Shaping the future of produced water solutions

Produced Water
Treatment Systems
Solutions to meet the most stringent produced water requirements
Produced Water Treatment Solutions
Solutions to meet the most stringent produced water requirements

However stringent your produced water treatment requirements, we can design and supply a system that meets your needs,
surpasses environmental constraints while maximising the income from the oil/gas field assets.

The increasing water cut, normally

resulting from the age of the assets, 1
can have a significant effect on the
hydrocarbon process train; together with
a detriment to the environment if it is
discharged prior to suitable processing.
No single piece of equipment can
tackle the complex process of treating
produced water to meet increasingly
stringent regulations for discharge or
reuse.

At Alderley, we have a long experience

in the management and processing
of produced water, together with
handling some of the more difficult
applications. We can offer you advice
and guidance through a range of
services and technologies to ensure
you meet production and produced
water treatment goals. We provide the
complete solution, from stand-alone or
fully integrated, skid mounted produced
water treatment systems covering
Primary, Secondary and Tertiary
Treatment processes.

Installation and delivery is implemented

in-house, including all design
project management, engineering,
procurement, construction installation
and commissioning.

Vast experience in offshore, onshore and FPSO applications

Highly efficient compact solutions
Guaranteed to meetyour compliance levels
Full range of solutions covering all areas of produced water treatment processes

PRIMARY SECONDARY TERTIARY

TREATMENT TREATMENT TREATMENT

ALDERLEY
Well head
W
De
Desanding
METERING
SYSTEMS
Production Fluids

Tertiary
Treatment
Degasser/
Separators
Sepa
p ratorss Flotation

Liquid Clean Water out

Hydrocyclone

Desanding
ng Solids
S o
Hydrocyclone
ne Cleaning
C l

We have total focus on integrating systems to meet the

 Primary Treatment
Worldwide experience in delivering the solution you need on time and on budget

The primary treatment of produced

2 water in itself involves multiple
technologies from upstream
sand removal utilising solid/liquid
hydrocyclones at wellhead conditions
through multi-phase separators and
collection vessels to further solid/liquid
and liquid/liquid hydrocyclones.

At Alderley we have a proven track

record of delivering solutions that meet
or exceed your expectations on every
level from performance to timescale to
budget.

Upstream sand removal Separators/collection vessels Deoiling hydrocyclones Desanding hydrocyclones

A world of experience
Extensive, global references lists are available covering all technologies and applications to demonstrate our capability and
delivery. Please see below for examples of just a few of the projects we have delivered.

Customer/Contractor Project Description

Saudi Arabian Khurais Central Processing 8 off compact flotation units in 4 parallel streams. Each stream comprises
1 Oil Company Facility, Saudi Arabia 2 CFUs in series to treat 225000 bwpd. The system is designed to achieve
Snamprogetti less than 10ppm oil-in-water at the outlet. Vessels were manufactured from
low temperature carbon steel with glass flake lining.
AOIC (operated by BP Azeri, Chirag, Deepwater Produced water treatment modile comprising 5 off AP20 deoiling
2 Exploration) Gunashli (ACG) Phase 3 - hydrocyclone vessels, 3 off AP50 desanding hydrocyclone vessels and 1 off
Halliburton Internation DUQ platform, Azerbaijan degasser vessel. The package outlet specification is 29mg/l oil-in-water and
Inc. 98% removal of sand particles above 50 microns. The hydrocyclones were
manufactured from duplex stainless steel and the degasser from carbon
steel with glass flake lining.
Murphy Sabah Oil Kikeh FPSO, Malaysia 2 off AP20 deoiling hydrocyclones designed to treat 151000 bwpd to
3 Co. Ltd/MDFT (SBM & meet the discharge requirement of 20ppm oil-in-water. Vessels were
MISC) manufactured red from carbon steel with glass flake lining.

BP/Aker Solutions Skarv and Indun Fields Produced water treatment package consisting of 2 off AP20 deoiling
4 FPSO project, Northern hydrocyclone vessels, 1 off compact flotation unit and 1 off oil adsorption
North Sea, Norway media unit. The target outlet oil-in-water concentration is 5 ppm
downstream of adsorption media. All vessels were manufactured from
duplex stainless steel.

demands of the oil, gas and petrochemical industries

Ultimate Efficiency Desanding Hydrocyclones
Produced water desanding with exceptional performance

High efficiency design (removal down

to 10 microns)
High online turndown (>5:1)
Compact vessel ideal for offshore
applications
High erosion resistance
(manufactured from high purity
alumina)
Individually removable or cartridge
d
esign
Continuous or batch sand removal
Easy integration with solids clean-up
and disposal systems
Low maintenance

Solid/Liquid Hydrocyclone 3 x 50% desanding hydrocyclones with internal accumulators

Operation
A desanding hydrocyclone uses the rapid
increase in rotational velocity to create
centrifugal acceleration of the fluid. This
forces the solids towards the outside
of the hydrocyclone liner, before they
are dropped into the vessel where they
are accumulated. Discharge of solids
from the accumulator can be manual or
automatic to suit your application needs.

Whether you are removing solids from

production fluids to protect downstream
equipment or treating produced water
for discharge or re-injection, our
desanding hydrocyclones use the latest
technology to meet the most diverse of
requirements.

Considering throughput, pressure drop,

reliability and the efficiency of solids AP-50 desanding cyclones
removal are all important factors when
specifying a hydrocyclone, the Alderley
desanding hydrocyclone is designed to
tolerate higher pressure drops and pass
higher flow rates to bring highly efficient
solids removal all in the most compact
of vessels.

We have total focus on integrating systems to meet the

 Highest Performing Deoiling Hydrocyclone
A liquid/liquid hydrocyclone that reduces oil-in-water levels to less than half that of some hydrocyclone
designs

Low investment and running costs

Ideal for retrofitting/upgrading
existing produced water treatment
systems
Compact and efficient
High turndown
High erosion resistance
Low fouling

Alderleys industry leading AP-20

deoiling hydrocyclone reduces outlet
levels of oil-in-water to less than
half that of other hydrocyclones.
Designed and manufactured in-house
it has been field proven and is used
extensively both onshore and offshore.
Deoiling Hydrocyclone With high efficiency, high online
turndown and high erosion resistance,
this hydrocyclone offers a cost-
effective, proven solution that is
regularly utilised in new projects
and for retrofitting old systems. The
liner can be fitted to existing vessels
without the need for removal of the
vessel or any hot work. It is unaffected
by motion and suitable for vertical and
horizontal vessels.

We have a range of field evaluation

units that shall demonstrate the AP-
20s superior performance.

From a single skid mounted

hydrocyclone vessel to a fully
integrated package with our deoiling
and polishing equipment. Alderley
has demonstrated track record
of delivering total solutions to the
Hydrocyclone Package customer needs.

Liquid/Liquid Hydrocyclone Theory

Produced water is channelled into the hydrocyclone head tangentally to the wall.
The multiple tangential inlet design combined with a tapering internal geometry
creates an accelerating vortex in the fluid as it flows through. Because of the
difference in density between the oil and water, the induced centrifugal force
pushes the oil into a central core. Careful differential pressure control is used to
remove the oily core in a countercurrent flow.

Oily water Clean water

reject Inlet outlet

demands of the oil, gas and petrochemical industries

Secondary Treatment for Produced Water
Efficient complementary technologies to further reduce oil-in-water levels
At Alderley we have vast experience
in complete produced water treatment
solutions to meet even the most
demanding requirements. Secondary
treatment conditions produced water
and solids in preparation for discharge
or further polishing. Hydrocyclones
provide excellent removal of sand
and free oils in water but the latest,
stringent regulations often require
complementary technologies to
reduce the levels of oil and other
contaminants further.
Alderleys IGF and CFU systems may
also be used as the primary stage of
treatment where low pressure drop
combined with efficient oil removal is
required.
Alderley can provide a range of
secondary separation processes
along with project management and
customer support to deliver a fully-
integrated package on time and on
budget.
We are world experts in
meeting even the most
demanding of produced
water treatment
requirements.
Hydraulic induced gas
floatation unit
We have total focus on integrating systems to meet the
Solids Cleaning
Solids recovered from a separator or hydrocyclone, are cleaned to stringent
environmental standards prior to disposal. The system recirculates the sand
from the accumulator vessel multiple times to attain the desired oil-on-sand
concentration. A guaranteed level of oil on the solids can thus be achieved.
Alderleys solids treatment system design is such that it can be incorporated as
necessary in the overall produced water treatment package to meet your project
requirements for solids disposal.
Induced Gas Flotation (IGF)
We provide two and four cell Induced Gas Flotation (IGF) systems to meet the
performance requirements of your application. Our IGF works by recycling gas
bubbles into the produced water. These bubbles adhere to solids and oil within
the produced water and cause them to float to the top of the vessel where they
are skimmed off. The IGF vessels operate a controlled residence time system for
each cell to maximise the efficiency of the system.
Chemicals may also be added to the system to improve the adherence of
particles and break down emulsions. We will advise on the necessity for the use
of chemicals during our detailed design service to you.
Degassers
Typically used downstream of hydrocyclones, the Alderley degasser design can
halve the outlet oil-in-water levels. Alderley can design and supply a degasser to
fit your process requirements and needs. Produced water degassers are typically
operated at close to atmospheric pressure, the produced water entering the
vessels de-gasses liberating millions of tiny gas bubbles that adhere to residual
oil requirements and ensure maximum hydrocable recovery.
Compact Flotation Units (CFU)
Alderleys CFU utilises our proprietary swirl device hydrocyclone, resulting in a
soft spin cyclone. Our design has been optimised to maximise oil recovery while
minimising the use of floatation gas. With our multi step pressure drop inlet we
maximise the efficiency while reducing chemical usage.
1 x 4 cell mechanical induced gas floatation vessel
 Tertiary Produced Water Treatment
Where stringent standards are required for reinjection or environmental discharge

Alderley provide a range of polishing

technologies including nutshell media
filters, cartridge filters and adsorption
filters. These systems remove the
very fine suspended solids and oil
droplets, and the adsorption filters
treat dissolved oils and organics such
as BTEX (Benzene, Toluene, Ethyl
Benzene and Xylene).

Supplied as either stand-alone or fully

integrated skid-mounted systems,
these units can be manufactured at a
number of international locations within
Alderleys global fabrication network,
as appropriate to the project build
location and schedule needs.

Adsorption Filters
Oil adsorption media vessel
Our advanced adsorption filters utilise
a range of cartridges and bulk media
to treat dissolved oils and organics
such as BTEX (Benzene, toluene,
Ethyl Benzene and Xylene) as well
as free oil to achieve the highest
environmental standard required.

Cartridge Filters
Alderleys cartridge based technologies
cover both particulate and oil removal
for polishing prior to water injection.

Based around a range of both

cartridge and inline proprietary
designs our coalescing technology are
used to maximise and enhance the
performance of traditional separation
equipment, or the stand polishing
stage or simply as a guard filter to
protect downstream equipment.

Nutshell Filters

Alderleys range of polishing filters

using nutshell media are typically
used onshore to remove the final free
oil and suspended solids entrained in
the produced water.

Our superior design of media

management minimises backwash
duration while stimulating media
attrition typically caused by other
mechanical machinery.

Nutshell filter vessel

demands of the oil, gas and petrochemical industries

A total focus on the needs of the oil and gas industry

Contact us for your metering, hydraulic control systems and produced water treatment needs

www.alderley.com

Registered Office Regional Facilities

Alderley plc
Alderley House
Arnolds Field Estate
The Downs, Wickwar
Gloucestershire, UK
GL12 8JD
Tel: +44 (0) 1454 294556
Alderley Process Technologies
Wickwar, UK
Tel: +44 (0) 1454 294556
Aberdeen, UK
Tel: +44 (0) 1224 300451
Alderley FZE Alderley East Asia
Dubai, UAE Singapore
Tel: +971 4804 2777 Tel: +65 6408 0151
Alderley ICD
Dammam, Saudi Arabia
Tel: +966 3 8100262

sales@alderley.com Produced Water Treatment Systems Brochure Rev. 3

Solutions to meet the most stringent produced water requirements