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MEMBRANE TECHNOLOGY: THE FUTURE OF DEAERATION OF INJECTION WATER Paul Peterson| Business Development Manager Industrial Business Group | Membranes Business Unit
Friday, February 5, 16 The Produced Water Society Seminar 2016 © 3M 2016
OUTLINE • What is a Membrane Contactor • How does it work • Features & Benefits • Application: Injection Water Deoxygenation • Economic Comparisons w/ Vacuum Tower • Oil & Gas Applications Update • Next Steps
Friday, February 5, 16 The Produced Water Society Seminar 2016 © 3M 2016 2
3M Membrane Business Unit
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What is a Membrane Contactor? • Liqui-Cel® Membrane Contactors Bring Immiscible
Phases in Contact Without Dispersion • Gas Stripping • Gas Absorption • Liquid-Liquid Extraction
• Liqui-Cel® Membrane Contactors are Made From: • Microporous Non-Selective Polypropylene Hollow Fiber Membranes • Asymmetric Gas Permeable PMP Hollow Fiber Membrane
• Liqui-Cel® Membrane Contactors are not used to: • Filter Water or Other Liquids • Separate Gases (like CO2 from natural gas)
Friday, February 5, 16 The Produced Water Society Seminar 2016 © 3M 2016 4
DISSOLVED GASES/HENRY’S LAW
• Gas in contact with water will dissolve into water • Solubility is governed by Henry’s Law
• Pi = Hi xi, where Pi is partial pressure of species ‘i’, Hi is Henry Coefficient, xi is dissolved gas concentration
Air-saturated water: Dissolved oxygen ~ 8 ppmw (~mg/L) Dissolved nitrogen ~14 ppmw (~mg/L)
Air at atmospheric pressure and ambient temperature
Chemistry 101
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What is a Hollow Fiber Membrane?
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Each fiber variant has attributes more suited for certain applications
- Polypropylene X40: O2 Removal - Polypropylene X50: CO2 Removal - Polyolefin: Low Surface Tension
Liquid Degassing
PRINCIPLES OF GAS TRANSFER m Gases in the atmosphere
dissolve into water until equilibrium is reached
m Equilibrium between the liquid and gas phase is CHANGED when a vacuum and/or source of Sweep gas is applied
m This creates a driving force to move gasses from the liquid phase into the gas phase
How Does a Membrane Contactor Operate?
Friday, February 5, 16 The Produced Water Society Seminar 2016 © 3M 2016 7
EXTRA-FLOW MEMBRANE CONTACTOR
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OPERATING MODES
Sweep Gas
Sweep Gas Mode Water Outlet
Water Inlet
To Vacuum
Water Outlet
Water Inlet
Sweep Gas
Combo Mode
Vent
• By changing the partial pressure of the gas we can either remove gas from or dissolve gas into water.
• Increase the partial pressure and gas will dissolve into the water
• Lower the partial pressure and gas will be removed from the water
Water Outlet
Vacuum Mode
Water Inlet
To Vacuum Pump
* CO2 Removal
Blower Mode
Blower in Suction Mode*
Water Outlet
Water Inlet
Ambient air
Friday, February 5, 16 The Produced Water Society Seminar 2016 © 3M 2016 9
SYSTEM CONFIGURATION
Liquid Inlet
Parallel Configuration for Flow
Liquid Outlet
Liquid Outlet
Liquid Inlet
Series Configuration for Efficiency
Friday, February 5, 16 The Produced Water Society Seminar 2016 © 3M 2016 10
0.1
1
10
100
1000
10000
99.0% 99.5% 99.9% 99.95% 99.99% 99.995% 99.999%
Theo
retic
al m
inim
um D
O, p
pb
Sweep N2 purity, %
Effect of sweep N2 purity on minimum achievable DO outlet level
50 torr
150 torr
760 torr
SYSTEM PERFORMANCE LIMITS ON THE BASIS OF OPERATING VARIABLES
Temperature: 25 C
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Theoretically minimum achievable Oxygen levels in vacuum-only mode
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LIQUI-CEL® MEMBRANE CONTACTORS
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LIQUI-CEL® INSTALLATION HISTORY • Proven in the Field with >300 Installations from
1996 • Met uptime requirements for semiconductor plants • Average System Flow rate: 400 m3/h • Design Oxygen outlet levels from < 1 ppb to 50 ppb • Maximum Flow System: 2100 m3/h
• 20 systems > 1000m3/hr • 55+ systems > 500 m3/h
MDA is not a new technology – it is only being applied into a new Market
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Typical Installations
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Placement of MDA
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The preferred placement of the MDA is downstream of: 1. Reverse Osmosis RO
2. Sulfate Removal Unit (SRU)
3. MF/UF
4. Cartridge Filtration - 5 um ABS beta 1000+
Main reason for this ranking is the fouling probability increases as the water quality decreases.
Mitigation of MDA Fouling
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The placement of the MDA will affect its fouling and subsequent cleaning frequency.
• Fouling (biological, mineral scale) is mitigated using typical CIP procedures. Oxygen performance is key parameter to begin CIP cycle. Pressure drop secondary
• Particulate fouling can be mitigated by using high quality 5 um Absolute rated filters.
More data is needed on fouling during seasonal water quality changes
Product For Offshore: 8x80 Contactor
FRP Vessel Code Rated • ASME BPVC Section X
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19
19
Vacuum Tower Deaeration (80k BPD)
Courtesy of
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20
Membrane DA Vacuum Tower Membrane DA Vacuum Tower Membrane DA Vacuum Tower 30,000 bpd 125,000 bpd 250,000 bpd
Dry Weight (MT) 23.5 61.8 41.4 121.0 63.0 197.3 Operating Weight (MT) 33.0 80.9 56.4 164.7 79.8 269.9
0.0
50.0
100.0
150.0
200.0
250.0
300.0
Wei
ght (
Met
ric T
ons)
Membrane Deaeration vs. Vacuum Tower Weight
Note:Weightisthetotalinstalledweightofthemodule/skid.Courtesy of
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21
Membrane DA
Vacuum Tower
Membrane DA
Vacuum Tower
Membrane DA
Vacuum Tower
30,000 bpd 125,000 bpd 250,000 bpd Footprint (m2) 51.9 34 60.7 68.3 81 87.8
0
10
20
30
40
50
60
70
80
90
100
Foot
prin
t (m
2)
MEMBRANE DEAERATION VS. VACUUM TOWER FOOTPRINT
Courtesy of
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22
Membrane DA Vacuum Tower Membrane DA Vacuum Tower Membrane DA Vacuum Tower 30,000 bpd 125,000 bpd 250,000 bpd
Volume (m3) 380.3 543.5 445.7 1160.3 595.1 1579.5
0.0
200.0
400.0
600.0
800.0
1000.0
1200.0
1400.0
1600.0
1800.0
Volu
me
(m3)
Note:Volumereferstototalspaceconsumedbytheskid.
Membrane Deaeration vs. Vacuum Tower Volume C
ourtesy of
Friday, February 5, 16 The Produced Water Society Seminar 2016
Membrane Deaeration Vs. Vacuum Tower CAPEX/OPEX
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VACUUMTOWERVS.MEMBRANEDEAERATIONSIDE-BY-SIDECOMPARISON
PARAMETER VACUUMTOWER MEMBRANEDEAERATION
VacuumPackage Approx.15mmHg(a)vacuumpressure.Requireslargepumpsandejectors.HighpowerconsumpHon.
50mmHg(a)vacuumpressure.Smallerpumpsandnoejectorsrequired.LeadstoCAPEX&OPEXsavings.
MechanicalOxygenRemovalPerformance 50–100ppb <10ppb
ChemicalOxygenScavenger Requiredduetopoormechanicaloxygenremovalperformance. Notrequired.LeadstoCAPEX&OPEXsavings.
AnF-FoamChemical RequiredinjecHonattowerinlet.HazardouschemicalcreatesHSEissues.
Notrequired.LeadstoCAPEX&OPEXsavingsandlessHSEhazards.
Size&Weight LargetowerrequireshigherstructuralexpenseandinstallaHoncost.
Smaller,moreefficientdesignleadstodeliveryandinstallaHoncostsavings.
BiocideChemical MulHplebiocidesrequiredtocontrolgrowthintowerinternals.
Ifnecessary,asinglebiocidecanbeused.LeadstoCAPEX&OPEXsavings.
InjecFonBoosterPumps RequiredduetolowpressureoperaHonofvacuumtower. CanbeeliminatedinmostconfiguraHons.
LifeCycleConsumables Noreplacementofinternalsrequired.HighchemicalconsumpHoncost.
Membranereplacementrequiredonceevery5years.Canbelessfrequentdependingonfeedwaterquality.
TechnologyReadiness Fieldprovenformanyyears. Pilotedonseawaterandfieldproveninonshore,industrialapplicaHons.
Membrane deaeration provides value through approximately 20% reduction in CAPEX & OPEX.
Courtesy of
Progress Update • When will it happen? o 2016
o North Sea Platform – RO Water deoxygenation for Crude oil washing
o 2017 o North Sea Platform - RO Water deoxygenation for Crude oil washing o North Sea Platform - RO Water deoxygenation for Crude oil washing
o GOM Platform – Water deoxygenation (not injection water)
o 2020+ o Full Scale Water Injection System –180,000 BWPD system
Friday, February 5, 16 The Produced Water Society Seminar 2016 © 3M 2016 24
Next Steps Seawater Pilot studies are essential to moving forward
o Three Major Operating Companies have been involved in various pilot trials during past 4 years to validate performance in seawater. All are moving forward in their next steps of evaluation.
o A long term (+6 months) pilot study to assess operational life is planned for 2016. This will assess seasonal ocean changes and the impact on pre-treatment.
Friday, February 5, 16 The Produced Water Society Seminar 2016 © 3M 2016 25
Acknowledgement: Thank you to Water Standard for the comparison data on vacuum towers and MDA systems
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CONCLUSIONS • MDA is a viable alternative to vacuum towers for offshore use • Weight savings of 50+ % vs. vacuum towers • Capital and Operating Costs are favorable vs. Vacuum Towers • Further studies on pre-treatment options to be determined
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