Applications of an innovative mixing technology in separation and Produced Water Treatment. December PDF Free Download

Applications of an innovative mixing technology in separation and Produced Water Treatment December 2014

PROSEP OVERVIEW ProSep is an industry-leading provider of integrated process separation solutions to the global oil and gas industry Upstream Midstream Downstream Petrochemical Full suite of proprietary and conventional technologies oil, gas & water Global HQ in Houston, TX, USA Manufacturing facility Houston, TX, USA Regional office Aberdeen, UK Regional office Kuala Lumpur, Malaysia Regional office Abu Dhabi, UAE Backed by private equity firms Energy Ventures (Norway) and Harris & Harris Group (New York, USA) 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 2

PROCESS & TECHNOLOGY CAPABILITIES Proprietary Technology Separator Gas Treatment / Dehydration Gas Nitrogen Generation Compression Compression ProDry & TEG Gas Dehydration Gas Sweetening Membranes Fuel Gas / Seal Gas ProScav and H 2 S Removal Export Oil ProMix Chemicals Production Separator FWKO ProMix Chemicals Heater Treater / Dehydrator 2/3 Phases Solids Handling ProSalt Wash Water Desalter 2/3 Phases Solids Handling Export Hydrocyclone Wellhead Desander ProMix CPI IGF Osorb Media Nutshell Filter Sand Disposal Skimmer Chemicals IGF / CFU TORR Coalescer Water Seawater Injection CTour Process Hydrocyclone Degasser Reinjection / Discharge Condensate 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 3

PROCESS & TECHNOLOGY CAPABILITIES - REFERENCES ProScav H2S Scavenging TEG Package Gas Sweetening Membranes Fuel Gas System ProMix Demulsifier Inj. Crude Dehydration Crude Desalting Crude Treatment Train ProBlend Crude Blending Skid Osorb Media NSF IGF & Hydrocyclone Package CTour PWT TORR PWT Treatment Seawater Injection 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 4

ENERGY SERVICES Mobile equipment for: Temporary Requirements Shutdowns Upset Management Technology Evaluations Experienced field operators and technical service chemists provide: Site Services Commissioning, operation, maintenance, and troubleshooting Extensive experience with water treatment and filtration requirements for upstream and downstream installations Services applied for both onshore and offshore installations 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 5

RESEARCH & DEVELOPMENT R&D facility provides the resources required to optimize the performance of our technology portfolio including: Flow loops, Prototype units Tools for simulating field conditions available Complete analysis of oil, gas, and produced water streams in our state of the art laboratory using instrumentation, including: Spectrometers (infrared, UV/VIS, and fluorescence) Particle analyzers (ViPA) Gas chromatography Associated detectors (FID, MS, and TCD). Working with ProSep Energy Services division, portable equipment skids allow us to test products at clients sites with live fluids to demonstrate real time solutions to operator issues. 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 6

MANUFACTURING 56,000 sq. ft. purpose built manufacturing & fabrication facility in Houston, TX. 70 Ton lifting capacity. Capability to manufacture: Large structural fabrications Vessels up to 14 diameter, 60 long and 3 thick Piping spools, Packaged equipment Exotic material welding ISO 9001 approved, FPAL & Achilles registered, and ASME certified to Section VIII, Division 1 & 2. Skid packages can be fabricated with dimensions up to 18 ft. wide & 30 ft. in length European manufacture is through our network of fabrication partners in UK, Europe and Norway. Malaysian manufacture though network of fabrication partners. 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 7

Proprietary Mixing Technology - Overview Co-current chemical injection and mixing Liquid-liquid & gas-liquid Generic benefits across all applications: Low shear Homogeneous mixing - Typically 90% mixing efficiency Very low pressure drop (0.03-0.3 bar typically) resulting in energy savings and efficiencies Reduction in chemical injection consumption by 20-60% depending on the installation. High Turndown ratio 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 9

PROMIX Co-current chemical injection and mixing Liquid-liquid & gas-liquid Flow-driven Low shear Homogeneous mixing Low dp Quill Quill + Static Mixer ProSep Mixer Low efficiency High dp Large contactor length Propensity to scale Low efficiency Heterogeneous Mixture Low dp Small contactor length Resistant to scale High efficiency Homogeneous Mixture 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 10

DESALTING - PROSALT Typically installed upstream of a dehydrator or desalter, ProSalt is a novel inline injection/mixer assembly that can be used for high efficiency multi-phase mixing. Features: Finger folding jet-flow - pattern giving minimum pressure drop Multiple mixing internals Ensure optimal performance Outlet channels give uniform outlet flux of the multiphase mixture Independent of upstream piping arrangement Automated online adjustability Provisions for online de-plugging are available Benefits: High efficiency capable of multiphase mixing Low pressure drop (0.1 to 0.3 bar) Drastically reduces wash water consumption by up to 60% Increases desalting wash water separation efficiency Small channels give high velocities resulting in the formation of small droplets / bubbles Excessive turbulence ensuring rapid mass transfer 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 12

PROSALT VS CONVENTIONAL ProSalt Up to 60% reduced water usage - one installation is saving 10,000,000 gallons of water per year for one major operator Up to 60% demulsifier saving (20-40% savings typical) Narrow water droplet size distribution Mixing efficiency increased by 30% Low pressure drop, high efficiency separation Increase efficiency of downstream water treatment Increased crude treatment capacity Conventional Broad water droplet size distribution High pressure drop Results in low efficiency separation 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 13

PROSALT CASE STUDIES SAUDI ARABIA Key Results Differential pressure decreased by more than 50% Wash water rate was reduced by 40% from 50 gpm to 30 gpm OIW content from the desalter was reduced by 60% - 18 pm to 7 ppm 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 14

PROSALT CASE STUDIES - NORWAY Case Study - Example 14 ProSalt unit at Statoil Mongstad refinery for mixing of crude and wash water. Installed in parallel to a conventional globe mixing valve upstream of the 1 st -stage desalter (in the 2-stage process) Two Stage Process for Desalting Crude Process Conditions Operating pressure: 145 psi Operating temperature: 230-266 F Crude API: 37 Crude oil flow rate: 2.20 M lbm/hr Volumetric flow rate @ op. T&P: 8200 bbl/hr KEY RESULTS PROSALT Pressure drop 3-12 psi Significantly reduced wash water consumption Salt spec typically below 2 mg/l; 0.70 ptb BS&W spec (0.10 0.15 vol %) 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 15

PROSALT CASE STUDIES - NORWAY 100 000 ProSalt Test Mixer, dp=0,35 bar Oil-in-water from 1st stage desalter (ProSalt Test Mixer installed upstream of 1st stage desalter) Globe valve, dp=0,35 bar Globe valve, dp=0,35 bar ProSalt Test Mixer dp=0,23 bar Oil-in-water [mg/l] 10 000 1 000 100 0 Time 28 Test Period 1 Test Period 2 (16-19.10.2006) (23-26.2006) 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 16

LIQUID H 2 S SCAVENGING - PROSCAV ProScav is a system for injecting and efficiently mixing liquid H 2 S scavenger in the natural gas stream to remove H 2 S. Features: Compact inline system; easy to install at any pipe angle Option for simultaneous flow metering & mixing Robust design for low maintenance Benefits: Highly efficient mixing with low pressure drop (0.03 to 0.3 bar) 20 60% reduction in liquid scavenger consumption High turndown ratio in scavenger injection rate typically 10 to 1 Low to zero maintenance if the required 50 micron filter is equipped in the scavenger injection line 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 17

LIQUID H 2 S SCAVENGING - PROSCAV CASE STUDIES ProScav mixers were installed on 4 applications including Gulfaks B and the Asgard B in the Norwegian sector. An average 37% reduction in scavenger consumption across the platforms Reduced environmental impact No clogging, minimal maintenance Reduce OPEX / chemical usage Reduced liquid H 2 S scavenger chemical usage 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 18

LIQUID H 2 S SCAVENGING - PROSCAV CASE STUDY ConocoPhilips China Technical Summary Location: China, CNOC Peng Bo FPSO Equipment: ProScav mixer ConocoPhilips China Commercial Summary Location: China, CNOC Peng Bo FPSO Equipment: ProScav mixer Process Conditions / Results Operating temperature 23 C increased to 60-70 C Pressure 5.2Mpa Gas flow rate 13MMSCF/d Inlet H2S content 400-510 ppm Outlet H2S content 50ppm Triazine based scavenger Reduction in scavenger consumption from 16m3 per day to 4m3 per day Commercial Benefit / Value Add: Triazine based scavenger $8-$15 per gallon (typically) If value at $8 per gallon $21K per day saving $7.6M saving annually Saving 75% of chemical (environmental impact factor (EIF) benefit) Saving 75% of cost of scavenger chemical. 4 ProSep mixer paid for (in this application) in under 1 month. 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 19

TERTIARY SEPARATION - TORR TORR Coalescing technology, with its small footprint and ability to replace less efficient oil removal equipment, is a scalable technology that addresses future increases in water cut for offshore operators. Features: Reduce 1000 ppm down to discharge regulation, often <5-10 ppm Maximum flow rate per vessel of 60,000 BWPD Operational temperatures up to 90 C Removes & recovers oil droplets larger than 2 microns Trial packages from 250-20k BWPD available for field testing of PW streams Benefits: Small footprint & low weight Increased polishing for reinjection applications Solids pre-treatment for reinjection Same high de-oiling efficiency during production start-up periods No additional treatment required for recovered oil Minimal pressure drop & maintenance Recovered hydrocarbons can be <0.5% BSW High flow rate turndown 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 21

TERTIARY SEPARATION - CTOUR CTour Process The CTour process removes dispersed oil and dissolved hydrocarbon contaminants in the produced water stream through injection of condensate. Injection of a condensate of light hydrocarbons (specific gravity of 0.5 to 0.75) into the produced water stream to extract harmful components. The key to the success of the CTour process is the ProMix. This enables the homogeneous mixing of the condensate into the produced water stream. Benefits: Performance - Removes OIW to below 4-5 ppm Reduces dissolved hydrocarbons (PAH, phenols, BTEX) by 80 95% No waste products no disposal/transportation costs No chemicals added Easy to install in existing systems Very low operating costs Robust process, low maintenance Removal of < 5 micron oil droplets Removal down to 14 API crude 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 23

TERTIARY SEPARATION - CTOUR. PROCESS PRINCIPLES Solvent extraction process for dissolved and dispersed hydrocarbons Critical process parameter is injection & mixing of the condensate in our proprietary mixer Condensate acts as extraction solvent Spent solvent is removed by a standard separator: Hydrocyclone Flotation Axial cyclone Gravity vessel Coalescing filter 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 24

TERTIARY SEPARATION OSORB MEDIA OSORB MEDIA Organically-modified silica Porous, flexible matrix Hydrophobic Adsorption & absorption Regenerable & reusable APPLICATION METHODS Bulk media vessel Canisters Injection into flow line Removal of vapor phase and micro-droplet hydrocarbons from gas Removal of free, dispersed, emulsified, and soluble hydrocarbons and some oilfield chemicals from water APPLIED TO: Produced water Flowback & completion returns Pipeline fluids Membrane protection Chemical EOR Hydrocarbon dew point (HDP) Gas emissions control 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 27

OFFSHORE TEST COLUMNS Low flow feasibility testing & performance evaluations Tie into existing sample point for evaluation on slip stream of live fluids In situ regeneration evaluations 3 Diameter Column 6 Diameter Column 6 Acrylic Column 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 28

PRODUCED WATER FOR OIL RECOVERY & STEAM REGENERATION Kuwait 6 Test Column Onshore treatment for reinjection 18-20 API Oil 43-52 C > 120% w/w oil Osorb Media loading 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 29

OIW (mg/l) OFFSHORE PRODUCED WATER North America 6 Test Column Offshore treatment for discharge Management of offshore excursions 10-18 API Oil High asphaletene concentrations 79 C 225 200 175 150 125 100 75 50 25 0 Oil in Water (OIW) Concentration 0 100 200 300 400 500 600 700 800 Time (min) Inlet (mg/l) After Osorb media (mg/l) 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 30

OSORB MEDIA REGENERATION HYDROCARBON DEW POINT REDUCTION ppm in DCM Sorbate in Osorb RT BP % Media (min) ( o C) Before After Regenerated Regeneration Regeneration benzene 2.63 80 26 0 100 heptane 2.98 98 429 0 100 methylcyclohexane 3.35 101 734 0 100 toluene 4.17 111 338 0 100 octane 4.96 126 730 0 100 ethylcyclohexane 5.95 131 325 0 100 p-xylene 6.92 138 510 0 100 m-xylene 7.49 139 171 0 100 nonane 7.65 151 706 0 100 propylcyclohexane 8.31 155 274 0 100 Capture of the liquid and vapor-phase heavier hydrocarbons in the gas stream Regeneration of Osorb Media with heat and nitrogen purge results in pure condensate value stream. 8 December 2014 Copyright 2014 ProSep. All Rights Reserved. 33

Applications of an innovative mixing technology in separation and Produced Water Treatment. December 2014