pwe2013 cameron

Advances in Compact Flotation Unitsfor the Treatment of Produced Water

Produced Water & EnvironmentalConference - Aberdeen

June 5-6, 2013

Mike BhatnagarSr. Product Manager

TST-CFUTM

Process & Compression SystemsCustom Process Systems2

Cameron is a leading provider of branded flow equipment products,systems and services to worldwide oil, gas and process industries.

OIL GAS WATER SOLIDS

• Free Water Knockout

• TS WKO™ CompactFree Water Knockout

• NATCO® MechanicalHeater Treaters

• Multi PhaseSeparators

• PORT-TESTRevolution®

• CONSEPT ICD®

• NATCO® DualFrequency®

• NATCO® DualPolarity®

• PETRECO® Bilectric®

• PETRECO® MeterCell

• CES™ CompactCoalescer

• Bilectric HF™

• Cynara® CO2

• PureMEG™ MEGReclamation

• Shell / Paques• THIOPAQ®

• PORT-TESTWhirlyScrub I™, V™

• PORT-TESTRevolution®

• CONSEPT DC™• CONSEPT IVD™• CONSEPT SI™• CONSEPT Spinlet™• CONSEPT ACI™• NATCO® CHF® Heater• NATCO® BTEX Buster®

• NATCO® Desi-Dri®

• NATCO® SHV™Flare/Combuster

• NATCO® Water BathHeaters

• NATCO® Glymine• Amine Treating• Glycol Dehydration• Mechanical

Refrigeration• NATCO® Jewel T®

Produced Water Seawater • MOZLEY™ WellheadDesander

• MOZLEY™Desanding SLC

• MOZLEY™Microspin

• MOZLEY™Hydrotrans™

• MOZLEY™Fluidizer™

• MOZLEY™Deltaclone™

• MOZLEY™Sandcleaning

• UNICEL®Vertical SkimVessel

• WEMCO® Pacesetter®

• NATCO® Cross-FlowScrubber

• VORTOIL® DeoilingCyclones

• WEMCO® ISF®

• WEMCO®Depurator®

• UNICEL® IGF• NATCO® Versaflo™• PETRECO®

Hydromation® Nutshell• PETRECO® Silverband

Nutshell• PETRECO® Softeners• NATCO® Skim Pile• NATCO® DOX®• TS CFU™ Compact

Flotation

• METROL® SeaCell®

• METROL® BFCC™

• METROL SeaScreen& SeaScreen Max

• Media Filters

• Vacuum Deaerators

• Gas Strip Deaerators

• Polymem UF

• NATCO® SulphateRemoval

• CDX™ CompactDeaeration

Custom Process Systems - Portfolio

TS Technology acquired by Cameron Custom Process Systems

Custom Process Systems

2004 2011

1990 20101997 20011999 2002 2007

Baker HughesProcessSystems(BHPS)

formed fromBaker HughesIndustries &WEMCO with

Metrol

Custom ProcessSystems

PetrecoInternationalacquired byCameron

BHPSacquiresBFCC

BHPSacquiresVortoil

1990 20101993 1995 1997

BHPSacquiresPetreco

19981996 2001

Sequal Holdingspurchases BakerHughes Process

Systems fromBaker Hughes

creating PetrecoInternational

2002

PetrecoInternational

acquiresKCC

Process

PetrecoInternational

acquires

Unicel

TEST

CYNARAMembranes

MPE

ESI

Axsia

PORTA-TEST

ConSepT

Mozley

BakerHughes

Industries

WEMCOOil &

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BHPSacquiresKrebs

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NATCOAcquired by

Cameron

Cameronacquires

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Custom Process Systems5

Produced Water Treatment TrendsNext Generation Compact Flotation - TST CFU

Field Trials – North SeaField Test Results

Summary of other Field Test Results and Full Scale InstallationsConclusions and Future Work

Produced Water Trends – Onshore Applications

• Globally produced water associated with the oil & gas productionis between three and seven times than the oil production and itcontinues to increase over the lifespan of the well.

• Onshore produced water is usually treated and re-injected intounderground formations, or treated and discharged underpermits issued by regional agencies.

• Cameron’s WEMCO Depurator Flotation Systems and thePetreco Hydromation Nut Shell Filters are well established inthese applications.


Produced WaterTreatment

Compression Compression Gas Export

Knockout

DrumGas

Treatment /Dehydration

CrudeExport

ProducedWater for re-

injection

HYDROMATIONNutshell Filter

WEMCOFlotation

WEMCOCPI

SkimmingsSeparation

HPProductionSeparator

LP ProductionSeparator

ElectrostaticDehydrator

WellheadChoke

Typical OnshoreSeparation PFD

Bulk PhaseSeparation

ElectrostaticCrudeConditioning

Gas Treatmentand Conditioning

Solids SeparationSystem

WellheadDesanders

Pressurereducing

Pressurereducing

SandClean System

SandDisposal

Water

FromWellhead

Cartridge FilterAdsorption

8

WEMCO ® Depurator ®

ConventionalBox Design

CylindricalDesign


Petreco® Hydromation® Nut Shell Filters

Produced Water Trends – Offshore Applications

• Most offshore produced water is treated and discharged to theocean as permitted by the regional agencies.

• In the past, many offshore operators have adopted a trendtoward the use of de-oiling hydrocyclones followed byconventional flotation, degasser or conventional compactflotation to treat produced water prior to overboard discharge.


Compression Compression Gas Export

Knockout

DrumGas

Treatment /Dehydration

CrudeExport

ProducedWater forDisposal

SkimmingsSeparation

HP ProductionSeparator

LP ProductionSeparator

ElectrostaticDehydrator

Cartridge FilterAdsorption

WaterRecycle

OilRecycle

DesandingHydrocyclone

Deoiler

Deoiler

ProducedWater for re-

injection

ConventionalFlotation /

Degasser/ CFU

Typical OffshoreSeparation PFD

Produced WaterTreatment

ElectrostaticCrudeConditioning

Gas Treatmentand Conditioning

Bulk PhaseSeparation

DeltaClone

Solids SeparationSystem

WellheadDesanders

PressureReducing

Pressurereducing

SandClean System

SandDisposal

WellheadChoke

12

Vortoil ® Deoiling Hydrocyclone

Inserted Sandwiched OriginalOffset

ModifiedManufacturedOffset

Super Offset

Value Engineeredover 20+ years

13

Unicel ® Vertical Flotation

Offshore Production Trends, continued…

• Oilfield operating companies continue moving to ever-increasing waterdepths to produce oil and gas reserves. The high cost of constructingfloating platforms, is driving the need to reduce the size and weight oftopsides processing equipment on these platforms.

• The challenges for the operators are increasing and the need for highperformance, compact and more cost effective technologies exists thatcan handle the high water cuts.

• This has lead to the development of the next generation TST-CFUTM, thathas multiple stages in a single vessel making it capable of handlinghigher inlet OIW concentrations.

• The TST-CFUTM offers better performance than that achieved by acombination of multiple technologies like Hydrocyclones, ConventionalFlotation or Compact Flotation units, considerably reducing the need forfoot print and weight.


Next Generation Compact Flotation – TST CFUTM

• The TST-CFUTM uses gas flotation andadditional hydraulic forces to separateand remove hydrocarbons, aromaticcompounds, hydrophobic substancesand fine solid particles from producedwater.

• The TST-CFU is available as a singlestage vessel or as a single vessel withmultiple internal stages offering acompact solution specially designed tohandle higher inlet oil concentrations,over 1,000mg/l.

• It requires a smaller foot print, has areduced weight than competitivetechnologies.

• The technology is world wide patentpending.


TST CFU – Compact Flotation Technology

• The Technology uses bothinduced, and dissolved gasflotation to removehydrocarbons.

• Special internals for mixingof gas and oil have beendeveloped to achieve easyseparation of this mixturefrom the water.

• The water can be treatedthrough several stages withinone vessel. It s available inconfigurations up to 4stages.

• The numbers of stagesdepend on the inlet fluidconditions.

17 Custom Process Systems

Direction of flow

Orifice /Valve/Mixer

Gas

Water

Orifice /Valve

Gassaturated water at pressure P1

Pressure P2Pressure P1P1 > P2

Direction of flow

Induced gas flotation

Dissolved gas flotation

TST CFU Basic (Single stage vessel)

• The TST-CFUTM design consists of specialinternals that include a static mixture, ariser pipe, distribution arms and guidevanes.

• Improved produced water circulation andre-mixing is crucial to the design of TST-CFUTM system to enhance the oilseparation efficiency and reduce theretention time down to 20 seconds perstage.

• Key parameters like downward fluidvelocity, gas bubble size, fluid circulation,internal flow paths, gas bubble re-mixing aswell as cell residence time, gas inductionrates, skimming rates, and their effects onprocess hydrodynamics have been takeninto consideration when designing this nextgeneration compact flotation technology.


1st stagewithoverlappingguide vanes

Cleanwaterwithoutbubblesbelow thevanes

Inletnozzle

CUSTOM PROCESS SYSTEMS19

TST CFU – Gas bubble distributuion and re-mixing

TST CFUTM MS3 (Three stage vessel)


• CFD analysis was used to improve theefficiency of the internal guide vanes byretaining more of the swirling oil watermixture and providing an upward flowpattern to the rising gas bubblesattached to the oil.

• The proper distribution of gas bubblesover the entire cross-sectional area ofthe vessel, the re-mixing of the gasbubbles, the size of the bubbles inducedinto the produced water are all critical topromote good oil separation

• Much shorter retention times of around20 seconD/S per stage has resulted in amore compact vertical pressure vesseland smaller reject volumes.

• The result is an enhanced CFU designwith multiple stages in a single vessel ascompared to the single stage design ofthe conventional vertical IGFs andconventional Compact Flotation Units.

Stage 1

Stage 2

Stage 3

PW inlet

Treated waterOutlet

TST CFUTM MS3 (Gas inlet and oil reject lines)


Gas recycleStage 1

Reject stage 1

Reject stage 2

Reject stage 3

Gas InletStage 2

Produced Water Inlet

Treated Water outlet

Field Trials – North Sea


Existing System:• 1st stage separator• 2nd stage separator• Flocculation tank• 1st stage hydrocyclones• 2nd stage hydrocyclones• Degassing tank• Single stage existing

compact flotation unit

Tie-in points :• Downstream of the

degasser• Downstream of the 1st

stage hydrocyclones• Downstream of the 2nd

stage hydrocyclones• Downstream of the 1st

stage separator

TST-CFUTM Test Skid

• The TST-CFU test-skidconsisted of two compactflotation units, the CFU Aand CFU B with differentinternal designs.

• The test allowed CFU Aand CFU B to be operatedindividually, in series or inparallel.


Inlet Oil/ water Specifications


Oil API 30.0Oil Density (150 C) [kg/l] 0.8759

PW Temperature[°C] 70PW pH 7.1-7.2

OIW levels in PW from existing treatment system

Test Procedures

• Tests at different tie-in points

• Flow rate (Typical 50; 100; 150% of design)

• Gas rate injection variation

• Tests performed with and without flocculants

• Testing with the normal variation of incoming water

• Measure OIW & Oil droplet size


Testing instruments

• OIW field instrument calibrated with the existing plant’spermit monitoring instrument

• Malvern Mastersizer Oil droplet size and particle sizemonitoring

• Malvern Zeta-sizer used when oil droplet surface chargewas problematic (especially for condensate water)

North Sea Test Results - Tie in Points


Single Stage TST-CFU - D/S of the degasser

• The incoming OIW wasaround 20 mg/l with afew peaks of up to 50mg/l.

• Initially no gas wasinjected into the TST-CFUs, but when gaswas added to the unit,the effluent OIWconcentration stabilizedat around 2-3 mg/l.

• No additionalflocculants were usedduring this test.

• The effluent from theexisting CFU wasaround 7.8 mg/l.


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10

20

30

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/lO

IW

Inlet Outlet

Oil droplet size changes over the TST-CFU – D/S of the degasser

• The median (d0.5) oildroplet size changedfrom 3 to 2 μm from inlet to outlet of the TST-CFU.

• The measuredconcentration D/S theTST-CFU was very low.

• The size distribution dataand the low OIWconcentration from thislocation both indicateexcellent treatability.

• The TST-CFU removesvery small diameter oildroplets.


Single Stage TST-CFU - D/S of 1st stage hydrocyclones


• The OIW resultsshow that the OIWwas reduced from~45 mg/l to 5 mg/lover one stage.

• The lowest OIWconcentration out ofthe TST-CFUwithout flocculantswas 3.5 mg/l andwith flocculants was2.5 mg/l.

• The median oildroplet size wasreduced from 3.1 to1.8μm over the TST-CFU.

Single Stage TST-CFU –D/S of 2nd stage hydrocyclones

• The test wasperformed usinga single stageCFU B.

• Flocculantsimproved theOIWperformancefrom ~ 4 mg/l to~2 mg/l in theeffluent.


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5

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8 911

8 8 8 79 9 9

7 8 7

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0

5

10

15

20

25

30

35

40

45

50

mg

/lO

IW

Inlet OIW values between 850 and 1,000 mg/l


3 Stage TST-CFU – D/S of the 1st stage Separator

• The inlet oil in waterconcentrations werebetween 850 and 1000mg/l.

• The oil in the waterfrom the 1st stageseparator containedsmall oil droplet sizewith 50% of the oildroplets < 5.7 μm.

• The first stage of theTST-CFU removed> 95 % and moved thed0.5 to 2.5 μm.

• The second and thirdstage of the TST-CFUremove a further 60%and reduce the d0.5 to2.3 μm

TST-CFU – North Sea Field test Summary

• D/S of the degassing vessel – Single stage TST-CFU treated the water from an inletOIW concentration of 20 mg/l down to 2 mg/l, (90 % reduction). The existing CFU had anoutlet OIW concentration of ~7.8 mg/l, (61% OIW reduction).

• D/S of the 1st stage separator - A two stage TST CFU reduced the OIW to 20 mg/l.With subsequent treatment over a three stage TST-CFU, the effluent OIW concentrationwas reduced to 8-11 mg/l., the same level as four separate existing produced watertechnologies- flocculant vessel, hydrocyclones, degasser and existing CFU

• D/S of the 1st stage hydrocyclones - A single stage TST-CFU treated the water to anOIW concentration below that achieved by using the existing degasser and the existingCFU. With subsequent treatment over a second stage TST-CFU, the effluent OIWconcentration was further reduced by 1-2 mg/l.

• D/S of the 2nd stage hydrocyclones - A single stage TST-CFU treated the water to aconcentration down to 2 mg/l OIW, and a treatment efficiency of 90% OIW, much betterthan the level reached by using the existing degasser and the existing CFU.


Tie-in Points InletOIW

OIW (mg/l)Outlet 1st

stage

OIW (mg/l)Outlet 2nd

stage

OIWRemoval %

1st Stage

OIWRemoval %2nd Stage

OIWRemoval %

Total

D/S Degasser ~20 ~2 90 90

D/S 1st StageSeparator

>1000 50 20 95 60 98

D/S 1st Stage HC 50 3.5 93 93

D/S 2nd Stage HC 20 2 90 90

TST-CFUTM Configurations and Applications


TST CFU 2 stages

TST CFU 1 stage

TST CFU 3 or 4 stages

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340

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Inlet

Stage 4

Pilot test results – GOM D/S of Separator

Custom process Systems

3 stage CFU – South Sea China

• Outlet from Separator- 100 to 180 ppm

• Outlet from existing HC - 80 ppm

• Outlet from existing Degasser vessel - 50 ppm


39

3 stage CFU D/S of inlet separator – South Sea China


40

3 stage CFU D/S of inlet separator – South Sea China


Full Scale Unit Startup 3 stage CFU – South Sea China

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110130150170190210230250270290310330350370390410430450470490510530550

1 2 3 4 5 6 7 8 9 10 11 12 13 14

Inlet

Stage 3


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3 stage CFU – China

Pilot test - 4 stage CFU – China


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Stage 4

Full scale unit Startup 4 stage CFU – China

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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Inlet CFU B

Stage 4 Outlet of CFU B


Pilot test TST- WKO Water Knock Out - China


• Inlet to WKO – 100,000 mg/l

• Outlet from WKO - 500 mg/l

• Outlet from CFU – <20 mg/l

WKO/ CFU Test Units – China

46

Full Scale Startup of WKO - China


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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Inlet OIW values between 80,000 and 100,000 mg/l

Parameters impacting performance

Oil droplet size

Important parameter for efficiency

Oil slugs

Minor effect on performance. Free oil iseasy to separate.

Gas bubble size

Smaller bubbles will give biggersurface and better contact between oildroplets and gas bubbles.

Salinity

Affects gas bubble size.

Temperature

No effect on performance, tested from250C to 950C

Pressure

No effect, tested from 0.5 to 20 bar

49 Custom process Systems

50

Dissolved gas in the feedPositive effect on gas flotation

FlocculantsImproved performance with use of flocculants

Shearing across valvesShearing across upstream valves can create small oildroplets and should be avoided


Other parameters impacting performance

CONCLUSIONS

Multiple separation stages within one single vessel

Can handle OIW inlet concentrations over 1,000 mg/l

No need for several vessels in series

Less space required and easier adaptation into existing installation

More flexible design

Multiple internal feed distribution instead of an external tangential inlet

Better fluid distribution and internal re-mixing

Higher probability of contact between gas bubbles and oil droplets

Not impacted by scaling up of vessels

The technology is world wide patent pending


CONCLUSIONS

• Better performance than traditional IGFs and conventional CFU’s

90 to 98% efficiency

• Less equipment as it can replace multiple technologies

Lower weight

Smaller footprint

• Less dependent on chemicals than the first generation CFUs

Lower OPEX

• Simple skid design

Compact single vessel option


FUTURE WORK

• Thus far the next generation TST-CFUTM

compact flotation technology has beeninstalled at several platforms performingsatisfactorily.

• Other operating companies in the GoMand other deepwater locations are alsotesting the TST-CFUTM.

• As feedbacks from existing and new fieldinstallations are received, additionalenhancements will be made to the TST-CFUTM design.


pwe2013 cameron

Documents

onshore produced water

oil gas productionis

compact flotation unitsfor

worldwide oil

oil production

scale installationsconclusions

defined gray box

discharged underpermits