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  • Produced Water TreatmentProject Profile

    Project Name: Melut Basin Oil DevelopmentProject Name: Melut Basin Oil Development

    Client Name: PDOC, Client Name: PDOC, PetroliumPetrolium

    EPC: EPC: DodsalDodsal

    Consultant: Mott MacDonaldConsultant: Mott MacDonald

    Plant Location: Adar/ Agordeed Field Plant Location: Adar/ Agordeed Field

    Scope: Scope: Design, Build, and installation Super.Design, Build, and installation Super.

    Go Ahead Date: January Go Ahead Date: January -- 20052005

    Delivery Date: May Delivery Date: May -- 20052005

    Capacity: 1920 M3/dayCapacity: 1920 M3/day

    Source of Water: Oil Wells Source of Water: Oil Wells Produced WaterProduced Water

    Development Oman CompanyDevelopment Oman Company

    SudanSudan

    Sudan Oil Production: 250,000 bbl/d (2004)Sudan Oil Production: 250,000 bbl/d (2004)

  • Criteria for Awarding the Job

    Critical Delivery < 5 MonthsCritical Delivery < 5 Months

    Compact DesignCompact Design

    Robust and Reliable DesignRobust and Reliable Design

    Economic ApproachEconomic Approach

  • Design Conditions

    Inlet Pressure: AtmosphericInlet Pressure: Atmospheric

    Outlet Pressure: 1.29 BargOutlet Pressure: 1.29 Barg

    Operating Temperature: 55 Deg. C.Operating Temperature: 55 Deg. C.

    Design Pressure: 10 BarDesign Pressure: 10 Bar

    Design Temperature: 80 Deg. C.Design Temperature: 80 Deg. C.

    ANSI Class: 150#ANSI Class: 150#

  • Water to Oil RatioWater to Oil Ratio

    New Well: < 1New Well: < 1

    Old Well: > 3 up to 10Old Well: > 3 up to 10

    North Sea:North Sea: 70% water, 30% oil70% water, 30% oil

    N. America: N. America: 92% water, 8% oil92% water, 8% oil

  • Main Impurities in Produced WaterDissolved SolidsDissolved SolidsHeavy MetalsHeavy MetalsVarious Oils (emulsified and nonVarious Oils (emulsified and non--emulsified)emulsified)Suspended SolidsSuspended SolidsDissolved Gases (ODissolved Gases (O22, CO, CO22, and H, and H22S)S)Iron ScalesIron ScalesBacteriaBacteriaPhenols, toluene, and other toxic compoundsPhenols, toluene, and other toxic compoundsRust and Corrosion ByproductsRust and Corrosion ByproductsSand GrainsSand GrainsRadioactive ElementsRadioactive ElementsBacteriaBacteriaTreatment ChemicalsTreatment Chemicals

  • WHAT DO WE REMOVE?Free OilFree OilSand and TurbiditySand and TurbidityDissolved gasesDissolved gasesBacteria and VirusesBacteria and Viruses

    WHY?

    Reduce harmful emissions to the environmentReduce harmful emissions to the environmentProtect downstream equipment from erosionProtect downstream equipment from erosionPrevent harmful & dangerous gasses from entering Prevent harmful & dangerous gasses from entering the atmospherethe atmosphereImprove well Improve well injectivityinjectivity

  • Typical Oil Discharge Limits

    Location Limit North Sea 40 mg/l

    Arabian Gulf 15 to 40 mg/l Gulf of Mexico 29 mg/l

    India 48 mg/l Onshore 0-5 mg/l

    Sudan 50 mg/l

  • Raw Water Analysis

  • Injected Water Quality

  • Equipment Typically Used inEquipment Typically Used inProduced Water TreatmentProduced Water Treatment

    Surge DrumsSurge Drums

    22--phase separatorsphase separators

    33--phase separatorsphase separators

    Liquid/Liquid HydrocyclonesLiquid/Liquid Hydrocyclones

    Solid/Liquid HydrocyclonesSolid/Liquid Hydrocyclones

    Multiphase Wellhead DesandersMultiphase Wellhead Desanders

    DegassersDegassers

    Single Cell FlotationSingle Cell Flotation

    Induced Gas FlotationInduced Gas Flotation

    Filter Filter Coalescer

    Cartridge FiltersCartridge Filters

    Chemical Injection PackagesChemical Injection Packages

    Gas Pressure LetGas Pressure Let--down Stationsdown Stations

    Hydraulic Wellhead Control Hydraulic Wellhead Control

    Gas FiltersGas Filters

    Packed TowersPacked Towers

    Gas CyclonesGas Cyclones

    Control PanelsControl Panels

    Analyser Houses and LaboratoryAnalyser Houses and Laboratory

    Coalescer

  • PRODUCED WATER DEOILING EQUIPMENT OPTIONSPRODUCED WATER DEOILING EQUIPMENT OPTIONS

    Surge TanksSurge Tanks To collect fluids that are subject to regular surge To collect fluids that are subject to regular surge or upset conditionsor upset conditions

    Collection VesselsCollection Vessels To collect fluids from multiple sourcesTo collect fluids from multiple sourcesDeoiling HydrocyclonesDeoiling Hydrocyclones Primary Separation for the removal of oil from Primary Separation for the removal of oil from

    waterwaterTitled Plate InterceptorsTitled Plate Interceptors Primary separation for the removal of oil from Primary separation for the removal of oil from

    waterwaterCentrifugesCentrifuges Primary Separation for the removal of oil from Primary Separation for the removal of oil from

    waterwaterDegassersDegassers Removal of gas from water and a final polishing Removal of gas from water and a final polishing

    stagestageInduced Gas FlotationInduced Gas Flotation Secondary Separation for the removal of oil from Secondary Separation for the removal of oil from

    waterwaterFilter CoalescersFilter Coalescers Removal of oil from waterRemoval of oil from waterDeep Bed Media FiltrationDeep Bed Media Filtration Removal of solids and oil from waterRemoval of solids and oil from waterAdsorption FiltrationAdsorption Filtration Removal of oil from waterRemoval of oil from water

  • PRODUCED WATER DESANDING EQUIPMENT OPTIONSPRODUCED WATER DESANDING EQUIPMENT OPTIONS

    Cyclonic Wellhead Cyclonic Wellhead DesanderDesander

    Coarse Sand Removal between 100 to Coarse Sand Removal between 100 to 150 microns150 microns

    Coarse StrainerCoarse Strainer All solids removal down to about 80 All solids removal down to about 80 micronsmicrons

    Produced Water Produced Water Desanding Desanding HydrocycloneHydrocyclone

    Mid range sand removal down to about Mid range sand removal down to about 30 to 40 microns30 to 40 microns

    Deep Bed Multi Media Deep Bed Multi Media FiltrationFiltration

    Fine Solids removal down to 5 micronsFine Solids removal down to 5 microns

    Cartridge FiltersCartridge Filters Coarse to Fine Solids removalCoarse to Fine Solids removal

  • KEY DESIGN FACTORS:KEY DESIGN FACTORS:

    -- Onshore or Offshore?Onshore or Offshore?-- Destination of Produced Water?Destination of Produced Water?-- New Plant, Expansion, Upgrade New Plant, Expansion, Upgrade or Retrofit?or Retrofit?-- Type of Field Type of Field Oil or Gas?Oil or Gas?

    Process Conditions:Process Conditions:Flow rate /TurndownFlow rate /TurndownPressure/Temperature/ViscosityPressure/Temperature/ViscosityComposition of Feed StreamComposition of Feed Stream

  • Main Process Diagram

  • Main Process Diagram

    2 m3/hr20,000 ppm

    82 m3/hr500 ppm

    80 m3/hr50 ppm

  • See Through View

  • Parameters affecting PerformanceParameters affecting Performance

    Stokes Low

    -- Oil Droplet Size (Shear, Valve location, bends)Oil Droplet Size (Shear, Valve location, bends)-- Pressure Differential Ration (PDR = 1.9)Pressure Differential Ration (PDR = 1.9)

    --Example: Feed 7 Bar; Water: 4.5 Bar; Oil: 2 BarExample: Feed 7 Bar; Water: 4.5 Bar; Oil: 2 Bar-- Reject Ratio > 2%Reject Ratio > 2%-- Water lower viscosity at higher temperatureWater lower viscosity at higher temperature-- Oil viscosity: Low viscosity oil can shear easilyOil viscosity: Low viscosity oil can shear easily-- Specific Gravity Difference.Specific Gravity Difference.-- Cyclone Diameter, Length.Cyclone Diameter, Length.-- Emulsion breakers, coagulants, surface tensionEmulsion breakers, coagulants, surface tension-- Gases up to 10% (Displaces Oil on the overflow)Gases up to 10% (Displaces Oil on the overflow)

  • Advantages of HydrocyclonesAdvantages of Hydrocyclones

    High efficiencyHigh efficiency compact designcompact design Low weightLow weight Directly replacementDirectly replacement Low CAPEX and low OPEXLow CAPEX and low OPEX No moving partsNo moving parts Little or no maintenance costsLittle or no maintenance costs Reliable and PredictableReliable and Predictable Consistently PerformanceConsistently Performance Wide material selection Wide material selection

    (stainless & duplex steels, (stainless & duplex steels, ceramics, etc) ceramics, etc)

    Insensitive to motion or Insensitive to motion or orientation

    Modular (parallel to handle Modular (parallel to handle changes in treating capacities.changes in treating capacities.

    Portable.Portable. Little instrumentation for Little instrumentation for automautom.. WellWell--understoodunderstood Simple to operate, maintain, Simple to operate, maintain,

    troubleshoot.troubleshoot. No special tools and little No special tools and little

    operator training required.operator training required.

    orientation

  • Typical Production FluidsFluids in

    Separator =Oil & Water

    PW Package Inlet (from Separator)

    < 500 ppm

    Hydrocyclone Outlet

    < 50 ppm

    PW Package Outlet

    < 30 ppm

  • Multimedia FiltersMultimedia FiltersSpecial Design FeaturesSpecial Design Features

    Low Operational Flux (6 to 9 m3/hr/m2 or 2.5 to 3.5 gpm/ft2)Low Operational Flux (6 to 9 m3/hr/m2 or 2.5 to 3.5 gpm/ft2) Extended Media Height (1.7 m or 5.5 ft)Extended Media Height (1.7 m or 5.5 ft) Special Wedge wire collection systemSpecial Wedge wire collection system High Backwash flow rate: 35 m3/hr/m2 on two intervalsHigh Backwash flow rate: 35 m3/hr/m2 on two intervals Provision for future air scouringProvision for future air scouring

  • Multimedia

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