AIES Desanding Hydrocyclones - Arabian, Industries · 2014. 11. 27. · AIES Desanding Hydrocyclones Our brochure makes no offers, representations or warranties (express or implied),

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Primary treatment stageEfficient solids removal from wellstream fluids

Solids are a problem in Oil & Gas production facilities and management of separated solids is a critical component of any production process. Using advanced engineering design tools, AIES (AI Energy Solutions) has developed the latest generation in hydrocyclone technology, the AIES Hydrocyclone.

The AIES design consists of an involute inlet geometry which minimizes fluid turbulence and reduces inlet wear. The innovative hydrocyclone geometry produces finer separation and increased throughput at lower design pressure drops than conventional designs. AIES hydrocyclones are designed to meet the harsh conditions of the upstream market and are constructed of wear resistant alumina ceramic and nitiride bonded silicon carbide. Solids are typically removed from the process:

• At the well head upstream of the choke• Downstream of the choke and before the production separator• From the separator in the aqueous phase or sand jetting effluent

AIES Desanding Hydrocyclones



Process OverviewThe hydrocyclone uses pressure energy from the flow stream to achieve cyclonic separation of solids. The change in flow direction forces the mixture to spin in a radial vortex pattern. This vortex flow is accelerated as the internal diameter is reduced over the length of the cone. Solids that exit through the apex collect into an accumulation chamber, where they are periodically purged, while the overflow discharges continually.

AIES provides a variety of hydrocyclone sizes designed to achieve the most efficient separation while managing pressure drop in any given system. Sizing options include: 1”, 2”, or 3” diameter hydrocyclones (liners) made of alumina ceramic and housed inside a larger pressure-containing vessel. Additionally AIES can provide larger single hydrocyclone liners for applications requiring

coarser separation and lower pressure drop.

Primary treatment stageEfficient solids removal from wellstream fluids

Mechanical FeaturesWith multiple installations and over 50 years of experience for support, AIES systems engineers will work with you to develop the most efficient, cost effective system for your application.

Benefits of a AIES separation unit are:

lExisting installations and detailed knowledge of high pressure, multiphase systems (15,000 psig and 100% gas flow)

lCompact design for reduced footprint and weight

lWear resistant materials of construction for increased reliability and low maintenance

lFlexible operation for variations in rates

lManual or fully automated

laies-1 D98 of 5 μ 1” body diameter Wear resistant alumina ceramic

laies-2 2” body diameter Wear resistant alumina ceramic

laies-3 3” body diameter Wear resistant alumina ceramic

laies 4” – 30” body diameter Nitride bonded silicon carbide

Turn downWhen turn down requirements exeed the normal hydrocyclone ratio of 3:1, AIES can offer the turn down design. Turndown ratios that exceed 50:1 are achievable with this design. This is accomplished by compartmentalizing the overflow section and including isolation valves for each compartment. The number of operating liners is determined by the system differential pressures and the entire process can be manual or automated.

AIES Desanding Hydrocyclones

Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change any time. Please contact us for specific information or data that may relate to your interest.

T +44 1635 799 249 M +44 777 6201 984 E [email protected]

Primary treatment stageGross oil removal in a single pass

AIES (AI Energy Solutions) has access to the latest generation Deoiling hydrocyclone. These hydrocyclones have a unique inlet geometry which helps minimize turbulence and reduces inlet wear. The innovative liner geometry produces finer, sharper separations at higher unit capacities, allowing fewer cyclones to be used for optimal performance and cost. These liners are made of Duplex SS and are fully replaceable, thus providing a cost effective wear solution for the hydrocyclone.

Principles of OperationFeed enters the deoiling hydrocyclone through an involute inlet. Its velocity is converted into tangential velocity in the inlet area, imparting a centrifugal force on the fluids. As the feed moves down the conical section, tangential velocity increases as does the centrifugal force.

The heavier water phase, which is subjected to higher centrifugal forces, moves to the outer wall of the cyclone. The lighter particles, primarily oil droplets, are displaced towards the inner core of the cyclone. The water phase exits the tailpipe as the deoiling hydrocyclone underflow.

The core of the light phase (oil) moves axially up the cyclone, due to back pressure on the underflow, and exits out the reject orifice as overflow. By maintaining a certain back-pressure on the underflow, the oil core is forced out through the overflow outlet which has a reject orifice sized to achieve a flow of approximately 2-3% of the total inlet flow.

AIES Deoiling Hydrocyclones





Pumped HydrocyclonesWhen the existing process pressure is too low (<25psi), a low shear booster pump can be included to increase inlet pressure. To ensure that minimal shearing of oil droplets takes place, strict guidelines on pump selection, piping configuration, and system operation must be followed. With many existing pumped hydrocyclone systems in operation, AIES has the experience and knowledge to assist in designing a successful pumped system.

Produced Water SystemsIn addition to a stand alone vessel, the AIES hydrocyclone systems can be incorporated into a complete produced water treatment system. The AIES hydrocyclone reduces the Oil in Water concentration to manageable levels for downstream polishing equipment. AIES offers complete packages for treatment of produced water from the production separator to overboard discharge or reinjection. Typical process equipment included in an AIES produced water treatment package are AIES hydrocyclones, along with flotation or filtration units. The system can use natural pressure or pumps that can be included to boost inlet pressure. Operation can be automated or manual and the equipment can be constructed of almost any material.

Primary treatment stageGross oil removal in a single pass

Turn downIn order to accommodate large turndown requirements that exceed 50:1, AIES offers its turn down design.

Turn down allows for continuous operation without ever shutting down the vessel. This is accomplished by compartmentalizing the overflow and underflow of the deoiling vessel. Isolation valves are opened or closed to adjust the number of liners in operation depending on the system flow rate and pressure drop.

AIES Deoiling Hydrocyclones





Primary treatment stageRemoving free oil and suspended solids from contaminated water streams

AIES Corrugated Plate Interceptor (CPI)The AIES Corrugated Plate Interceptor (CPI) is a high efficiency gravity separator used for removing free oil and suspended solids from contaminated water streams. With excellent strength and rigidity, due to the lattice-type pack structure, the AIES CPI has been widely used as a primary treatment step for produced water, rain water run-off and plant washdown wastewater treatment.

AIES Corrugated Plate Interceptor (CPI)



Principle of OperationThe AIES CPI operates as a two-step process; Coalescence and Separation. Firstly, the influent water, containing free oil and suspended solids, passes through a primary coalescer.

The coalescer, which is trapezoidal in flow direction, increases the collisions between the suspended oil droplets. When the oil droplets collide they group together to form one larger droplet (coalesce). A similar effect is experienced by the suspended solids whereby they collide and form an agglomerated particle that is larger in size.

Water from the coalescer then passes, in a sinusoidal path, through the horizontal cross flow plate pack. The cross flow plate pack, which is composed of tilted corrugated plates, helps guide oil droplets to the top of the vessel and suspended solids to the bottom. The free oil droplets rise until they reach the underside of the above plate where they coalesce and follow the angle of the plate until it reaches the water surface. The suspended solids will fall to the top of the plate below and follow the plate angle to the bottom of the vessel where they accumulate.

Oil is stored in the oil trough until it is temporarily discharged. Similarly the solids are stored at the bottom of the vessel and periodically discharged. The clean water flows over the water weir and through the outlet nozzle.

Primary treatment stageRemoving free oil and suspended solids from contaminated water streams

Applicationsl Produced Water Treatment

l Wasteware (Refinery or Petrochemical)

l Rain water runoff

l Ballast and Bilge water treatment

l Tank water drain down

l Oilspillcontainment

Advantagesl High removal efficiency of suspended oil and

solids

l Recovered oil with low water content

l Low energy consumption

l Nomovingparts-LowMaintenance/LowCost

l Low energy consumption

l Vessels can be retrofitted with AIES plate packs

AIES Corrugated Plate Interceptor (CPI)





Secondary treatment stageRemoving fine oil droplets and solid particulate from contaminated water streams

AIES ISF Flotation

The AIES (AI Energy Solutions) ISF package is a fully contained induced gas flotation system designed for removing oil and suspended solids from produced water and industrial waste streams. The ISF unit uses an eductor based hydraulic flotation process to remove the contaminants from the water stream.

AIES Induced Static Flotation



Process OverviewFluid enters the vessel through the inlet chamber and passes successively through each of the four flotation chambers. Blanket gas from a common volume inside the top of the vessel is pulled by a venturi action into each flotation chamber through an eductor assembly. The eductor system is one of the most important aspects of the AIES ISF System. As the recirculated process water flows through the converging nozzle, the high velocity creates a pressure reduction at the throat of the gas nozzle assembly. This low pressure zone results in the induction of the free-board gas through the nozzle, with subsequent in-line mixing with the process water. The gas/ water mixture encounters the striker plate, which causes the mixture to exit radically, assuring uniform distribution across the full cross section area of the flotation chamber.

Advantagesl Complete Off Gas Containment (eliminates potential H2S or other toxic gas exposure)

l Low power requirements

l Reduced Skimmings Volume

l No internal moving parts

l External skimmings control

l Skid Mounted System

l Small footprint, compact horizontal or single cell, vertical configuration

l Eliminates environmental pollution

l ASME code rated if needed for pressure applications

Secondary treatment stageRemoving fine oil droplets and solid particulate from contaminated water streams

Applicationsl Produced water (or Oilfield Produced Water)

l Wasteware (Refinery or Petrochemical)

l Offshore storm water runoff

l Refinery & Petrochem

l Tank water drain down

l Process waste stream

AIES Induced Static Flotation





Secondary treatment stageIncreased recovery for fine oil droplets and solid particulates from contaminated water streams

AIES Compact Flotation Unit (CFU)The AIES (AI Energy Solutions) Flotation Units have been engineered to meet our specific end-user requirements. Developed to meet our customer’s demand for smaller footprint, increased capacity and better performance.

Each flotation unit is configured to provide the optimum process conditions to match oil particle size distribution and low density particulates removal. Our application engineers will generate the best solution by optimizing each component of your flotation unit, such as:

l Gas flow and pressure

l Tank geometry

l Residence time

AIES Compact Flotation Unit (CFU)



Mechanism of Separation

The mechanism of fine oil droplet flotation relies on attachment of the introduced gas bubble to the dispersed oil droplet. The combined oil droplet/bubble, having a lower density than the oil droplet alone, can then be separated by gravity settlement.

The flotation unit relies partly on gas effervescing from solution (due to pressure letdown), but the primary bubble source is hydraulic entrainment of gas through an eductor. The entrained gas is recycled from the gas space at the top of the Flotation vessel.

Additional key internals that are utilized on a specific case basis may include coalescing media placed in the annulus to capture fine oil droplets and nucleate further growth.

The AIES Compact Flotation Unit (CFU) operates at a nominal pressure, usually 10psig, so there is a driving force for the gas and liquid streams to exit the vessel. Apart from the level control valves and pressure control valves there is very little pressure drop across the CFU. To maintain the separation in the CFU vessel a proportion of the outlet water flow is recycled back to the inlet through an eductor. The eductor is employed to entrain gas from the vessel headspace into the recycled water flow, this ensures that there is a fine dispersion of bubbles inside the CFU to facilitate oil droplet flotation.

Secondary treatment stageIncreased recovery for fine oil droplets and solid particulates from contaminated water streams

AIES Compact Flotation Unit (CFU)



The recycle flow and gas entrainment are independent of the inlet flow. This means that regardless of inlet flow there is always a fine dispersion of bubbles in the CFU and the unit effectively has a 100% turndown.

The liquid gas interface in the CFU is maintained at a constant level by the level control valve on the produced water outlet. Periodically the level will be raised (typically 30 seconds every 2 hours) above the level of the oil skim weir to remove the oil pad that has formed on the surface of the produced water.



Effective sand removalEfficient sand removal from separators and accumulators

AIES Sand Fluidisation Cyclone

The AIES (AI Energy Solutions) Sand Fluidising Cyclone (SFC) allows safe, controlled and efficient removal of sand and solids from the bottom of separators, accumulators and any simple gravity settling devices.

The AIES Sand Fluidising Cyclone are equally effective installed in new vessels or retrofitted into existing facilities. Providing good floor coverage each unit generates a high solids slurry for easy sand




AIES Sand Fluidisation CycloneThe AIES SFC allows for on-line solids fluidization and transport of solids which settle to the bottom of vessels. This device has no moving parts; it uses a motive fluid to fluidize solids in a controlled manner in a defined region of a vessel.

The AIES SFC creates a vortex which evacuates settled solids in an approximate area of 1 meter in diameter. This area of the vessel is swept clean of solids using a low energy low flow cyclonic pattern. The solids are evacuated through the center of the AIES SFC out of the process vessel. AIES SFC manifolds can be designed to cover all or part of a vessel.

The resultant slurry created by application of the AIES SFC can be up to 70% by weight solids. This dense slurry makes it possible to handle solids in an efficient and effective manner as the amount of produced water delivered with the solids is minimized.

When compared to conventional sand jetting systems, slurry density is as much as 9 times heavier. A 1” AIES SFC can transport up to 4 tons of solids per hour.

Process OverviewThe AIES SFC is installed just above the floor of a vessel. Each device covers about a 1m2 area of floor space in terms of its ability to fluidize solids. As such the devices are located about 1m apart.

When the motive fluid is applied to the aiesa vortex is created at its base. Solids around the vortex are drawn into the AIES SFC discharge port. To transport the resultant slurry, the vessel’s native pressure or the assistance of an eductor is used. The AIES SFC manifold is the evolution of the traditional sand jet into a more efficient device for transporting solids.

Mechanical Design & System FeaturesNominal motive fluid feed requirements for a 1” AIES SFC system amounts to 3 to 4 m3 / hr. The fluid is supplied at a pressure of approximately 8 to 10 psi above the operating pressure of the vessel.

AIES will assist in the application and design of the of the AIES SFC. The piping manifold design is critical to the transport of solids. The piping design must maintain flow velocities to avoid the settling of solids.

Effective sand removalEfficient sand removal from separators and accumulators

AdvantageslEffectively removes solids from O&G streams

which create emulsions, instrument failure, erosion and corrosion, damage pumps, create off-spec product, etc.

lUses minimal flow and pressure of motive fluids- eliminates erosion

lCreates a dense slurry eliminating the need for downstream fluid handling equipment

lSlurry transport over long distances is possible

lNo moving parts – highly reliable

lRequires minimal support instrumentation and control equipment

lAllows for on-line removal of solids

lCan be used in conjunction with other AIES solids management equipment such as sand cleaning, and bagging equipment.




Tertiary treatment stageRemoving fine oil droplets and solid particulate from contaminated water

The AIES (AI Energy Solutions) Nut Shell Filter (NSF) provides tertiary treatment and is the preferred choice in removing fine oil droplets and solid particulate (>2 micron) from contaminated water streams. The AIES NSF is a down flow, deep bed media filter consisting of a blend of pecan and walnut graded shells. The key feature of the AIES operation is the fluidization process (backwash) that strips oil contaminants and suspended solids from the nut shell media. The concentrated waste stream is discharged from the vessel while the media is retained. The fluidization mechanism utilizing internal scrubbing of the media results in very low attrition rates; typical replenishment of the nut shell media is <5% per year.

AIES Deep Bed Nut Shell Filters



Process OverviewIn the filtration mode, the AIES Nut Shell Filter acts as a down flow filter. Oily inlet water is introduced through a header that provides even flow distribution across the media bed. The influent flows down through the media bed and exits the filter through a wedge wire stainless steel support screen at the base of the vessel.

As fine oil droplets and solids are removed from the influent stream, the differential pressure across the filter increases until it reaches a predetermined level causing the filter backwash cycle to commence.

If the filter differential pressure does not activate, the backwash cycle is activated by a timer once every 24 hours. During the backwash sequence, the flow direction is reversed and the fluid flow helps with the media bed as it is fluidized.

An integral fluidization pump located on top of the vessel is activated and circulates the media through a scrubber nozzle and across a wedge wire scrubber screen. The wedge wire screen allows contaminates to pass through and out of the vessel while retaining the nutshell media. Backwash fluid exits out the bottom of the vessel through the backwash line.

Once cleaned, the media is allowed to gravity settle so that the filtration cycle can resume.

Tertiary treatment stage

Mechanical FeatureslDeep (48”) bed filter consisting of pecan/walnut

shell media for maximum separation efficiency and low attrition rates

lHigh flux rates (recommended range of 11-15 gpm/ft 2)

lSimple automatic operation

lTypically performance of 98% removal of contaminants (insoluble hydrocarbons and suspended solids) of >2μ

lIntegral scrubber pump nozzle and screen

lAutomated controls with presets for backwash

lStandard sizes range from 2,500 – 80,000 BPD per system

lMedia particle size: 12/20 mesh

lMedia is not “force set” after cleaning as is necessary in other filters.

lBackwash step averages 14 minutes

lNo air/gas scour backwash step

lHigh volumes of backwash water are not required

lPositive Regeneration cycle prevents bed channeling and mud balling of nut shell media

lRegeneration volume is less than 1% of throughput.

ApplicationsThe tertiary treatment step filtration is typically the final stage before disposal or reuse of the produced water.

lProduced water reinjection systems that demand near oil free effluent

lPretreatment of produced water prior to softening for steam generation

Performance CharacteristicsThe performance of the AIES NSF is typically

l98% removal of free and dispersed oil droplets

l98% removal of solids > 2 microns

l10-15 minute backwash cycle/offline time every 24 hours

lBackwash volumes are typically less than 1% of throughput capacity.



AIES Deep Bed Nut Shell Filters

Removing fine oil droplets and solid particulate from contaminated water streams





Final treatment stageRemoving fine oil droplets and suspended solids from contaminated water streams

The AIES (AI Energy Solutions) Ceramic Membrane Filtration Packages offer a unique option as a final stage in our produced water treatment systems.

Utilising the LiqTech SiC industry leading Ceramic Membrane, AIES are able to offer very high quality outlet water with exceptionally low suspended solids and oil concentration.

These filtration packages are an ideal final treatment stage for clients who demand high quality water for reinjections, steam generation or desalination units.

AIES Ceramic Membrane Filtration Packages



Process OverviewDischarge and re-injection of Produced Water from oil production is becoming increasingly challenging because as oil wells mature, the water cut increases. Many regions are now tightening the legislation for discharge of Produced Water which means that the oil producers have to look for new technologies.

Ceramic ultra filtration membranes can very easily produce permeate with well under 5 mg/l oil. Due to the unique hydrophilic properties of Silicon Carbide it is possible to obtain higher water fluxes on the LiqTech SiC based CoMem mem¬branes than with other membrane materials. Continuous process flux for oil/water separation is recorded between 200 -2000 L/m2/h

depending on the oil type.

Final treatment stage

Mechanical Features

High Permeability

The high permeability is achieved due to

l High porosity

l Large pore sizes in support/carrier

l Low contact angle to water

l The high permeability/flux means low resistance to transport water

l The benefit is a large filtration capacity per

installation volume (reduced footprint) and/or

reduced energy consumption

l The large capacity per membrane volume means

reduced costs for auxiliary valves, piping, instruments and installation area.

Temperature Resistance

l Tolerates temperatures up to 800 degrees C lFiltration possible at higher temperatures without compromising the selectivity l Steam can be used to clean/sterilize the membranes l Increased lifetime of membrane elements.

ApplicationsThis treatment package is typically the final stage before disposal or reuse of the produced water

l Produced water reinjection systems that demand near oil free effluent

l Pretreatment of produced water prior to softening for steam generation.

Advantages

l Highest water flux compared to any other membrane material - High capacity, reduce your foot print

l Chemically resistant for the full pH-range, pH 0-14 - No need to worry about harsh chemicals

l Thermally resistant up to 800 degree C - Produced Water of any temperature can be treated with SiC membranes

l SiC membrane with selective layer, negatively charged surface and hydrophilic material - Consistently removes oil and TSS regardless of feed conditions

l Extremely hard and durable material - Long life time, reduced down time and less maintenance.



AIES Ceramic Membrane Filtration Packages

Removing fine oil droplets and suspended solids from contaminated water streams

Documents

AIES Desanding Hydrocyclones - Arabian, Industries · 2014. 11. 27. · AIES Desanding Hydrocyclones Our brochure makes no offers, representations or warranties (express or implied),