Gas Well Deliquification Workshop Sheraton 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 Stream Thomas J. Steinke – Product Manager CoMag Johnson Screens – A Weatherford Company
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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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Existing SystemProduced Water
Injection Well
In-Line Strainers, 25 microns
Sock Filters, 10 microns
Automatic Backwash Waste
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Conventional chemical coagulation/flocculation + high rate ballasted sedimentation + high rate magnetic filtration
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Ballasted Clarification
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Ballasted Clarification
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Conventional chemical coagulation/flocculation + high rate ballasted sedimentation + high rate magnetic filtration
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Solids HandlingSolids Handling
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Magnetic Drum to Recover the Magnetite
Waste Sludge and Magnetite Pass Under a Magnetic Drum to Recover the Magnetite
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Comparison of Pilot System to Alternate Test Site
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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Comparison of Pilot System to Alternate Test Site
•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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Pilot Study Results vs. Objectives
• 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.
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Pilot Study Results vs. Objectives
• 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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Pilot Study Results vs. Objectives
• 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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Pilot Study Results vs. Objectives
• 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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Pilot Study Results vs. Objectives
• 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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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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
Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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Feb. 23 - 26, 2009 2009 Gas Well Deliquification Workshop Denver, Colorado
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