2013 9th Annual

Practical “WATER Issues & Technologies” Short Course

Sponsored by:

Food Protein R&D Center

Texas A&M University

College Station, TX

Daniel Christodoss, Ph.D., P.E. (Principal Municipal Engineer)

John Kovski, P.E. (Department Manager - Engineering)

URS Corporation, Houston, TX

(713) 914-6699 | daniel.christodoss@urs.com | john.kovski@urs.com

Water Reuse: Technologies for Industrial & Municipal Applications

World Water Stress

Water Use by Industry Sector

Water Demand 2010 to 2060

Case for Reclamation (reuse)

Water Reuse Process (Food Industry)

Water Reuse Process (Oil & Gas)

Water Reuse Process (Municipal)

Water Reuse Process (Agricultural)

Outline

Critical worldwide concern

Previously developing nation’s issues

Now Global Crisis

Quantity and Quality Issues

From Surplus to Limited

Diminishing Water Resources

World Water Stress

EPA 2012

Source: Earth Forum: Houston Museum of Natural Science

Source: www.fracfocus.org & Estimated Use of Water in the United States, USGS 2005

3% FreshwaterTX Surface Water

TX Ground Water

Municipal

Source: AiChE 2011 Eastman Kodak Co.

Industrial

Mining

Manufacturing

Texas (TWDB)

“I am convinced that, under present conditions and with the

way water is being managed, we will run out of water long before

we run out of fuel.” – former CEO of Nestle, Peter Brabeck-

Letmathe in The Economist

(2008)

Source: AiChE 2011 Eastman Kodak Co.

Process Water Recovery Treatment Plant Frito Lay, AZ

EPA, 2012

EPA, 2012

EPA, 2012

Refinery WW Reuse for Boiler Feed Water (BFW)

Source: 2012 Industrial Waste and Pretreatment Seminar, Virginia Water Env Assn., AECOM

Source: SAWEA 2005 Workshop, ZENON Environmental, Inc.

Membranes Dominate Industrial Water Reuse

Source: SAWEA 2005 Workshop, ZENON Environmental, Inc.

(a) direct osmosis (b) osmotic-equilibrium (c) reverse osmosis

Fresh water Saline water Semipermeable

membrane

Osmotic pressure

Wastewater Recycle for Boiler Feed-Houston Ship Channel

KBR 2005

Wastewater Recycle for Boiler Feed-Houston Ship Channel

KBR 2005

EPA, 2012

Example Resource Recovery Center

Primary Clarifier or Filter

Low Energy Membrane for BOD and TSS Removal

Nutrient Removal and

Recovery

Anaerobic Digester

Electricity Generation

Algae Conversion to Biodiesel

Final Filter

Sewage

Food waste, misc. organics

CO2

Methane

Electricity

Primary Revenue Ultrapure water for industry makeup and aquifer recharge

Peak electricity sales to grid

Secondary RevenueIrrigation water

Fuel savingsInorganic fertilizer

AICHE 2011 Eastman Kodak Co

Settling tank

Equalization Tank

Trickling Filter

Drip Irrigation

Wetlands CellRainwater is collected from the roof top, stored in UG Cisterns and used to flush toilets

Water Purification Eco-Center

Rainwater UG Cistern

EPA, 2012

North American Shale Plays

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Water management is a key element in all of the shale plays

KEY ELEMENT OF WATER MANAGEMENT is: The Water Lifecycle Development

Approach to Flowback and Produced Water Treatment and Management

� Data Collection

� Concept/Feasibility Studies

� Bench-/Pilot-scale Testing

� Technology Screening and Identification

� Lifecycle Cost Evaluation

North American Experience

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Variations within and between shale plays

� Flowback %

� Salinity /TDS Values

� Formation-Derived Inputs(e.g., Scale Formers, NORM)

Locational differences but common treatment and disposal scenarios

MULTIPLE SHALE PLAYS

Play Characteristics

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Play Flowback %

Salinity/

TDS Values

Other

Issues*

Barnett

Medium to

high (30-

70%) 50,000 to 140,000

Black Warrior 500 to 140,000

Eagle Ford 2,000 to 10,000 BTEX, Boron, Ammonia

Haynesville Low (5%) 90,000 to 200,000

NORM, BTEX, Scale formers, Boron,

Ammonia

Marcellus 40,000 to 240,000 NORM, BTEX, Ammonia

Niobara 1,000 to 10,000

Permian 30,000

NORM, BTEX, Scale formers, Boron,

Ammonia

Piceance

Medium to

high 1,000 to 15,000

Utica >100,000

COMPONENTS OF UNCONVENTIONAL GAS

LIFECYCLE WATER MANAGMENT

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Reuse for Development

Discharge to Receiving Waters

Potential Treatment Skid or Facility

Reuse

Waste

Flow Back/ Brines

Groundwater Withdrawals

Stream Withdrawals

Treated Effluent from WWTP

Public Water Supply

Water Sources

Conveyance

Tank Truck Delivery

Pipe Delivery

Storage

Portable Storage Tanks at Well Sites

Holding Ponds at Well Sites

Uses

Fracture Stimulation

Well Drilling/ Construction

Well Completion and Appurtenances

Hydrostatic/ Geophysical/ Other Testing

Dust Control

Incorporated into Products/ By-Products/Waste

Injection

Solid Waste

Reuse for Development

Discharge to Receiving Waters

Potential Treatment Skid or Facility

Reuse

Waste

Flowback/Produced Water & Brines

Groundwater Withdrawals

Stream Withdrawals

Treated Effluent from WWTP

Public Water Supply

Water Sources

Conveyance

Tank Truck Delivery

Pipe Delivery

Storage

Portable Storage Tanks at Well Sites

Holding Ponds at Well Sites

Uses

Fracture Stimulation

Well Drilling/ Construction

Well Completion and Appurtenances

Hydrostatic/ Geophysical/ Other Testing

Dust Control

Incorporated into Products/ By-Products/Waste

Solid Wastes

Current Flowback Water Management

Approaches

• Evaporation in pits/ponds

• Trucked off-site for:

− Reinjection into Class II disposal wells

− Treatment at a commercial wastewater treatment plant or a POTW if disposal wells are not available.

• Direct reuse for fracing by diluting it with makeup water-considered best practice

• Treatment for reuse or surface discharge

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Available Treatment Technologies

Contaminant Process Comments

Free oil, TSS, Bacteria DGF/Filtration/ UV Biocides Low cost technologies $2/bbl

Scale formers(Ba,Ca,Fe,Mg,Mn) Clarifier water softening ,electrocoagulation,

ceramic membranes

Attractive for reuse in fraccing,

waste stream created, $2-8/bbl

Dissolved solids Membranes/RO/Evaporators/Crystallisers See table

Volatile organics Stripping and incineration, AC, Ozone oxidation air discharge and energy usage

Create waste AC, ozone energy

intensive

up to $4/bbl

Dissolved organics Biological oxidation Susceptible to toxic shocks,

operating knowledge, not short

term

general Chemical treatments Wide range offered

Summary of Characteristics of Major Flowback Water

Treatment Technologies-discharge and or reuse

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Characteristics Ion Exchange Reverse Osmosis EDR

Thermal

Distillation

Energy Cost Low Moderate High High

Energy Usage vs TDS Low Increase High Increase Independent

Applicable to All Water types Moderate TDS High TDS High TDS

Plant/Unit size Small/Modular Modular Modular Large

Microbiological Fouling Possible Possible Low N/A

Complexity of Technology Easy Moderate/High

Maintenance

Regular

Maintenance

Complex

Scaling Potential Low High Low Low

Theoretical TDS Feed Limit N/A 32,000 40,000 100,000+

Pretreatment Requirement Filtration Extensive Filtration Minimal

Final Water TDS 200-500 ppm 200-500 ppm 200-1000 ppm < 10 mg/L

Recovery Rate

(Feed TDS >20,000mg/L)

N/A Low (30-50%) Medium (60-80%) High (75-85%)

Play Characteristics and Treatment

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Play Flowback %

Salinity/

TDS Values

Other

Issues* Typical Treatment System Components Residual Water Disposal

Barnett Medium to high

50,000 to

140,000

solids removal, chem precip, thermal

evaporation

Black Warrior 500 to 140,000

solids removal, chem precip, RO or

evaporation

surface discharge or

injection well

Eagle Ford 2,000 to 10,000

BTEX, Boron,

Ammonia Solids removal, chem precip, RO Injection well

Haynesville Low

90,000 to

200,000

NORM, BTEX,

Scale formers,

Boron, Ammonia Organics / solids removal, evaporator Injection well

Marcellus

40,000 to

240,000

NORM, BTEX,

Ammonia Organics and solids removal, evaporation Injection wells in Ohio

Niobara 1,000 to 10,000 Solids removal, chem precip, RO Injection well

Permian 30,000

NORM, BTEX,

Scale formers,

Boron, Ammonia

Organics and solids removal, chem precip,

RO or evaporation Injection well

Piceance Medium to high 1,000 to 15,000

solids removal, chem precip, RO or

evaporation

surface discharge or

injection well

Powder River Ba, Iron, Na, TDS Greensands, Ion exchange , RO

Flowback Pre-treatment Followed by Thermal

Evaporation for Disposal

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Flowback Pre-treatment Followed by Membrane

Separation for Disposal

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Frac Fluid Lifecycle

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Intermediate Storage

Modular MovableTreatment

Treated W

ater

LastWell

MakeupWater

Frac Chemicals

FraccingFluid

Excess water requiring disposalor beneficial use

Flowback

Storage Pond

Residues

Flowback/Produced Water

Gas

Hydrocarbon/Water

Fraccing Fluid

FirstWell

Hydrocarbon

Flowback

~25 – 70%TYPICAL

TREATMENTSYSTEM

COMPONENTS

� Solids/Organics Removal

� Chemical Precipitation

� Filtration

� (RO)

Lifecycle Water Management Approach

• Optimize Water Re-use in Fracing

• Minimize Lifecycle Costs while Meeting Production Needs

• Minimize environmental footprints

By

Reuse of frac water

modular mobile unit for frac water reuse

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