How A Vertical Tube Falling Film Evaporator Can Be Used to Deliver the Lowest Total Life Cycle Cost for Alberta Produced Water Treatment

Overview Minimizing Installation Costs Evaporator Pilot Program Oil Excursions High Efficiency Evaporation

Oil Sands Market Alberta oil reserves are 3 rd largest globally Only about 1% of reserves are conventional crude Energy Independence as key market driver Globally, the largest unrestricted access to oil Alberta Government; www.oilsands.alberta.ca, reports proven reserves of 170.8 billion barrels with only 1.5 billion barrels as conventional crude

Sustainability Waste Disposal Water Recycle Source Water Limitations Steam Generation Deoiling Heavy Oil for Upgrading Power & Chemical Consumption High Front- End Investment Costs Technology must continue to develop to allow these vast resources to be tapped

Steam Generation Water Recycle Steam Generation Deoiling

Steam Generation OTSG 20% Blowdown Loose BFW Requirements Drum Boiler 1-2% Blowdown Strict BFW Requirements

Quantifying Blowdown Parameter OTSG Drum Boiler Vaporization Rate 80% 98% Feed Rate, t/d 8,163 6,663 Steam Rate, t/d 6,530 6,530 Blowdown Rate, t/d 1,633 133 OTSG Feed rate is 23% higher Drum Boiler Blowdown rate is 92% lower

Boiler Feed Water Constituent OTSG Drum Boiler TDS, mg/l < 8,000 < 5 TSS, mg/l < 1.0 0 Iron, mg/l < 0.25 < 0.01 Hardness, mg/l as CaCO3 < 0.5 < 0.05 Silica, mg/l < 50 < 0.5 TOC, mg/l N/A < 0.2 Oil & Grease, mg/l < 10 < 0.2

Water Recycle Water Recycle Steam Generation Deoiling

Produced Water Chemistry Constituent Typical Case A Case B Case C TDS, mg/l 3,000 10,000 1,400 3,600 Chloride, mg/l 1,500 5,000 50 2,150 Hardness, mg/l 20 150 15 270 Bicarbonate, mg/l 500 200 700 20 Silica, mg/l 250 150 275 275 TOC, mg/l 300 500 250 300 Oil & Grease, mg/l 10 5 25 20 11

Bridging the Gap Constituent Typical PW OTSG Feed Drum Boiler Feed TDS, mg/l 3,000 < 8,000 < 5 Iron, mg/l < 1 < 0.25 < 0.01 Hardness, mg/l < 100 < 0.5 < 0.05 Silica, mg/l 250 < 50 < 0.5 TOC, mg/l 300 N/A < 0.2 Oil & Grease, mg/l < 15 < 10 < 0.2

VTFF Evaporators Unmatched ability to produce high purity distillate Water recovery > 98% Total reduction of waste volume Flexible to manage feed water changes Reliable water production (Availability > 98%) Extensively proven for Alberta SAGD PW

Produced Water Conventional Approach Chemicals Hot/Warm Lime Softening Filter Chemicals Weak Acid Cation OTSG Injection Steam Sludge to Disposal Filter Waste Regeneration Waste Evaporator Blowdown to Disposal (< 2%) 20% Blowdown

Drum Boiler Approach Chemicals Injection Steam Produced Water Evaporator Drum Boiler or OTSG Blowdown to Disposal (< 2%) Blowdown Recycle

Sustainable Market Needs Lowering Investment Costs Faster Project Execution Lower Project Schedule Risk Improving Evaporator Performance

Lowering Investment Costs Big Idea How can a VTFF Evaporator minimize total installed cost?

Evaporator System Installation

Installing Evaporator Towers Most Equipment is Modularized Evaporators are not Modularized Large Capacity Cranes Extensive Civil Works Evaporator Building Construction Field Labor for Construction

Evaporator Tower: TIC 10,000 bpd Case Study CAPEX = $25 Million TIC Factor = ~ 2.0 3.5 Total Installed Cost = $50 Million Installation Schedule is 4-6 months Construction restricted due to road bans

Repackaging the VTFF Evaporator

Repackaging the VTFF Evaporator Conventional SmartMOD TM

Installing SmartMOD Evaporator All Equipment is Modularized Including Evaporators Standard Capacity Cranes Minimal Civil Works Modular Evaporator Building Field Labor for Bolt-up Assembly

Parameter CAPEX Total Installed Cost Evaporator Towers $25 MM SmartMOD Evaporator $25 MM TIC Factor 2.0 3.5 1.3 1.5 Installation Cost TIC Installation Schedule (weeks) Limited Delivery (Road Bans) $25 MM $50 MM 16-24 Yes $8 MM $ 33 MM 6 No 27

SmartMOD Process Advantages Lower Power Consumption Better Distillate Quality Higher Availability

SmartMOD

Blended Feed Feed Water Tank Process Overview Preheater Deaerator SRV SmartMOD Evaporator Waste Tank BFW Tank To Boiler Distillate Tank Brine Disposal

SmartMOD Evaporator Configuration Feed Blowdown Section #1 Section #2 Section #3 Section #4 Distillate Distillate Distillate Distillate Feed Section #1 Section #2 Section #3 Section #4 Concentration (ppm) 3,000 3,900 5,850 11,115 150,000 Cycles (per Section) 1.3 1.5 1.9 13.3 Cycles (cummulative) 1.3 2.0 3.7 50 Cascaded brine path slowly increases brine concentration

SmartMOD Pilot Overview Total pilot test duration was 3 months Longest single test > 350 hours (15 days) Total PW water processed > 14 m3 Total BW water processed > 2 m3

SmartMOD Evaporator Configuration Feed Blowdown Section #1 Section #2 Section #3 Section #4 Distillate Distillate Distillate Distillate Analyte Feed Section #1 Sectoin #2 Section #3 Section #4 TDS 0.70% 0.90% 1.30% 2.40% 13% Silica (as ion) 237 311 452 825 4747 Calcium (ppm as ion) 101 132 192 351 2022 Magnesium (ppm as ion) 62 81 118 215 1237 Carbonate (as ion) 53 69 100 183 1053

Inhibitor Selection Use of antiscalants to help minimize scale formation Disrupting crystalline structure preventing growth Allow solids to remain dispersed Prevents deposition Inject downstream of SRV & upstream of VTFF Selected for effectiveness in dispersing the targeted scaling ions Polymeric inhibitor used for pilot testing

SmartMOD Pilot Approach 4% Concentration (First 3 Sections) 13% Concentration (Final Section) 25% Concentration (Final Section) Distillate Study

SmartMOD Pilot Conclusions Majority of hardness precipitated in SRV No scaling in SmartMOD sections 1 + 2 + 3 Sections 1 + 2 + 3 best practice is to plan for annual wash SmartMOD section 4 showed minimal fouling after 360 hours Section 4 would require washing every 4-6 months

SmartMOD Pilot Conclusions In-Line chemical wash in section 4 restored transfer efficiency Tubes were visually inspected and determined to be clean No mechanical cleaning required

SmartMOD Pilot Conclusions Concentrations up to 13% were found to have minimal fouling Concentration to 25% experienced fouling after 1 week Nature of fouling at 25% was organic phase and not mineral Fouling was quickly removed with simple rinsing with distillate

Deoiling Upset Conditions Big Idea How does a VTFF Evaporator perform during deoiling upset? Distillate Quality Heat Transfer Efficiency (Fouling)

Understanding Distillate Quality Evaporated water vapor is pure water vapor H 2 O Temp.vap <<< NaCl Temp.vap Entrained liquid droplets contain impurities Mist eliminators achieve distillate quality

Deoiling Upset Conditions Distillate was consistently suitable for BFW service Majority of organics were characterized as volatile O&G excursions in feed water did not carry to distillate O&G excursions did not impact heat transfer efficiency

Improving Performance Big Idea How can performance be improved on a VTFF Evaporator? Lower chemical consumption Longer run times between washes

HIGH EFFICIENCY RO (HERO TM ) Process developed in the 1990 First applied for semi- conductor chip manufacturing HERO TM increased recovery from 50% up to 90% Patented technology is licensed and applied globally Aquatech has over 32 HERO TM installations worldwide One third are ZLD by incorporating evaporation

HIGH EFFICIENCY RO (HERO TM ) ACID CO 2 Softening (WAC/SAC) CAUSTIC FEED P/T IX DECARB RO PERMEATE Ca +2 Mg +2 HCO 3 - + H + CO 2 + H 2 0 REJECT (BRINE)

HERO Pilot Testing with Alberta Produced Water

PILOT TEST ON ALBERTA PRODUCED WATER WITH HERO TM High Efficiency Process demonstrated for Alberta Produced Water Pilot of HERO Conducted in early 2000. Testing duration was 3 months Piloting proved successful for treating produced water with no membrane fouling ACID CO 2 CAUSTIC FEED WAC Decarbonator ph 4.2-4.6 H/E RO Cartridge Filter RO ph 10.6-10.8 Ca +2 Mg +2

Water Chemistry for Pilot Test Brackish Water Produced Water ph 8-9 8.4 TDS ppm 7060 2000-2800 TSS ppm 32 Hardness ppm as CaCO 3 500 15 Silica ppm 24 200-250 P. Alkalinity ppm as CaCO 3 0 40 Total Alkalinity ppm 400 200 Oil & Grease ppm <5 15-60 COD ppm 140 800

High Efficiency Evaporation (HEVAP TM ) Similar to HERO TM applied to evaporation technology Increases Evaporation Efficiency by producing a scale- free chemistry Key Process Steps: Hardness Reduction (Ca +2 and Mg +2 ) Alkalinity Reduction Elevating ph to about 9 or higher

High Efficiency Evaporation (HEVAP TM ) CO 2 ACID CAUSTIC FEED IX HX DEA EVAP Ca +2 Mg +2 HCO 3 - + H + CO 2 + H 2 0

Process Comparison HEVAP TM ACID CO 2 CAUSTIC FEED IX HX DEA EVAP Ca +2 Mg +2 HERO TM ACID CO 2 CAUSTIC FEED IX DECARB RO Ca +2 Mg +2

HEVAP TM Advantage Increased recovery as high quality BFW Lower blowdown volumes Non- scaling operation No anti- scalant requirement No EDTA Dosing required No Mechanical Cleaning

Case Study for 10,000 BPOD Plant High ph Evaporation Process Produced Water to Evaporator After Deaerator After Softening Reaction Vessel with NaOH addition ph 7.8 8.5 10.8 TDS ppm 3135 3135 3135 Hardness ppm as CaCO 3 134 134 < 25 Silica ppm 250 250 250 Alkalinity ppm as CaCO 3 200 120 120

Case Study for 10,000 BPOD Plant HEVAP TM Produced Water A to HEVAP AFTER SAC After HCl addition & Deaerator At inlet of Evaporator ph 7.8 7.8 6.5 10.8 TDS ppm 3135 3135 3135 3135 Hardness ppm as CaCO 3 134 < 0.7 < 0.7 < 0.7 Silica ppm 250 250 250 250 Alkalinity ppm as CaCO 3 200 200 < 25 < 25

Comparison High ph and HEVAP Processes Consumption Kg/day Unit costs $/kg Total Costs per day In USD High ph HEVAP TM High ph HEVAP TM NaCl 0 3968 0.10 0 397 HCl (35%) 0 1410 0.4 0 564 NaOH (50%) 3175 1930 0.5 1587 965 Anti Scale 70 0 9.40 658 0 Antifoam (Neat) 35 35 22.6 791 791 Total OPEX Per day 3036 2717

HEVAP TM Advantage Increased recovery as high quality BFW Lower blowdown volumes Non- scaling operation No Anti Scalant requirement No EDTA Dosing required No Mechanical Cleaning Lower Chemical Consumption (OPEX)