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Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Process to Recycle Shale Gas
Produced Water
Utilizing By-Product Recovery
Eliminating
Disposal via Deep Well Injection
by Tom Lewis III
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
WHO’S LEWIS ENVIRONMENTAL…
• COMPANY HAS SEVERAL PATENTS - HEAVY
METAL REMOVAL AND CYANIDE DESTRUCTION.
• NEW PATENT ISSUED - SHALE GAS WATER
RECYCLING
MISSION STATEMENT…
TO PROVIDE ITS CUSTOMERS WITH A “SINGLE
SOURCE” FOR WATER MANAGEMENT WITH
“GREEN “ SERVICES, RESOURCE RECOVERY,
WATER RECYCLING AND ECONOMIC SAVINGS.
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
•Crane Naval Base
Customers Who Have Used Our
Products And Services
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
TRILLION DOLLAR
NATURAL GAS RESERVE
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Hydraulic Fracturing…• FRACING” - INJECTING WATER, SAND AND
CHEMICALS UNDER HIGH PRESSURE INTO THE
SHALE FORMATION.
• SEPARATES THE PORES IN THE ROCK , SAND
"HOLD" THE CRACKS OPEN – RELEASES GAS
FLOWBACK: 20% - 25% OF INJECTED WATER IS
RECOVERED FROM THE WELL.
• NASTY STUFF: THERE’S AS MUCH AS TWO
POUNDS OF SALT IN A GALLON OF FRAC WATER.
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
HYDROFRAC REQUIRES 6,000,000 GALLONS WATER
THAT’S 1200 TRUCKLOADS OF WATER OR 9 OLYMPIC SIZE SWIMMING POOLS
1,940M
1,405M 1,697M
1,147M
895M
435M 631M
272 M
2nd
2010
1st
2011
2nd
2011
1st
2012
2nd
2012
1st
2013
2nd
2013
1st
2014
MARCELLUS SHALE GAS PRODUCTION….
613% INCREASE OVER 4 YEARS
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
*GAS VOLUME in MCF
PA PRODUCES 20% OF UNITED STATES NATURALGAS SUPPLY!
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
MULTIPLE WELL PAD LAYOUT
DRILL MORE WELLS WITH LESS RIGS
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
WATER MANAGEMNT TRENDS…
SMALL and MEDIUM SIZE DRILLERS
• OFF-SITE DISPOSAL COSTLY TRUCKING AND
DISPOSAL FEES
LARGE SIZE DRILLERS
• REUSE “DIRTY” FRAC WATER AND FRESH WATER
• DEEP WELL INJECT CONCENTRATED
BRINE WATER
LOSS OF VALUABLE WATER AND
RECOVERABLE RESOURCES
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
DIRTY FRAC WATER
SOFTENED FILTERED
FRAC WATER
RECYCLED FRAC WATER
DEEP WELL INJECTION
FRESH WATER
FRAC WATER MANAGEMENT
DRILL SITE
2nd
FRAC WATER
RECYCLED
5 – 6 TIMES
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
FRAC WATER RECYCLING CRITERIA…
• INORGANIC IMPURITIES
BARIUM, STRONTIUM, IRON, SULFATE
CALCIUM AND CHLORIDE LEVELS
• ANY THING ELSE…
ORGANICS CONTAMINANTS
NORMALLY OCCURRING RADIOACTIVE MATERIALS
• IS THAT IT?
SCALING FACTORS – DISSOLVED GAS CO2
ALL IMPACT THE REUSE OF FRAC WATER
2013 RECYCLING / FLOWBACK TREND ANALYSIS
ITEMS FLOWBACK
YEAR 2009
FLOWBACK
YEAR 2011
FLOWBACK
YEAR 2013
Sodium 12,200 15,500 18,800
Calcium 7,500 19,500 25,800
Magnesium 570 1,680 1,550
Iron 39 109 43.1
Barium 95 3,310 6,610
Strontium 103 4,040 7,630
Chloride 80,200 148,000 164,000
Bicarbonate 36 56 ND
Ammonia 107 135 148
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
SUMMARY…
•CHLORIDE CONCENTRATION
INCREASED BY 100%.
•BARIUM AND STRONTIUM CONCENTRATIONS
INCREASED 30 – 40 TIMES.
•CALCIUM CONCENTRATION INCREASED
2 – 3 TIMES.
•TDS LEVELS INCREASED 2 – 3 TIMES.
THESE INCREASES ARE GAME CHANGERS
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
FRAC AND PRODUCED WATERS ARE TRANSPORTED TO VARIOUS TREATMENT FACILITIES FOR RECYCLING OR FOR DISPOSAL VIA DEEP WELL INJECTION.
SHALE WASTE TRANSPORTATION ISSSUES…
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
CLASS II INJECTION WELL
ANNULUS ACCESS
DRILLING MUD
CEMENT
TUBING
INJECTION ZONE
WHAT IS DEEP WELL INJECTION…
WASTE IS PUMPED INTO THE EARTH UNDER A SEALED PIPING SYSTEM.
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
OHIO, PA and OK COMPARISON…
•PA HAS SIX INJECTION WELLS
•OHIO HAS OVER 170 INJECTION WELLS
•OKLAHOMA HAS OVER 3,000 INJECTION WELLS
• PA FIRMS PAID $1.6 MILLION TO OHIO IN FEES
FOR INJECTION WELL DISPOSAL
• OHIO FIRMS PAID $400K (1/5) TO STATE IN
INJECTION WELL DISPOSAL FEES
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
DEEP WELL INJECTION
THE GOOD, THE BAD AND THE UGLY…• GOOD – IF AVAILABLE, LOW COST; HANDLES A
WIDE RANGE OF WASTE W/ COMPLETE DISPOSAL.
• IF THE REGION’S GEOLOGY SUPPORTS DISPOSAL
ITS HEAVILY USED.
• BAD – LIMITED CAPACITY AND NOT CHEAP-$5M
• LOCATION LIMITED; MAY HAVE TO TRUCK.
• UGLY – WELLS CAN BE PLUGGED WITH SCALE.
• INJECTION WELLS CAN CAUSE EARTH TREMORS.
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
OHIO INJECTION WELL VOLUMES…
IN-STATE vs OUT of STATE
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
INCREASED TREMORS…
COMPLICATED INJECTION WELL PERMITING
SEISMISITY MONITORING
LOWER PRODUCTION VOLUMES
SHUT DOWN IF NEAR TREMORS
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
THREE MAJOR ISSUES INTERSECT…
• LOW TDS DISCHARGE REGULATIONS
FOR FRACK WATER DISPOSAL.
• NEED TO REDUCE FRESH WATER
USAGE FOR FRACKING.
• ALTERNATIVES TO DEEP WELL INJECTION
ADVANCED FRACK WATER PROCESSING
INDUSTRY LOOKING FOR A
WINNING STRATEGY
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
TITLE 25 PA CODE CHAPTER 95...
NEW SOURCES OF HIGH TDS WASTE WATERS
AFTER AUGUST 1, 2010
SHALE GAS WASTE WATER DISCHARGE LIMITS
TOTAL DISSOLVED SOLIDS 500 mg/l
TOTAL CHLORIDES 250 mg/l
TOTAL SULFATES 250 mg/l
TOTAL BARIUM 10 mg/l
TOTAL STRONTIUM 10 mg/l
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
FRAC WATER TREATMENT CHOICES…
•REVERSE OSMOSIS (RO)
•OZONE DESTRUCTION TECHNOLOGY
•DISTILLATION AND EVAPORATION
• CRYSTALLIZER
•EC / UV
•ESP - BY-PRODUCT RECOVERY
LET’S REVEIW HOW EACH ONE WORKS
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
DISTILLATION STRENGTH WEAKNESS
GE WATER (USA) RECOVERS AND
CONCENTRATES
FINANCIALLY
STRONG
EXPENSIVE
EQUIPMENT
HIGH ENERGY
CONSUMPTION
FOUNTAIN QUAIL
(USA)
INDUSTRY
ACCEPTANCE
THREE UNITS IN
MARCELLUS
PLAY
CONCENTRATE
DISPOSAL
HIGH
MAINTENANCE
COSTS
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
Cost Effective Solutions For …. Today’s Problems
EVAPORATION STRENGTH WEAKNESS
ALTELA PRODUCES
CLEAN
DISTILLATE
MODERATELY
EXPENSIVE
EQUIPMENT
DOES USE ENERGY
PURE STREAM HAVE SEVERAL
COMMERCIAL
UNITS IN THE
FIELD
CONCENTRATE
DISPOSAL
LIMITED
PROCESSING
VOLUMES
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
EXTENSIVE RECYCLING OF FRAC FLUIDS HAS REDUCED THE EFFECTIVENESS OF RECOVERY TECHNOLOGIES DUE TO THE HIGH TDS AND CONTAMINANT CONCENTRATIONS
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
120K – 180K PPM
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
• REUSE: FEASIBLE?
• RO: PROBLEMS
WITH HIGHER TDS
• EVAPORATION: LOW
TDS SWEET SPOT
• CRYSTALLIZATION:
COST & IMPURE BY-
PRODUCT
RECOVERY TECHNOLOGY COMPARISON
CRYSTALLIZER STRENGTH WEAKNESS
GE WATER (USA) CONCENTRATES
HIGH TDS
FEED STOCKS
FINANCIALLY
STRONG
VERY EXPENSIVE
EQUIPMENT
HIGH ENERGY
CONSUMPTION
AQUA-TECH
(USA)
TWO UNITS IN
MARCELLUS
PLAY
CONCENTRATE
DISPOSAL
HIGH
MAINTENANCE
COSTS
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
MAJOR PROBLEM …
MULTIPLE CONTAMINANTS –LOW QUALITY SALT
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
CRYSTALLIZER OPERATIONAL REVIEW…
•MARCELLUS SHALE OPERATION TALKED ABOUT
SALT AND BY-PRODUCT QUALITY ISSUES
• 1ST SALT CONTAINED BARIUM. LEVELS NOT HIGH
BUT STILL THERE
• 2ND FEEDSTOCKS WITH MULTIPLE CONTAMINANTS
PROVED DIFFICULT TO PROCESS
• 3RD PURGE STREAM HAD HIGH LEVELS OF
CALCIUM WITH OTHER CONTAMINANTS- BARIUM
BOTTOM LINE…
BY-PRODUCTS NOT READILY SALABLE
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
RECOVERY INNOVATIONS …
•COMBINING TECHNOLOGY WITH BY-PRODUCT
RECOVERY
•ENVIRO-SHALE PROCESS (PATENTED)
•MOBILE (ON-SITE) TREATMENT PRODUCES
SUITABLE WATER FOR REUSE
•LOW ENERGY USAGE
• ELIMINATE FRAC FLUIDS FOR DISPOSAL
• RECOVERS BRINE AS SALEABLE SALT AND BY-
PRODUCTS – CALCIUM, BARIUM AND STRONTIUM
INCREASE REVENUES …
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
ENVIRO-SHALE PROCESS (ESP)
TWO STAGE PROCESS
• 1st STAGE – REMOVES OIL/GREASE, INORGANICS
SUCH AS IRON
• 2nd STAGE – REMOVES TRACE ORGANICS AND
NONDESIRED INORGANIC CONSTITUENTS
• ESP EFFLUENT IS CLEAR AND ORGANIC FREE
• SCALING FACTORS REDUCED
ESP EFFLUENT CAN BE RECYCLED BACK TO DRILLING OPERATION OR DISTILLATION / CRYSTALLIZER FEEDSTOCK
Cost Effective Solutions For ….
Today’s Problems
HOW THE ENVIRO-SHALE PROCESS WORKS
Ba
Ba
Sr
SrCl
Cl
Cl
CARBON
CARBON
CARBON
RAW FRAC WATER WITH BARIUM, STRONTIUM AND CHLORIDES
THE FRACK WATER COMES IN CONTACT WITH THE LEWIS CARBON
THE BARIUM AND STRONTIUM ARE ADSORBED SEPARATELY ON THE
CARBON’S SURFACE
THE FRAC WATER IS UPGRADED WITH A “CLEAN” CHLORIDE STREAM
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
FEED WATER CHARACTERIZATION
ITEM RAW
VALUE
FEED
RANGES
TDS 306,000 - 138,000
pH 7.4 - 5.4
TOTAL IRON 109 - 93
TOTAL CHLORIDE 185,600 - 130,000
TOTAL BARIUM
TOTAL STRONTIUM
CALCIUM
3,479
5,420
23,000
- 1,360
- 3,600
- 18,800
TOC 136 - 52
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
RAW FRAC
WATER
ESP
EFFLUENT
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
HIGH PURITY BRINE PURIFICATION RAW FINAL %
Barium 12,100 3.4 99.97%Calcium 24,200 0 100.00%
Iron 36.2 0 100.00%
Magnesium 1,540 110 92.86%
Sodium 24,000 75,100 -212.92%
Strontium 12,900 4.8 99.96%
Total Dissolved Solids 259,000 245,000 5.41%
Bromide 1,030 1,150 -11.65%
Chloride 186,000 181,000 2.69%
Sulfate 0 0
Carbon Dioxide 8.9 0 100.00%
CLEAN BRINE TO
DISTILLATION / CRYSTALLIZER
SALABLE BY-PRODUCTS.
ENVIRO-SHALE PROCESS TEST RESULTS
ITEM RAW FEED ESP -
STAGE 1&2
DISTILLATE %
REMOVED
TDS (mg/l) 181,000 191,000 306 99.77%
pH 5.63 6.42 6.82
TOTAL IRON 143 <0.1 <0.1 99.93%
TOTAL CHLORIDE 78,000 71,900 95 99.87%
TOTAL BARIUM
TOTAL STRONTIUM
OIL & GREASE
95.3
108
77.0
1.04
0.94
<5
<0.1
<0.1
<5
99.89%
99.90%
99.70%
TOC 62.76 0.61 <0.1 99.84%
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
•THIS MEETS THE NEW HIIGH TDS
DISCHARGE LIIMITS
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
CAN WE DO BETTER?
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
HIGH PURITY BARIUM SULFATE
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
HIGH PURITY CALCIUM SULFATE
RECOVERING HIGH PURITY BARIUM, STRONTIUM AND CALCIUM IS MORE THAN
RECOVERED SALT VALUE
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
ECONOMICS OF BY-PRODUCT RECOVERYBASED ON PROCESING 210K GPD (5,000 BPD)
MONTHLY SALT & BY-PRODUCT REVENUES
ITEM UNIT $ TONS
SALT $45/ton $292,032 6,489 tons
BARIUM SULFATE $0.50/lb. $103,834 104 tons
STRONTIUM CARBONATE $0.50/lb. $155,750 156 tons
CALCIUM SULFATE $0.05/lb $131,000 1,310 tons
SALT ONLY - $292K; SALT W BY-PRODUCT - $682K
BY-PRODUCTS INCREASE REVENUES BY $390K!
Cost Effective Solutions For …. Today’s Problems
LEWIS ENVIRONMENTAL
SUMMARY…
NEW INNOVATIONS IN ADVANCED
PROCESSING CAN POSITIVELY IMPACT
RECYCLING OPTIONS.
PROVIDE ALTERNATIVE TO DEEP WELL
INJECTION AND SUPPLY CLEAN WATER
REDUCE COST, INCREASE REVENUES
AND ENVIRONMENTAL IMPACT.
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