Water Solutions

in the Oil & Gas Industry

Up-stream Water Treatment
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Water Treatment in the Oil & Gas Industry – Up-stream
Content

• Produced Water Treatment Objectives

• Primary Separation
• Secondary Separation
• Tertiary Separation
• Reference Installations
ü acc. RoK Standards
ü acc. Intl. Standards

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Serving All Sectors of the Oil & Gas Industry

Exploration & Production Transport & Storage Refining & Processing

„Upstream“ „Midstream“ „Downstream“

Oil production Gas/Oil separation Pipeline Tankfarms

Tank farms Refinery
Petro chemistry

GasGas
production
production Gas treatment Pipeline Terminal Gas processing
Liquefaction Distribution

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Treatment Objectives

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Overview Treatment Objectives – Up-Stream

Produced Water Treatment for Reinjection

Removal of …
• Free Oil & Grease
• Suspended Solids

Sea Water Treatment

Removal of … for Injection
Removal of …
• Suspended Solids
• Oxygen
• Sulfate Production
(Oil Well)
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Limitations of Separation Technology

Separator Type Technology Oil Droplet Removal Range

API Gravity Down to 150 micron

CPI Gravity Coalescer Down to 50 micron

IGF Hydraulic Down to 50 Microns

IGF Mechanical Down to 75 Microns
Flotation
DGF Brise Pump Down to 30 micron
Sparge Technology Down to 75 microns

Hydrocyclones Centrifugal Force Down to 15 – 20 micron

Centrifuge Centrifugal Force Down to 5 – 20 micron

Walnut Shells/Carbon/
Filtration/Coalescing Down to 2 micron
Cartridge

UF,RO, Micro, Nano Membrane Less than 1 micron

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Oil & Gas Production
Produced Water Treatment Process Map

Primary Secondary Tertiary Discharge or

Produced Solids
Produced Water Produced Water Produced Water
Separation Reinjection for
Water Separation Separation Separation Water Flood

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Primary Separation

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Primary Separation - Hydrocyclones

• Liquid/liquid, solid/liquid designs

• Maximum separation in a small footprint

• Low weight and small footprint, important in offshore

applications

• Used primarily to remove concentrations of oil (200

to 2,000 ppm) from Produced Water as an initial
separation step prior to polishing by flotation systems

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Primary Separation – Hydrocyclones Vessel with Active Liners

Inlet

Tangential Inlet

Clean Water

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Oil Reject
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Primary Separation - Hydrocyclones

Inlet Flow

Clean Water

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Oil Reject PD SLN WS
Factors Governing Performance

A number of factors influence oily water

separation performance:

• Droplet Size of the dispersed phase (i.e., oil)

• Fluid Temperature
• Differential density of the two fluids to be separated.
• Inlet Concentration
• Oil Slugging
• Interfacial Tension
• Chemical Treatment and Solids
• Free and Dissolved Gas Content

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Primary Separation - CPS

Corrugated Plate Separators

• Gravity-design separator
• Corrugated plate interceptor minimizes distance free oil droplets
must rise before coming into contact with other oil droplets, Oil Skimmer
facilitating free oil removal Water
Inlet
Overflow

Water Pre-
Pre-
outlet settling
Chamber

CPI Packs

Solids Outlet

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Primary Separation - Skimmers

Skimmers

• Typically upstream of secondary treatment

products. Can be Vertical or Horizontal vessels.

• Used primarily to remove concentrations of oil

(200 to 2,000 ppm)

• Can be packages with Flotation on a common skid

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Primary Separation – Selection Criteria

Process Conditions Corrugated Plate Separator L-L Hydrocyclone

Flow Rate (per unit) 2,5 – 570 m³/h 7 – 1 135 m³/h

Influent

Free Oil & Grease < 2 000 ppm up to 20 000 ppm

Total Suspended Solids < 300 ppm < 2 000 ppm

Effluent

Free Oil & Grease < 150 ppm < 150 ppm

Total Suspended Solids < 50 ppm -

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Secondary Separation

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Flotation Technology

DGF Technology
• Greater bubble dynamic flexibility
• Reduced maintenance costs
• Capable of dissolving gas into solution
• Bubble sizes ranging from 1 to 100 microns

IGF Technology
• Hydraulic or Mechanical design
• Increased maintenance
• Bubble size from 50 to 200 microns

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Flotation Technology

By attaching a small gas bubble to an oil droplet, it will decrease the density of the droplet
which will increase the rate at which it will rise to the surface.

• Critical Flotation Criteria • Distribution of Gas Bubbles

• Population of Gas Bubbles • Oil Droplet “Rate of Rise”
• Size of Gas Bubbles

DGF System Off DGF System On 5 Seconds DGF System On 30 Seconds

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DGF Technology

• Impeller has dual sides and special seal

• Sub-atmospheric pressure region where the vapor is dissolved/emulsified into micro-fine bubbles

• Therefore, no need for eductors and the maintenance that eductors require

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Secondary Separation - SPINSEP™ System

SPINSEP™ System
• Uses specialized cyclonic and flotation technology that
removes oil, grease and solids in a single vessel
arrangement.
• “Head-in-Head” design aids in pitch and roll conditions
(TLP, Spars, FPSO, etc.)

Design Notes:
• Single celled vertical vessel for reduced footprint
• Designed for <100 ppm inlet TSS
• Designed for <300 ppm inlet O&G
• Receptive to DGF and IGF technology
• Preferred product line for floating production facilities were
motion is an issue.

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Secondary Separation - VEIRSEP™ System

VEIRSEP™ System
• Incorporates several unique technologies to separate oil
and various other contaminates from Produced Water and
contaminated wastewater streams

Design Notes:
• 6 cells (4 flotation cells and 2 quiet separation cells)
Horizontal vessel
• Designed for <200 ppm inlet TSS
• Designed for <500 ppm inlet O&G
• Receptive to DGF, IGF, and Sparge technology
• Greater retention time equates to greater efficiency

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Secondary Separation - Selection Criteria

Process Conditions SPINSEP – DGF VEIRSEP - DGF

Flow Rate (per unit) 7 – 930 m³/h 7 – 1 125 m³/h

Influent

Free Oil & Grease < 300 ppm < 500 ppm

Total Suspended Solids < 100 ppm < 200 ppm

Effluent

Free Oil & Grease < 30 ppm* < 30 ppm*

Total Suspended Solids < 50 ppm* < 50 ppm*

* Chemical pre-conditioning (coagulation/flocculation) is needed

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Tertiary Separation

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Tertiary Separation –
High Flow Walnut Shell Filter System

WALNUT SHELL FILTER

• Patented Siemens Walnut Shell Filter
• Removes oily contaminants – free oil and grease, suspended solids
• Simplified design – lower costs
• Industry leader with proven track-record
ü Oil field produced water
ü Refinery waste water
ü Ethylene plant quench water
THE BLACK WALNUT SHELL
• Excellent surface characteristics for
ü Coalescence, Filtration and Superior resistance to attrition
• Deepest nutshell bed in industry
ü Superior effluent quality
ü Longer filtration runs
ü Greater throughput efficiency

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Tertiary Separation –
Advantages of the Siemens Filter Design

High Flow Walnut Shell Filter

• Constant Flux during Forward Flow throughout entire

Bed

• Even Bed Fluidization during Cleaning Cycle – Ensures

Longer Filter Run Times and Overall Media Longevity

• Full Depth Capture of Oil and Particulates

• Minimum Chance for Suspended Solids Break Through

without Indication of Increased Filter Resistance

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Tertiary Separation –
Advantages of the Siemens Filter Design

High Flow Walnut Shell Filter Characteristics

• Complete turn over and mixing of the media

• Fully fluidize the walnut shell bed

• No rotating equipment or moving parts

• The ability to use a finer walnut shell media to improve

oil and solids removal

• Smaller footprint and weight

52 %
• A reduction in backwash water volume

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Tertiary Separation –
Siemens Walnut Shell Filtration Re-Design

High Flow Walnut Shell Filter System

• Eliminated External Scrubber for Internal Design

• Reduced Backwash Time by 20% to 30%
• Reduced Footprint by 20% to 40%
• Increased Flux Rate by 40% to 100%
• Significantly Reduced Piping Requirements
• Reduced Maintenance Requirements
• Low Reoccurring Costs

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Tertiary Separation –
Key Facts of the High Flow Walnut Shell Filter (1)

• Oil is not Absorbed by the Nuts,

but Attached (=Adsorption)

• Backwash is Typically Performed

every 24 hours with Raw Inlet Water for 30 min

• Fully Automatic Backwash Cycle

removes Oil and Solids

• Standard Granular Size: 16 - 20 mesh

• 5% Loss of Nuts per Year

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Tertiary Separation –
Key Facts of the High Flow Walnut Shell Filter (2)

System Features
• Walnut Bed Thickness: 1660 mm
• Standard Vessel Height is 2700 mm
• Seam to Seam only Diameters change
• Max. Filter Velocity: 53 m/h
• Maximum Oil Loading: 100 ppm free oil
• Max. Solids Loading: 50 ppm TSS
• Efficiency: 95% removal > 10 micron
• Effluent Quality: < 5 ppm free oil/TSS

PerforMediaTM
• Load up to 500 mg/L with oil spikes >1000 mg/L
• Higher feed TSS concentrations - not as prone to plugging

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Tertiary Separation –
Siemens Media Filtration Evolution

AutoShell™ Monosep™ High-flow WSF PerforMedia™

• External Media Scrubber • New Backwash Design • Feed O&G up to 500 ppm

• Increased Flux • Higher Oil Loading

• Eliminated Rotating Equipment • Synthetic Media

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 Tertiary Separation –
Benefits of PerforMediaTM

PerforMedia™ is a game changing filtration media and its benefits include:

• ELIMINATES one entire treatment step

• Requires ZERO upstream chemical treatment

• COST SAVINGS for both OpEx and CapEx

• Proprietary Siemens technology

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Tertiary Separation –
Selection Criteria

Process Conditions MONOSEP™ WSF

Flow Rate (per vessel) 20 – 450 m³/h

Influent

Free Oil & Grease < 100 ppm (<500 ppm*)

Total Suspended Solids < 50 mg/L (<100 mg/L*)

Effluent

Free Oil & Grease < 5 ppm

Total Suspended Solids 95% removal > 10 micron

* PerforMedia

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Reference Installations

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Autor SLN WS
/ Abteilung
Reference Installations in the Oil & Gas Industry

NCOC (KAZ)
OMV Petrom (RO) PWTP Kashagan Field
PWTP Tazlau Field UA
CZ
SK
KomMunai (KAZ)
AT MD PWTP Komsomolskoe Field
HU
RO
SI GE
HR AZ
AR
INA (HR) BIH
RS
OMV Petrom (RO) AZ
PWTP Zutica Field BG
MN
KO PWTP Oprisenesti Field
TK

OMV Petrom (RO)

PWTP Bordei Verde

OMV Petrom (RO) OMV Petrom (RO)

PWTP Vata Field PWTP Videle Field

IL

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Water Management in the O&G Industry
Up-stream Water Treatment

Dr. Robert Vranitzky MBA

Head of Water Solutions
Water Solutions / Austria / PD SLN WS
Siemensstraße 90
1210 Vienna
Fax: +43 51707 51337
Mobil: +43 664 80117 22338
E-Mail:
robert.vranitzky@siemens.com

www.siemens.com/water-solutions

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