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Treatment of Crude Oil-BrineEmulsions with Ceramic
Membranes
RTC 21 Jun 2006 1
Ian Rubinstein Ph.D. P.Chem.
Rubinstein Technical Corporation
Phone/Fax: (403) 281-8259 E-mail: [email protected]
PO Box 1382, Station M, Calgary, Alberta T2P 2L6, Canada
Industrial Water Consulting
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PRODUCED WATER DEOILING CHALLENGES
Variable feed rate, pressures, temperaturesVariable levels of
oil, solids, contaminants
Harsh operating environment
Upset, shutdown, startup events
Minimize maintenance events
Minimize chemical stockage and disposal
Minimize capital and operating expenses
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OBJECTIVES
Remove solids and oil droplets to
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OIL SANDS PRODUCED WATER DEOILING
Skim Tank Gas Flotation Coalescer
ORF
OilRecycle
Emulsion Water
Oil
RecycleEmulsion Water
Membrane Bank
90C
140C
CURRENT PROCESS
MEMBRANE PROCESS
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CROSSFLOW MEMBRANE PROCESS
E
L
E
ME
N
T
S
CONCENTRATE
PERMEATE
Feed Pump Backpulse Pump
Perm
Tank
FEED
EMULSION
gross
net
ForwardFlush
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OPERATING ISSUES AND RESPONSES
Coalescing of oil droplets in gel layerTurbulent crossflow
through feed channels
Droplet deformation and squeeze through
High shear to create rigid charged oil droplets
Droplet and bubble blockage of pores
Permeate backpulse
Deposition of scales
Non-chemical cleaning regimes
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FIELD TESTS IN CSS OIL SANDS PLANTFirst Generation Bench Scale
Elements
Primary Separator Emulsion
0 100 200 300 400 500 600 7000
10
20
30
40
50
60
Hours
Flux(m3/m2
.day) Feed: 400 KPa, 1.5 metres/sec, 95C
With cleaning regime
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PILOT PERFORMANCE SUMMARY
Good efficiency
Net f lux > 10m3/m2.day
High quality of treated water
< 30 mg/L hydrocarbon spillover (mainly dissolved
organics),
no detectable solids
Thermomechanical stabilityWithstands 100C temperature, 1% sand,
10% oil in feed
Fouling overcome
Membrane surface modification, cleaning regimes
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POTENTIAL OILY WATER APPLICATIONS
SeparatorUF Bank Demin/Soften
Evaporator/Crystallizer
High OilSeparator
PlantProcesses
Oil out
Feed
Chemicals/Heat
Salt disposalSolids disposal
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Free Oil/
Water
Emulsion
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2ndGENERATION CeraMem MEMBRANES
Current: 142 mm diameter, 864 mm length
Future: Up to 200 mm diameter, 1500 mm
length
- Silicon carbide supports
eliminate durabil ityproblems of 1st generation
- Chemically durable,abrasion and solvent-
resistant- High process flux
- High temperaturecapability
- Easy cleaning,backflushable
- Low-cost, long li fe
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1000 m3/DAY MEMBRANE SYSTEM
FEED
PERMEATE
CONCENTRATE
1036 m3/d
0 KPa
49 m3/d
414 KPa
987 m3/d
0 KPa
Recycle 5451 m3/d; 414 KPa1090 m3/d
689 KPa
Feed Pump: 1090 m3/d, p 414 KPa = 10 HPRecycle Pumps: 5724 m3/d,
p 276 KPa = 45 HP totalBackpulse Pump: 545 m3/d, p 1034 KPa = 15
HP
Membranes: 5 Trains of 2 elements (142 mm diam, 864 mm long) per
train
Backpulse
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DE-OILING COST COMPARISON
40,000 m3/d Produced Water
100,000 bopd Facility. SOR = 2.5
ConventionalDeoiling.
(Skim Tank, ISF,Filters)
CeramicMembraneDeoiling.
(Surge Tank,Membranes)
CAPEX.
Total Installed
Cost
$28,122,000 Can $22,949,000 Can
OPEX.
Per m3 watertreated
$0.165 Can
(power + chemicals)
$0.056 Can
(power +membrane
replacement every3 years)
FOOTPRINT.
Square metres
14,250 6,400
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RESULTS AND CONCLUSIONS
Accepts % levels of oil and solids in water
Permeate has no visible oil or solids
Membrane surface and cleaning regimes tailored
for oil sands produced water deoiling
Flux maintained above economic target level
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Next step: Full sized demonstration
Evaluate stability, lifespan, process economics
18% lower Capex, 66% lower Opex than conventional process
