produced water management treatment overvie - wilson ge-en.pdf · © 2012, general electric company...

Produced Water ManagementTreatment Overview

2GE Power & Water© 2012, General Electric Company

* Large range of regional variation exists

Water use

Air quality

Land disturbance

Related to frac process

Low High

Water availability Frac flowback water

Produced waterLand clearing

Wastewater treatment/disposal

Chemical composition of frac fluid

Water rights

Venting or flaring from completions/workovers

Truck traffic

Regional ozone attainment

Quantity Source

Uncontrolled release -blowout

Western Issue

Source: GE Energy, Global Strategy & Planning; based on customer discussion not a statistical survey

Degree of public scrutiny*

Water issues elevated in national debate

Environmental issues in upstream gas


Key Unconventional Gas Basins

Barnett Shale• Water availability• Emissions

Haynesville Shale• Wastewater disposal• Water availability

Marcellus Shale• Wastewater disposal• Water impoundment ponds

Fayetteville Shale• Wastewater disposal• Source of water supply

Source: GE Energy, Global Strategy & Planning

Resource (Size, concentration)

Proximity to (urban or wilderness areas)

O&G industry maturity

Low

High

Forces driving Environmental sensitivity

Moderate

High

Rockies basins• CBM Wastewater disposal• Water availability• Emissions

Large gas plays, in close proximity to urban or pristine areas with little local familiarity to the O&G industry are likely to draw the most intense scrutiny

Environmental focus stronger in some regions


Areas of focus…1. Discharge water quality- membranes, thermal,

pretreatment, others.

2. Chemistry reduction- membranes, others.

3. Trucking reduction- membranes, thermal, other.

4. Storage management- membranes, thermal, other.

5. Well and formation integrity- membranes, thermal, others.

6. Water sustainability- membranes, thermal, other.


Frac Water LifecycleCurrent

Collect the brine

Transport the brine

Dispose of the brine

Find the SourceWater

Transport SourceWater

Store the SourceWater

Pump the SourceWater

THE

WELL

THE

WELL

Source Water Filtration

• Removes TSS

• Removes sulphate reducing bacteria and acid producing bacteria

• Reduces scaling and corrosion potential

• Reduces chemical demand during fracturing

7

GE Mobile Water

Largest Water Rentals Fleet in the World

Technology leader with broad portfolio of water treatment solutions• SWRO• BWRO• EDR• MBR• UF• DI

8

Identified Need:• TSS Reduction• Elimination/Minimization of Chemicals• Mobile• 4200 GPM

Conventional Pretreatment0.02-0.1 μm SRB/APB Range

9

Building Block DesignFiber Module Rack Train

Mobile

10

Conceptual Flows: 4 Trailers

4600 GPM 4200 GPM

~400 GPM

Produced Water Reuse

• Promote water sustainability

• Provide best water quality for reuse or discharge

• Reduce trucking and transportation costs

12GE Water & Process Technologies© 2012, General Electric Company

Investing in future reuse technology

Increasing Value for Recovery

• Water priced at true cost to supply, encouraging reuse

• Energy and materials cost expected to trend upward

What Drives Reuse?

• Past: Water scarcity and environmental regulation

• Future: Value recovery & continued regulation

Waste Ponds Disposal Well

“Waste” stream

Efficient separations

Metals

ReuseWater

Salts Nutrients

13GE Water & Process Technologies© 2012, General Electric Company

Disposal/Reuse of the brineDisposal/Reuse of the brine

• Capacity Issues• Transport Issues• Regulatory Issues


High TDS Water Treatment TestingThe specific objectives of the Flowback &

Produced Water Treatment Test Program involved four areas:

1. Develop process design basis

2. Evaluate feed pretreatment requirements

3. Identify optimum evaporator design parameterso Maximum concentration factor

(CF)o Boiling point rise (BPR)o Tendencies for foaming,

fouling, scalingo Distillate composition

4. Evaluate Crystallizer Designs & Performanceo Boiling point rise (BPR)o Foaming, foulingo Salt purification / separation


Technologies & water recovery60-96% Recovery Beneficial Reuse

Waste WaterByproducts

Recovery systems

Thermal Evaporation, Crystallization,

Bio Polishing


5,000

100,000

50,000

250,000

10,000

130,000

50% 75% 100%

TDS Removed, mg/l

Water Recovery

SWRO

BWRO

Crystallizer

Evaporator

Application of Desal Technology:Salt Removal and Recovery in Frac Water


Thermal Products & ZLD Summary

• World leader in zero liquid discharge (ZLD) technology

• 40 years of thermal waste water re-use experience

• Over 275 operating evaporator and crystallizer units

• Supplied over 70% of all global ZLD systems

• Replaced or modified competitors system


Evaporator and Crystallizer Technology Summary

ZLD is achieved through the combination of evaporation followed by crystallization

Evaporator Crystallizer


Thermal and ZLD Drivers

• Environmental discharge regulations

• Water reuse quantity and quality

• Reduction of brine disposal costs

• Waste to value


Brine Concentrators/Evaporators

• Brine Concentrators cover a specific application of evaporator technology

• Used in waste water treatment to reduce the volume of waste and produce high quality distilled water as a product

• Seeded slurry technology allows concentration without scaling of surfaces

• Good candidate streams are waste waters that are ususally high in TDS


Crystallizers

• Pure Salt and Mixed Salt Crystallizers• Evaporate highly concentrated waste water (such as

Brine Concentrator blowdown) to dry solids• Ideal for waste waters of greater than 60,000 ppm• Solids are harvested from the crytsallizer by filter

press, centrifuge or dryer• Pure Salt experience in NaCl, Na2SO4, CaCl2,

NaNO3, K2SO4, Na2S, NH4SO4, MAP and DAP

FIXED FACILITY THERMAL TREATMENT PLANTS


Fully Modularized Plants

Complete Centralized Treatment Facilities

Solution Generation22000 BBL/Day Fixed system


Recovered Salt Product

MOBILE EVAPORATOR


1715 BBL/Day Mobile system1715 BBL/Day Mobile system


GE’s Mobile EvaporatorTreat Shale Gas Frac Water at the Well Site• Horizontal Shell & Tube Forced

Circulation Evaporator

• Proprietary sequential stage MVR design with cyclonic coupling reduces energy costs by approximately 35%

• Partial Vacuum

• Completely self-contained with all ancillary equipment included within the trailer

• Single drop trailer provides maximum clearance for remote site access


Solution Generation

Single Well Completion• Completion Fluid and Materials 10 - 20 Truckloads

• Completion Equipment (pipe, wellhead) 5 Truckloads

• Hydraulic Fracture Equipment (pump trucks, tanks) 150 - 200 Truckloads

• Hydraulic Fracture Water 800 - 2400 Tanker Trucks

• Hydraulic Fracture Sand 20 - 25 Trucks

• Flow Back Water Removal 120 - 480 Truckloads(either to treatment or disposal)

• Well Production Equipment 5 – 10 Truckloads

REDUCE THE TRUCKS

TOTAL REDUCTION IN TRUCKING (per single well completion, 72 – 556)

Up to 42 % REDUCTION IN WASTEWATER TRUCKING COSTS AND WASTEWATER TREATMENT / DISPOSAL COSTS

Up to 9 % REDUCTION IN FRESH WATER TRUCKING COSTS

Disposal Well FiltrationOne Pass Filter

31GE Customer Presentation

8/22/2012

Disposal Well Filtration Objectives

1. Reduction of total operating costs2. Reduction of solids in tanks3. Reduction of chemistry through

bacteria filtration4. Extended pump and well life


8/22/2012

Filter Candle

Complete liquid filter with high tech membrane


8/22/2012

Filter Vessel

Engineered Vessels


8/22/2012

Filter Performance

1.0

10.0

100.0

1000.0

10000.0

100000.0

1000000.0

0.1 1 10 100

Particle Size (microns)

Part

icle

s pe

r ml

Tank w/o Bio Filter Trial FiltrateSWD w/o Bio Filter Trial In

produced water management treatment overvie - wilson ge-en.pdf · © 2012, general electric company...

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