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HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
SPECIAL THANKSSPECIAL THANKSThanks to Jim Bellows for nominating me, I am truly honored toThanks to Jim Bellows for nominating me, I am truly honored toaccept this award on behalf of the Produced Water Consensus accept this award on behalf of the Produced Water Consensus Document Task Group working under the ASME Water Document Task Group working under the ASME Water SubcommitteeSubcommittee
THERE ARE MANY GREAT PRODUCED WATER AND THERE ARE MANY GREAT PRODUCED WATER AND INDUSTRY EXPERTS THAT I HAVE HAD THE OPPORTUNITY INDUSTRY EXPERTS THAT I HAVE HAD THE OPPORTUNITY TO SOLVE WATER TREATING AND/OR BOILER PROBLEMS TO SOLVE WATER TREATING AND/OR BOILER PROBLEMS WITH OVER THE PAST 10 YEARSWITH OVER THE PAST 10 YEARS
THANKS TO EACH OF YOU, ESPECIALLYTHANKS TO EACH OF YOU, ESPECIALLYBOB HOLLOWAY, HOLLOWAY ASSOCIATESBOB HOLLOWAY, HOLLOWAY ASSOCIATESGUY MOMMAERTS, ION EXCHANGE SERVICESGUY MOMMAERTS, ION EXCHANGE SERVICESGORDON PAGEGORDON PAGEED HOFFMAN, EDVENTURESED HOFFMAN, EDVENTURESDEBORAH BLOOM, NALCO UTILITY BOILER EXPERTDEBORAH BLOOM, NALCO UTILITY BOILER EXPERTMARTY GODFREY, NALCO CHEMISTMARTY GODFREY, NALCO CHEMISTAnd thanks to anyone that I have not mentionedAnd thanks to anyone that I have not mentioned
““TO SCALE OR NOT TO TO SCALE OR NOT TO SCALE IN 2500 PSIG SCALE IN 2500 PSIG
ONCE THROUGH STEAM ONCE THROUGH STEAM GENERATORSGENERATORS””
HELMHOLTZ AWARD LECTUREHELMHOLTZ AWARD LECTURENIAGARA FALLS, ONTARIONIAGARA FALLS, ONTARIO
JULY 21, 2010JULY 21, 2010
By: By: MelonieMelonie MyszczyszynMyszczyszyn, P. Eng, P. Eng
NORTHERN ALBERTA, NORTHERN ALBERTA, CANADA OILSANDS AREACANADA OILSANDS AREA
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
Source: Wikipedia, Oilsands, internet site
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
LIFE CYCLE OF THERMAL LIFE CYCLE OF THERMAL STEAMSTEAM
CSS CSS –– CYCLIC STEAM CYCLIC STEAM STIMULATIONSTIMULATION
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
THERMAL STEAM WELLSTHERMAL STEAM WELLSONE TYPE IS THE CSS (CYCLIC STEAM ONE TYPE IS THE CSS (CYCLIC STEAM STIMULATION ) WELLSSTIMULATION ) WELLS
HIGH OR LOW PRESSURE 80 HIGH OR LOW PRESSURE 80 –– 95% STEAM QUALITY IS 95% STEAM QUALITY IS INJECTED INTO CSS (CYCLIC STEAM STIMULATION) WELL 480 INJECTED INTO CSS (CYCLIC STEAM STIMULATION) WELL 480 TO 520 M (1574 TO 1706 FT) DEEPTO 520 M (1574 TO 1706 FT) DEEP
STEAM IN CSS WELL IS ALLOWED TO SOAK FOR A PERIOD STEAM IN CSS WELL IS ALLOWED TO SOAK FOR A PERIOD OF TIME BECOMING WATER AND THEN FLOWS BACK WITH OF TIME BECOMING WATER AND THEN FLOWS BACK WITH THE OIL AT THE WELLSTHE OIL AT THE WELLS’’ PRESSURE AND TEMPERATUREPRESSURE AND TEMPERATURE
IS CYCLICAL PROCESS ALSO CALLED IS CYCLICAL PROCESS ALSO CALLED ““HUFF AND PUFFHUFF AND PUFF”” ––LOTS OF WATER VAPOUR WHEN WELL INITIALLY FLOWS LOTS OF WATER VAPOUR WHEN WELL INITIALLY FLOWS BACK AND THEN ANNULUS GAS (SOLUTION) GAS FROM OIL BACK AND THEN ANNULUS GAS (SOLUTION) GAS FROM OIL RELEASINGRELEASING
SAGD SAGD –– STEAM ASSISTED STEAM ASSISTED GRAVITY DRAINAGEGRAVITY DRAINAGE
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
THERMAL STEAM WELLSTHERMAL STEAM WELLSTHE SECOND TYPE IS SAGD (STEAM ASSISTED THE SECOND TYPE IS SAGD (STEAM ASSISTED GRAVITY DRAINAGE) WELLSGRAVITY DRAINAGE) WELLS
LOW PRESSURE 90 LOW PRESSURE 90 –– 100% STEAM QUALITY IS INJECTED 100% STEAM QUALITY IS INJECTED INTO SAGD (STEAM ASSISTED GRAVITY DRAINAGE) WELL INTO SAGD (STEAM ASSISTED GRAVITY DRAINAGE) WELL 480 TO 520 M (1574 TO 1706 FT) DEEP480 TO 520 M (1574 TO 1706 FT) DEEP
STEAM IN WELL RETURNS WITH EMULSION UP THE STEAM IN WELL RETURNS WITH EMULSION UP THE PRODUCING WELL IN THE SAGD PAIRPRODUCING WELL IN THE SAGD PAIR
IS CONTINUOUS RETURN OF PRODUCED WATER WITH OILIS CONTINUOUS RETURN OF PRODUCED WATER WITH OIL
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
OUTLINEOUTLINE
What is produced water?What is produced water?
Produced Water Consensus DocumentProduced Water Consensus Document
Debate:Debate: ““To scale or not to scale 2500 psig Once To scale or not to scale 2500 psig Once Through Steam Generators utilizing Produced Through Steam Generators utilizing Produced WaterWater””
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
PRODUCED WATERPRODUCED WATER
Produced Water is separated from the Produced Water is separated from the heavy oil when it returns from the well in heavy oil when it returns from the well in oil treating plant facilities oil treating plant facilities
Three phase (oil, water/sand, gas) separation Three phase (oil, water/sand, gas) separation vesselsvessels
Slug Catcher, Separator, Slug Catcher, Separator, TreaterTreater
SEPARATION VESSELSSEPARATION VESSELS
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
source: http://www.netl.doe.gov – US Environmental Protection Agency
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
PRODUCED WATERPRODUCED WATER
As each thermal reservoir is different the As each thermal reservoir is different the properties of produced water are unique for properties of produced water are unique for each thermal oil recovery site each thermal oil recovery site
No two produced waters created are identicalNo two produced waters created are identical
Thus, the produced water returns with many Thus, the produced water returns with many contaminants resulting in boiler feed water with contaminants resulting in boiler feed water with ranges of componentsranges of components
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
TRADITIONAL PRODUCED TRADITIONAL PRODUCED WATER TREATINGWATER TREATING
Main way used to treat the produced water to boiler feed Main way used to treat the produced water to boiler feed water consists of water consists of
Warm or Hot Lime Softener and Weak Acid Warm or Hot Lime Softener and Weak Acid CationCation Exchange UnitsExchange Units
Such systems result in a boiler feed water with Such systems result in a boiler feed water with contaminants as listed in the following detailed produced contaminants as listed in the following detailed produced water analysiswater analysis
A boiler feed water with high scaling tendencies when heated to A boiler feed water with high scaling tendencies when heated to boiler operating pressures and temperaturesboiler operating pressures and temperatures
WATER COMPARISONSWATER COMPARISONS
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
Contaminant Pure Water, BFWTreated Produced Water,
BFW Error in Field Testing pH 8.8 to 10 7.5 to 9.8
Conductivity, umhos Specific 0.5 to 5 658 to 12000
Cation exchanged 0.06 to 0.3Total M Alkalinity (ppm as CaCO3)
<0.001 184 to 1600+/- 15 ppm
Chloride, ppm <0.005 11 to 5500
Total Hardness (ppm as CaCO3)
<0.001 0.23 to 1.0+/- 0.25 to 2.0 ppm
Total Boron , ppm 0 except nuclear 0 to 29.4
Total Iron, ppm 0.02 0 to 0.184+/- 0.25 ppm
Lithium, ppm 0 0 to 7
Total Silica (as SiO2) ppm 0.01 4.93 to 150 +/- 5 ppm
Total Organic Carbon, ppm <0.1 3 to 250
Oil & Grease, ppm <0.1 0.5 to 1.0
Total Dissolved Solids, ppm 0.05 350 to 8000
Turbidity, NTU 0 0 to 2.2
Tannin & Lignin, ppm 0 0 to 35
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
CHALLENGES OF CREATING CHALLENGES OF CREATING BOILER FEED WATER QUALITY BOILER FEED WATER QUALITY
FROM PRODUCED WATERSFROM PRODUCED WATERS
Field testing variance from detailed lab testingField testing variance from detailed lab testingAlkalinity, Iron, Hardness and Silica VaryAlkalinity, Iron, Hardness and Silica Vary
Process ExcursionsProcess ExcursionsTreating Upsets release higher levels of silica, hardness, Treating Upsets release higher levels of silica, hardness, and/or organics into boiler feed waterand/or organics into boiler feed water
Contaminants cycling as produced water returns to Contaminants cycling as produced water returns to facility over timefacility over time
Chlorides Chlorides –– slowly increase with timeslowly increase with time
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
PRODUCED WATER CONSENSUS PRODUCED WATER CONSENSUS DOCUMENT DOCUMENT -- PWCDPWCD
IN 2008, AN ASME WATER SUBCOMMITTEE IN 2008, AN ASME WATER SUBCOMMITTEE TASK GROUP WAS FORMED TO DEVELOP A TASK GROUP WAS FORMED TO DEVELOP A PRODUCED WATER CONSENSUS PRODUCED WATER CONSENSUS DOCUMENTDOCUMENTTHE GROUP HAS GROWN TO AROUND 55 THE GROUP HAS GROWN TO AROUND 55 VOLUNTEER MEMBERS FROM CANADA AND VOLUNTEER MEMBERS FROM CANADA AND USAUSA
PARTICIPANTS ARE FROM ALL ASPECTS OF PARTICIPANTS ARE FROM ALL ASPECTS OF INDUSTRY : INDUSTRY : OPERATORS, CHEMISTS, BOILER OPERATORS, CHEMISTS, BOILER MANUFACTURERS, CHEMICAL REPRESENTATIVES, AND WATER MANUFACTURERS, CHEMICAL REPRESENTATIVES, AND WATER EXPERTSEXPERTS
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
PWCD GOALPWCD GOAL
GOAL IS TO CREATE A DOCUMENT GOAL IS TO CREATE A DOCUMENT THAT CAN BE USED BY INDUSTRY AS THAT CAN BE USED BY INDUSTRY AS A REFERENCE OR STARTING POINT A REFERENCE OR STARTING POINT TO ASSIST OPERATORS TO ENSURE TO ASSIST OPERATORS TO ENSURE MINIMIZATION OF ONCE THROUGH MINIMIZATION OF ONCE THROUGH STEAM GENERATOR TUBE STEAM GENERATOR TUBE CORROSION OR FAILURESCORROSION OR FAILURES
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
ULTIMATELY WANT TO ULTIMATELY WANT TO MITIGATE TUBE FAILURESMITIGATE TUBE FAILURES
Scaling can result in tube failure or pipe Scaling can result in tube failure or pipe damage damage
Thin Lip Tube FailuresThin Lip Tube Failures
Weld Erosion/Corrosion FailuresWeld Erosion/Corrosion Failures
Pipe Wall LossPipe Wall Loss
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
THIN LIP TUBE FAILURETHIN LIP TUBE FAILURE
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
BOILER PIPING WELD BOILER PIPING WELD CORROSIONCORROSION
TO BE SIMILAR TO EXISTING TO BE SIMILAR TO EXISTING ASME CONSENSUS ASME CONSENSUS
DOCUMENTS DOCUMENTS
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
PWCD INVITATIONPWCD INVITATION
Open Invitation to anyone interested in Open Invitation to anyone interested in participating participating –– next meeting is being held next meeting is being held in person at the upcoming IWC 2010 in in person at the upcoming IWC 2010 in San Antonio, TexasSan Antonio, Texas
scheduled for October 28scheduled for October 28thth, 2010 from 8 am to noon, 2010 from 8 am to noon
We also host We also host webexwebex meetings to work on meetings to work on each section of the document each section of the document
LOCATIONS OF THERMAL LOCATIONS OF THERMAL INSITU OPERATIONS?INSITU OPERATIONS?
Known Locations:Known Locations:Northeastern Alberta, CanadaNortheastern Alberta, CanadaBakersfield, California, USABakersfield, California, USAVenezeulaVenezeulaChinaChina
Where else are there thermal inWhere else are there thermal in--situ situ locations?locations?
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
SCALE SCALE –– PART OF PART OF OPERATINGOPERATING
Part of operating Once Through Steam Part of operating Once Through Steam GeneratorsGeneratorsOperate for around 10 months then Operate for around 10 months then shutdown and shutdown and descaledescale the boilerthe boiler
Mechanical pigs are used to clean boiler Mechanical pigs are used to clean boiler tubestubesOr acid washing if tubes requireOr acid washing if tubes require
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
CRYSTALLINE / AMORPHOUS CRYSTALLINE / AMORPHOUS SCALESCALE
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
TYPES OF SCALE CREATEDTYPES OF SCALE CREATED
75 to 95% of the scale consists of forms of some 75 to 95% of the scale consists of forms of some or all of the followingor all of the following
AcmiteAcmite –– sodium iron silicatesodium iron silicateIron silicatesIron silicatesMagnesium silicatesMagnesium silicatesCalcium silicatesCalcium silicatesIron oxidesIron oxides
5 to 25% of the scale5 to 25% of the scaleIs usually carbonIs usually carbon
WHERE IS THE CARBON WHERE IS THE CARBON FROM?FROM?
Is another debatable topic,Is another debatable topic,Carbon could be from Organic or Inorganic Carbon could be from Organic or Inorganic SourcesSources
There are many organic sources as depicted in the There are many organic sources as depicted in the following slidefollowing slide
(Ed Hoffman, (Ed Hoffman, EdventuresEdventures, 2003), 2003)
There are also many Inorganic sourcesThere are also many Inorganic sources
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
ORGANICSORGANICSTYPES OF ORGANICS IN PRODUCED FLUIDS SEPARATION
Paraffinic Hydrocarbon Oilsome Aromatic Hydrocarbon &Some Cyclic Hydrocarbon GreaseNapthenic AcidsAsphaltene & Non-Hydrocarbon Organic Matter(solids)Process Chemicals - corrosion inhibitor, demulsifier
??depends
Volatile hydrocarbon BTEX on Semi-volatile Phenols, carboxylic acids analyticalNon-volatile hydrocarbon method
TOCNon-volatile hydrocarbonBase soluble Humic AcidsAcid / Base soluble Fulvic Acids
Process Chemicals -* water soluble Reverse Emulsion Breaker* water soluble clarifier (polymer)
ERH/2003
Produced
WaterEmulsified
Oil(O/W)
Water Soluble
Hydrocarbo
Other Water Soluble
Organics
ProcessChemicals
Free Oil
SOURCE: Ed Hoffman, Edventures, Organics Charts, 2003
INORGANICSINORGANICS
Many different inorganic carbon species Many different inorganic carbon species could be source of carbon in scale could be source of carbon in scale
OxocarbonsOxocarbons such as COsuch as CO33, C, C22OO44
Carbonyls such as (CN)Carbonyls such as (CN)22, , BrCNBrCN, , Carbides such as AlCarbides such as Al44CC33, FeC, FeC33, ,
More testing and determination of the carbon More testing and determination of the carbon source still needs to be donesource still needs to be done
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
OTHER TYPES OF SCALE OTHER TYPES OF SCALE SEENSEEN
At some facilities, the following other At some facilities, the following other scales are createdscales are created
Lithium Silicate ScaleLithium Silicate ScaleCan be created when water treating WAC ion exchange units are noCan be created when water treating WAC ion exchange units are not leaking t leaking hardness (no calcium, magnesium, or iron leakage) hardness (no calcium, magnesium, or iron leakage) –– lithium next ion to lithium next ion to attach to silica and create silicate scaleattach to silica and create silicate scale
Ammonium Carbonate ScaleAmmonium Carbonate ScaleAs both the ammonia and carbon dioxide are volatile, when the elAs both the ammonia and carbon dioxide are volatile, when the elements ements liquefy in steam condensate can create scale inside the downstreliquefy in steam condensate can create scale inside the downstream piping am piping and valvesand valves
(Marty Godfrey, Nalco Research, IWC Conference IWC(Marty Godfrey, Nalco Research, IWC Conference IWC--0909--36, 2009)36, 2009)
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
UPSETS CREATE SCALE LIKE TREE UPSETS CREATE SCALE LIKE TREE RINGS RINGS –– CAN SEE WHAT HAPPENED CAN SEE WHAT HAPPENED
PROCESS WISEPROCESS WISE
NOTE: PICTURE OF REGEN WASTE SCALE NOTE: PICTURE OF REGEN WASTE SCALE –– ILLUSTRATIVE PURPOSES ONLYILLUSTRATIVE PURPOSES ONLY
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
TO SCALE OR NOT TO SCALETO SCALE OR NOT TO SCALE
DebatableDebatableWhether or not to treat the water only to a Whether or not to treat the water only to a manageable scaling state or to clean the manageable scaling state or to clean the water to not scale in boilerswater to not scale in boilers
Ideal option is to selectively remove scaling Ideal option is to selectively remove scaling ions from water ions from water
Minimize amount of ions in waterMinimize amount of ions in water
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
SELECTIVE ION REMOVALSELECTIVE ION REMOVALIf can remove the key scaling ions and leave the rest in If can remove the key scaling ions and leave the rest in the water, then would not result in scale formationthe water, then would not result in scale formation
Due to contaminants such as organics, chlorides, silica, Due to contaminants such as organics, chlorides, silica, and alkalinity in the produced water is very costly to try and alkalinity in the produced water is very costly to try to remove these ions from the water specificallyto remove these ions from the water specifically
Thus, adding downstream equipment to existing warm or Thus, adding downstream equipment to existing warm or hot lime softening/WAC systems to purify the produced hot lime softening/WAC systems to purify the produced water like a reverse osmosis system is currently not water like a reverse osmosis system is currently not feasiblefeasible
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
SILICA REDUCTION EXAMPLESILICA REDUCTION EXAMPLEIt has been attempted to lengthen the boiler runtime by It has been attempted to lengthen the boiler runtime by reducing silica reducing silica ppmppm in boiler feed water from a warm lime in boiler feed water from a warm lime softening / softening / WacWac systemsystem
Normal target for silica is from 30 to 50 Normal target for silica is from 30 to 50 ppmppm and reduced and reduced down to range of 12 to 15 down to range of 12 to 15 ppmppm
As is difficult to maintain an exact range As is difficult to maintain an exact range -- silica values ranged silica values ranged from 5 from 5 ppmppm to 15 to 15 ppmppm over the reduction periodover the reduction period
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
LITHIUM SILICATE SCALELITHIUM SILICATE SCALE
Running with lower silica levels and Running with lower silica levels and minimal hardness leakage out of the minimal hardness leakage out of the WACWAC’’s (good water treating hardness s (good water treating hardness wise) resulted in creation ofwise) resulted in creation of
Lithium Silicate ScaleLithium Silicate ScaleVery hard, tenacious scaleVery hard, tenacious scaleHarder to remove by mechanical piggingHarder to remove by mechanical piggingExtra cost downtime and maintenance wiseExtra cost downtime and maintenance wise
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
LITHIUM SILICATE SCALELITHIUM SILICATE SCALE
Theoretically you need a 4:1 molar ratio of Theoretically you need a 4:1 molar ratio of Lithium to Silica (lithium battery research) to Lithium to Silica (lithium battery research) to create lithium silicate scalecreate lithium silicate scale
Was able to recreate Lithium Silicate Scale in Was able to recreate Lithium Silicate Scale in Laboratory with less than 4:1 molar ratioLaboratory with less than 4:1 molar ratio
•• Recreated scaling in a Kettle type of boiler experimentRecreated scaling in a Kettle type of boiler experiment(Presented by Marty Godfrey, Nalco Research, at Conrad Conferenc(Presented by Marty Godfrey, Nalco Research, at Conrad Conference 2006)e 2006)
Operationally as well seems when no calcium, magnesium, or ironOperationally as well seems when no calcium, magnesium, or ironpresent (good treating out of WAC ion exchange units) are able tpresent (good treating out of WAC ion exchange units) are able to o create lithium silicate scale with less than a 4:1 molar ratiocreate lithium silicate scale with less than a 4:1 molar ratio
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
LITHIUM SILICATE SCALELITHIUM SILICATE SCALE
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
ALTERNATELY ALTERNATELY --EVAPORATIONEVAPORATION
In some of the newer facilities, operators have In some of the newer facilities, operators have chosen to treat the produced water to boiler feed chosen to treat the produced water to boiler feed water quality by installing Evaporators water quality by installing Evaporators
Results in an ideally cleaner boiler feed water Results in an ideally cleaner boiler feed water (though the resultant water does get (though the resultant water does get contaminants carryover) to once through steam contaminants carryover) to once through steam generator but, a highly concentrated generator but, a highly concentrated blowdownblowdownstream that an operator has to deal withstream that an operator has to deal with
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
BLOWDOWN STREAM BLOWDOWN STREAM COMPONENTSCOMPONENTS
Contaminants Evaporator Blowdown Water
pH 13
sodium chloride, ppm 100,000
Silica, ppm 6000 - 9000
organics, ppm 20 - 25000
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
EVAPORATOR BLOWDOWN EVAPORATOR BLOWDOWN DISPOSAL WELLDISPOSAL WELL
Deep well injectionDeep well injectionpH < 9 pH < 9 –– ERCB requirement ERCB requirement
and < 200 mg/L silica for and < 200 mg/L silica for deep well disposal.deep well disposal.
High pH evaporator High pH evaporator blowdownblowdown wastewater is wastewater is difficult to dispose and difficult to dispose and requires complex treatment requires complex treatment process. process.
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
EVAPORATOR BLOWDOWN EVAPORATOR BLOWDOWN SALT CAVERNSALT CAVERN
Site availability is the Site availability is the primary concernprimary concern
Can accept Can accept blowdownblowdownfluid with high values of pH, fluid with high values of pH, TDS, and silica TDS, and silica
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
EVAPORATOR BLOWDOWN TO EVAPORATOR BLOWDOWN TO CRYSTALLIZER CRYSTALLIZER –– ZLD (ZERO ZLD (ZERO
LIQUID DISCHARGE)LIQUID DISCHARGE)technology is both capital and technology is both capital and energy intensive energy intensive (~200(~200--250 kwh/1000 gal of 250 kwh/1000 gal of distillate). distillate). Elevated levels of organic Elevated levels of organic content in SAGD produced content in SAGD produced water prevents formation of dry water prevents formation of dry solids from the crystallizerssolids from the crystallizers
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
SCALE FUNCTION OF WATER SCALE FUNCTION OF WATER CONTAMINANTSCONTAMINANTS
So no matter which treating system you So no matter which treating system you use use –– Warm or Hot Lime / WAC or Warm or Hot Lime / WAC or Evaporation Evaporation -- seems you can end up with seems you can end up with some type of scale to handle somewhere some type of scale to handle somewhere in your systemin your systemEither scaling in the once through steam Either scaling in the once through steam generator tubes or scaling in generator tubes or scaling in blowdownblowdown or or disposal systemdisposal system
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
STILL NEED TO FIGURE OUTSTILL NEED TO FIGURE OUTWhat is the right contaminant mixture What is the right contaminant mixture –– boiler feed water boiler feed water limits per ion limits per ion –– to minimize scaling up to the 2500 psig to minimize scaling up to the 2500 psig operating condition and still provide protection to the operating condition and still provide protection to the boiler tubes from erosion, corrosion, or failure?boiler tubes from erosion, corrosion, or failure?
What is the best testing What is the best testing method(smethod(s) for hardness, silica, ) for hardness, silica, organics, chlorides, alkalinity, etcorganics, chlorides, alkalinity, etc…… for boiler feed waters for boiler feed waters created from a produced water source? Operators have created from a produced water source? Operators have been utilizing own methods modified to resemble been utilizing own methods modified to resemble laboratory detailed testing resultslaboratory detailed testing results
Is the required ratio of total alkalinity versus silica still 3:Is the required ratio of total alkalinity versus silica still 3:1 1 at a 2500 psig operating condition to prevent silica at a 2500 psig operating condition to prevent silica polymerization?polymerization?
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
STILL NEED TO FIGURE OUTSTILL NEED TO FIGURE OUT
What affect does the increasing contaminants in the What affect does the increasing contaminants in the steam condensate (20% of steam to field) have on the steam condensate (20% of steam to field) have on the downholedownhole reservoir scaling wise and ability to return reservoir scaling wise and ability to return emulsion fluid effectively flow wise?emulsion fluid effectively flow wise?
What are the geochemical limits in terms of max What are the geochemical limits in terms of max concentration per ion in steam condensate to concentration per ion in steam condensate to reservoirreservoir
Need to figure out an easy way to keep the evaporator Need to figure out an easy way to keep the evaporator blowdownblowdown water contaminants in solution?water contaminants in solution?
Or from emitting hazardous gases like H2S when pH Or from emitting hazardous gases like H2S when pH adjustments are made for disposing or recycling adjustments are made for disposing or recycling blowdownblowdown streamstream
HelmHoltzHelmHoltz Lecture July 21, 2010 Lecture July 21, 2010
REFERENCESREFERENCESCNRL Wolf Lake Thermal Operation, near CNRL Wolf Lake Thermal Operation, near BonnyvilleBonnyville, Alberta, Canada , Alberta, Canada -- photosphotos
Marty Godfrey and Paul Marty Godfrey and Paul DeschDesch, Nalco Research, Naperville, Illinois , Nalco Research, Naperville, Illinois –– scale photosscale photos
Produced Water Consensus Document, ASME Water SubProduced Water Consensus Document, ASME Water Sub--committee, Boiler Feed Water committee, Boiler Feed Water PropertiesProperties
TIW Western, Boiler Manufacturer, OTSG photo from websiteTIW Western, Boiler Manufacturer, OTSG photo from website