December 2014 - · PDF fileTEG Package Gas Sweetening Membranes Fuel Gas System ... 8...

Applications of an innovative mixing technology in separation and

Produced Water Treatment

December 2014

Copyright © 2014 ProSep. All Rights Reserved.

PROSEP OVERVIEW

8 December 2014 2

ProSep is an industry-leading provider of integrated process separation solutions to the global oil and gas

industry

Upstream

Midstream

Downstream

Petrochemical

Full suite of proprietary and conventional technologies –

oil, gas & water

Global HQ in Houston, TX, USA

Manufacturing facility – Houston, TX, USA

Regional office – Aberdeen, UK

Regional office – Kuala Lumpur, Malaysia

Regional office – Abu Dhabi, UAE

Backed by private equity firms Energy Ventures (Norway) and Harris & Harris Group (New York, USA)


PROCESS & TECHNOLOGY CAPABILITIES

8 December 2014 3

Osorb® Media

Production

SeparatorProMix

Heater Treater /

Dehydrator Desalter

Compression Compression

Separator Gas Treatment / Dehydration

ProDry & TEG

Gas

Dehydration

Export

Export

Chemicals

Desander

CPI

Hydrocyclone

Wash

Water

IGF

Nutshell

Filter

CTour®

Process

2/3 Phases2/3 Phases

Gas Sweetening

Membranes

FWKOProSalt

ProScav and H2S

Removal

Water

TORR

Coalescer

Solids HandlingSolids Handling

Skimmer

Oil

Gas

Wellhead ProMix

Reinjection /

Discharge

Sand

Disposal

ProMix

Hydrocyclone

Chemicals

Fuel Gas /

Seal Gas

Chemicals IGF / CFU

Condensate

Degasser

Nitrogen

Generation

Seawater

Injection

Proprietary Technology


PROCESS & TECHNOLOGY CAPABILITIES - REFERENCES

8 December 2014 4

Crude Dehydration Crude Desalting Crude Treatment Train ProBlend Crude Blending Skid

TEG Package Gas Sweetening Membranes Fuel Gas System

IGF & Hydrocyclone Package CTour™ PWT Seawater InjectionTORR™ PWT Treatment

ProMix™ Demulsifier Inj.

ProScav™ H2S Scavenging

Osorb Media NSF


ENERGY SERVICES

8 December 2014 5

Mobile equipment for:– Temporary Requirements

– Shutdowns

– Upset Management

– Technology Evaluations

Experienced field operators and technical

service chemists provide:– Site Services

– Commissioning, operation, maintenance, and

troubleshooting

Extensive experience with water treatment

and filtration requirements for upstream

and downstream installations

Services applied for both onshore and

offshore installations


RESEARCH & DEVELOPMENT

8 December 2014 6

R&D facility provides the resources required to

optimize the performance of our technology

portfolio including: – Flow loops,

– Prototype units

– Tools for simulating field conditions available

Complete analysis of oil, gas, and produced

water streams in our state of the art laboratory

using instrumentation, including: – Spectrometers (infrared, UV/VIS, and fluorescence)

– Particle analyzers (ViPA)

– Gas chromatography

– Associated detectors (FID, MS, and TCD).

Working with ProSep Energy Services division,

portable equipment skids allow us to test

products at clients’ sites with live fluids to

demonstrate real time solutions to operator

issues.


MANUFACTURING

8 December 2014 7

56,000 sq. ft. purpose built manufacturing & fabrication

facility in Houston, TX. 70 Ton lifting capacity.

Capability to manufacture:– Large structural fabrications

– Vessels – up to 14’ diameter, 60’ long and 3” thick

– Piping spools,

– Packaged equipment

– Exotic material welding

ISO 9001 approved, FPAL & Achilles registered, and

ASME certified to Section VIII, Division 1 & 2.

Skid packages can be fabricated with dimensions up to 18

ft. wide & 30 ft. in length

European manufacture is through our network of

fabrication partners in UK, Europe and Norway.

Malaysian manufacture though network of fabrication

partners.


Mixing Technology

8 December 2014 8


Proprietary Mixing Technology - Overview

8 December 2014 9

Co-current chemical injection and mixing

Liquid-liquid & gas-liquid

Generic benefits across all applications:

– Low shear

– Homogeneous mixing - Typically 90% mixing efficiency

– Very low pressure drop (0.03-0.3 bar typically) – resulting in energy savings and efficiencies

– Reduction in chemical injection consumption by 20-60% depending on the installation.

– High Turndown ratio


PROMIX™

8 December 2014 10

Co-current chemical injection and mixing

Liquid-liquid & gas-liquid

Flow-driven

Low shear

Homogeneous mixing

Low dP

Quill

Quill + Static Mixer

ProSep Mixer

High dP

Large contactor

length

Propensity to

scale

Low efficiency

Heterogeneous

Mixture

Low efficiency

Low dP

Small contactor

length

Resistant to

scale

High efficiency

Homogeneous

Mixture


PROMIX™ - PRIMARY SEPARATION

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DESALTING - PROSALT™

8 December 2014 12

Typically installed upstream of a dehydrator or desalter, ProSalt is a

novel inline injection/mixer assembly that can be used for high efficiency

multi-phase mixing.

Features:

Independent of upstream piping arrangement

Automated online adjustability

Provisions for online de-plugging are available

Benefits:

High efficiency capable of multiphase mixing

Low pressure drop (0.1 to 0.3 bar)

Drastically reduces wash water consumption by up to 60%

Increases desalting wash water separation efficiency

Excessive turbulence ensuring rapid mass transfer

Outlet channels give uniform outlet flux of the multiphase mixture

Small channels give high

velocities resulting in

the formation of small

droplets / bubbles

Finger folding jet-flow-pattern giving minimumpressure drop

Multiple mixing internalsEnsure optimal performance


PROSALT™ VS CONVENTIONAL

8 December 2014 13

ProSalt

Up to 60% reduced water usage - one installation is saving

10,000,000 gallons of water per year for one major operator

Up to 60% demulsifier saving (20-40% savings typical)

Narrow water droplet size distribution

Mixing efficiency increased by 30%

Low pressure drop, high efficiency separation

Increase efficiency of downstream water treatment

Increased crude treatment capacity

Conventional

Broad water droplet size distribution

High pressure drop

Results in low efficiency separation


PROSALT™ CASE STUDIES – SAUDI ARABIA

8 December 2014 14

Key Results

Differential pressure decreased by more than 50%

Wash water rate was reduced by 40% from 50 gpm to 30 gpm

OIW content from the desalter was reduced by 60% - 18 pm to

7 ppm


PROSALT™ CASE STUDIES - NORWAY

8 December 2014 15

Case Study - Example

14” ProSalt unit at Statoil Mongstad refinery for

mixing of crude and wash water.

Installed in parallel to a conventional globe

mixing valve upstream of the 1st-stage desalter

(in the 2-stage process)

Two Stage Process for Desalting Crude

Process Conditions

Operating pressure: 145 psi

Operating temperature: 230-266 °F

Crude API: 37

Crude oil flow rate: 2.20 M lbm/hr

Volumetric flow rate @ op. T&P: 8200 bbl/hr

KEY RESULTS PROSALT

Pressure drop 3-12 psi

Significantly reduced wash water

consumption

Salt spec typically below 2 mg/l; 0.70 ptb

BS&W spec (0.10 – 0.15 vol %)


PROSALT™ CASE STUDIES - NORWAY

8 December 2014 16

Oil-in-water from 1st stage desalter (ProSalt Test Mixer installed upstream of 1st stage desalter)

100

1 000

10 000

100 000

0 28 Time

Test Period 1 Test Period 2

(16-19.10.2006) (23-26.2006)

Oil-i

n-w

ate

r [m

g/l]

ProSalt Test Mixer,

dP=0,35 barGlobe valve,

dP=0,35 bar

Globe valve,

dP=0,35 bar

ProSalt Test

Mixer

dp=0,23 bar


LIQUID H2S SCAVENGING - PROSCAV™

8 December 2014 17

ProScav is a system for injecting and efficiently mixing liquid H2S scavenger in the natural

gas stream to remove H2S.

Features:

Compact inline system; easy to install at any pipe angle

Option for simultaneous flow metering & mixing

Robust design for low maintenance

Benefits:

Highly efficient mixing with low pressure drop (0.03 to 0.3 bar)

20 – 60% reduction in liquid scavenger consumption

High turndown ratio in scavenger injection rate typically 10 to 1

Low to zero maintenance if the required 50 micron filter is equipped in the scavenger injection line


LIQUID H2S SCAVENGING - PROSCAV™ CASE STUDIES

8 December 2014 18

Reduced environmental impact

No clogging, minimal maintenance

Reduce OPEX / chemical usage

Reduced liquid H2S scavenger chemical

usage

ProScav mixers were installed on 4 applications including Gulfaks B and

the Asgard B in the Norwegian sector.

An average 37% reduction in scavenger consumption across the platforms


LIQUID H2S SCAVENGING - PROSCAV™ CASE STUDY

8 December 2014 19

ConocoPhilips China – Technical Summary

Location: China, CNOC Peng Bo FPSO

Equipment: ProScav mixer

Process Conditions / Results

Operating temperature 23 C increased to 60-70 C

Pressure 5.2Mpa

Gas flow rate 13MMSCF/d

Inlet H2S content 400-510 ppm

Outlet H2S content 50ppm

Triazine based scavenger

Reduction in scavenger consumption from

16m3 per day to 4m3 per day

ConocoPhilips China – Commercial Summary

Location: China, CNOC Peng Bo FPSO

Equipment: ProScav mixer

Commercial Benefit / Value Add:

Triazine based scavenger $8-$15 per gallon (typically)

If value at $8 per gallon

– $21K per day saving

– $7.6M saving annually

Saving 75% of chemical (environmental impact factor (EIF) benefit)

Saving 75% of cost of scavenger chemical.

4” ProSep mixer paid for (in this application) in under 1 month.


PROPRIETARY PRODUCED WATER

TREATMENT PORTFOLIO


TERTIARY SEPARATION - TORR™

8 December 2014 21

Features:

Reduce 1000 ppm down to discharge regulation, often <5-10 ppm

Maximum flow rate per vessel of 60,000 BWPD

Operational temperatures up to 90˚C

Removes & recovers oil droplets larger than 2 microns

Trial packages from 250-20k BWPD available for field testing of PW streams

Benefits:

Small footprint & low weight

Increased polishing for reinjection applications

Solids pre-treatment for reinjection

Same high de-oiling efficiency during production start-up periods

No additional treatment required for recovered oil

Minimal pressure drop & maintenance

Recovered hydrocarbons can be <0.5% BSW

High flow rate turndown

TORR™Coalescing technology, with its small footprint and ability to replace less efficient oil removal equipment, is a scalable technology

that addresses future increases in water cut for offshore operators.


TERTIARY SEPARATION - TORR™

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TERTIARY SEPARATION - CTOUR™

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CTour™ Process

The CTour™ process removes dispersed oil and dissolved hydrocarbon contaminants in the

produced water stream through injection of condensate.

Injection of a condensate of light hydrocarbons (specific gravity of 0.5 to 0.75) into the produced

water stream to extract harmful components. The key to the success of the CTour process is the

ProMix. This enables the homogeneous mixing of the condensate into the produced water

stream.

Benefits:

Performance - Removes OIW to below 4-5 ppm

Reduces dissolved hydrocarbons (PAH, phenols, BTEX) by 80 – 95%

No waste products – no disposal/transportation costs

No chemicals added

Easy to install in existing systems

Very low operating costs

Robust process, low maintenance

Removal of < 5 micron oil droplets

Removal down to 14 API crude



8 December 2014 24

. PROCESS PRINCIPLES

Solvent extraction process for

dissolved and dispersed

hydrocarbons

Critical process parameter is injection

& mixing of the condensate in our

proprietary mixer

Condensate acts as extraction

solvent

Spent solvent is removed by a

standard separator:

Hydrocyclone

Flotation

Axial cyclone

Gravity vessel

Coalescing filter



8 December 2014 25


OSORB® MEDIA TECHNOLOGY

8 December 2014 26


TERTIARY SEPARATION – OSORB® MEDIA

8 December 2014 27

OSORB MEDIA

• Organically-modified silica

• Porous, flexible matrix

• Hydrophobic

• Adsorption & absorption

• Regenerable & reusable

APPLICATION METHODS

• Bulk media vessel

• Canisters

• Injection into flow line

Removal of free, dispersed,

emulsified, and soluble

hydrocarbons and some

oilfield chemicals from water

APPLIED TO:

• Produced water

• Flowback & completion

returns

• Pipeline fluids

• Membrane protection

• Chemical EOR

• Hydrocarbon dew point

(HDP)

• Gas emissions control

Removal of

vapor phase

and

micro-droplet

hydrocarbons

from gas


OFFSHORE TEST COLUMNS

8 December 2014 28

Low flow feasibility testing & performance evaluations

Tie into existing sample point for evaluation on slip stream of live fluids

In situ regeneration evaluations

3” Diameter Column 6” Diameter Column 6” Acrylic Column


PRODUCED WATER FOR OIL RECOVERY & STEAM REGENERATION

8 December 2014 29

Kuwait

6” Test Column

Onshore treatment for reinjection

18-20 API Oil

43-52°C

> 120% w/w oil Osorb Media loading


OFFSHORE PRODUCED WATER

8 December 2014 30

North America

6” Test Column

Offshore treatment for

discharge

Management of offshore

excursions

10-18 API Oil

High asphaletene

concentrations

79°C

0

25

50

75

100

125

150

175

200

225

0 100 200 300 400 500 600 700 800

OIW

(m

g/L

)

Time (min)

Oil in Water (OIW) Concentration

Inlet (mg/L) After Osorb® media (mg/L)


Downstream Process Water – Case 1

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Downstream Process Water – Case 2

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OSORB MEDIA REGENERATION – HYDROCARBON DEW POINT

REDUCTION

8 December 2014 33

Capture of the liquid and vapor-phase heavier hydrocarbons in the gas stream

Sorbate in Osorb® MediaRT

(min)

BP

(oC)

ppm in DCM%

RegeneratedBeforeRegeneration

After

Regeneration

benzene 2.63 80 26 0 100

heptane 2.98 98 429 0 100

methylcyclohexane 3.35 101 734 0 100

toluene 4.17 111 338 0 100

octane 4.96 126 730 0 100

ethylcyclohexane 5.95 131 325 0 100

p-xylene 6.92 138 510 0 100

m-xylene 7.49 139 171 0 100

nonane 7.65 151 706 0 100

propylcyclohexane 8.31 155 274 0 100

Regeneration of Osorb Media with heat and nitrogen purge results in

pure condensate value stream.


THANK YOU

AMERICAS | EUROPE & AFRICA | ASIA PACIFIC | MIDDLE EAST

prosep.com

December 2014 - · PDF fileTEG Package Gas Sweetening Membranes Fuel Gas System ... 8...

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