Professional Documents
Culture Documents
Tentative Agenda
g
Problem that triggered
gg
this research
Strategy to solve the problem and make it a revenue
source
Terminology (Basic principles)
Objectives and Tasks
Engineering Design and Optimization
Oil/water and reverse osmosis separation processes
Data collection and analysis
Process integration
g
Future
Discussions
Problems
Increasing costs of disposal of waste brine from
oil and gas production operations
Permian Basin produces over 400 million gallons of
water
t per d
day
Equivalent to the daily use of water in the city of
Houston
Oil Waste-b
Oil Waste-a
S-107
Source Brine
O1Coalescer / OS-101
S-106
CX-101
Centrifugal Extraction
S-108
Oil Waste-c
P-9 / FSP-103
Oil Separation
Flow Splitting
Flow Splitting
P-13 / CY-101
S-111
Hydrocyclone
S-109
S-103
Organo Clay / OC
Permeate
S-104
Reverse Osmosis / RO
Holding Tank / Vt
Reject
S-112
Disposal
S-110
Suspended/Dissolved Solid
Separation Levels
Micro Filtration (MF) (10- 0.1m)
Bacteria, suspended particles
Ultrafiltration (UF) (0.05-0.005m)
Colloids, macromolecules
Nanofiltration (NF) (5e-3-5.e-4 m)
Sugars, dyes, divalent salts
Reverse Osmosis (RO) (1.e-4-1e-5 m)
Monovalent salts, ionic metals
Water
Selective Membrane
Osmotic Pressure
( )
r
= f T , C
REVERSE OSMOSIS
Head = Osmotic
Pressure
Applied
Pressure
Semi-permeable
Membrane
Diluted Brine
Initial Brine
or pure water
Water Flow
Concentrated
Brine
Water Flow
Terminology
gy
Rejection
T
Transmembrane
b
pressure
Feed,
Feed permeate,
permeate reject
or concentrate rates
scale--up use fluxes
For scale
(volumetric rate/area)
Jw = flux of permeate
R = 1 CP / CF
P + PR
TMP = F
PP
P
x
C
F
~
Dw Cw v w (P )
Jw =
RTt
Dw =
kT
6 w rp
( )
r
= f T , C
Osmotic Pressure
Osmotic Pressure vs TDS**
Osm
motic Pre
essure (p
psia)
600
T = 200 F
500
T = 100 F
400
300
( )
r
= f T ,C
200
100
0
0
3
TDS %
2%
5%
10%
15%
Sucrose (342
(342))
24 *
63
134
215
Glucose (180
(180))
48
127
264
405
Seawater
220
550
1205
NaCl (58.5
(58.5))
250
620
KCl (74
((74.6
74.6)
74 6)
6)
170
455
965
K2SO4 (174.3
174.3))
92
235
470
g 4 (120.4
120.4))
MgSO
65
168
352
Molecular weight in ( )
* Pressure in (psia)
Brine Characteristics
Input Waste Product:
TOC up to 5,000 ppm (dissolved and emulsified)
TDS up to 100,000 ppm
Desired Output:
Water (TDS) < 500 - 15 ppm
Oil (TOC) < 20 ppm
Oil Waste-b
S-107
CX-101
Centrifugal Extraction
S-102
P-9 / FSP-103
S-105
Flow Splitting
S-101
Source Brine
S-103
Organo Clay / OC
Permeate
S-104
Holding Tank / Vt
S-112
Reverse Osmosis / RO
Reject
Disposal
Objectives
j
Maximize permeate production
Minimize waste volume (concentrated
brine))
Eliminate bottlenecks
Enable semisemi-continuous operation
p
(long
( g
batch cycles)
Provide low
low--cost process, maintenance,
and operation
Minimize manual intervention (automate)
Portable, reliable, controllable
Oil/Water Separation
Coalescing media
Oil adsorption in
packed columns
(
(organoclay
l
pellets)
Coalescer Media
Pump
Tank
Coalescer
800 ppm
1600 ppm
3200 ppm
6400 ppm
1440
1280
[Oill], ppm
1120
960
0.5219x
y = 0.3217e
2
R = 0.9437
0.4702x
y = 0.2499e
2
R = 0.9911
800
0.358x
y = 0.1949e
0 1949
2
R = 0.9934
640
480
320
0 2027x
0.2027x
y = 0.1166e
2
R = 0.7767
160
0
0.2
0.7
1.2
1.7
2.2
Q, L/min
2.7
3.2
Adsorption
Experiments
p
p
Packing organoclay
column
col mn
Flow loop and sample
preparation
Sample collection and
TOC Analysis
Modeling oil adsorption
Bed dimensions and
rate
Breakthrough times
C i / Cf (oil co
oncentrattion
rattio)
C final / C initial
0.8
Coutlet 0.6
Cinlet 0.4
02
0.2
0
0
50
100
150
Time (minute s)
200
250
OC Adsorption Modeling
g
Negligible axial dispersion
Process governed by mass-transfer
resistance
First-order kinetics
S
Sensitivity
iti it analysis
l i to
t residence
id
time
ti
125.0
100.0
75 0
75.0
S 115
S-115
50.0
P-1 / GMF-101
P-2 / GMF-102
OC Filtration
OC Filtration
25.0
0.0
0.0
50.0
100.0
150.0
200.0
250.0
ti
time,
hours
h
Column 1
Column 2
Desalination ((RO))
Feed
Permeate
Bl di
Blending
/ Storage
St
Reverse Osmosis
Recycle
RO System
y
- Pilot Unit Used
RO Experiments - Specs
SWC-1-4040
SWC 1 4040 spiral
TMP (600 1000 psi)
Am = 70 ft 2
Recycle on/off
Inlet TDS ((0 40,000
ppm)
Feed rate (6 14
GPM)
6 gpm
0.20
8 gpm
0 15
0.15
10 gpm
0.10
0.05
0.00
0
200
400
600
800
pressure,, psi
p
Transmembrane p
1000
Feed = 30,000
30 000 mg/L NaCl
0.20
0 16
0.16
6 gpm
0.12
8 gpm
0 08
0.08
10 gpm
0.04
0.00
450
550
650
750
Salt reje
ection, %
99.00
98.00
6 gpm
97.00
8 gp
gpm
10 gpm
96.00
95.00
550
600
650
700
750
Transmembrane pressure
pressure, psi
800
99.60
99.20
6 gpm
98.80
8 gpm
10 gpm
98.40
98.00
250
350
450
550
650
pressure,, psi
p
Transmembrane p
750
RO Data Summary
y
TDS range from 0 40,000
40 000 ppm
TMP range 200 800 psia
Feed rate 6 to 10 gpm
Data points triplicate (yes
(yes3 repetitions)
Over 450 data points
Uncertainty + 0.5 % in permeate
concentration measurement and + 1.5% in
rate measurement
TMP
J = a
1 J
w
F
a
a
2
TDS
TDS
4
+a
+a
5 J
3 TMP
a
6
TMP
= b
1 J
F
b
b
2
TDS
TDS
4
+b
+b
3 TMP
5 J
b
6
100
Predicted
99
98
97
96
95
94
94
95
96
97
Experimental
98
99
100
Pred
dicted
25
20
15
10
5
0
0
10
15
E
Experimental
i
t l
20
25
30
Operating
g Conditions Design
g
30
qP =15000 gal/day
25
L/A=25 m-1
10000
20
20
5000
4000
10000
15
15
3000
2000
10
10
8
1000
1000
0
0.3
0.4
0.5
0.6
0.7
(1 - / P)
0.8
0.9
1.0
0.028
8(qP/(qF-qP
P)k /(1-w S) v W Am
100000
Begin Design
Set up
p Operating
p
g Conditions:
Pump specifications, qF, T, and Brine Composition
Design
Stages
With obtained
bt i d value
l for
f x-axis
i - (1-/P)
(1 /P) and
d qP
evaluate Am from left y-axis
No
Is qF within allowed
range
Yes
End
No
Design
g Example
Given p
process parameters
p
and desired outcome
TDS
T
TMP
qP
=
=
=
=
18,000 ppm
160 F
500 psia
5,000 gal/day
Solution
= 192 psi
Left axis Am = 39
39.53
53 m2
Propose - L/A =
15 m-1
Right axis qF = 69,000 gal/day (7%)
Design issues
Number of units required
Series/parallel configuration
Partial/full recycle, makemake-up streams
Vt > 75 gallons
Vt < Feed rate
Feed
Permeate
Blending / Storage
Reverse Osmosis
Recycle
Transient Behavior
Cumulative
& Instantaneous
Permeate
Concentration
Cumulative
Permeate
Production
& Recovery
Efficiency
0.8
TDS, ppm
HoldingPrroduction,
Tank Volu
ume,
gal
Gallons
350.0
300.0
200.0
70.0
Inst - pp
ppm
07
0.7
Cum - ppm
0.6
250.0
150.0
0.5
200.0
100.0
150.0
50.0
0.4
60 0
60.0
0.3
02
0.2
50.0
100.0
0.1
40.0
0.0
50.0
0.00
30.0
0.0
0.0
0.00
RE = P/((P+R)
80.0
250.0
0
0.50
0.5
0.50
1.00
1.0
1.00
1.50
2.00
2.50
Time, hrs
1.5
2.0
1.50
2.00
3.00
2.5
2.50
Volume Permeate
Produced
Time hrs
Time,
hrs
Time
Time,
3.50
3.0
3.00
3.5
3.50
600 psia
150.0
800 psia
100.0
1000 psia
50.0
0.0
0
0
0.00
Specifications
RO - SWC
SWC-1-4040
1 4040 - 6GPM - (70SF)
1.00
2.00
3.00
4.00
5.00
Feed TDS, ppm
Permeate Produc
ced,
gallons
Specifications
RO - SWC-1-4040 - 6GPM - (70SF)
time, hours
50000.0
40000.0
30000.0
600 psia
20000.0
800 psia
10000.0
1000 psia
0.0
0.00
Ho
olding Tank
Volu
ume, gallons
Specifications
RO - SWC-1-4040 - 6GPM - (70SF)
60.0
600 psia
40.0
800 psia
1000 psia
20 0
20.0
1.00
2.00
3.00
time, hours
4.00
2.00
3.00
time, hours
80.0
0.0
0.00
1.00
5.00
4.00
5.00
Recovery Effic
ciency
TMP Analysis
y
Specifications
RO - SWC-1-4040 - 6GPM - (70SF)
1.2
1.0
08
0.8
600 psia
0.6
800 psia
0.4
1000 psia
0.2
0.0
0.00
1.00
2.00
3.00
4.00
5.00
time, hours
Specifications
RO - SWC-1-4040 - 6GPM - (70SF)
Permeate F
Fraction
0.40
0.30
600 psia
800 psia
0.20
1000 psia
0.10
0.00
1.00
2.00
3.00
time, hours
4.00
5.00
Increase size of
holding tank
Use two tanks
Increase feed rate
from OC train
b t
but
resize OC columns
Increase number of
OC columns
0.30
6 gpm
0 25
0.25
8 gpm
10 gpm
0.20
0.15
0.00
12 gpm
Permeate
e Fraction
Permeate F
Fraction
0.35
0.30
1.00
1.50
2.00
time, hours
Vt (50-150)
0.25
Vt (100-150)
0.20
0.15
0 00
0.00
Vt (150-150)
1 00
1.00
2 00
2.00
3 00
3.00
time, hours
4 00
4.00
5 00
5.00
6 00
6.00
Design
g Scenarios
Batch
Time
(h)
TDS (F)
(ppm)
Permeate
(gal)
TDS(P)
(ppm)
Recovery
Efficiency
TDS
(initial)
(ppm)
Volume
Holding
Tank (N,C)
Units
(OC,RO)
(OC
RO)
Feed
gpm
TMP
psia
3.92
4.03
4.13
2.07
2.12
2.17
0.47
0.88
0.75
0.65
0.50
0.42
0 32
0.32
0.58
0.60
0.52
0.75
32728
32241
31880
35920
35526
35245
39357
39594
39422
39426
36660
39242
38960
39557
39415
39026
11497
282
291
299
137
141
145
25
47
82
108
115
91
69
126
130
166
342
174
204
212
237
287
305
436
439
424
411
374
422
426
434
560
356
27
0.79
0.80
0.80
0.65
0.65
0.66
0.29
0.28
0.52
0.72
0.83
0.55
0 40
0.40
0.37
0.38
0.52
0.91
5000
5000
5000
10000
10000
10000
25000
25000
25000
25000
25000
25000
25000
25000
25000
25000
5000
50,75
50,75
50,75
50,75
50,75
50,75
50,80
100,150
100,150
100,150
100,150
100,150
100 150
100,150
200,300
200,300
200,300
200,300
,
2,1
2,1
2,1
2,1
2,1
2,1
2,1
2,1
2,2
2,3
2,4
4,4
44
4,4
4,4
4,4
4,4
4,4
,
6
8
10
6
6
6
6
6
6
6
6
6
6
6
8
8
8
800
800
800
800
800
800
800
800
800
800
800
800
800
800
800
1000
1000
Scale--Up Issues
Scale
S-115
S-110
S-116
P-1 / GMF-101
P-2 / GMF-102
OC Filtration
OC Filtration
S-113
S-102
S-114
P-3 / RO-101
Reverse Osmosis
S 107
S-107
S-103
P-4 / RO-102
S-101
S-106
Reverse Osmosis
P-11 / FSP-101 S-104
Flow Splitting
P-10 / V-102
P-9 / V-101
Storage
Holding Tank
S-108
Permeate
S-105
P-5 / RO-103
S-109
Reverse Osmosis
S-117
S-112
S-119
S-118
P-6 / RO-104
Reverse Osmosis
P-7 / GMF-103
P-8
OC Filtration
OC Filtration
P-12 / V-103
S-111
Future Work
Experiments with other membrane
materials at higher pressure
Expand RORO-model design for other
membrane specifications
Continue OC experimental design to
accommodate different packing
Analyze membranemembrane-regeneration cycles
Analyze scaling, fouling
Future Work
Membrane fouling: Causes (scale, oil, pH,
aging)
Monitoring,
g, cleaning
g frequency
q
y and agents
g
Prevention (extend membrane life)
Permeate
Flux
Cleaning
Time
Future Work
Oil/ t separation
Oil/water
ti with
ith
hydrocyclones
High separation efficiency
No chemicals or cleaning needed
Low maintenance and operating
cost
No Moving Parts
Recycle options
Interdisciplinary
y Program
g
Financial Support
DOE
CONACYT (Mexico, A&M)
GPRI (Marathon,
(Marathon Total Fina
Fina,
ChevronTexaco)
P l
Polymer
Ventures
V t
TWRI