water management lessons learned
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Water Management Lessons Learned
From The Oil & Gas Shale Drilling Boom
Ronald L. Coufal, Halliburton Energy
Daniel T. Eyde, St. Cloud Mining
Water Management in
Mining Conference, September 12, 2012
2© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
NUMBER 1 LESSON LEARNED
PUBLIC PERCEPTION
IS COSTLY
3© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
The advancements in Shale and Tight development is a
great thing for our industry, but…..
4© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Headlines
circa April 2011
5© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Liquid
Waste
Solidification
Applying The Lessons Learned
Water Management
Technology Drilling
Fluids
Technology
Water
Containment
Technology
Ion
Exchange
Technology
6© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
The oldest problem in the oilfield
Produced water
111 billion bbl produced annually worldwide
3 - 5 bbl of water produced per bbl of
hydrocarbon
$51 billion annually in water management costs
7© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
The newest problem in the oilfield
3-5 MM gallons to complete a well
which create further problems
Flow back volumes up to 2MM gallons
Water supply and disposal
Trucking Concerns
Regulations
8© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
HALLIBURTON WATER MANAGEMENT PHILOSOPHY
Maximize Reuse
•Increase % of produced water reused in frac fluids
•Reduce volume of water sent for disposal
•Lower fresh water demand by 25% by 2014
Minimize Waste Stream and costs for Producers
•Use less treatment
•Reduce Trucking
•Change frac fluid formulation to adjust to salinity
9© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Biggest myths about water use in completions
That drinking water quality is needed to make a frac fluid
and complete a well
That it is all about water treatment
That the industry can continue to use fresh water as a
once through commodity
That recycle and using new technologies is too
expensive
10© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Current Options for Produced/ Flow back
Haul and Dispose $ 1.50- $7.00/bbl
Clean to Discharge Quality $ 5.0- $15.00/bbl
Recycle $ Net Savings-15.00/bbl
11© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
80,000 BBL Well Completion Once Through Flow Sheet
Supply Transport Cost
Water Cost
Flowback Disposal
Flowback Transport
Total Cost of Water: $281,600 + Storage
$3.52/bbl + Storage
Supply H2O
Transport Cost
$/bbl
Water Cost
$/bbl
Flowback
Factor
Flowback Disposal
Cost, $/bblFlowback Transport
Cost, $/bbl
$1.10 $0.45 30.00% $0.75 $1.22
12© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Supply H2O
Transport Cost
$/bbl
Water Cost
$/bbl
Flowback
Factor
Flowback Disposal
Cost, $/bblFlowback Transport
Cost, $/bbl
$1.10 $0.45 30.00% $0.75 $1.22
For every BBL you Recycle
You eliminate these costs and reduce fresh
water usage, trucking and disposal impact
If you are over $3.00 per bbls in these costs,
you can likely recycle and save money.
13© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
ISSUES IN WATER REUSE
Fluid Formulation problems•High salinity can cause problems in polymer
hydration.
•Cross-linking of polymers is a bigger problem.
Formation Damage: •Suspended materials plug pore throats in shales leading
to production loss.
•Simple filtration cannot remove suspended colloids.
Scaling•Higher hardness can lead to more scaling – but not
always.
•Theoretical calculations and experimental verifications
needed
14© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Keys to taking cost out while you recycle….an
integrated approach
1. Effective Water
Treatment
2. Fluid Formulation
study
3. Efficient Logistical
Engineering for Well
Construction
15© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
EQUIPMENT: CleanWave™
• Electro coagulation Process
• Over 600MM gallons of treated
produced water
• 95-99% removal of TSS, Total
Hydrocarbon, Iron, and Heavy
Metals
16© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
17© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
0
Treatment Cost, $/bbl
Clean-
Wave™
Distillation
Evaporation
Ultrafiltration
RO
Chemical
Precipitation
Small percentage removal of
TSS/Hydrocarbon passing
residuals to the well
Treatment Cost $/ BBL
Water Treatment Technologies – Cost vs. Value Add
CleanWave™ Adds High Value at an Attractive Cost
High
Med
LowFiltration
Hydroclone
Wate
r V
alu
e A
dd
ed
TDS removal Not
Necessary for most water
re-use for frac fluids
0 2 4 6 8
18© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Halliburton Water Management System:
Water Transfer Data & Impact
Operational Example:
24 Horizontal Wells proximal to transfer infrastructure
100,000 BBL of Water per Well
• 2.4 MM BBL Total
Each Water Tanker can haul approximately 130 BBL
Assuming 22 mile round trip
• 18,462 Round Trips
• Assuming $1.05 /bbl truck transport =$2.52MM for
truck transport
These trucks will be removed from the roadways using a Water
Transfer Solution
19© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
CleanWave™ for the Mining Industry
Bariod Industrial Drilling Products introduces a new compact
CleanWave™ Water Treatment System for use in non-oil and gas
drilling applications to reduce water consumption and hauling costs.
20© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Baroid IDP CleanWave™ Water Treatment SystemInnovative Water Processing Solutions by Water Quality Management Professionals
Scalable from 1 gpm to 1000’s gpm covering full range
of mining industry needs
Typical footprint ranges from 600 ft2 to 1600ft2
Purchase or lease programs available
Treatability and solution design
Installed in <3 days once on site
Typical mobilization time in North America < 2 weeks
Baroid IDP turnkey service or on-site customer training
21© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Provide
Economical
Disposal of
Used Fluids
Applying Shale Drilling Fluids Technology to Mining
Reduce Water
Consumption
at the Drill Site
Reduce
Trucking Costs
and Damage to
Local Roads
22© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Baroid Industrial Drilling Products
System 360™ Total Fluids Management™ System
23© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Core Drilling Case Study Project Overview
Project Owner: Minera Hampton Peru
SAC
Drill Contractor: AK Drilling International,
SA
Project: Resource definition drilling
program at the Los Calatos Cu-Mo Mine
Location: Department of Moquegua, 70
km SE of Arequipa in southern Peru
Year: 2011
Goal: Reduce industrial water
consumption and disposal of fluids
Area: Subtropical montane perarid desert
ranging from 2500 to 3000 meters above
sea level
Water transported by truck from the City of
Moquegua, approximately 65 km from
project
All but 10 km of the road is rough gravel
Round trip time for each load of water
hauled by truck is approximately 4 hours
System 360™ Total Fluids Management™ System
Case Study
24© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Project Scope
Use the System 360™ unit with
an engineered fluid to address
the water consumption and
disposal issues and optimize the
drilling operations:
Rigs at Los Calatos had been
consuming an average 13,000
gallons of water per rig, per day
Each water truck made a round
trip of 130 km to supply 6000
gallons of water. Limited to two
round trips per day.
Additives were needed to treat
high solids in muds, thereby
increasing costs. Used fluids
were disposed of in large
settling ponds for evaporation.
Water costs were in excess of
$50.00 USD per drilled meter.
25© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
System 360™ Total Fluids Management™ SOLUTION
Use a highly efficient mud mixing system coupled with a patent-
pending flocculent additive process which concentrates and
removes solids from spent drilling fluid on a core rig.
Remove fine solids allowing re-use of a fluid that would normally be
discarded.
Create cross-linked structures in the fluid containing the solids which
can be quickly separated from the water phase.
Cleaned drilling fluid is directed back to the active circulating
system.
Water generated in the final filtration step can be returned to the
mixing tank to mix new drilling fluid.
26© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
System Floc-360™ Flocculent
Aqueous polymeric flocculent causes rapid flocculation of the
drilled solids exposed to PHPA polymer in the drilling fluid.
Mixing occurs within the System 360™ solids separation unit.
Once the flocculation of drilled solids and PHPA polymer occurs,
flocculants are produced, which are separated from the liquid
phase in the filter bags.
27© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
System Floc-360™ Flocculent
Flocculants are easily disposed of in a semi-solid form using the
bagging feature on the System 360™ unit.
28© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
System Floc-360™
Clean water recovered from the drill fluid is returned to the holding
tank for reuse in the mud mixing tank.
29© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Project Results
Drilled from surface to 1,137 m. (52 shifts worked)
Fluid Treated – 416,000 (Ltrs.)
Water Recovered – 187,200 (Ltrs.)
Fluid cleaned and returned to system for drilling – 137,800 (Ltrs.)
Water consumption prior to using System 360™ - 13,000 gal/day
Water used when running the System 360™ - 2,789 gal/day
Total water savings using the System 360™ - 10, 211 gal/day
A total of 72, 514 gallons of water were used during the 26 days of
drilling the hole, an average of 2,789 gallons per day.
Total water consumption was reduced by 78.5%.
Total water savings on this hole was approximately 265,486
gallons
30© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Economic Value Created
Use of the System 360™ reduced water usage by almost 80%.
Safety was enhanced by the substantial reduction of water hauls
and truck time traversing rough terrain.
Drill sump size was reduced by 90%, reducing disposal costs.
No stuck tubes or broken lines occurred using the System 360™,
indicating cleaner fluid with less solids to centrifuge inside the rods
and tube heads.
Water separated by the System 360™ unit was re-used for the
preparation of new drilling fluid.
Because the System 360™ unit effectively removed fine clays from
the drilling fluid, the amount of additives necessary to maintain the
mud system was greatly reduced.
Drill crews were easily trained to use the system.
31© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
GSE Liner Technology, Inc.
Regulatory Concerns/Variables
Develop Strategic
Partnerships
Utilizing Shale Oil &
Gas Mud Fluids
Technology to
Create Enhanced
Water Containment
Products.
BARA-KADE™ 30 LP
High performance
granular engineered
barrier bentonite for
sealing and
containment in
chemically complex
near surface
environments.
BARA-KADE™ CR
High performance
granular polymer
enhanced barrier
bentonite for sealing
and containment of
harsh coal ash
contaminant
environments.
USES
Mud Pit Ponds
Flow-back Water
Ponds
Fresh/Potable Water
Impoundments
Temporary Surface
Impoundments
Coal Ash Ponds
Site Owner Objectives
Geosynthetic Clay Liners (GCL)
32© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Mine Pit in South America
Stormwater Pond in South America
Shrimp Pond in Asia Diamond Mine in Europe
Landfill in AsiaCoal Ash Pond in the U.S.
Reservoir in Thailand
Decorative Pond in the Middle East Landfill in the U.S.
Diverse Applications
33© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
BARA-KADE™ DWD (Dry Waste Disposal)
Liquid Waste Solidification – Drill Cuttings and Fluid
34© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
CHALLENGE:
Replace current technology to solidify/stabilize wet solids/liquid
Reduce volume of waste generated by current methods
Meet all Class II Landfill (Non-Hazardous Waste) Regulations
Reduce cost of disposal for the operator
SOLUTION:
A proprietary, patent-pending blend of unique reagents
Highly effective low-dose application
Utilize existing equipment to meter and mix the additive for
precise loading and cost control
RESULT:
Reduced Volume – Waste volume cut by 50%
Lower Cost – Lower transport and landfill dumping fees
Reduced Transit Risk – Eliminates transport of liquid waste
Meets Regulatory Requirements – Passes EPA Tests
BARA-KADE™ DWD (Dry Waste Disposal)
CASE STUDY
35© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Water
Purification
Contaminants
Absorption
Ion Exchange Technology – Zeolite Molecular Sieve
36© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Natural zeolites are hydrated
aluminosilicates.
There are over 40 natural zeolite
minerals with similar structures and
molecular makeup, all with their own
particular attributes.
U.S. commercial zeolite deposits are
located in Arizona, California, Idaho,
New Mexico, Oregon, Texas and
Wyoming.
Zeolites are used commercially for
several reasons:
• Unique Absorption
• Ion Exchange
• Molecular Sieve
• Catalytic Abilities
Zeolite pore structure
36
What is a Zeolite?
37© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Types of Zeolites – St. Cloud Mining
Bowie
Chabazite
Ash Meadows
Clinoptilolite
38© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
38
Water Purification Applications
Water Treatment Products
Clinoptilolite and chabazite based
products for ion exchange
applications
SCM proprietary functionalized
mineral based zeolites are fast,
reliable, low-cost water treatment
alternatives to chemical treatment
and activated carbon
NSF 60 Certified for Potable
Water Treatment Systems
NSF 50 products for swimming
pools
39© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Kurion - Goal: Create 1st Ever External Reactor Water
Cooling System Using St. Cloud Chabazite
Unprecedented Challenges: Saline Oily Water, Volume, Schedule, & Mother Nature
Approximate volumes:
67 500 MT of highly contaminated water (April 20)
+ 800 MT/day cooling water, rain, in-leakage
120 000 MT of highly contaminated water (June 28)
Additionally:
• Near continuous aftershocks to > Magnitude 7
• Summer Rainy Season came early – mid May
• Many unknowns about site conditions
• Protestors, police, camera crews on streets
1200 MT/day
Cesium
Removal
System
Oil Removal
System
Salt Removal
System
Lagoon has
~120 000 MT
of water
Contains ~200 MT of oil &
grease from Turbine
Buildings
Fukushima Daiichi Nuclear Plant
40© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Proposed Applications at Fukushima Using Lessons
Learned in the Shale Oil & Gas Boom
41© 2012 HALLIBURTON. ALL RIGHTS RESERVED.
Thank you. Questions?
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