AIES Desanding Hydrocyclones

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1 AIES Desanding Hydrocyclones Efficient solids removal from wellstream fluids Primary treatment stage Solids are a problem in Oil & Gas production facilities and management of separated solids is a critical component of any production process. Using advanced engineering design tools, AIES (AI Energy Solutions) has developed the latest generation in hydrocyclone technology, the AIES Hydrocyclone. The AIES design consists of an involute inlet geometry which minimizes fluid turbulence and reduces inlet wear. The innovative hydrocyclone geometry produces finer separation and increased throughput at lower design pressure drops than conventional designs. AIES hydrocyclones are designed to meet the harsh conditions of the upstream market and are constructed of wear resistant alumina ceramic and nitiride bonded silicon carbide. Solids are typically removed from the process: At the well head upstream of the choke Downstream of the choke and before the production separator From the separator in the aqueous phase or sand jetting effluent

2 AIES Desanding Hydrocyclones Efficient solids removal from wellstream fluids Primary treatment stage Process Overview The hydrocyclone uses pressure energy from the flow stream to achieve cyclonic separation of solids. The change in flow direction forces the mixture to spin in a radial vortex pattern. This vortex flow is accelerated as the internal diameter is reduced over the length of the cone. Solids that exit through the apex collect into an accumulation chamber, where they are periodically purged, while the overflow discharges continually. AIES provides a variety of hydrocyclone sizes designed to achieve the most efficient separation while managing pressure drop in any given system. Sizing options include: 1, 2, or 3 diameter hydrocyclones (liners) made of alumina ceramic and housed inside a larger pressure-containing vessel. Additionally AIES can provide larger single hydrocyclone liners for applications requiring coarser separation and lower pressure drop. aies-1 aies-2 aies-3 aies Turn down D98 of 5 μ 1 body diameter Wear resistant alumina ceramic 2 body diameter Wear resistant alumina ceramic 3 body diameter Wear resistant alumina ceramic 4 30 body diameter Nitride bonded silicon carbide When turn down requirements exeed the normal hydrocyclone ratio of 3:1, AIES can offer the turn down design. Turndown ratios that exceed 50:1 are achievable with this design. This is accomplished by compartmentalizing the overflow section and including isolation valves for each compartment. The number of operating liners is determined by the system differential pressures and the entire process can be manual or automated. Mechanical Features With multiple installations and over 50 years of experience for support, AIES systems engineers will work with you to develop the most efficient, cost effective system for your application. Benefits of a AIES separation unit are: Existing installations and detailed knowledge of high pressure, multiphase systems (15,000 psig and 100% gas flow) Compact design for reduced footprint and weight Wear resistant materials of construction for increased reliability and low maintenance Flexible operation for variations in rates Manual or fully automated T M E info@ Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change any time. Please contact us for specific information or data that may relate to your interest.

3 AIES Deoiling Hydrocyclones Gross oil removal in a single pass Primary treatment stage AIES (AI Energy Solutions) has access to the latest generation Deoiling hydrocyclone. These hydrocyclones have a unique inlet geometry which helps minimize turbulence and reduces inlet wear. The innovative liner geometry produces finer, sharper separations at higher unit capacities, allowing fewer cyclones to be used for optimal performance and cost. These liners are made of Duplex SS and are fully replaceable, thus providing a cost effective wear solution for the hydrocyclone. Principles of Operation Feed enters the deoiling hydrocyclone through an involute inlet. Its velocity is converted into tangential velocity in the inlet area, imparting a centrifugal force on the fluids. As the feed moves down the conical section, tangential velocity increases as does the centrifugal force. The heavier water phase, which is subjected to higher centrifugal forces, moves to the outer wall of the cyclone. The lighter particles, primarily oil droplets, are displaced towards the inner core of the cyclone. The water phase exits the tailpipe as the deoiling hydrocyclone underflow. The core of the light phase (oil) moves axially up the cyclone, due to back pressure on the underflow, and exits out the reject orifice as overflow. By maintaining a certain back-pressure on the underflow, the oil core is forced out through the overflow outlet which has a reject orifice sized to achieve a flow of approximately 2-3% of the total inlet flow.

4 AIES Deoiling Hydrocyclones Gross oil removal in a single pass Primary treatment stage Pumped Hydrocyclones When the existing process pressure is too low (<25psi), a low shear booster pump can be included to increase inlet pressure. To ensure that minimal shearing of oil droplets takes place, strict guidelines on pump selection, piping configuration, and system operation must be followed. With many existing pumped hydrocyclone systems in operation, AIES has the experience and knowledge to assist in designing a successful pumped system. Produced Water Systems In addition to a stand alone vessel, the AIES hydrocyclone systems can be incorporated into a complete produced water treatment system. The AIES hydrocyclone reduces the Oil in Water concentration to manageable levels for downstream polishing equipment. AIES offers complete packages for treatment of produced water from the production separator to overboard discharge or reinjection. Typical process equipment included in an AIES produced water treatment package are AIES hydrocyclones, along with flotation or filtration units. The system can use natural pressure or pumps that can be included to boost inlet pressure. Operation can be automated or manual and the equipment can be constructed of almost any material. Turn down In order to accommodate large turndown requirements that exceed 50:1, AIES offers its turn down design. Turn down allows for continuous operation without ever shutting down the vessel. This is accomplished by compartmentalizing the overflow and underflow of the deoiling vessel. Isolation valves are opened or closed to adjust the number of liners in operation depending on the system flow rate and pressure drop. T M E info@ Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change any time. Please contact us for specific information or data that may relate to your interest.

5 AIES Corrugated Plate Interceptor (CPI) Removing free oil and suspended solids from contaminated water streams Primary treatment stage AIES Corrugated Plate Interceptor (CPI) The AIES Corrugated Plate Interceptor (CPI) is a high efficiency gravity separator used for removing free oil and suspended solids from contaminated water streams. With excellent strength and rigidity, due to the lattice-type pack structure, the AIES CPI has been widely used as a primary treatment step for produced water, rain water run-off and plant washdown wastewater treatment.

6 AIES Corrugated Plate Interceptor (CPI) Removing free oil and suspended solids from contaminated water streams Primary treatment stage Principle of Operation The AIES CPI operates as a two-step process; Coalescence and Separation. Firstly, the influent water, containing free oil and suspended solids, passes through a primary coalescer. The coalescer, which is trapezoidal in flow direction, increases the collisions between the suspended oil droplets. When the oil droplets collide they group together to form one larger droplet (coalesce). A similar effect is experienced by the suspended solids whereby they collide and form an agglomerated particle that is larger in size. Water from the coalescer then passes, in a sinusoidal path, through the horizontal cross flow plate pack. The cross flow plate pack, which is composed of tilted corrugated plates, helps guide oil droplets to the top of the vessel and suspended solids to the bottom. The free oil droplets rise until they reach the underside of the above plate where they coalesce and follow the angle of the plate until it reaches the water surface. The suspended solids will fall to the top of the plate below and follow the plate angle to the bottom of the vessel where they accumulate. Oil is stored in the oil trough until it is temporarily discharged. Similarly the solids are stored at the bottom of the vessel and periodically discharged. The clean water flows over the water weir and through the outlet nozzle. Advantages High removal efficiency of suspended oil and solids Recovered oil with low water content Low energy consumption No moving parts - Low Maintenance/Low Cost Low energy consumption Vessels can be retrofitted with AIES plate packs Applications Produced Water Treatment Wasteware (Refinery or Petrochemical) Rain water runoff Ballast and Bilge water treatment Tank water drain down Oil spill containment T M E info@ Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change any time. Please contact us for specific information or data that may relate to your interest.

7 AIES Induced Static Flotation Removing fine oil droplets and solid particulate from contaminated water streams Secondary treatment stage AIES ISF Flotation The AIES (AI Energy Solutions) ISF package is a fully contained induced gas flotation system designed for removing oil and suspended solids from produced water and industrial waste streams. The ISF unit uses an eductor based hydraulic flotation process to remove the contaminants from the water stream.

8 AIES Induced Static Flotation Removing fine oil droplets and solid particulate from contaminated water streams Secondary treatment stage Process Overview Fluid enters the vessel through the inlet chamber and passes successively through each of the four flotation chambers. Blanket gas from a common volume inside the top of the vessel is pulled by a venturi action into each flotation chamber through an eductor assembly. The eductor system is one of the most important aspects of the AIES ISF System. As the recirculated process water flows through the converging nozzle, the high velocity creates a pressure reduction at the throat of the gas nozzle assembly. This low pressure zone results in the induction of the free-board gas through the nozzle, with subsequent in-line mixing with the process water. The gas/ water mixture encounters the striker plate, which causes the mixture to exit radically, assuring uniform distribution across the full cross section area of the flotation chamber. Advantages Complete Off Gas Containment (eliminates potential H 2 S or other toxic gas exposure) Low power requirements Reduced Skimmings Volume No internal moving parts External skimmings control Skid Mounted System Small footprint, compact horizontal or single cell, vertical configuration Eliminates environmental pollution ASME code rated if needed for pressure applications Applications Produced water (or Oilfield Produced Water) Wasteware (Refinery or Petrochemical) Offshore storm water runoff Refinery & Petrochem Tank water drain down Process waste stream T M E info@ Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change any time. Please contact us for specific information or data that may relate to your interest.

9 AIES Compact Flotation Unit (CFU) Increased recovery for fine oil droplets and solid particulates from contaminated water streams Secondary treatment stage AIES Compact Flotation Unit (CFU) The AIES (AI Energy Solutions) Flotation Units have been engineered to meet our specific end-user requirements. Developed to meet our customer s demand for smaller footprint, increased capacity and better performance. Each flotation unit is configured to provide the optimum process conditions to match oil particle size distribution and low density particulates removal. Our application engineers will generate the best solution by optimizing each component of your flotation unit, such as: Gas flow and pressure Tank geometry Residence time

10 AIES Compact Flotation Unit (CFU) Increased recovery for fine oil droplets and solid particulates from contaminated water streams Secondary treatment stage Mechanism of Separation The mechanism of fine oil droplet flotation relies on attachment of the introduced gas bubble to the dispersed oil droplet. The combined oil droplet/bubble, having a lower density than the oil droplet alone, can then be separated by gravity settlement. The flotation unit relies partly on gas effervescing from solution (due to pressure letdown), but the primary bubble source is hydraulic entrainment of gas through an eductor. The entrained gas is recycled from the gas space at the top of the Flotation vessel. Additional key internals that are utilized on a specific case basis may include coalescing media placed in the annulus to capture fine oil droplets and nucleate further growth. The AIES Compact Flotation Unit (CFU) operates at a nominal pressure, usually 10psig, so there is a driving force for the gas and liquid streams to exit the vessel. Apart from the level control valves and pressure control valves there is very little pressure drop across the CFU. To maintain the separation in the CFU vessel a proportion of the outlet water flow is recycled back to the inlet through an eductor. The eductor is employed to entrain gas from the vessel headspace into the recycled water flow, this ensures that there is a fine dispersion of bubbles inside the CFU to facilitate oil droplet flotation. The recycle flow and gas entrainment are independent of the inlet flow. This means that regardless of inlet flow there is always a fine dispersion of bubbles in the CFU and the unit effectively has a 100% turndown. The liquid gas interface in the CFU is maintained at a constant level by the level control valve on the produced water outlet. Periodically the level will be raised (typically 30 seconds every 2 hours) above the level of the oil skim weir to remove the oil pad that has formed on the surface of the produced water. T M E info@ Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change any time. Please contact us for specific information or data that may relate to your interest.

11 AIES Sand Fluidisation Cyclone Efficient sand removal from separators and accumulators Effective sand removal AIES Sand Fluidisation Cyclone The AIES (AI Energy Solutions) Sand Fluidising Cyclone (SFC) allows safe, controlled and efficient removal of sand and solids from the bottom of separators, accumulators and any simple gravity settling devices. The AIES Sand Fluidising Cyclone are equally effective installed in new vessels or retrofitted into existing facilities. Providing good floor coverage each unit generates a high solids slurry for easy sand

12 AIES Sand Fluidisation Cyclone Efficient sand removal from separators and accumulators Effective sand removal AIES Sand Fluidisation Cyclone The AIES SFC allows for on-line solids fluidization and transport of solids which settle to the bottom of vessels. This device has no moving parts; it uses a motive fluid to fluidize solids in a controlled manner in a defined region of a vessel. The AIES SFC creates a vortex which evacuates settled solids in an approximate area of 1 meter in diameter. This area of the vessel is swept clean of solids using a low energy low flow cyclonic pattern. The solids are evacuated through the center of the AIES SFC out of the process vessel. AIES SFC manifolds can be designed to cover all or part of a vessel. The resultant slurry created by application of the AIES SFC can be up to 70% by weight solids. This dense slurry makes it possible to handle solids in an efficient and effective manner as the amount of produced water delivered with the solids is minimized. When compared to conventional sand jetting systems, slurry density is as much as 9 times heavier. A 1 AIES SFC can transport up to 4 tons of solids per hour. Process Overview The AIES SFC is installed just above the floor of a vessel. Each device covers about a 1m 2 area of floor space in terms of its ability to fluidize solids. As such the devices are located about 1m apart. When the motive fluid is applied to the aiesa vortex is created at its base. Solids around the vortex are drawn into the AIES SFC discharge port. To transport the resultant slurry, the vessel s native pressure or the assistance of an eductor is used. The AIES SFC manifold is the evolution of the traditional sand jet into a more efficient device for transporting solids. Advantages Effectively removes solids from O&G streams which create emulsions, instrument failure, erosion and corrosion, damage pumps, create off-spec product, etc. Uses minimal flow and pressure of motive fluids- eliminates erosion Creates a dense slurry eliminating the need for downstream fluid handling equipment Slurry transport over long distances is possible No moving parts highly reliable Requires minimal support instrumentation and control equipment Allows for on-line removal of solids Can be used in conjunction with other AIES solids management equipment such as sand cleaning, and bagging equipment. Mechanical Design & System Features Nominal motive fluid feed requirements for a 1 AIES SFC system amounts to 3 to 4 m 3 / hr. The fluid is supplied at a pressure of approximately 8 to 10 psi above the operating pressure of the vessel. AIES will assist in the application and design of the of the AIES SFC. The piping manifold design is critical to the transport of solids. The piping design must maintain flow velocities to avoid the settling of solids. T M E info@ Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change any time. Please contact us for specific information or data that may relate to your interest.

13 AIES Deep Bed Nut Shell Filters Removing fine oil droplets and solid particulate from contaminated water Tertiary treatment stage The AIES (AI Energy Solutions) Nut Shell Filter (NSF) provides tertiary treatment and is the preferred choice in removing fine oil droplets and solid particulate (>2 micron) from contaminated water streams. The AIES NSF is a down flow, deep bed media filter consisting of a blend of pecan and walnut graded shells. The key feature of the AIES operation is the fluidization process (backwash) that strips oil contaminants and suspended solids from the nut shell media. The concentrated waste stream is discharged from the vessel while the media is retained. The fluidization mechanism utilizing internal scrubbing of the media results in very low attrition rates; typical replenishment of the nut shell media is <5% per year.

14 AIES Deep Bed Nut Shell Filters Removing fine oil droplets and solid particulate from contaminated water streams Tertiary treatment stage Process Overview In the filtration mode, the AIES Nut Shell Filter acts as a down flow filter. Oily inlet water is introduced through a header that provides even flow distribution across the media bed. The influent flows down through the media bed and exits the filter through a wedge wire stainless steel support screen at the base of the vessel. As fine oil droplets and solids are removed from the influent stream, the differential pressure across the filter increases until it reaches a predetermined level causing the filter backwash cycle to commence. If the filter differential pressure does not activate, the backwash cycle is activated by a timer once every 24 hours. During the backwash sequence, the flow direction is reversed and the fluid flow helps with the media bed as it is fluidized. An integral fluidization pump located on top of the vessel is activated and circulates the media through a scrubber nozzle and across a wedge wire scrubber screen. The wedge wire screen allows contaminates to pass through and out of the vessel while retaining the nutshell media. Backwash fluid exits out the bottom of the vessel through the backwash line. Once cleaned, the media is allowed to gravity settle so that the filtration cycle can resume. Performance Characteristics The performance of the AIES NSF is typically 98% removal of free and dispersed oil droplets 98% removal of solids > 2 microns minute backwash cycle/offline time every 24 hours Backwash volumes are typically less than 1% of throughput capacity. Mechanical Features Deep (48 ) bed filter consisting of pecan/walnut shell media for maximum separation efficiency and low attrition rates High flux rates (recommended range of gpm/ft 2) Simple automatic operation Typically performance of 98% removal of contaminants (insoluble hydrocarbons and suspended solids) of >2μ Integral scrubber pump nozzle and screen Automated controls with presets for backwash Standard sizes range from 2,500 80,000 BPD per system Media particle size: 12/20 mesh Media is not force set after cleaning as is necessary in other filters. Backwash step averages 14 minutes No air/gas scour backwash step High volumes of backwash water are not required Positive Regeneration cycle prevents bed channeling and mud balling of nut shell media Regeneration volume is less than 1% of throughput. Applications The tertiary treatment step filtration is typically the final stage before disposal or reuse of the produced water. Produced water reinjection systems that demand near oil free effluent Pretreatment of produced water prior to softening for steam generation T M E info@ Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change any time. Please contact us for specific information or data that may relate to your interest.

15 AIES Ceramic Membrane Filtration Packages Removing fine oil droplets and suspended solids from contaminated water streams Final treatment stage The AIES (AI Energy Solutions) Ceramic Membrane Filtration Packages offer a unique option as a final stage in our produced water treatment systems. Utilising the LiqTech SiC industry leading Ceramic Membrane, AIES are able to offer very high quality outlet water with exceptionally low suspended solids and oil concentration. These filtration packages are an ideal final treatment stage for clients who demand high quality water for reinjections, steam generation or desalination units.

16 AIES Ceramic Membrane Filtration Packages Removing fine oil droplets and suspended solids from contaminated water streams Final treatment stage Process Overview Discharge and re-injection of Produced Water from oil production is becoming increasingly challenging because as oil wells mature, the water cut increases. Many regions are now tightening the legislation for discharge of Produced Water which means that the oil producers have to look for new technologies. Ceramic ultra filtration membranes can very easily produce permeate with well under 5 mg/l oil. Due to the unique hydrophilic properties of Silicon Carbide it is possible to obtain higher water fluxes on the LiqTech SiC based CoMem mem branes than with other membrane materials. Continuous process flux for oil/water separation is recorded between L/m 2 /h depending on the oil type. Advantages Highest water flux compared to any other membrane material - High capacity, reduce your foot print Chemically resistant for the full ph-range, ph No need to worry about harsh chemicals Thermally resistant up to 800 degree C - Produced Water of any temperature can be treated with SiC membranes SiC membrane with selective layer, negatively charged surface and hydrophilic material - Consistently removes oil and TSS regardless of feed conditions Extremely hard and durable material - Long life time, reduced down time and less maintenance. Mechanical Features High Permeability The high permeability is achieved due to High porosity Large pore sizes in support/carrier Low contact angle to water The high permeability/flux means low resistance to transport water The benefit is a large filtration capacity per installation volume (reduced footprint) and/or reduced energy consumption The large capacity per membrane volume means reduced costs for auxiliary valves, piping, instruments and installation area. Temperature Resistance Tolerates temperatures up to 800 degrees C Filtration possible at higher temperatures without compromising the selectivity Steam can be used to clean/sterilize the membranes Increased lifetime of membrane elements. Applications This treatment package is typically the final stage before disposal or reuse of the produced water Produced water reinjection systems that demand near oil free effluent Pretreatment of produced water prior to softening for steam generation. T M E info@ Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change any time. Please contact us for specific information or data that may relate to your interest.