Ph.D. Thesis, Environmental Engineering Subject The Effect ...srbiau.ac.ir/Files/environment/25749.pdf · Figure 2-9 Schematic showing flow pattern of cross-flow plate pack . Figure

b

Islamic Azad University

Science and Research Branch

Ph.D. Thesis, Environmental Engineering

Subject

The Effect of Different Parameters on the Efficiency

and Design Of IGF Systems at High TDS and Temperature

Supervised by

Dr. Seyed Mehdi Borghei

Dr. Seyed Mahmoud Borghei

Consultant

Dr. Emad Roayaei

by

Reza M astouri

2008-2009

c

Table of Contents 1 - Introduction

2- Theoretical Part

Part 1: Produced water

2-1 -1 Nature of Produced Water

2-1 -2 Composition

2-1 -3 Produced Water Discharge Volumes

2-1 -4 Environmental Fate and Effects of Produced Water

2-1 -5 Environmental Regulations for Discharge of Produced Water

2-1 -6 Produced Water Treatment Technologies

2-1 -6-1 Gra vity sep aration

2-1 -6-1 -1 A PI separator

2-1 -6-1 -2 Skimmer tanks and vessels

2-1 -6-1 -2-1 Vertical skimmer tanks

2-1 -6-1 -2-2 Horizontal skimmer tanks

2-1 -6-1 -3 Disposal piles

2-1 -6-1 -4 Skim piles

2-1 -6-2 Plate coalescence

2-1 -6-2-1 Parallel Plate In terceptors (PPI)

2-1 -6-2-2 C orrug ated Plate Interceptor (C PI)

2-1 -6-2-3 Cross-flow separators

2-1 -6-3 En hanced coalescence

2-1 -6-3-1 Free-flow turbulent coalescers

2-1 -6-3-2 Pre-coalescers

2-1 -6-3-2-1 PECT -F

2-1 -6-3-2-2 Mare’s Tail

2-1 -6-4 En hanced gravity separation

2-1 -6-4-1 Hydrocyclones

2-1 -6-4-2 Centrifuges

2-1 -6-4-3 Ctour process

d

2-1 -6-5 Ad sorption/Filtration

2-1 -6-5-1 N on-regenerative absorbent medias

2-1 -6-5-1 -1 Nutshell filter/Walnutshell filters

2-1 -6-5-1 -2 Sand filters

2-1 -6-5-1 -3 Multi-media filters

2-1 -6-5-1 -4 Organoclay

2-1 -6-5-1 -5 Total oil remediation and recovery (TORR)

2-1 -6-5-1 -6 Symons A dsorption media (SAM )

2-1 -6-5-1 -7 Cetco’s polishing sys tem

2-1 -6-5-1 -8 Kapok filter

2-1 -6-5-1 -9 MYC ELX

2-1 -6-5-2 Regenerative absorbent medias

2-1 -6-5-2-1 Micro porous polymer extraction (MPPE)

2-1 -6-5-2-2 Activated carbon

2-1 -6-5-2-3 Zeolite

2-1 -6-6 Me mbrane filtration

2-1 -6-6-1 Modified membrane filtration

2-1 -6-7 Electrodialys is (ED)

2-1 -6-8 Freeze–thaw /evaporation

2-1 -6-9 Biological treatment

2-1 -6-10 Flotation separation

2-1 -6-10 -1 Pressurized gas/air injection

2-1 -6-10 -1 -1 Gas s parging system

2-1 -6-10 -1 -2 Dissolved gas/air flotation (DGF/DAF)

2-1 -6-10 -1 -3 Gas liquid reactors (GLRs) o r M icrobubble flotation (M BF)

2-1 -6-10 -2 Induced gas /air

2-1 -6-10 -2-1 Induce d g as/air flotation (IGF/IAF)

2-1 -6-10 -2-1 -1 Hydraulic educ tor g as indu ction units

2-1 -6-10 -2-1 -2 Mec hanical induced gas flotation units

2-1 -6-10 -2-2 Gas induc ing pumps

2-1 -6-10 -2-2-1 DG F pumps

2-1 -6-10 -2-2-2 ON YXTM

micro-bubble pumps

e

2-1 -6-10 -2-3 Tank based flotation

Part 2: Flotation

2-2-1 Background

2-2-2 Appl ications of flotation

2-2-3 Differences between flotation in mining and environmental applications

2-2-4 Comparison of flotation in DAF and IA F systems

2-2-5 Gas f lotation process

2-2-5-1 Stoke’s law

2-2-5-2 Gas flotation in oily wast ewater treatment process

2-2-5-2-1 O il droplet size

2-2-5-2-2 G as bubble contact

2-2-5-2-3 O il-gas b ubble hydrodynamics

2-2-5-2-4 O il-bubble attachment and detachment

2-2-6 Layer thinning phenomenon in flotation process

2-2-6-1 A ttachment of oil drops to oil drops (flocculation) and of oil drops with gas

bubbles

2-2-6-2 Gibbs-Marangoni effects

2-2-6-3 Oil/bubble attachment through rupture

2-2-6-4 Sp reading

2-2-6-4-1 A n example of spreading oil on gas

2-2-7 Factors affecting flotation in oil-water separation

2-2-7-1 The effect of hydraulic residence time (HRT) on oil removal efficiency

2-2-7-2 The effect of adding chemicals to the effluent on oil removal efficiency

2-2-7-3 The effect of gas flow rate on oil removal efficiency

2-2-7-4 The effect of inlet/initial oil concentration on oil removal efficiency

2-2-7-5 The effect of pH on recovery on oil removal efficiency

2-2-7-6 The effect of crude oil type on oil removal efficiency

2-2-7-7 The effect of the air distributer type on oil removal efficiency

2-2-7-8 The effect of distributor hole diameter on oil removal efficiency

2-2-7-9 The effect of liquid height in flotation cell on oil removal efficiency

2-2-7-10 T he effect of temperature on oil removal efficiency

2-2-7-11 T he effect of salinity on oil removal efficiency

f

2-2-7-12 T he effect of impeller speed on oil removal efficiency

2-2-7-13 T he effect of addition of wash w ater on oil removal efficiency

2-2-7-14 T he effect of applying different gasses

2-2-7-15 T he effect of bubble diameter on oil removal efficiency

2-2-7-16 T he effect of oil droplet diameter on oil removal efficiency

2-2-7-17 O ther parameters

2-2-8 Flotation Kinetics

2-2-8-1 Flotation Kinetics for solid particles

2-2-8-2 Flotation kinetics for oil droplets

3- Experimental

3-1 Material

3-1 -1 IGF pilot plant

3-1 -2 Crud e Oil

3-1 -3 Produced wat er

3-1 -4 Feed Gas

3-2 Procedure

3-2-1 Oil-water emulsion preparation

3-2-2 Power consumption measurements

3-2-3 Sample analys is

3-2-3-1 Oil & grease measurements

3-2-3-1 -1Ge neral methods for the measurement of oil & grease

3-2-3-1 -2 Soxhlet Extraction Method (5520 D)

3-2-3-1 -2-1 General discussion for Soxhlet Extraction Method (5520 D)

3-2-3-1 -2-2 Procedure of Soxhlet extraction method (5520 D)

3-2-3-2 A general note on the accuracy of the oil & grease measurements

4- Results and Discussion

4-1 Water interfacial tension versus different concentration of NaCl

4-2 IGF pe rformance in constent TDS versus different temperatures in different impeller

speeds in constent gas flowrate

4-3 IGF performance in constant impeller spe ed versus different temperatures in different

TDSes in constant gas flowrate

g

4-4 IGF pe rformance temperature versus different impeller speed in d ifferent TDSes in

constant flowrate

4-5 IGF performance in constant impeller spe ed versus different TDSes in different

temperatures in constant gas flowrate

4-6 IGF performance and power consumption in gassed and unga ssed conditions versus

different temperatures in constant TDS and impeller speed in constant gas flowrate

4-7 Environmental regulations and IGF g lobal oil removal efficiency

5- Conclusions and Recommendations

5-1 Conclu sions

5-2 Recommendations

References

h

List of Tables

Table 2-1 Comparison of major ions in formation water (produced w ater) and in seawater

(mg/L)

Table 2-2 C omparison of Heavy Metal Concentrations in Produced Waters (mg/l)

Table 2-3 O rganic Components of Produced Water (mg/L)

Table 2-4 Produced water disposal standards according to regional environmental

conventions

Table 2-5 C omparison of a SabianTM

Walnut shell filter and a typical sand filter

Table 2-6 Effluent characteristics of produc ed wa ter by VSEP

Table 2-7 Differences between flotation in mineral processing and in wastewater

treatment

Table 2-8 C omparison of DAF and IAF in treating oily w astewater

Table 2-9 A ir bubble properties as NaCl conc entration varies

Table 3-1 Characteristics of Kharg Island crude oil

i

List of Figures

Figure 2-1 Schematic of an API oil separator

Figure 2-2 Schematic of a skimmer tank

Figure 2-3 Schematic of a vertical skimmer tank

Figure 2- 4 Schematic of a horizontal skimmer tank

Figure 2-5 Cross section showing flow pattern of a skim pile

Figure 2-6 Cross s ection showing plate coalescer operation

Figure 2-7 Schematic showing flow pattern of a typical down -flow C PI design

Figure 2-8 CPI pla te pack

Figure 2-9 Schematic showing flow pattern of cross-flow plate pack

Figure 2-1 0 Sche matic showing cross-flow device installed in a horizontal press ure vessel

Figure 2-1 1 Principles of operation of an SP Pack

Figure 2-1 2 Conventional deoiling h ydrocyclone vessel equipped with PECT technolog y

Figure 2-1 3 Principle of operation of Mare’s Tail

Figure 2-1 4 Principles of operation of a hydrocyclone

Figure 2-1 5 Centrifuge s ys tem for oil-water separation

Figure 2-1 6 Flow diagram of the CTour process

Figure 2-1 7 A typical multi-media filter

Figure 2-1 8 Schematic of TORR process

Figure 2-19 CrudeS orb adsorption process for water treatment and polishing

Figure 2-20 The tu bular kapok fibre

Figure 2-21 Advan cement of the filtrate and diesel over time

Figure 2-22 A M yclex filter

Figure 2-23 MPPE extraction/ stripping sys tem

Figure 2-24 C omparison of crossflow and VS EP separation

Figure 2-25 A t ypical sparging tube gas flotation

Figure 2-26 Schematic of a dissolved gas flotation process s ys tem with the recirculation

line

Figure 2-27 A gas liquid reactor (GLR)

Figure 2-28 Schematic of a hydraulic induced gas flotation unit

Figure 2-29 Schematic showing the flow path through a hydraulic induced flotation unit

j

Figure 2-30 The sc hematic of the ISF sys tem

Figure 2-31 Cross section of a mechanical ind uced dispersed gas f lotation unit

Figure 2-32 Cross section of a four-cell mechanical induced flotation unit

Figure 2-33 The O NYXTM

micro bubble flotation pump

Figure 2-34 Tank Based Flotation Layout

Figure 2-35 A Four Ch ambered Flotation Tank & CFD Particle Trace

Figure 2-36 Ev olution of gas flotation in water and was tewater industry with the

emphasize on WE MC O DepuratorTM

s ystems

Figure 2-37 The oil/ gas bubble rise h ydrodynamics

Figure 2-38 The attachment process

Figure 2-39 Detail of the attachment process

Figure 2-40 Gas/oil/wa ter configuration for spreading oil spreading c onditions

Figure 2-41 Bubble diameter as a function of salinity

Figure 2-42 Bubble diameter as a function of superficial gas velocity and salinity

Figure 2-43 Oil recovery as a function of salt content salt content (batch- dispersed gas

flotation cell-5 minutes at 1800 rpm)

Figure 2-44 Settling test on feed to batch –dis peard gas flotation cell.With oil recovery as

a function of time

Figure 2-45 The influence of sodium chloride on oil separation using a single hole

distributor in the flotation column

Figure 3-1 Schematic of IGF pilot set up

Figure 3-2 Photograph of IGF pilot set up

Figure 3-3 Photograph of emulsion preparation tank for IGF pilot set up

Figure 3-4 Photograph of crude oil used for the tests

Figure 3-5 Photograph of digital multimeter and dimmer

Figure 3-6 Sample taking at the inlet point of IGF pilot plant

Figure 3-7 Vacuu m of oily water through filter paper

Figure 3-8 Extract oil and grease in a Soxhlet apparatus, at a rate of 20 c ycles/h

Figure 4.1a Interfacial tension versus different concentrations of pure NaCl in deionized

(DI) water in 22oC

Figure 4.1b Interfacial tension versus different concentrations of lite s alt in deionized (DI)

water in 22oC

k

Figure 4-2a IGF pe rformance in constant TDS (5 g/l) versus different temperatures (20 -

100oC) in different impeller speeds (N=450, N =900, N =1450, N = 2000 rpm) in constant gas

flowrate (10 l /m)

Figure 4-2b IGF p erformance in constant TDS (50 g /l) versus different temperatures (20 -


flowrate (10 l /m)

Figure 4-2c IGF pe rformance in constant TDS (100 g /l) versus different temperatures (20 -


flowrate (10 l /m)

Figure 4-2d IGF p erformance in constant TDS (150 g /l) versus different temperatures (20 -


flowrate (10 l /m)

Figure 4-2e IGF pe rformance in constant TDS (200 g /l) versus different temperatures (20 -


flowrate (10 l /m)

Figure 4-2f IGF pe rformance in constant TDS (250 g /l) versus different temperatures (20 -


flowrate (10 l /m)

Figure 4-2g IGF p erformance in constant TDS (300 g /l) versus different temperatures (20 -


flowrate (10 l /m)

Figure 4-3a IGF pe rformance in constant impeller speed (N=450 r pm) versus different

temperatures (20 -100oC) in different TDSes (5-300 g /l) in constant gas flowrate (10 l /m)

Figure 4-3b IGF p erformance in constant impeller speed (N=900 r pm) versus different


Figure 4-3c IGF pe rformance in constant impeller speed (N=1450 r pm) versus different


Figure 4-3d IGF p erformance in constant impeller speed (N=2000 r pm) versus different


Figure 4-4a IGF pe rformance in constant temperature (20 oC) versus different impeller

speed (N=450, N =900, N =1450, N =2000 r pm) in different TDSes (5-300 g /l) in constant gas

flowrate (10 l /m)

l

Figure 4-4b IG F performance in constant temperature (30 oC) versus different impeller

speed (N=450, N=900, N=1450, N=2000 rpm) in different TDSes (5-300 g/l) in constant gas

flowrate (10 l /m)

Figure 4-4c IG F performance in constant temperature (40 oC) versus different impeller


flowrate (10 l /m)

Figure 4-4d IG F performance in constant temperature (50 oC) versus different impeller


flowrate (10 l /m)

Figure 4-4e IG F performance in constant temperature (60 oC) versus different impeller


flowrate (10 l /m)

Figure 4-4f IGF performance in constant temperature (70 oC) versus different impeller


flowrate (10 l /m)

Figure 4-4g IG F performance in constant temperature (80 oC) versus different impeller


flowrate (10 l /m)

Figure 4-4h IG F performance in constant temperature (90 oC) versus different impeller


flowrate (10 l /m)

Figure 4-4i IG F performance in constant temperature (100 oC) versus different impeller


flowrate (10 l /m)

Figure 4-5a IG F performance in constant impeller speed (N=450 rpm) versus different

TDSes (5-300 g /l) in different temperatures (20 -100 oC) in constant gas flowrate (10 l /m)

Figure 4-5b IG F performance in constant impeller sp eed (N=900 rpm) versus different


Figure 4-5c IGF pe rformance in constant impeller speed (N=1450 r pm) versus different


Figure 4-5d IGF performance in constant impeller speed (N=2000 rpm) versus different


m

Figure 4-6a I GF performance and power cons umption in gassed and ungassed conditions

versus different temperatures (20 -100 oC) in constant TDS (5 g/l) and impeller speed (N=450

rpm) in constant gas flowrate (10 l /m)

Figure 4-6b I GF performance and power cons umption in gassed and ungassed conditions



Figure 4-6c I GF performance and power cons umption in gassed and ungassed conditions



Figure 4-6d I GF performance and power consumption in gassed and ungassed conditions



Figure 4-6e I GF performance and power cons umption in gassed and ungassed conditions



Figure 4-6f IGF performance and power consumption in gassed and ungassed conditions



Figure 4-6g I GF performance and power consumption in gassed and ungassed conditions

versus different temperatures (20 -100 oC) in constant TDS (50 g/l) and impeller speed

(N=1450 rpm) in constant gas flowrate (10 l /m)

Figure 4-6h I GF performance and power consumption in gassed and ungassed conditions



Figure 4-6i IGF performance and power cons umption in gassed and ungassed conditions



Figure 4-6j IGF performance and power cons umption in gassed and ungassed conditions



n

Figure 4-6k I GF performance and power consumption in gassed and ungassed conditions



Figure 4-6l IGF performance and power cons umption in gassed and ungassed conditions



Figure 4-6m IGF performance and power consu mption in gass ed and ungassed conditions



Figure 4-6n I GF performance and power consumption in gassed and ungassed conditions



Figure 4-6o I GF performance and power consumption in gassed and ungassed conditions



Figure 4-6p I GF performance and power consumption in gassed and ungassed conditions



Figure 4-6q I GF performance and power consumption in gassed and ungassed conditions



Figure 4-6r IGF performance and power consumption in gassed and ungassed conditions



Figure 4-6s I GF performance and power consumption in gassed and ungassed conditions



Figure 4-6t IGF performance and power cons umption in gassed and ungassed conditions



o

Figure 4-6u I GF performance and power consumption in gassed and ungassed conditions



Figure 4-6v I GF performance and power consumption in gassed and ungassed conditions



Figure 4-6w IGF performance and power consu mption in gas sed and ungassed conditions



Figure 4-6x I GF performance and power consumption in gassed and ungassed conditions



Figure 4-6y I GF performance and power consumption in gassed and ungassed conditions



Figure 4-6z I GF performance and power cons umption in gassed and ungassed conditions



Figure 4-6aa IGF performance and power consu mption in gasse d and ungassed conditions



Figure 4-6bb I GF performance and power consumption in gassed and ungas sed

conditions versus different temperatures (20 -1 00 oC) in constant TDS (300 g/l) and impeller

speed (N=2000 r pm) in constant gas flowrate (10 l /m)

1

Abstract Petroleum industry is a major source of oily wastewater. If cleanup goal is protection of

the environment by application of offshore/onshore environmental discharge regulations,

relying on conventional gravity-based s ys tems such as API (A merican Petroleum

Institute), CPI (C oalescing Plate Interceptor) and skimmer tanks are not advised.

Currently the flotation process is attracting much attention for produced water cleanup

due to its high separation efficiency, low capital investment and low operational costs.

Meanwhile, Ind uced Gas Flotation (IGF) process is preferred to other flotation devices

such as Dissolved Ga s Flotation (DGF) s ys tems because of its s mall footprint and high

efficiency. In the present thesis, the results of an innovative IGF pilot plant for the

treatment of s ynthetic produced water resembling the Kharg Island oil refinery/ terminal

produced water wh ich contains an average oil content of 150 mg/l and total dissolved

solids (T DS) up to 300 g/l are presented. The results of the innovative IGF s ys tem (w hich

could be referenced as the first pilot plant I G F s ystem in Iran), showed that oil removal

efficiencies up to 90% is reachable in high temperature (1 00oC) in just a single flotation

cell without adding any chemicals s uch as flotation aids. I t was also concluded that at a

constant impeller speed, an optimum TDS could not be defined for IGF oil removal

performance in different temperatures. Over the 40oC in constant impeller spe ed, at

different TDSes, under the conditions of these experiments, IG F oil removal performance

have many discrepancies which makes it some how impossible to correlate and model. In

order to meet the 15 mg/l regulation of Kuwait convention for onshore oily wastewat er

discharges to ROPME areas, an IGF s ystem with at least two flotation cells in series

should be sup plied without the need of adding any chemicals provided that the

temperature does not fall below 70 oC.

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چکیده

در هاردی ک ذف اس تصفی پساب رسیذى ب . صؼت فت یکی اس هابغ اصلی آلدگی ای فتی هی باشذ

حیط سیست دریایی در خشکی دریا باشذ، ب کار گیزی سیستن ای هحیط سیستی حوایت کذ اس مقایي

A)جذاساسی ثقلی ظیز merican Petroleum In s titute) A PI ،CPI (Coales cing Plate

In terceptor) چذاى تصی وی گزدد، اسکیوز تاک ا .

در سال ای اخیز فزایذ شارساسی با تج ب راذهاى باالی جذاساسی، شی کوتز سزهای گشاری شی

. کوتز گذاری جت تصفی پاکساسی آب وشاد فت تج سیادی را ب خد هؼطف ود است

IGیا در ایي هیاى سیستن شارساسی ب کوک القاء گاس F (In duced G as Flotation) ب سایز رش ای

Dis)شارساسی ظیز شارساسی ب کوک گاس هحلل یا s olved G as Flotation) DGF تزجیح داد هی

IGدر ایي پایاى اه تایج حاصل اس یک سیستن . شد ک ػلت آى راذهاى باال فضای اشغالی کن هی باشذ F

آب وشاد فت پاالیشگا فت جشیز خارک شبی ابتکاری در تصفی پساب هصػی آب وشاد فت ک هشاب

T) هجوع هاد هحلل mg/l150ساسی گزدیذ بد، با هتسط غلظت فت ردی DS) تاg/l 300 ارائ

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در ( درج ساتیگزاد 100)در دهای باال % 90شاخت هی شد شاى داد ک راذهاى حذف فت تا هیشاى در ایزاى

تا یک سلل شارساسی بذى افشدى یچگ هاد شیویایی ظیز کوک کذ ای شارساسی قابل

را هشخصی TDS دهاای هختلف، یزی گزدیذ ک در در پزا ثابت بزایوچیي تیج گ. حصل است

IGبزای ػولکزد سیستن بی TDSوی تاى ب ػاى F درج ساتیگزاد 40در دهاای باالی . هؼزفی ود

Tدر در پز ای ثابت در DS ای هختلف در شزایط اجام آسهایشات ایي تحقیق ػولکزد جذاساسی فت

IGدر سیستن F جت . رائ هذل احذ رابط هشخص هی گزددپزاکذگی ای هختلفی داشت ک هاغ اس ا

طبق کاسیى کیت حذاقل د سیستن شارساسی ب صرت سزی بایذ ب mg/l15حصل خزجی فت

.درج ساتیگزاد باشذ 70پاییي تز اس کار گزفت شذ دها یش بایذ

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Ph.D. Thesis, Environmental Engineering Subject The Effect ...srbiau.ac.ir/Files/environment/25749.pdf · Figure 2-9 Schematic showing flow pattern of cross-flow plate pack . Figure