Document22

Mechanical Separation / Westfalia Separator


Presentation about:

Disk stack centrifuge technology for the

oil-water separation of heavy crude oil emulsions

GEA Westfalia Separator Systems GmbH GEA Westfalia Separator Norway AS

Business Unit Oilfield

Michael Miedek Jarle Richter Flaata

Thomas Fislage


content

2

1.0 Basics of GEA Westfalia Separator disc stack centrifuges

2.0 Disc stack centrifuges used for heavy crude oil de-hydration

- Performance limitation

3.0 Disc Stack Centrifuges integrated in the crude oil process

incl. status of actually activities

4.0 Conclusion

- Strength and Weakness of disc stack centrifuges

Discussion


basic function

3

1.0 Basics of GEA Westfalia Separator

disc stack centrifuges


basic function

4

To be successful in the separation/de-hydration of heavy crude oil

emulsions is mainly determent by the following influence able parameters:

- g-force

(created by

centrifugal

acceleration)

- settling path

Extreme high g-force influence the velocity/settling time of water droplets

and the coalescence force effect positive.


basic function

5

The stokes’ law is the basic calculation of the settling velocity for water droplets

v

Slightly

controlable by the

selection of low

share force

equipment.

Controlable

parameters

via the centrifugal

technology.

Controlable

parameters

via the separation

temperature.

v


basic function

6

Untreated Product Inlet

Treated Oil OutletTreated Water Outlet

Sludge Outlet

Disc Stack Centrifuges provides highest g-force and lowest settling path

Disc Stack Centrifuges

multiply will provide

5,000 – 10,000 x g

The settling path will be

0.35 – 0.5 mm only.

The extremely high

clarification area

(up to 260,000 m²)

provided by the

hundreds of separation

discs can offer very low

foot print requirements

for this technology

Mechanical Separation / Westfalia Separator7

The optimal solution for the crude oil

de-hydration will be provided with disc stack

centrifugal technology as nozzle design

• Continues operation

• Higher solid load can be

handle

• Biggest heavy crude oil

centrifuge on the market

• Centrifuge housing

suitable for inert gas

blanketing up to 2 bar g

• Separation temperature

up to 130 C

• Direct drive with coupling Symbolic Sketch.

Not To Scale!

basic function


basic function

8

Make Up

Water

Start

Production

Animation, click on buttons:

After pre-filling the bowl with make-up

water product can be introduced into the

rotating bowl.

Symbolic Sketch.

Not To Scale!

Operating Principles:

Production


2.0 Disc stack centrifuges used for

oil-water separation of

heavy crude oil emulsions


disc stack centrifuges for heavy crude oil

10

Disc stack separator performance figures

o Water Droplets with a size of approximately 5-15 micron and bigger will be

separated from the heavy crude oil

²18

)(²

r

fsdVst

This water drop let will

be present in the

treated crude oil

This water drops will be

separted from the crude oil

To improve the separation result it might be necessary to:

- Increase the retention time of the product in the centrifuge -> reduce the throughput

- Adding of demulsifier -> break emulsion more easily and create bigger water droplets



11

Disc stack separator performance figures

o Sediments with a size of approximately 3-10 micron and a density bigger

than 1.4 g/ml and bigger shall be separated from the crude oil.

²18

)(²

r

fsdVst

This sediment particle

will be present in the

treated crude oil

This sediment particles will be

separated from the crude oil

To improve the separation result it might be necessary to:

- Increase the retention time of the product in the centrifuge -> reduce the throughput

- Adding of demulsifier -> break emulsion more easily and create sediment agglomeration



12

Ri

w

Start

“Big” Droplet

Start

“Stokes“

Droplet

Start

Main Feed

Flow In

vF

vC

vR

Start

“To Small“

Droplet

Separation of water droplets

inside A disc gap

Ro

VC =

Centrifugal

Velocity

VF =

Main Flow

Velocity

VR =

Resulting

Velocity

Clarified

Liquid Out

Animation, click on buttons:

Symbolic Sketch.

Not To Scale!



13

Disc stack centrifuges for crude oil desalting/dewatering! – Why?

o The extremely high g-force provide the best achievable BS&W content

within the treated product (between 0.5% – 1%) .

o Increased requirement of the water cut and can be handle with the same

technology with out major adjustments.

o The disc stack centrifuge reduce the content of ultra fine sediments

to excellent levels (3-Phase Separation).

o For higher sediment load of the pre-treated crude oil (> 0.2-0.3%)

our nozzle centrifuges provide the optimum solution.

o This technology can handle heavy crude oil up to API 12.5

(approximately 0.935 kg/m³ @ 95 C).

With high separation temperature up to 130 C even lower (API 10 -11 ) !!!

o With the support of a demulsifier even stable emulsions are

breakable and separable (temperature stable - does not influence process).



14

Capacity limitation of single centrifuges

o The capacity of centrifuges will be mainly influenced by:

- Viscosity of the crude oil

- Density of the crude oil

(Can influence by separation temperature)

o Further points are extremely important:

- Emulsions

- Particle sizes

- Water droplet sizes

The biggest single centrifuge systems Westfalia can provided are:

- The WSD 200 is the actual biggest self cleaning centrifuge

Max. capacity up to 15000 bpd (100 m³/h )

For Heavy Crude Oil needs to reduce to 6000 – 9000 bpd (40-60 m³/h)

- The ODB 260 is the actual biggest nozzle centrifuge

Max. capacity up to 37500 bpd (250 m³/h )

For Heavy Crude Oil needs to reduce to 15000 – 22500 bpd (100 – 150 m³/h)


3.0 Heavy Crude oil

process for the

oil-water separation

of heavy crude

oil emulsions


Heavy crude oil treatment process

16



17

The pressure drop create emulsions

Produced

Water Stream

Crude Oil

Stream



18


crude oil treatment process

19

Pictures as example of our nozzle centrifuge ODB 260 system



20

The ODB 260 systems on the test bench



21

The FPSO where our ODB 260 system are installed



22



23



24



25

A view inside the building with 30 ODB 260 systems

Total Capacity for 17 centrifuges for heavy crude oil: 255,000 – 300,000 bpd



26


4.0 Conclusion

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Strength

• Best achievable performance results

• Minimal footprint requirements

• Less chemical consumption

• Less operation temperature

• Centrifuges can be converted from crude oil centrifuges into produced water centrifuges for de-oiling

• Separation of water and sediments in one step

Weakness

• Rotating equipment – is that really a weakness?

• Investment may appear higher

• Knowledge and well trained operator

• Crude Oil needs to be degassed


Produced Water De-Oiling

ODB 260-71-107

Conversion Kit for

Produced Water Deoiling

• Feed & Discharge Assembly

– centripetal pump for oil

- centripetal pump for water

• Ringulating ring

• Centripetal pump chamber

cover

• Disc stack

• Distributor

Conversion can be done

on site!

Produced Water


Systems overview

29

DrillingProduction Utilities Oil Management

• Drain Water

• Drilling mud

• Slop Water

• Solids Control

• Tank Cleaning

• Brine

• Crude Oil

• Produced Water

• Drain Water

• Bilge Water

• Fuel Oil

• Hydraulic Oil

• Lube Oil

• Cat fines

• MEG

(Mono Ethylene Glycol)

• Slop Oil

• Slop Water

• Tank Bottoms

Our Systems for upstream and downstream oilfield applications

Downstream

On- and Offshore Installations

Oil & Gas Production

Oil Refineries

Gas Treatment Plant

Tank Terminal

Upstream

Mechanical Separation / Westfalia SeparatorAdd text using "Insert -> Header & Footer"30


5.0 Disc stack centrifuges used for

produced water treatment

applications


disc stack centrifuges for produced water

32

The Following Parameter influence the Separator Type

Parameter Criteria

1.) Limitation of oil content in treated produced water < 40 ppm

in relation of the oil content in the feed < 30 ppm

< 15 ppm

2.) Maximum Solid content in the feed - Self Cleaning Centrifuge

- Nozzle Centrifuge

3.) Maximum Salt content in the feed under influence - Duplex Material or

of the product temperature - Super Duplex Material

Comments:

Item 1.) A lower level of hydrocarbons in the treated produced water requested a

throughput reduction of the centrifuge. The same effect for an higher feed level.

Item 2.) In case of solid content will be above approx 0.1% a nozzle centrifuge could be

selected.

Item 3.) WS recommend a separation temperature of 50 C to max. 70 C.

In case of chloride content will be above 8000 ppm super duplex material shall be

selected.



33

WS offered a weight range of Centrifugal Separators

for the Produced Water Treatment application

Centrifuge Type Treatment Capacity*

Disc Stack Self Cleaning Centrifuges

WSD 8 up to 3,000 l/h or 450 BPD

WSD 18 up to 6,000 l/h or 900 BPD

WSD 35 up to 16,000 l/h or 2,400 BPD

WSD 60 up to 28,000 l/h or 4,200 BPD

WSD 200 up to 100,000 l/h or 15,000 BPD

Disc Stack Nozzle Centrifuges

ODC 45 up to 25,000 l/h or 3,750 BPD

ODB 260 up to 200,000 l/h or 30,000 BPD

* This is an optimum capacity and is calculated for an oil content in the feed produce

water below 1,000 mg/l and a oil content in the treated produced water of 40 mg/l.

Higher oil content in the feed and lower oil content in the treated product required

a throughput reduction. Real throughput for individual projects will be checked

case by case by WS with real product data.



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Biggest self cleaning centrifuge from Westfalia Separator

• Centrifuge type WSD 200-01-573

• Design for use: De-watering of crude oil / De-oiling of water

• Max. capacities of up to 100 m³/h

• Suitable for installation in Ex-Zone 1- Electrical component in Ex-design- Hood and sludge catcherequipped with inert gas blanketing

• Material selection- Hood: stainless steel- Frame: ductile cast iron- Bowl: super duplex stainless steel

• Technical Data WSD 200- Bowl Speed: 4300 rpm- Bowl Volume: 70 Litre

• Drive: 110 kW electrical motor operated via frequency converter


6.0 Produced water treatment process


Produced water treatment process

36


Produced water treatment process

37

Produced Water Treatment Systems – Example:

Double Centrifuge System WSC 50-01-506 for Chevron Alba FSU

SCOPE OF SUPPLY:

2 – Centrifuges WSC 50

1 – Duplex Filter

2 – Feed Pumps

3 – Base frames

2 – Sludge Pumps

1 - Control Panel

DESIGN FEATURE:

- Capacity: 2 x 20 m³/h

- Fluid: Produced Water

- Ex- design

- N2 blanketing

EXPECTED PERFORMANCE:

- Oil content in feed:

up to 1000 ppm

- Oil content outlet:

< 40 ppm


produced water treatment process

38

Produced Water Treatment Systems – Example:

Double Centrifuge System WSC 50-01-506 for Chevron Alba FSU

Performance

• Separation temperature

20 - 50 C

• Oil content in feed

up to 1000 ppm

• Oil content in treated PW

Min. : 8 ppm

Cumulative Average : 16 ppm

Max. : 29 ppm

Outlet Results WSC-50 PW Unit

8

16

29

0

5

10

15

20

25

30

35

Oil C

on

ten

t (p

pm

)


produced water treatment process

39

Produced Water Treatment System – Conversion TI Asia / TI Africa

3 x Triple unit WSD 200

For a TOTAL of 800m³/h oily water

Documents

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