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بسم هللا الرحمن الرحیم

Brine Treatment Pilot Plant at SWWT&RP (SulaibyaWaste Water Treatment and Reclamation Plant)

Imad AL-Maheimid & Ahmed Kh. Al-Jasmi

Research & Technology Group, KOC

Surface Team

2/19/2015

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Arid and semi-arid climate areas such as Kuwait are affected by watershortages, especially shortage in the water intended for industrialapplications. So in this particular climatic context, treating and reuse of anyavailable source of wastewater will partially overcome the industrial watershortage problem.

The available water sources for KOC/ HO industrial applications is:1. Desalted Sea Water, the discussion was mad to treat 60,000 bbls/day to produce low

salinity water for HO applications, this option is not an optimal one due to the low recovery ,environment protection issues and logistic problems.

2. Brackish water, this also not an optimal option due to the limited reserve of brackish water inNorth Kuwait, also brackish water in NK is considered as strategic reserve for the state ofKuwait.

3. KNPC effluent treated water from MAB & MAA refineries is not feasible option due to thelong distance and logistic problems.

4. RO treated water from SWWT&RP, this treated water is mainly used for agriculturalpurposes in AL-Abadaly and AL-Waffra farms.

5. RO reject (Brine) from SWWT&RP which is sustainable source water for KOC. HistoricalBrine specifications and fresh Brine samples specifications has been studied by KOC,numerous reputed companies were approached to explore the feasibility of treating thissecond generation of waste (Brine) and the conclusion mad by few companies that this watercan be treated to a desired specifications.

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Introduction

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Sulaibya WWT&RP Overview

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Diagram of the general layout of the SWWT&RP

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25 km

PIPELINE

KOC Pilot Plant Location in SWWT&RP

PRELIMINARYTREATMENT PLANT

ARDIYASCREENS

GRIT & FOGREMOVAL

MAINPUMPS

BIOLOGICALTREATMENT PLANT

TO SLUDGETREATMENT

SECONDARYCLARIFIERS

MIXINGAERATION

BASINS

SULAIBIYA

TOOFF-TAKER

CHLORINE CLEARWELL

CHLORINE

RECLAMATION PLANT

SULAIBIYA

ULTRA-FILTRATIONREVERSEOSMOSIS

KOC Pilot Plant

RO Reject,15%

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A scope of work has been created by KOC to construct two pilot plant toexplore the feasibility of treating RO Brine in order to achieve a treatedwater suitable for KOC industrial applications.

The main objectives of the scope of work is to treat RO Brine to a desiredspecifications.

The selected technologies were integrated with ZLD to avoid anygeneration of waste water (third generation of waste), by this integration,recovery ratio designed to exceed 98%.

Implementing ZLD concept will reflect KOC contribution and responsibility tothe community. The plant will not generate any liquid waste; hence it willprovide a good opportunity to safe Kuwaiti marine life and environment.

The major part of the scope covers design, construction, operation andtroubleshooting of the Brine treatment pilot Plant. The feed water to Brinetreatment pilot Plant were supplied from MPW (Ministry of Public Work)from Sulaibya Waste Water Treatment and Reclamation Plant (SWT&RP)RO reject.

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Scope of Work

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More than 12 companies which shows their interest to treat this

Brine were invited and the tender was released, more than 12

companies were participated in pre-tender meeting and sit visit.

Due to a challenging scope of work only three companies passed

the technical evaluation and the contracts were awarded to two

companies.

2/19/2015

Invited Companies

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Effluent WaterType of Analysis Unit Average Maximum

AnionsNO3 mg/l 34.97 66.00Total PO4 mg/l 12.75 100.00Total Alkalinity as CaCo3 (TA) mg/l 269.54 600.00Alkalinity as HCO3 mg/l 328.70 732.00Alkalinity as Co3 mg/l 0.00 0.00Cl- mg/l 1251 3000SO4 mg/l 1259 3000F mg/l 0.79 1.44Total Anions as CaCo3 mg/l 3431 8165.3CationsN-NH4 mg/l 26.50 75.00K mg/l 77.80 127.40Na mg/l 804.1 2444.4Mg mg/l 82.20 134.50Ca mg/l 646.0 759.5Sr mg/l 5.50 9.10Ba mg/l 0.05 0.09Fe++ mg/l 0.21 0.70Li mg/l 0.03 0.06Total Hardness as CaCo3 (TH) mg/l 1498 2452Total; Cations as CaCo3 mg/l 3431 5663Inert Species

B mg/l 0.26 0.49SiO2 mg/l 3.64 10.00Other Quality ParametersTDS mg/l 4306 7166pH - 7.24 8.4Temperature C° 30 <40H2S mg/l 0.003 0.10Color Pt-Co Unit 137.4 182Total Coliform Colonies/100 ml 787.4 38000

BOD mg/l 5.52 23.9Conductivity μs/cm 6535 10890TSS mg/l 2.05 50COD mg/l 156.3 1157Grease mg/l <0.1 <6.0Residual Free Chlorine mg/l 0.09 19.5

SWWT&RP, Brine Specifications (RO Reject)

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Careful inspection of the data reveals that 55% of the ions on thereported average Brine specifications are notorious scale species(Sulfate, Magnesium, Bicarbonate, Phosphate….Transition metalsand Silica), while 66% of ions in the maximum Brine constitutes aresuch notorious species. The remaining ions in the Brine are mainlySodium & Chloride (Sodium Chloride).

Moreover, there are a major parameters that have the greatestimpact on selecting design options and treatment equipments like,TH, TDS, Sulfate, Iron and total suspended solids. Therefore ,

The selected Brine treatment technology shall be:

1. Focused on proper conditioning (effective de-scaling & de-salting) of Brine.

2. Integrated with Zero Liquid Discharge , ZLD.

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SWWT&RP RO Reject Data Interpretation

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KOC Pilot Plant Produced Water Identified Specifications

Important Parameters Concentration Unit

Total Hardness (as CaCO3) <0.5 PPM

Silica (SiO2) <50 PPM

Oil & Grease <5.0 PPM

Total Dissolved Solids (TDS) 2500 ±10% PPM

Total Suspended Solids (TSS) <0.1 PPM

Dissolved Oxygen (DO) <7 PPb

Sulfate Concentration <10 PPM

Iron <0.2 PPM

Produced Water Specifications

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Since any further liquid waste generation will:

1. Reduce the quantity of the treated water from Brine (300 bbls/day) to meet the required

amount of treated water for KOC industrial applications.

2. Is an environmentally prohibited because of the disposal of third generation of concentrated

liquid stream is not an option.

The blow down (concentrate) stream from Once Through Steam Generators

OTSG or any other types of Steam Generator, which constitutes a significant

amount of the conditioned feed water shall be of a sufficient quality (readily de-

salted and de-scaled) to be efficiently reutilized without further treatment to:

1. Recover its inherited thermal energy to pre-heat the OTSG conditioned feed water without

causing any scaling problems within heat exchanger, and then,

2. Partially recycle it to supplement the OTSG feed water, and /or

3. Directly reuse for other oil fields activities such as crude oil washing and de-salting or

injected into crude reservoirs for pressure maintenance (pressure support) without formation

of scale deposition problems.

Why De-salting, De-scaling and Zero Liquid Discharge ZLD

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Brine feed water (RO reject) will be collected in storage tankprior to mix it with treatment chemicals.

The precipitation step is the main one that aims at the efficientremoval of the bulk of notorious species (Sulfate, Magnesium,Phosphate, Silica and Transition metals including Iron)., thisinvented crystallization step is based on inter-mixing brine witha suitable additives at ambient temperature and low pressureto form selective precipitation of targeted notorious species.

This step is followed by press filter which is operated in lowpressure (less than 100 PSI) to remove all precipitates whichformed in the previous step.

The calcium polishing step is based on exchanging calciumwith sodium and recycling the recovered calcium to thesecond step to bring the total hardness in the treated water tothe TH desired level, sodium chloride or sodium hydroxide canbe used to regenerate the exchange of ions.

TDS polishing step is based on using low-pressure loosemembrane to control the TDS (2250 – 2750 mg/liters) betweentheir permeate and concentrate stream.

Removal of Oxygen in the pilot plant is based on thepatented membrane gas separation unit.

The design of this pilot is that a recovery ratio of more than98% have been achieved.

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Contractor -1 Pilot Process Flow Diagram

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Brine will be softened by using a cold lime sodaash softening process., this to promote theprecipitation of Calcium Carbonate & MagnesiumHydroxide, also organic matter will be incorporatedin the scale and eventually will be loweredsignificantly, organisms will be inhibited due to highpH.

Softened/clarified effluent water pH will be adjustedby dosing suitable acid.

MMF is a foreseen to insure that the feed waterquality for reverse osmosis is meet.

A set up of reverse osmosis consist of feed pumps,cartridge filters and anti scalant addition before thewater inters the 2-stages high recovery ROsystem.

The recovery of RO system designed to be 95% oftreated water meeting KOC specifications.

The remaining 5% Brine will be subjected to furthertreatment to achieve ZLD.

The design of this pilot is that to achieve recoveryratio of 98%.

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Contractor - 2 Pilot Process Flow Diagram

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Parameters SpecificationsPPM

Number ofSamples

KOC Results KISR Results Contractor Results OverallRemarks

Total Dissolved Solids 2250 – 2750 51 100 % 100 % 100 % Exceeding theexpectation

Silica (SiO2) < 50 51 - Within thespecifications

100 % Exceeding theexpectation

Oil & Grease < 5.0 51 - 100 % 100 % Exceeding theexpectation

Dissolved Oxygen,(On-line DO)

< 7 PPB 51 - - 100 % Exceeding theexpectation

Sulfate Concentration < 10 51 100 % 100 % 100 % Exceeding theexpectation

Iron < 0.2 51 100 % 100 % 100 % Exceeding theexpectation

Total Hardness (asCaCO3)

< 0. 5 51 73 % <10 84 % < 10 100 % GoodAchievement

Total SuspendedSolids (TSS)

< 0.1 51 24 % is 0 ppm59 % < 2 ppm

33 % is 0 ppm30 % < 2 ppm

100 % GoodAchievement

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KOC, KISR and Contractor Samples Results

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Thank You