PWE2013 Cameron

Advances in Compact Flotation Units
for the Treatment of Produced Water

Produced Water & Environmental
Conference - Aberdeen
June 5-6, 2013
Mike Bhatnagar
Sr. Product Manager
TST-CFU
TM
Process & Compression Systems
Custom Process Systems
2
Cameron is a leading provider of branded flowequipment products,
systems and services to worldwide oil, gas and process industries.
OIL GAS WATER SOLIDS
Free Water Knockout
TS WKOCompact
Free Water Knockout
NATCO
Mechanical
Heater Treaters
Multi Phase
Separators
PORT-TEST
Revolution
CONSEPT ICD
NATCO
Dual
Frequency
NATCO
Dual
Polarity
PETRECO
Bilectric
PETRECO
MeterCell
CESCompact
Coalescer
Bilectric HF
Cynara
CO
2
PureMEGMEG
Reclamation
Shell / Paques
THIOPAQ
PORT-TEST
WhirlyScrub I, V
PORT-TEST
Revolution
CONSEPT DC
CONSEPT IVD
CONSEPT SI
CONSEPT Spinlet
CONSEPT ACI
NATCO
CHF
Heater
NATCO
BTEX Buster
NATCO
Desi-Dri
NATCO
SHV
Flare/Combuster
NATCO
Water Bath
Heaters
NATCO
Glymine
Amine Treating
Glycol Dehydration
Mechanical
Refrigeration
NATCO
Jewel T
Produced Water Seawater MOZLEYWellhead

Desander
MOZLEY
Desanding SLC
MOZLEY
Microspin
MOZLEY
Hydrotrans
MOZLEY
Fluidizer
MOZLEY
Deltaclone
MOZLEY
Sandcleaning
UNICEL
Vertical Skim
Vessel
WEMCO
Pacesetter
NATCO
Cross-Flow
Scrubber
VORTOIL
Deoiling
Cyclones
WEMCO
ISF
WEMCO
Depurator
UNICEL
IGF
NATCO
Versaflo
PETRECO
Hydromation
Nutshell
PETRECO
Silverband
Nutshell
PETRECO
Softeners
NATCO
Skim Pile
NATCO
DOX
TS CFUCompact
Flotation
METROL
SeaCell
METROL
BFCC
METROL SeaScreen
& SeaScreen Max
Media Filters
Vacuum Deaerators
Gas Strip Deaerators
Polymem UF
NATCO
Sulphate
Removal
CDXCompact
Deaeration
Custom Process Systems - Portfolio
TS Technology acquired by Cameron Custom Process Systems
2004
2011
1990
2010 1997 2001 1999 2002
2007
Baker Hughes
Process
Systems
(BHPS)
formed from
Baker Hughes
Industries &
WEMCO with
Metrol
Custom Process
Systems
Petreco
International
acquired by
Cameron
BHPS
acquires
BFCC
BHPS
acquires
Vortoil
1990
2010 1993 1995 1997
BHPS
acquires
Petreco
1998 1996 2001
Sequal Holdings
purchases Baker
Hughes Process
Systems from
Baker Hughes
creating Petreco
International
2002
Petreco
International
acquires
KCC
Process
Petreco
International
acquires
Unicel
TEST
CYNARA
Membranes
MPE
ESI
Axsia
PORTA-TEST
ConSepT
Mozley
Baker
Hughes
Industries
WEMCO
Oil &
Gas with
Metrol
BHPS
acquires
Krebs
2000 1998
NATCO
Acquired by
Cameron
Cameron
acquires
TS
Technology
Divider graphic should fill and not
exceed the defined gray box.
Custom Process Systems 5
Produced Water Treatment Trends
Next Generation Compact Flotation - TST CFU
Field Trials North Sea
Field Test Results
Summary of other Field Test Results and Full Scale Installations
Conclusions and Future Work
Produced Water Trends Onshore Applications
Globally produced water associated with the oil & gas production
is between three and seven times than the oil production and it
continues to increase over the lifespan of the well.
Onshore produced water is usually treated and re-injected into
underground formations, or treated and discharged under
permits issued by regional agencies.
Camerons WEMCO Depurator Flotation Systems and the
Petreco Hydromation Nut Shell Filters are well established in
these applications.
Produced Water
Treatment
Compression
Compression Gas Export
Knock
out
Drum
Gas
Treatment /
Dehydration
Crude
Export
Produced
Water for re-
injection
HYDROMATION
Nutshell Filter
WEMCO
Flotation
WEMCO
CPI
Skimmings
Separation
HP
Production
Separator
LP Production
Separator
Electrostatic
Dehydrator
Wellhead
Choke
Typical Onshore
Separation PFD
Bulk Phase
Separation
Electrostatic
Crude
Conditioning
Gas Treatment
and Conditioning
Solids Separation
System
Wellhead
Desanders
Pressure
reducing
Pressure
reducing
SandClean System
Sand
Disposal
Water
From
Wellhead
Cartridge Filter
Adsorption
8
WEMCO
Depurator
Conventional
Box Design
Cylindrical
Design
Petreco Hydromation Nut Shell Filters
Produced Water Trends Offshore Applications
Most offshore produced water is treated and discharged to the
ocean as permitted by the regional agencies.
In the past, many offshore operators have adopted a trend
toward the use of de-oiling hydrocyclones followed by
conventional flotation, degasser or conventional compact
flotation to treat produced water prior to overboard discharge.
Compression
Compression Gas Export
Knock
out
Drum
Gas
Treatment /
Dehydration
Crude
Export
Produced
Water for
Disposal
Skimmings
Separation
HP Production
Separator
LP Production
Separator
Electrostatic
Dehydrator
Cartridge Filter
Adsorption
Water
Recycle
Oil
Recycle
Desanding
Hydrocyclone
Deoiler
Deoiler
Produced
Water for re-
injection
Conventional
Flotation /
Degasser/ CFU
Typical Offshore
Separation PFD
Produced Water
Treatment
Electrostatic
Crude
Conditioning
Gas Treatment
and Conditioning
Bulk Phase
Separation
Delta
Clone
Solids Separation
System
Wellhead
Desanders
Pressure
Reducing
Pressure
reducing
SandClean System
Sand
Disposal
Wellhead
Choke
12
Vortoil
Deoiling Hydrocyclone
Inserted Sandwiched Original
Offset
Modified
Manufactured
Offset
Super Offset
Value Engineered
over 20+ years
13
Unicel
Vertical Flotation
Offshore Production Trends, continued
Oilfield operating companies continue moving to ever-increasing water
depths to produce oil and gas reserves. The high cost of constructing
floating platforms, is driving the need to reduce the size and weight of
topsides processing equipment on these platforms.
The challenges for the operators are increasing and the need for high
performance, compact and more cost effective technologies exists that
can handle the high water cuts.
This has lead to the development of the next generation TST-CFU
TM
, that
has multiple stages in a single vessel making it capable of handling
higher inlet OIW concentrations.
The TST-CFU
TM
offers better performance than that achieved by a
combination of multiple technologies like Hydrocyclones, Conventional
Flotation or Compact Flotation units, considerably reducing the need for
foot print and weight.
Field Test Results
Next Generation Compact Flotation TST CFU
TM
The TST-CFU
TM
uses gas flotation and
additional hydraulic forces to separate
and remove hydrocarbons, aromatic
compounds, hydrophobic substances
and fine solid particles from produced
water.
The TST-CFU is available as a single
stage vessel or as a single vessel with
multiple internal stages offering a
compact solution specially designed to
handle higher inlet oil concentrations,
over 1,000mg/l.
It requires a smaller foot print, has a
reduced weight than competitive
technologies.
The technology is world wide patent
pending.
TST CFU Compact Flotation Technology
The Technology uses both
induced, and dissolved gas
flotation to remove
hydrocarbons.
Special internals for mixing
of gas and oil have been
developed to achieve easy
separation of this mixture
from the water.
The water can be treated
through several stages within
one vessel. It s available in
configurations up to 4
stages.
The numbers of stages
depend on the inlet fluid
conditions.
17 Custom Process Systems
Direction of flow
Orifice /Valve/Mixer
Gas
Water
Orifice /Valve
Gassaturated water at pressure P
1
Pressure P
2
Pressure P
1
P
1
> P
2
Direction of flow
Induced gas flotation
Dissolved gas flotation
TST CFU Basic (Single stage vessel)
The TST-CFU
TM
design consists of special
internals that include a static mixture, a
riser pipe, distribution arms and guide
vanes.
Improved produced water circulation and
re-mixing is crucial to the design of TST-
CFU
TM
system to enhance the oil
separation efficiency and reduce the
retention time down to 20 seconds per
stage.
Key parameters like downward fluid
velocity, gas bubble size, fluid circulation,
internal flow paths, gas bubble re-mixing as
well as cell residence time, gas induction
rates, skimming rates, and their effects on
process hydrodynamics have been taken
into consideration when designing this next
generation compact flotation technology.
1
st
stage
with
overlapping
guide vanes
Clean
water
without
bubbles
below the
vanes
Inlet
nozzle
CUSTOM PROCESS SYSTEMS 19
TST CFU Gas bubble distributuion and re-mixing
TST CFU
TM
MS3 (Three stage vessel)
CFD analysis was used to improve the
efficiency of the internal guide vanes by
retaining more of the swirling oil water
mixture and providing an upward flow
pattern to the rising gas bubbles
attached to the oil.
The proper distribution of gas bubbles
over the entire cross-sectional area of
the vessel, the re-mixing of the gas
bubbles, the size of the bubbles induced
into the produced water are all critical to
promote good oil separation
Much shorter retention times of around
20 seconD/S per stage has resulted in a
more compact vertical pressure vessel
and smaller reject volumes.
The result is an enhanced CFU design
with multiple stages in a single vessel as
compared to the single stage design of
the conventional vertical IGFs and
conventional Compact Flotation Units.
Stage 1
Stage 2
Stage 3
PW inlet
Treated water
Outlet
TST CFU
TM
MS3 (Gas inlet and oil reject lines)
Gas recycle
Stage 1
Reject stage 1
Reject stage 2
Reject stage 3
Gas Inlet
Stage 2
Produced Water Inlet
Treated Water outlet
Field Test Results
Existing System:
1st stage separator
2
nd
stage separator
Flocculation tank
1st stage hydrocyclones
2nd stage hydrocyclones
Degassing tank
Single stage existing
compact flotation unit
Tie-in points :
Downstream of the
degasser
Downstream of the 1st
stage hydrocyclones
Downstream of the 2nd
stage hydrocyclones
Downstream of the 1st
stage separator
TST-CFU
TM
Test Skid
The TST-CFU test-skid
consisted of two compact
flotation units, the CFU A
and CFU B with different
internal designs.
The test allowed CFU A
and CFU B to be operated
individually, in series or in
parallel.
Inlet Oil/ water Specifications
Oil API 30.0
Oil Density (15
0
C) [kg/l] 0.8759
PW Temperature[C] 70
PW pH 7.1-7.2
OIW levels in PW from existing treatment system
Test Procedures
Tests at different tie-in points
Flow rate (Typical 50; 100; 150% of design)
Gas rate injection variation
Tests performed with and without flocculants
Testing with the normal variation of incoming water
Measure OIW & Oil droplet size
Testing instruments
OIW field instrument calibrated with the existing plants
permit monitoring instrument
Malvern Mastersizer Oil droplet size and particle size
monitoring
Malvern Zeta-sizer used when oil droplet surface charge
was problematic (especially for condensate water)
Field Test Results
North Sea Test Results - Tie in Points
Single Stage TST-CFU - D/S of the degasser
The incoming OIW was
around 20 mg/l with a
few peaks of up to 50
mg/l.
Initially no gas was
injected into the TST-
CFUs, but when gas
was added to the unit,
the effluent OIW
concentration stabilized
at around 2-3 mg/l.
No additional
flocculants were used
during this test.
The effluent from the
existing CFU was
around 7.8 mg/l.
4
5
2
3
2
4
5
3
4
1 1
2
3
2 2
6
4
3
2 2 2 2 2 2 2
1
2 2
2
0
10
20
30
40
50
60
m
g
/
l
O
I
W
Inlet Outlet
Oil droplet size changes over the TST-CFU D/S of the degasser
The median (d
0.5
) oil
droplet size changed
from 3 to 2 m from inlet
to outlet of the TST-CFU.
The measured
concentration D/S the
TST-CFU was very low.
The size distribution data
and the low OIW
concentration from this
location both indicate
excellent treatability.
The TST-CFU removes
very small diameter oil
droplets.
Single Stage TST-CFU - D/S of 1st stage hydrocyclones
The OIW results
show that the OIW
was reduced from
~45 mg/l to 5 mg/l
over one stage.
The lowest OIW
concentration out of
the TST-CFU
without flocculants
was 3.5 mg/l and
with flocculants was
2.5 mg/l.
The median oil
droplet size was
reduced from 3.1 to
1.8m over the TST-
CFU.
Single Stage TST-CFU D/S of 2nd stage hydrocyclones
The test was
performed using
a single stage
CFU B.
Flocculants
improved the
OIW
performance
from ~ 4 mg/l to
~2 mg/l in the
effluent.
33
9
5
11
12
8
9
11
8 8 8
7
9 9 9
7
8
7
10
0
5
10
15
20
25
30
35
40
45
50
m
g
/
l
O
I
W
Inlet OIW values between 850 and 1,000 mg/l
3 Stage TST-CFU D/S of the 1st stage Separator
The inlet oil in water
concentrations were
between 850 and 1000
mg/l.
The oil in the water
from the 1
st
stage
separator contained
small oil droplet size
with 50% of the oil
droplets < 5.7 m.
The first stage of the
TST-CFU removed
> 95 % and moved the
d0.5 to 2.5 m.
The second and third
stage of the TST-CFU
remove a further 60%
and reduce the d0.5 to
2.3 m
TST-CFU North Sea Field test Summary
D/S of the degassing vessel Single stage TST-CFU treated the water from an inlet
OIW concentration of 20 mg/l down to 2 mg/l, (90 % reduction). The existing CFU had an
outlet OIW concentration of ~7.8 mg/l, (61% OIW reduction).
D/S of the 1st stage separator - A two stage TST CFU reduced the OIW to 20 mg/l.
With subsequent treatment over a three stage TST-CFU, the effluent OIW concentration
was reduced to 8-11 mg/l., the same level as four separate existing produced water
technologies- flocculant vessel, hydrocyclones, degasser and existing CFU
D/S of the 1st stage hydrocyclones - A single stage TST-CFU treated the water to an
OIW concentration below that achieved by using the existing degasser and the existing
CFU. With subsequent treatment over a second stage TST-CFU, the effluent OIW
concentration was further reduced by 1-2 mg/l.
D/S of the 2nd stage hydrocyclones - A single stage TST-CFU treated the water to a
concentration down to 2 mg/l OIW, and a treatment efficiency of 90% OIW, much better
than the level reached by using the existing degasser and the existing CFU.
Tie-in Points Inlet
OIW
OIW (mg/l)
Outlet 1
st
stage
OIW (mg/l)
Outlet 2
nd
stage
OIW
Removal %
1
st
Stage
OIW
Removal %
2
nd
Stage
OIW
Removal %
Total
D/S Degasser ~20 ~2 90 90
D/S 1
st
Stage
Separator
>1000 50 20 95 60 98
D/S 1
st
Stage HC 50 3.5 93 93
D/S 2
nd
Stage HC 20 2 90 90
Field Test Results
TST-CFU
TM
Configurations and Applications
TST CFU 2 stages
TST CFU 1 stage
TST CFU 3 or 4 stages
37
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
320
340
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
Inlet
Stage 4
Pilot test results GOM D/S of Separator
Custom process Systems
3 stage CFU South Sea China
Outlet from Separator- 100 to 180 ppm
Outlet from existing HC - 80 ppm
Outlet from existing Degasser vessel - 50 ppm
39
3 stage CFU D/S of inlet separator South Sea China
40
3 stage CFU D/S of inlet separator South Sea China
Full Scale Unit Startup 3 stage CFU South Sea China
41
-10
10
30
50
70
90
110
130
150
170
190
210
230
250
270
290
310
330
350
370
390
410
430
450
470
490
510
530
550
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Inlet
Stage 3
42
3 stage CFU China
Pilot test - 4 stage CFU China
0
20
40
60
80
100
120
140
160
180
200
220
240
260
280
300
320
Inlet
Stage 4
Full scale unit Startup 4 stage CFU China
44
0
50
100
150
200
250
300
350
400
450
500
550
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Inlet CFU B
Stage 4 Outlet of CFU B
Pilot test TST- WKO Water Knock Out - China
Inlet to WKO 100,000 mg/l
Outlet from WKO - 500 mg/l
Outlet from CFU <20 mg/l
WKO/ CFU Test Units China
46
Full Scale Startup of WKO - China
0
50
100
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Inlet OIW values between 80,000 and 100,000 mg/l
Field Test Results
Parameters impacting performance
Oil droplet size
Important parameter for efficiency
Oil slugs
Minor effect on performance. Free oil is
easy to separate.
Gas bubble size
Smaller bubbles will give bigger
surface and better contact between oil
droplets and gas bubbles.
Salinity
Affects gas bubble size.
Temperature
No effect on performance, tested from
25
0
Cto 95
0
C
Pressure
No effect, tested from 0.5 to 20 bar
49 Custom process Systems
50
Dissolved gas in the feed
Positive effect on gas flotation
Flocculants
Improved performance with use of flocculants
Shearing across valves
Shearing across upstream valves can create small oil
droplets and should be avoided
Other parameters impacting performance
CONCLUSIONS
Multiple separation stages within one single vessel
Can handle OIW inlet concentrations over 1,000 mg/l
No need for several vessels in series
Less space required and easier adaptation into existing installation
More flexible design
Multiple internal feed distribution instead of an external tangential inlet
Better fluid distribution and internal re-mixing
Higher probability of contact between gas bubbles and oil droplets
Not impacted by scaling up of vessels
The technology is world wide patent pending
CONCLUSIONS
Better performance than traditional IGFs and conventional CFUs
90 to 98% efficiency
Less equipment as it can replace multiple technologies
Lower weight
Smaller footprint
Less dependent on chemicals than the first generation CFUs
Lower OPEX
Simple skid design
Compact single vessel option
FUTURE WORK
Thus far the next generation TST-CFU
TM
compact flotation technology has been
installed at several platforms performing
satisfactorily.
Other operating companies in the GoM
and other deepwater locations are also
testing the TST-CFU
TM
.
As feedbacks from existing and new field
installations are received, additional
enhancements will be made to the TST-
CFU
TM
design.

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PWE2013 Cameron

Uploaded by

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Advances in Compact Flotation Units

for the Treatment of Produced Water

Produced Water Seawater MOZLEYWellhead

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