Shaping the future of produced water solutions

Produced Water Treatment Systems

Solutions to meet the most stringent produced water requirements

Produced Water Treatment Solutions

Solutions to meet the most stringent produced water requirements
However stringent your produced water treatment requirements, we can design and supply a system that meets your needs, surpasses environmental constraints while maximising the income from the oil/gas field assets. The increasing water cut, normally resulting from the age of the assets, can have a significant effect on the hydrocarbon process train; together with a detriment to the environment if it is discharged prior to suitable processing. No single piece of equipment can tackle the complex process of treating produced water to meet increasingly stringent regulations for discharge or reuse. At Alderley, we have a long experience in the management and processing of produced water, together with handling some of the more difficult applications. We can offer you advice and guidance through a range of services and technologies to ensure you meet production and produced water treatment goals. We provide the complete solution, from stand-alone or fully integrated, skid mounted produced water treatment systems covering Primary, Secondary and Tertiary Treatment processes. Installation and delivery is implemented in-house, including all design project management, engineering, procurement, construction installation and commissioning.

Vast experience in offshore, onshore and FPSO applications Highly efficient compact solutions Guaranteed to meetyour compliance levels Full range of solutions covering all areas of produced water treatment processes

PRIMARY TREATMENT
Well head W De Desanding

SECONDARY TREATMENT ALDERLEY METERING SYSTEMS

TERTIARY TREATMENT

Production Fluids

Separators Sepa p rators s

Degasser/ Flotation

Tertiary Treatment

Liquid Hydrocyclone Desanding ng Hydrocyclone ne Solids S o Cleaning C l

Clean Water out

We have total focus on integrating systems to meet the

Primary Treatment
Worldwide experience in delivering the solution you need on time and on budget
The primary treatment of produced water in itself involves multiple technologies from upstream sand removal utilising solid/liquid hydrocyclones at wellhead conditions through multi-phase separators and collection vessels to further solid/liquid and liquid/liquid hydrocyclones. At Alderley we have a proven track record of delivering solutions that meet or exceed your expectations on every level from performance to timescale to budget.

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Upstream sand removal Separators/collection vessels Deoiling hydrocyclones Desanding hydrocyclones

A world of experience
Extensive, global references lists are available covering all technologies and applications to demonstrate our capability and delivery. Please see below for examples of just a few of the projects we have delivered. Customer/Contractor Project
Khurais Central Processing Facility, Saudi Arabia

Description
8 off compact flotation units in 4 parallel streams. Each stream comprises 2 CFUs in series to treat 225000 bwpd. The system is designed to achieve less than 10ppm oil-in-water at the outlet. Vessels were manufactured from low temperature carbon steel with glass flake lining. Produced water treatment modile comprising 5 off AP20 deoiling hydrocyclone vessels, 3 off AP50 desanding hydrocyclone vessels and 1 off degasser vessel. The package outlet specification is 29mg/l oil-in-water and 98% removal of sand particles above 50 microns. The hydrocyclones were manufactured from duplex stainless steel and the degasser from carbon steel with glass flake lining. 2 off AP20 deoiling hydrocyclones designed to treat 151000 bwpd to meet the discharge requirement of 20ppm oil-in-water. Vessels were manufactured red from carbon steel with glass flake lining. Produced water treatment package consisting of 2 off AP20 deoiling hydrocyclone vessels, 1 off compact flotation unit and 1 off oil adsorption media unit. The target outlet oil-in-water concentration is 5 ppm downstream of adsorption media. All vessels were manufactured from duplex stainless steel.

Saudi Arabian Oil Company Snamprogetti AOIC (operated by BP Exploration) Halliburton Internation Inc.

Azeri, Chirag, Deepwater Gunashli (ACG) Phase 3 DUQ platform, Azerbaijan

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Murphy Sabah Oil Co. Ltd/MDFT (SBM & MISC) BP/Aker Solutions

Kikeh FPSO, Malaysia

Skarv and Indun Fields FPSO project, Northern North Sea, Norway

demands of the oil, gas and petrochemical industries

Ultimate Efficiency Desanding Hydrocyclones

Produced water desanding with exceptional performance

High efficiency design (removal down to 10 microns) High online turndown (>5:1) Compact vessel ideal for offshore applications High erosion resistance (manufactured from high purity alumina) Individually removable or cartridge d esign Continuous or batch sand removal Easy integration with solids clean-up and disposal systems Low maintenance

Solid/Liquid Hydrocyclone Operation

A desanding hydrocyclone uses the rapid increase in rotational velocity to create centrifugal acceleration of the fluid. This forces the solids towards the outside of the hydrocyclone liner, before they are dropped into the vessel where they are accumulated. Discharge of solids from the accumulator can be manual or automatic to suit your application needs. Whether you are removing solids from production fluids to protect downstream equipment or treating produced water for discharge or re-injection, our desanding hydrocyclones use the latest technology to meet the most diverse of requirements. Considering throughput, pressure drop, reliability and the efficiency of solids removal are all important factors when specifying a hydrocyclone, the Alderley desanding hydrocyclone is designed to tolerate higher pressure drops and pass higher flow rates to bring highly efficient solids removal all in the most compact of vessels.

3 x 50% desanding hydrocyclones with internal accumulators

AP-50 desanding cyclones

We have total focus on integrating systems to meet the

Highest Performing Deoiling Hydrocyclone

A liquid/liquid hydrocyclone that reduces oil-in-water levels to less than half that of some hydrocyclone designs
Low investment and running costs Ideal for retrofitting/upgrading existing produced water treatment systems Compact and efficient High turndown High erosion resistance Low fouling Alderleys industry leading AP-20 deoiling hydrocyclone reduces outlet levels of oil-in-water to less than half that of other hydrocyclones. Designed and manufactured in-house it has been field proven and is used extensively both onshore and offshore.

Deoiling Hydrocyclone

With high efficiency, high online turndown and high erosion resistance, this hydrocyclone offers a costeffective, proven solution that is regularly utilised in new projects and for retrofitting old systems. The liner can be fitted to existing vessels without the need for removal of the vessel or any hot work. It is unaffected by motion and suitable for vertical and horizontal vessels. We have a range of field evaluation units that shall demonstrate the AP20s superior performance. From a single skid mounted hydrocyclone vessel to a fully integrated package with our deoiling and polishing equipment. Alderley has demonstrated track record of delivering total solutions to the customer needs.

Hydrocyclone Package
Liquid/Liquid Hydrocyclone Theory
Produced water is channelled into the hydrocyclone head tangentally to the wall. The multiple tangential inlet design combined with a tapering internal geometry creates an accelerating vortex in the fluid as it flows through. Because of the difference in density between the oil and water, the induced centrifugal force pushes the oil into a central core. Careful differential pressure control is used to remove the oily core in a countercurrent flow.

Oily water reject

Inlet

Clean water outlet

demands of the oil, gas and petrochemical industries

Secondary Treatment for Produced Water

Efficient complementary technologies to further reduce oil-in-water levels
At Alderley we have vast experience in complete produced water treatment solutions to meet even the most demanding requirements. Secondary treatment conditions produced water and solids in preparation for discharge or further polishing. Hydrocyclones provide excellent removal of sand and free oils in water but the latest, stringent regulations often require complementary technologies to reduce the levels of oil and other contaminants further. Alderleys IGF and CFU systems may also be used as the primary stage of treatment where low pressure drop combined with efficient oil removal is required. Alderley can provide a range of secondary separation processes along with project management and customer support to deliver a fullyintegrated package on time and on budget.

Solids Cleaning
Solids recovered from a separator or hydrocyclone, are cleaned to stringent environmental standards prior to disposal. The system recirculates the sand from the accumulator vessel multiple times to attain the desired oil-on-sand concentration. A guaranteed level of oil on the solids can thus be achieved. Alderleys solids treatment system design is such that it can be incorporated as necessary in the overall produced water treatment package to meet your project requirements for solids disposal.

Induced Gas Flotation (IGF)

We provide two and four cell Induced Gas Flotation (IGF) systems to meet the performance requirements of your application. Our IGF works by recycling gas bubbles into the produced water. These bubbles adhere to solids and oil within the produced water and cause them to float to the top of the vessel where they are skimmed off. The IGF vessels operate a controlled residence time system for each cell to maximise the efficiency of the system. Chemicals may also be added to the system to improve the adherence of particles and break down emulsions. We will advise on the necessity for the use of chemicals during our detailed design service to you.

Degassers
Typically used downstream of hydrocyclones, the Alderley degasser design can halve the outlet oil-in-water levels. Alderley can design and supply a degasser to fit your process requirements and needs. Produced water degassers are typically operated at close to atmospheric pressure, the produced water entering the vessels de-gasses liberating millions of tiny gas bubbles that adhere to residual oil requirements and ensure maximum hydrocable recovery.

We are world experts in meeting even the most demanding of produced water treatment requirements.

Compact Flotation Units (CFU)

Alderleys CFU utilises our proprietary swirl device hydrocyclone, resulting in a soft spin cyclone. Our design has been optimised to maximise oil recovery while minimising the use of floatation gas. With our multi step pressure drop inlet we maximise the efficiency while reducing chemical usage.

Hydraulic induced gas floatation unit

1 x 4 cell mechanical induced gas floatation vessel

We have total focus on integrating systems to meet the

Tertiary Produced Water Treatment

Where stringent standards are required for reinjection or environmental discharge
Alderley provide a range of polishing technologies including nutshell media filters, cartridge filters and adsorption filters. These systems remove the very fine suspended solids and oil droplets, and the adsorption filters treat dissolved oils and organics such as BTEX (Benzene, Toluene, Ethyl Benzene and Xylene). Supplied as either stand-alone or fully integrated skid-mounted systems, these units can be manufactured at a number of international locations within Alderleys global fabrication network, as appropriate to the project build location and schedule needs.

Adsorption Filters

Oil adsorption media vessel

Our advanced adsorption filters utilise a range of cartridges and bulk media to treat dissolved oils and organics such as BTEX (Benzene, toluene, Ethyl Benzene and Xylene) as well as free oil to achieve the highest environmental standard required.

Cartridge Filters
Alderleys cartridge based technologies cover both particulate and oil removal for polishing prior to water injection. Based around a range of both cartridge and inline proprietary designs our coalescing technology are used to maximise and enhance the performance of traditional separation equipment, or the stand polishing stage or simply as a guard filter to protect downstream equipment.

Nutshell Filters
Alderleys range of polishing filters using nutshell media are typically used onshore to remove the final free oil and suspended solids entrained in the produced water. Our superior design of media management minimises backwash duration while stimulating media attrition typically caused by other mechanical machinery.

Nutshell filter vessel

demands of the oil, gas and petrochemical industries

A total focus on the needs of the oil and gas industry

Contact us for your metering, hydraulic control systems and produced water treatment needs

www.alderley.com
Registered Office
Alderley plc Alderley House Arnolds Field Estate The Downs, Wickwar Gloucestershire, UK GL12 8JD Tel: +44 (0) 1454 294556

Regional Facilities
Alderley Process Technologies Wickwar, UK Tel: +44 (0) 1454 294556 Alderley FZE Dubai, UAE Tel: +971 4804 2777 Alderley ICD Dammam, Saudi Arabia Tel: +966 1 3810 0262 Alderley East Asia Singapore Tel: +65 6408 0151

Aberdeen, UK Tel: +44 (0) 1224 300451

sales@alderley.com

Produced Water Treatment Systems Brochure Rev. 3

Solutions to meet the most stringent produced water requirements