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2005 Water Efficiency and 2005 Water Efficiency and Innovation Forum for the Oil Patch Innovation Forum for the Oil Patch June 23, 2005 Calgary, Alberta June 23, 2005 Calgary, Alberta World’s First SAGD Facility Using World’s First SAGD Facility Using Evaporators, Drum Boilers, and Zero Evaporators, Drum Boilers, and Zero Discharge Crystallizers to Treat Discharge Crystallizers to Treat Produced Water Produced Water Bill Heins, GE Ionics RCC Bill Heins, GE Ionics RCC Bellevue, Washington Bellevue, Washington

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Page 1: ge -saltmaker

2005 Water Efficiency and 2005 Water Efficiency and Innovation Forum for the Oil PatchInnovation Forum for the Oil Patch

June 23, 2005 Calgary, AlbertaJune 23, 2005 Calgary, Alberta

World’s First SAGD Facility Using World’s First SAGD Facility Using Evaporators, Drum Boilers, and Zero Evaporators, Drum Boilers, and Zero

Discharge Crystallizers to Treat Discharge Crystallizers to Treat Produced WaterProduced Water

Bill Heins, GE Ionics RCCBill Heins, GE Ionics RCCBellevue, WashingtonBellevue, Washington

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Presentation OverviewPresentation Overview♦♦ Water Treatment Needs for Heavy Oil Recovery Water Treatment Needs for Heavy Oil Recovery

ProcessesProcesses♦♦ Evolution from “Traditional” WLS or HLS / WAC / Evolution from “Traditional” WLS or HLS / WAC /

OTSG Approach to Evaporator / Boiler Approach, OTSG Approach to Evaporator / Boiler Approach, Including the Use of Zero Liquid Discharge (ZLD)Including the Use of Zero Liquid Discharge (ZLD)

♦♦ Evaporation and ZLD Experience in Heavy Oil Evaporation and ZLD Experience in Heavy Oil Recovery and Other ApplicationsRecovery and Other Applications

♦♦ Technical Overview of Produced Water Treatment Technical Overview of Produced Water Treatment Using Falling Film EvaporatorUsing Falling Film Evaporatorand Zero Liquid Discharge Technologyand Zero Liquid Discharge Technology

♦♦ Specifics of Deer Creek Project Including Technical Specifics of Deer Creek Project Including Technical Approach and EconomicsApproach and Economics

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Water Treatment Needs for Water Treatment Needs for Heavy Oil Recovery FacilitiesHeavy Oil Recovery Facilities♦♦ Produced Water Treatment for Boiler FeedProduced Water Treatment for Boiler Feed♦♦ DeDe--coupling Produced Water System From Boiler coupling Produced Water System From Boiler

Feed System Feed System –– Boiler ReliabilityBoiler Reliability♦♦ Maximum Equipment ReliabilityMaximum Equipment Reliability♦♦ Maximize Water Recovery For ReMaximize Water Recovery For Re--UseUse♦♦ Minimize Capital and Operating CostsMinimize Capital and Operating Costs♦♦ Maximize OnMaximize On--Stream Availability and Oil ProductionStream Availability and Oil Production♦♦ Organics ConcernsOrganics Concerns♦♦ Regulatory ConcernsRegulatory Concerns♦♦ Zero Liquid Discharge (Brine Concentrators and Zero Liquid Discharge (Brine Concentrators and

Crystallizers) if Disposal Not an OptionCrystallizers) if Disposal Not an Option

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Evaluation of Traditional Approach Evaluation of Traditional Approach Compared to Evaporative MethodCompared to Evaporative Method♦♦ Why have OTSGs historically been used when 100% Why have OTSGs historically been used when 100%

quality steam is required for SAGD?quality steam is required for SAGD?♦♦ Does the HLS or WLS / WAC / OTSG approach still Does the HLS or WLS / WAC / OTSG approach still

make technical and economic sense for SAGD?make technical and economic sense for SAGD?♦♦ Need for greater steam generator reliability and Need for greater steam generator reliability and

means of protection of steam generatorsmeans of protection of steam generators♦♦ Desire for simplified approach, improved economics, Desire for simplified approach, improved economics,

and increased onand increased on--stream availabilitystream availability♦♦ Can liquid waste be minimized or eliminated where Can liquid waste be minimized or eliminated where

deep well is not viable or not desirable (i.e., ZLD)?deep well is not viable or not desirable (i.e., ZLD)?♦♦ Status of industry changing to new evaporative Status of industry changing to new evaporative

approach in Alberta and worldwide (MacKay River, approach in Alberta and worldwide (MacKay River, Suncor, Deer Creek, and others overseas)Suncor, Deer Creek, and others overseas)

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Traditional Produced Water Treatment Traditional Produced Water Treatment SystemSystem

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Characteristics of Traditional ApproachCharacteristics of Traditional Approach♦♦ OTSG Susceptible to Upsets in DeOTSG Susceptible to Upsets in De--Oiling ProcessOiling Process♦♦ Significant Chemical Handling and Chemical Significant Chemical Handling and Chemical

AdditionAddition♦♦ Sludge Disposal and Several Waste Streams Sludge Disposal and Several Waste Streams

Requiring Handling and DisposalRequiring Handling and Disposal♦♦ Significant Operations Labor RequirementsSignificant Operations Labor Requirements♦♦ Requires Vapor / Liquid Separators to Make 100% Requires Vapor / Liquid Separators to Make 100%

Quality Steam From 20% OTSG BlowdownQuality Steam From 20% OTSG Blowdown♦♦ Deep Well Injection RequiredDeep Well Injection Required♦♦ Relatively High Capital and O&M CostsRelatively High Capital and O&M Costs♦♦ Long Project Execution SchedulesLong Project Execution Schedules♦♦ System ComplexitySystem Complexity

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Vertical Tube Falling Film Vapor Vertical Tube Falling Film Vapor Compression Evaporator Produced Compression Evaporator Produced Water Treatment System With ZLDWater Treatment System With ZLD

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Simplified Vapor Compression Simplified Vapor Compression Falling Film Evaporator SystemFalling Film Evaporator System

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Evolution of Use Of Evaporators and Evolution of Use Of Evaporators and ZLD in Produced Water TreatmentZLD in Produced Water Treatment♦♦ Traditional Approach Used Until 1999Traditional Approach Used Until 1999♦♦ First Two SAGD ZLD Systems Installed First Two SAGD ZLD Systems Installed

Between 1999 and 2002Between 1999 and 2002♦♦ First Three SAGD Facilities Implement Use First Three SAGD Facilities Implement Use

of Evaporation for Produced Water of Evaporation for Produced Water Treatment Feeding OTSGTreatment Feeding OTSG

♦♦ In 2004, Deer Creek Joslyn Phase II Project In 2004, Deer Creek Joslyn Phase II Project Implements Evaporators Feeding Drum Implements Evaporators Feeding Drum Boilers for Steam Production and Implements Boilers for Steam Production and Implements ZLD Crystallizer System ZLD Crystallizer System –– 11stst Fully Integrated Fully Integrated System WorldwideSystem Worldwide

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Advantages of Produced Water Advantages of Produced Water Treatment With Brine ConcentratorsTreatment With Brine Concentrators♦♦ DeDe--couples the produced water system from the boiler feed couples the produced water system from the boiler feed

system, increasing boiler reliabilitysystem, increasing boiler reliability♦♦ Lower capital, operating, and lifecycle costs compared to Lower capital, operating, and lifecycle costs compared to

traditional methodtraditional method♦♦ Increases heavy oil recovery process availability and reliabilitIncreases heavy oil recovery process availability and reliability y

by 2by 2--3%, increasing oil production3%, increasing oil production♦♦ Eliminates traditional produced water treatment systems (WLS Eliminates traditional produced water treatment systems (WLS

or HLS, WAC, etc.)or HLS, WAC, etc.)♦♦ Minimizes softener sludge and other waste streams requiring Minimizes softener sludge and other waste streams requiring

disposaldisposal♦♦ Minimizes chemical use, cost, storage, and handlingMinimizes chemical use, cost, storage, and handling♦♦ May reduce amount of deMay reduce amount of de--oiling equipmentoiling equipment♦♦ Reduces maintenance materials and laborReduces maintenance materials and labor♦♦ Reduces ZLD system size by 80% (if ZLD is required)Reduces ZLD system size by 80% (if ZLD is required)

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Advantages of Produced Water Treatment Advantages of Produced Water Treatment With Brine Concentrators (cont’d)With Brine Concentrators (cont’d)♦♦ Boiler blowdown and heat recovery equipment Boiler blowdown and heat recovery equipment

reduced in size by 15%reduced in size by 15%♦♦ Increases OTSG feed quality and reliabilityIncreases OTSG feed quality and reliability♦♦ Boiler blowdown recycled to Brine Concentrator Boiler blowdown recycled to Brine Concentrator

feed, eliminating disposalfeed, eliminating disposal♦♦ Can allow for the substitution of packaged boilers in Can allow for the substitution of packaged boilers in

lieu of OTSGs due to dramatically increased boiler lieu of OTSGs due to dramatically increased boiler feed qualityfeed quality–– Reduced capital costReduced capital cost–– Reduced blowdown volume, feed system size, heat Reduced blowdown volume, feed system size, heat

recovery system size, and evaporation system sizerecovery system size, and evaporation system size–– Eliminates vapor / liquid separatorsEliminates vapor / liquid separators–– Accelerated project scheduleAccelerated project schedule

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500 GPM Vertical Tube Falling Film 500 GPM Vertical Tube Falling Film Vapor Compressor Evaporative SystemVapor Compressor Evaporative System

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Installation of 500 gpmInstallation of 500 gpmRCCI Brine Concentrator VesselRCCI Brine Concentrator Vessel

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5,800 m5,800 m33/day (1,100 gpm)/day (1,100 gpm)Evaporator TransportationEvaporator Transportation

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17,300 m17,300 m33/day (3,200 gpm)/day (3,200 gpm)Evaporator InstallationEvaporator Installation

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RCCI Experience RCCI Experience –– Proven TechnologyProven Technology

♦♦ 30 Years Experience in Evaporation and Zero Liquid Discharge 30 Years Experience in Evaporation and Zero Liquid Discharge (ZLD), Proven Technology. About 150 Installations.(ZLD), Proven Technology. About 150 Installations.

♦♦ 90% of All Vapor Compression Brine Concentrator Systems 90% of All Vapor Compression Brine Concentrator Systems Worldwide are RCCI, including all Produced Water EvaporatorsWorldwide are RCCI, including all Produced Water Evaporators

♦♦ RCCI Recently Provided World’s First Three ZLD Systems in RCCI Recently Provided World’s First Three ZLD Systems in SAGD Heavy Oil RecoverySAGD Heavy Oil Recovery

♦♦ RCCI is Currently Installing Produced Water Treatment Brine RCCI is Currently Installing Produced Water Treatment Brine Concentrators for the Suncor Firebag Stage 2 Project, the Deer Concentrators for the Suncor Firebag Stage 2 Project, the Deer Creek Energy Project, and 2 Other Systems OverseasCreek Energy Project, and 2 Other Systems Overseas

♦♦ Wastewater Evaporation is RCCI’s Sole EmphasisWastewater Evaporation is RCCI’s Sole Emphasis

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What is a Brine Concentrator?What is a Brine Concentrator?

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Brine Concentrator Process FlowBrine Concentrator Process Flow

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Brine Concentrator DistillateBrine Concentrator Distillate

♦♦ High quality, 1High quality, 1--5 mg/l non5 mg/l non--volatile TDSvolatile TDS♦♦ Boiler makeup / demineralizer makeupBoiler makeup / demineralizer makeup♦♦ Process water recycle and reProcess water recycle and re--useuse♦♦ ABMA Water Specification Requires Special ABMA Water Specification Requires Special

Design Features to Maximize Distillate Design Features to Maximize Distillate Quality and Protect Boiler Quality and Protect Boiler

♦♦ Quantification of Organics in Produced Water Quantification of Organics in Produced Water and Distillateand Distillate

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When is Zero Discharge Utilized When is Zero Discharge Utilized and What Are Advantages?and What Are Advantages?

♦♦ No (or Limited) deep well injection capacity or risk of No (or Limited) deep well injection capacity or risk of plugging a concernplugging a concern

♦♦ Fresh Water Aquifer Near Deep WellFresh Water Aquifer Near Deep Well♦♦ Maximize water reMaximize water re--use and minimize onuse and minimize on--site water site water

storage or discharge (ZLD provides nearly 100% storage or discharge (ZLD provides nearly 100% recycle)recycle)

♦♦ Simpler and faster permitting, community acceptanceSimpler and faster permitting, community acceptance♦♦ Water supply is limitedWater supply is limited♦♦ Mandated by regulatory requirementsMandated by regulatory requirements♦♦ Occasionally driven by economicsOccasionally driven by economics♦♦ Deer Creek is 3Deer Creek is 3rdrd SAGD ZLD FacilitySAGD ZLD Facility

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Traditional Produced Water Treatment Traditional Produced Water Treatment SystemSystem

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Vertical Tube Falling Film Vapor Vertical Tube Falling Film Vapor Compression Evaporator Produced Compression Evaporator Produced Water Treatment SystemWater Treatment System

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Typical Zero Liquid Discharge Typical Zero Liquid Discharge Crystallizer SystemCrystallizer System

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130 gpm RCCI130 gpm RCCIZero Discharge SystemZero Discharge System

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Crystallizer SolidsCrystallizer Solids

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Organic Laden Crystallizer SolidsOrganic Laden Crystallizer Solids

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Overview of Deer Creek Joslyn Overview of Deer Creek Joslyn Phase II Water Treatment ProcessPhase II Water Treatment Process♦♦ Integrates produced water evaporation, use Integrates produced water evaporation, use

of conventional boilers, and ZLD technologyof conventional boilers, and ZLD technology♦♦ Evaporators produce 205 mEvaporators produce 205 m33/hr of boiler /hr of boiler

feed, providing 10,000 bpd oil productionfeed, providing 10,000 bpd oil production♦♦ 2 x 50% evaporators provide flexibility and 2 x 50% evaporators provide flexibility and

increased reliabilityincreased reliability♦♦ ZLD Crystallizer produces dry solids for ZLD Crystallizer produces dry solids for

disposaldisposal♦♦ Provides all advantages discussed for Provides all advantages discussed for

evaporators, drum boilers, and ZLDevaporators, drum boilers, and ZLD

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Economics of Deer Creek Produced Economics of Deer Creek Produced Water Evaporators / Drum BoilersWater Evaporators / Drum Boilers♦♦ Total installed cost of evaporators and boilers 10% Total installed cost of evaporators and boilers 10%

less than traditional approachless than traditional approach♦♦ Overall operating costs 6% lowerOverall operating costs 6% lower♦♦ OnOn--stream availability estimated to be 2% higher stream availability estimated to be 2% higher

than traditional approachthan traditional approach♦♦ Increased turndown capability during 18 month Increased turndown capability during 18 month

rampramp--up phaseup phase♦♦ Reduced labor costsReduced labor costs♦♦ Shortened project schedule by 6 monthsShortened project schedule by 6 months♦♦ Potential for alternate fuelsPotential for alternate fuels♦♦ Reduced boiler maintenance due to increased feed Reduced boiler maintenance due to increased feed

qualityquality

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SummarySummary♦♦ Deer Creek Joslyn Phase II is the first facility to integrate Deer Creek Joslyn Phase II is the first facility to integrate

evaporators, boilers, and ZLD technologyevaporators, boilers, and ZLD technology♦♦ Use of evaporators and drum boilers in lieu of WLS, WAC, and Use of evaporators and drum boilers in lieu of WLS, WAC, and

OTSG has several technical advantages, increases reliability, OTSG has several technical advantages, increases reliability, decreases chemical handling, and increases simplicitydecreases chemical handling, and increases simplicity

♦♦ Lower capital, operating, and lifecycle costs are realized Lower capital, operating, and lifecycle costs are realized compared to the traditional approachcompared to the traditional approach

♦♦ Evaporators deEvaporators de--couple the produced water system from the couple the produced water system from the boiler feed system, greatly improving boiler reliabilityboiler feed system, greatly improving boiler reliability

♦♦ Evaporators and ZLD have a 30 year proven track record, Evaporators and ZLD have a 30 year proven track record, including 6 installations in produced waterincluding 6 installations in produced water

♦♦ Zero Liquid Discharge (ZLD) eliminates deep well risks, greatly Zero Liquid Discharge (ZLD) eliminates deep well risks, greatly reduces makereduces make--up water requirements, and results in simplified up water requirements, and results in simplified permitting and community acceptancepermitting and community acceptance