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

Water Solutionsin the Oil & Gas IndustryUp-stream Water Treatment

www.siemens.com/water-solutionsUnrestricted © Siemens AG 2017

Unrestricted © Siemens AG 2017 PD SLN WS

Water Treatment in the Oil & Gas Industry – Up-streamContent

• Produced Water Treatment Objectives• Primary Separation• Secondary Separation• Tertiary Separation• Reference Installations

ü acc. RoK Standardsü acc. Intl. Standards


Serving All Sectors of the Oil & Gas Industry

Exploration & Production„Upstream“

Transport & Storage„Midstream“

Refining & Processing„Downstream“

Gas production

Oil production Gas/Oil separation Pipeline Tank farms RefineryPetro chemistry

Pipeline Terminal Gas processingDistribution

Gas treatmentLiquefaction

Gas production

Oil production Gas/Oil separation Pipeline Tank farms


Treatment Objectives


Overview Treatment Objectives – Up-Stream

Removal of …

• Free Oil & Grease• Suspended Solids

Removal of …

Removal of …

• Suspended Solids• Oxygen• Sulfate

Produced Water Treatment for Reinjection

Sea Water Treatment for Injection

Production

(Oil Well)


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 HydraulicIGF Mechanical

DGF Brise PumpSparge Technology

Down to 50 MicronsDown to 75 MicronsDown to 30 micronDown to 75 microns

Hydrocyclones Centrifugal Force Down to 15 – 20 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


Oil & Gas ProductionProduced Water Treatment Process Map

Discharge orReinjection forWater Flood

ProducedWater

SolidsSeparation

PrimaryProduced Water

Separation

SecondaryProduced Water

Separation

TertiaryProduced Water

Separation


Primary Separation


Primary Separation - Hydrocyclones

• Liquid/liquid, solid/liquid designs

• Maximum separation in a small footprint

• Low weight and small footprint, important in offshoreapplications

• Used primarily to remove concentrations of oil (200to 2,000 ppm) from Produced Water as an initialseparation step prior to polishing by flotation systems


Primary Separation – Hydrocyclones Vessel with Active Liners

Tangential Inlet

Clean Water

Oil Reject

Inlet


Primary Separation - Hydrocyclones

Oil Reject

Inlet Flow

Clean Water


Factors Governing Performance

A number of factors influence oily waterseparation 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


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 WaterWater

InletInlet

PrePre--settlingsettling

ChamberChamber

CPI PacksCPI Packs

Solids OutletSolids Outlet

WaterWateroutletoutlet

OverflowOverflow

Oil SkimmerOil Skimmer


Primary Separation - Skimmers

Skimmers

• Typically upstream of secondary treatmentproducts. 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


Primary Separation – Selection Criteria

Process Conditions Corrugated Plate Separator L-L Hydrocyclone

Influ

ent Flow Rate (per unit) 2,5 – 570 m³/h 7 – 1 135 m³/h

Free Oil & Grease < 2 000 ppm up to 20 000 ppm

Total Suspended Solids < 300 ppm < 2 000 ppm

Efflu

ent

Free Oil & Grease < 150 ppm < 150 ppm

Total Suspended Solids < 50 ppm -


Secondary Separation


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


Flotation Technology

By attaching a small gas bubble to an oil droplet, it will decrease the density of the dropletwhich will increase the rate at which it will rise to the surface.

DGF System On 30 SecondsDGF System Off DGF System On 5 Seconds

• Critical Flotation Criteria• Population of Gas Bubbles• Size of Gas Bubbles

• Distribution of Gas Bubbles• Oil Droplet “Rate of Rise”


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


Secondary Separation - SPINSEP™ System

SPINSEP™ System• Uses specialized cyclonic and flotation technology that

removes oil, grease and solids in a single vesselarrangement.

• “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.


Secondary Separation - VEIRSEP™ System

VEIRSEP™ System• Incorporates several unique technologies to separate oil

and various other contaminates from Produced Water andcontaminated 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


Secondary Separation - Selection Criteria

Process Conditions SPINSEP – DGF VEIRSEP - DGF

Influ

ent Flow Rate (per unit) 7 – 930 m³/h 7 – 1 125 m³/h

Free Oil & Grease < 300 ppm < 500 ppm

Total Suspended Solids < 100 ppm < 200 ppm

Efflu

ent

Free Oil & Grease < 30 ppm* < 30 ppm*

Total Suspended Solids < 50 ppm* < 50 ppm*

* Chemical pre-conditioning (coagulation/flocculation) is needed


Tertiary Separation

XX.XX.20XX


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


Tertiary Separation –Advantages of the Siemens Filter Design

High Flow Walnut Shell Filter

• Constant Flux during Forward Flow throughout entireBed

• Even Bed Fluidization during Cleaning Cycle – EnsuresLonger Filter Run Times and Overall Media Longevity

• Full Depth Capture of Oil and Particulates

• Minimum Chance for Suspended Solids Break Throughwithout Indication of Increased Filter Resistance


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 improveoil and solids removal

• Smaller footprint and weight

• A reduction in backwash water volume52 %


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


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: 16 - 20 mesh

• 5% Loss of Nuts per Year


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

PerforMediaTM

• Load up to 500 mg/L with oil spikes >1000 mg/L

• Higher feed TSS concentrations - not as prone to plugging


Tertiary Separation –Siemens Media Filtration Evolution

AutoShell™

• External Media Scrubber

Monosep™ High-flow WSF

• New Backwash Design

• Increased Flux

• Eliminated Rotating Equipment

PerforMedia™

• Feed O&G up to 500 ppm

• Higher Oil Loading

• Synthetic Media


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

Tertiary Separation –Benefits of PerforMediaTM


Tertiary Separation –Selection Criteria

Process Conditions MONOSEP™ WSF

Influ

ent Flow Rate (per vessel) 20 – 450 m³/h

Free Oil & Grease < 100 ppm (<500 ppm*)

Total Suspended Solids < 50 mg/L (<100 mg/L*)

Efflu

ent

Free Oil & Grease < 5 ppm

Total Suspended Solids 95% removal > 10 micron

* PerforMedia


Reference Installations

XX.XX.20XX Autor / Abteilung


Reference Installations in the Oil & Gas Industry

IL

CZ

AT

SK

HU

SIHR

BIHRS

MN KO

BG

RO

UA

MD

TK

GEAZ

AR

AZ

NCOC (KAZ)PWTP Kashagan Field

INA (HR)PWTP Zutica Field

OMV Petrom (RO)PWTP Vata Field

OMV Petrom (RO)PWTP Videle Field

OMV Petrom (RO)PWTP Tazlau Field

OMV Petrom (RO)PWTP Oprisenesti Field

KomMunai (KAZ)PWTP Komsomolskoe Field

OMV Petrom (RO)PWTP Bordei Verde


Water Management in the O&G IndustryUp-stream Water Treatment

Dr. Robert Vranitzky MBAHead of Water SolutionsWater Solutions / Austria / PD SLN WS

Siemensstraße 901210 Vienna

Fax: +43 51707 51337Mobil: +43 664 80117 22338

E-Mail:[email protected]

www.siemens.com/water-solutions

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