Recovering Produced Water for Well Injection – Protecting ... · Recovering Produced Water for...

Gas Well Deliquification WorkshopSheraton Hotel, Denver, Colorado

February 23 - 26, 2009

Recovering Produced Water for Well Injection – Protecting a 10 Micron Aquifer with Zero Liquid Discharge from the Waste StreamThomas J. Steinke – Product Manager CoMag

Johnson Screens – A Weatherford Company

Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado

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Presentation OverviewPresentation Topics• Objective: To Recover Produced Water from the Field

and Create an Asset from a Waste Stream• Review Existing System• Pilot Study Objectives• Review Processes Tested in Pilot Study• Pilot Results• System Design• Conclusions


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Existing SystemProduced Water

Injection Well

In-Line Strainers, 25 microns

Sock Filters, 10 microns

Automatic Backwash Waste


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Existing SystemTargeted Improvements• Provide protection to injection well formation• Provide protection to aquifer classified as a drinking

water source• Provide a system with zero liquid discharge• Provide a system that allows landfill of solids• Decrease labor requirements of existing system


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Pilot Study Objectives• Demonstrate system capabilities to remove particles

greater than 10 microns with comparison to existing system

• Demonstrate a treated water free from any chemicals that would clog the injection well formation

• Meet Wyoming Class III water qualities• Demonstrate a system with zero liquid discharge• Determine optimal chemical treatment regime to

achieve objectives• Collect sufficient data to design and price full scale

system


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Conventional chemical coagulation/flocculation + high rate ballasted sedimentation + high rate magnetic filtration


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Ballasted Clarification


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Ballasted Clarification


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Ballasted Clarification• Conventional chemical floc ballasted by magnetite (Fe3 O4 )

• 20 to 40 times faster settling rates than conventional technologies

• Results in very low Hydraulic Retention Times (HRT)

• Faster clarification

smaller clarifiers


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Conventional chemical coagulation/flocculation + high rate ballasted sedimentation + high rate magnetic filtration


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Magnetic Filtration• Magnetite is an iron ore, Fe3 O4 ; doesn’t rust or degrade

• Enables magnetic filtration: magnetic matrix captures micro- flocs producing very clean water

• Open matrix has very high flow rates, no risk of clogging

• Low energy requirements


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Solids HandlingSolids Handling


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Sheer Mixer Separates Magnetite from Sludge

• High speed mixer breaks apart the chemical flocs of contaminants that are infused with magnetite;

• Resulting slurry of sludge and magnetite are fed to a magnetic recovery drum


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Magnetic Drum to Recover the Magnetite

Waste Sludge and Magnetite Pass Under a Magnetic Drum to Recover the Magnetite


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Magnetic Drum Enables 99+% Reuse of Magnetic Ballast Magnetic Drum Enables 99+% Reuse of Magnetic Ballast

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Long used, reliable, system for removing magnetic material from slurry;Used to recapture 99+ % of

magnetite from sludge for reuse;Very Low operating costs

Permanent magnets require no power

Very low power required to turn the drum In presentation

mode, click the picture to the right to see the film clip


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Pilot Study Results vs. Objectives

• Objective: Removal particles greater than 10 microns

• Results: Technology demonstrated sufficiently greater removal of 10 micron particles than existing system

• Discussion: – Piloted system demonstrated a 95% reduction of

particles in the 5-15 micron range as reported by independent Spectrex Labs.

– Piloted system demonstrated a 93% removal of particles greater than 10 microns as demonstrated by ChemTrac particle counter


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Pilot System Particle Count Graph - ChemTrac

CoMag Particle Count Reduction (ChemTrac 2400)

2,340

2,881

1,770

156417 401

122 80

500

1,000

1,500

2,000

2,500

3,000

3-5 u 5-10 u 10-25 u >25 u

Particle Size Range

Parti

cle

Coun

t per

mL

CoMag FeedCoMag Effluent

Produced Water

Pilot Effluent

Produced Water Particle Counts vs Pilot Effluent Particle Counts


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Comparison of Pilot System to Alternate Test Site

Particle Count Comparison (County Line vs CoMag Pilot)October 31, 2008

900

2,700

4,600

1,000750

375180 0

0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

5,000

3-5 u 5-10 u 10-25 u >25 uParticle Size Range

Parti

cle

Coun

t per

mL

CL Post SockCoMag PilotSock Filter Effluent

Pilot Effluent

Sock Filter Effluent Particle Counts vs Pilot Effluent Particle Counts


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Particle Count Comparison (County Line Post Sock vs CoMag Pilot) November 4, 2008

4,723

4,072

1,189

65

2,660

611170 9

0

500

1,000

1,500

2,000

2,500

3,000

3,500

4,000

4,500

5,000

3-5 u 5-10 u 10-25 u >25 u

Particle Size Range

Parti

cle

Coun

t per

mL

CL Post SockCoMag PilotSock Filter Effluent

Pilot Effluent

Sock Filter Effluent Particle Counts vs Pilot Effluent Particle Counts


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•Left beaker is untreated produced water

•Second from left is post in-line screened water

•Third from left is post sock filter water

•Right beaker is produced water with pilot tested process


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• Objective: Determine optimal chemical treatment regime to achieve objectives

• Results: Tested various coagulants, including metal salts and polymeric coagulants to determine best treatment option.

• Discussion:– Focused on clarifier effluent particle count reduction

and clarifier effluent turbidities.


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Graph of Coagulant PerformanceAverage Coagulant Performance - Particle Count

0

100

200

300

400

500

600

700

800

900

1,000

Epic 58 Epic 70 Pac 9783 Alum

Coagulant

Parti

cle

Cou

nt p

er m

L

5-10 u10-25 u>25 u


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• Objective: Provide treated water that meets Wyoming Class III water qualities

• Results: Chemicals added to the water stream are commonly used in drinking water treatment plants throughout the US.

• Discussion:– Potable water quality chemicals can be used in

treatment of this water


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• Objective: Demonstrate capabilities to provide a system that has zero liquid discharge

• Results: Successfully dewatered solids from the piloted system, using several different chemical regimes. Solids ranged from 22% to 35%.

• Discussion: – Pilot system clarifier solids concentrated with DAF

system– DAF solids dewatered with plate and frame press– DAF clarifier effluent and plate and frame press filtrate

recirculated to head of piloted coagulation system


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• Objective: Provide treated water that is free from any chemicals that will clog the formation of the injection wells

• Results: Conducted 0.45 micron filtration testing of pilot system clarifier effluent as indicator to formation plugging by comparison to distilled water.

• Discussion:– Optimal chemical treatment regime for particle count

reduction and effluent turbidity also proved optimal for 0.45 micron filtration test


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• Objective: Collect sufficient data to design and price full scale system using pilot site as basis of design

• Results: Selected full scale components to provide a system to meet requirements

• Discussion: – System design follows


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System Design – Piloted System


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System Design – Solids Handling


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Conclusions of the Pilot Study

Demonstrated Improvements• Protection of injection well formation and reduced

maintenance requirements of injection well• Protection of aquifer classified as a drinking water

source• Demonstrated a system with zero liquid discharge• Demonstrated a system that allows landfill of solids• Decrease labor requirements of existing system


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CopyrightRights to this presentation are owned by the company(ies) and/or author(s) listed on the title page. By submitting this presentation to the Gas Well Deliquification Workshop, they grant to the Workshop, the Artificial Lift Research and Development Council (ALRDC), and the Southwestern Petroleum Short Course (SWPSC), rights to:

– Display the presentation at the Workshop.– Place it on the www.alrdc.com web site, with access to the site to be

as directed by the Workshop Steering Committee.– Place it on a CD for distribution and/or sale as directed by the

Workshop Steering Committee.Other uses of this presentation are prohibited without the expressed written permission of the company(ies) and/or author(s) who own it and the Workshop Steering Committee.


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DisclaimerThe following disclaimer shall be included as the last page of a Technical Presentation or Continuing Education Course. A similar disclaimer is included on the front page of the Gas Well Deliquification Web Site.The Artificial Lift Research and Development Council and its officers and trustees, and the Gas Well Deliquification Workshop Steering Committee members, and their supporting organizations and companies (here-in-after referred to as the Sponsoring Organizations), and the author(s) of this Technical Presentation or Continuing Education Training Course and their company(ies), provide this presentation and/or training material at the Gas Well Deliquification Workshop "as is" without any warranty of any kind, express or implied, as to the accuracy of the information or the products or services referred to by any presenter (in so far as such warranties may be excluded under any relevant law) and these members and their companies will not be liable for unlawful actions and any losses or damage that may result from use of any presentation as a consequence of any inaccuracies in, or any omission from, the information which therein may be contained.The views, opinions, and conclusions expressed in these presentations and/or training materials are those of the author and not necessarily those of the Sponsoring Organizations. The author is solely responsible for the content of the materials.The Sponsoring Organizations cannot and do not warrant the accuracy of these documents beyond the source documents, although we do make every attempt to work from authoritative sources. The Sponsoring Organizations provide these presentations and/or training materials as a service. The Sponsoring Organizations make no representations or warranties, express or implied, with respect to the presentations and/or training materials, or any part thereof, including any warrantees of title, non-infringement of copyright or patent rights of others, merchantability, or fitness or suitability for any purpose.

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