Low weight and small footprint, important in offshore applications Used primarily to remove concentrations of oil (200 to 2,000 ppm) from Produced Water as an initial separation step prior to polishing by flotation systems Page 9

10 Primary Separation Hydrocyclones Vessel with Active Liners Inlet Tangential Inlet Clean Water Page 10 Oil Reject

11 Primary Separation - Hydrocyclones Inlet Flow Clean Water Page 11 Oil Reject

12 Factors Governing Performance A number of factors influence oily water separation performance: Droplet Size of the dispersed phase (i.e., oil) Fluid Temperature Differential density of the two fluids to be separated. Inlet Concentration Oil Slugging Interfacial Tension Chemical Treatment and Solids Free and Dissolved Gas Content Page 12

13 Primary Separation - CPS Corrugated Plate Separators Gravity-design separator Corrugated plate interceptor minimizes distance free oil droplets must rise before coming into contact with other oil droplets, facilitating free oil removal Overflow Oil Skimmer Water Inlet Water outlet Pre - settling Chamber CPI Packs Solids Outlet Page 13

14 Primary Separation - Skimmers Skimmers Typically upstream of secondary treatment products. Can be Vertical or Horizontal vessels. Used primarily to remove concentrations of oil (200 to 2,000 ppm) Can be packages with Flotation on a common skid Page 14

15 Primary Separation Selection Criteria Process Conditions Corrugated Plate Separator L-L Hydrocyclone Flow Rate (per unit) 2,5 570 m³/h m³/h Influent Effluent Free Oil & Grease < ppm up to ppm Total Suspended Solids < 300 ppm < ppm Free Oil & Grease < 150 ppm < 150 ppm Total Suspended Solids < 50 ppm - Page 15

16 Secondary Separation Page 16

17 Flotation Technology DGF Technology Greater bubble dynamic flexibility Reduced maintenance costs Capable of dissolving gas into solution Bubble sizes ranging from 1 to 100 microns IGF Technology Hydraulic or Mechanical design Increased maintenance Bubble size from 50 to 200 microns Page 17

18 Flotation Technology By attaching a small gas bubble to an oil droplet, it will decrease the density of the droplet which will increase the rate at which it will rise to the surface. Critical Flotation Criteria Population of Gas Bubbles Size of Gas Bubbles Distribution of Gas Bubbles Oil Droplet Rate of Rise DGF System Off DGF System On 5 Seconds DGF System On 30 Seconds Page 18

19 DGF Technology Impeller has dual sides and special seal Sub-atmospheric pressure region where the vapor is dissolved/emulsified into micro-fine bubbles Therefore, no need for eductors and the maintenance that eductors require Page 19

20 Secondary Separation - SPINSEP System SPINSEP System Uses specialized cyclonic and flotation technology that removes oil, grease and solids in a single vessel arrangement. Head-in-Head design aids in pitch and roll conditions (TLP, Spars, FPSO, etc.) Design Notes: Single celled vertical vessel for reduced footprint Designed for <100 ppm inlet TSS Designed for <300 ppm inlet O&G Receptive to DGF and IGF technology Preferred product line for floating production facilities were motion is an issue. Page 20

21 Secondary Separation - VEIRSEP System VEIRSEP System Incorporates several unique technologies to separate oil and various other contaminates from Produced Water and contaminated wastewater streams Design Notes: 6 cells (4 flotation cells and 2 quiet separation cells) Horizontal vessel Designed for <200 ppm inlet TSS Designed for <500 ppm inlet O&G Receptive to DGF, IGF, and Sparge technology Greater retention time equates to greater efficiency Page 21

22 Secondary Separation - Selection Criteria Process Conditions SPINSEP DGF VEIRSEP - DGF Flow Rate (per unit) m³/h m³/h Influent Effluent Free Oil & Grease < 300 ppm < 500 ppm Total Suspended Solids < 100 ppm < 200 ppm Free Oil & Grease < 30 ppm* < 30 ppm* Total Suspended Solids < 50 ppm* < 50 ppm* * Chemical pre-conditioning (coagulation/flocculation) is needed Page 22

23 Tertiary Separation Page 23 XX.XX.20XX

24 Tertiary Separation High Flow Walnut Shell Filter System WALNUT SHELL FILTER Patented Siemens Walnut Shell Filter Removes oily contaminants free oil and grease, suspended solids Simplified design lower costs Industry leader with proven track-record ü Oil field produced water ü Refinery waste water ü Ethylene plant quench water THE BLACK WALNUT SHELL Excellent surface characteristics for ü Coalescence, Filtration and Superior resistance to attrition Deepest nutshell bed in industry ü Superior effluent quality ü Longer filtration runs ü Greater throughput efficiency Page 24

25 Tertiary Separation Advantages of the Siemens Filter Design High Flow Walnut Shell Filter Constant Flux during Forward Flow throughout entire Bed Even Bed Fluidization during Cleaning Cycle Ensures Longer Filter Run Times and Overall Media Longevity Full Depth Capture of Oil and Particulates Minimum Chance for Suspended Solids Break Through without Indication of Increased Filter Resistance Page 25

26 Tertiary Separation Advantages of the Siemens Filter Design High Flow Walnut Shell Filter Characteristics Complete turn over and mixing of the media Fully fluidize the walnut shell bed No rotating equipment or moving parts The ability to use a finer walnut shell media to improve oil and solids removal Smaller footprint and weight A reduction in backwash water volume 52 % Page 26

27 Tertiary Separation Siemens Walnut Shell Filtration Re-Design High Flow Walnut Shell Filter System Eliminated External Scrubber for Internal Design Reduced Backwash Time by 20% to 30% Reduced Footprint by 20% to 40% Increased Flux Rate by 40% to 100% Significantly Reduced Piping Requirements Reduced Maintenance Requirements Low Reoccurring Costs Page 27

28 Tertiary Separation Key Facts of the High Flow Walnut Shell Filter (1) Oil is not Absorbed by the Nuts, but Attached (=Adsorption) Backwash is Typically Performed every 24 hours with Raw Inlet Water for 30 min Fully Automatic Backwash Cycle removes Oil and Solids Standard Granular Size: mesh 5% Loss of Nuts per Year Page 28

29 Tertiary Separation Key Facts of the High Flow Walnut Shell Filter (2) System Features Walnut Bed Thickness: 1660 mm Standard Vessel Height is 2700 mm Seam to Seam only Diameters change Max. Filter Velocity: 53 m/h Maximum Oil Loading: 100 ppm free oil Max. Solids Loading: 50 ppm TSS Efficiency: 95% removal > 10 micron Effluent Quality: < 5 ppm free oil/tss PerforMedia TM Load up to 500 mg/l with oil spikes >1000 mg/l Higher feed TSS concentrations - not as prone to plugging Page 29

30 Tertiary Separation Siemens Media Filtration Evolution AutoShell External Media Scrubber Monosep High-flow WSF PerforMedia New Backwash Design Feed O&G up to 500 ppm Increased Flux Higher Oil Loading Eliminated Rotating Equipment Synthetic Media Page 30

31 Tertiary Separation Benefits of PerforMedia TM PerforMedia is a game changing filtration media and its benefits include: ELIMINATES one entire treatment step Requires ZERO upstream chemical treatment COST SAVINGS for both OpEx and CapEx Proprietary Siemens technology Page 31

32 Tertiary Separation Selection Criteria Process Conditions Flow Rate (per vessel) MONOSEP WSF m³/h Influent Effluent Free Oil & Grease Total Suspended Solids Free Oil & Grease Total Suspended Solids < 100 ppm (<500 ppm*) < 50 mg/l (<100 mg/l*) < 5 ppm 95% removal > 10 micron * PerforMedia Page 32

33 Reference Installations Page 33 XX.XX.20XX Autor PD / Abteilung SLN WS

34 Reference Installations in the Oil & Gas Industry OMV Petrom (RO) PWTP Tazlau Field UA NCOC (KAZ) PWTP Kashagan Field CZ INA (HR) PWTP Zutica Field AT SI HR BIH SK HU MN RS KO RO BG MD KomMunai (KAZ) PWTP Komsomolskoe Field GE AR OMV Petrom (RO) AZ PWTP Oprisenesti Field AZ TK OMV Petrom (RO) PWTP Bordei Verde OMV Petrom (RO) PWTP Vata Field OMV Petrom (RO) PWTP Videle Field IL Page 34

35 Water Management in the O&G Industry Up-stream Water Treatment Dr. Robert Vranitzky MBA Head of Water Solutions Water Solutions / Austria / Siemensstraße Vienna Fax: Mobil: robert.vranitzky@siemens.com Page 35