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Produced Water
Treatment SystemsSolutions to meet the most stringent produced water requirements
Shaping the future of produced water solutions
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Produced Water Treatment SolutionsSolutions to meet the most stringent produced water requirements
We have total focus on integrating systems to meet the
PRIMARY
TREATMENT
SECONDARY
TREATMENT
TERTIARY
TREATMENT
Well head
Desanding
Separators
Desanding
Hydrocyclone
Liquid
Hydrocyclone
Degasser/
Flotation
Tertiary
Treatment
Solids
Cleaning
P r o d u c t i o n
F l u i d s
l
ALDERLEY
METERING
SYSTEMS
g
e
Clean Water out
The increasing water cut, normally
resulting from the age of the assets,can have a signicant effect on thehydrocarbon 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 treatingproduced water to meet increasingly
stringent regulations for discharge or
reuse.
At Alderley, we have a long experience
in the management and processingof produced water, together with
handling some of the more difcultapplications. We can offer you advice
and guidance through a range of
services and technologies to ensure
you meet production and producedwater 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 installationand commissioning.
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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 eld assets.
• Vast experience in offshore, onshore and FPSO applications
• Highly efcient compact solutions• Guaranteed to meet your compliance levels
• Full range of solutions covering all areas of produced water treatment processes
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Primary TreatmentWorldwide experience in delivering the solution you need on time and on budget
emands of the oil, gas and petrochemical industries
Customer/Contractor Project Description
Saudi Arabian
Oil Company
Snamprogetti
Khurais Central Processing
Facility, Saudi Arabia
8 off compact otation units in 4 parallel streams. Each stream comprises
2 CFUs in series to treat 225000 bwpd. The system is designed to achieveless than 10ppm oil-in-water at the outlet. Vessels were manufactured fromlow temperature carbon steel with glass ake lining.
AOIC (operated by BP
Exploration)
Halliburton Internation
Inc.
Azeri, Chirag, DeepwaterGunashli (ACG) Phase 3 -
DUQ platform, Azerbaijan
Produced water treatment modile comprising 5 off AP20 deoilinghydrocyclone vessels, 3 off AP50 desanding hydrocyclone vessels and 1 offdegasser vessel. The package outlet specication 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 carbonsteel with glass ake lining.
Murphy Sabah Oil
Co. Ltd/MDFT (SBM &
MISC)
Kikeh FPSO, Malaysia 2 off AP20 deoiling hydrocyclones designed to treat 151000 bwpd to
meet the discharge requirement of 20ppm oil-in-water. Vessels weremanufactured red from carbon steel with glass ake lining.
BP/Aker Solutions Skarv and Indun FieldsFPSO project, Northern
North Sea, Norway
Produced water treatment package consisting of 2 off AP20 deoilinghydrocyclone vessels, 1 off compact otation 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.
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2
2
3
3
4
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The primary treatment of producedwater in itself involves multiple
technologies – from upstream
sand removal utilising solid/liquid
hydrocyclones at wellhead conditionsthrough multi-phase separators and
collection vessels to further solid/liquidand 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 tobudget.
• 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.
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Ultimate Efciency Desanding HydrocyclonesProduced water desanding with exceptional performance
We have total focus on integrating systems to meet the
Solid/Liquid Hydrocyclone
Operation
A desanding hydrocyclone uses the rapid
increase in rotational velocity to createcentrifugal acceleration of the uid. 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 uids to protect downstream
equipment or treating produced water
for discharge or re-injection, ourdesanding hydrocyclones use the latest
technology to meet the most diverse of
requirements.
Considering throughput, pressure drop,reliability and the efciency 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 ow rates to bring highly efcientsolids removal – all in the most compact
of vessels.
AP-50 desanding cyclones
• High efciency 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
design
• Continuous or batch sand removal
• Easy integration with solids clean-up
and disposal systems
• Low maintenance
3 x 50% desanding hydrocyclones with internal accumulators
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Highest Performing Deoiling Hydrocyclone A liquid/liquid hydrocyclone that reduces oil-in-water levels to less than half that of some hydrocyclone
designs
emands of the oil, gas and petrochemical industr ies
Deoiling Hydrocyclone
Alderley’s 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-houseit has been eld proven and is used
extensively both onshore and offshore.
With high efciency, high online
turndown and high erosion resistance,this hydrocyclone offers a cost-
effective, proven solution that is
regularly utilised in new projects
and for retrotting old systems. The
liner can be tted to existing vessels
without the need for removal of thevessel or any hot work. It is unaffected
by motion and suitable for vertical and
horizontal vessels.
We have a range of eld evaluation
units that shall demonstrate the AP-20’s superior performance.
From a single skid mounted
hydrocyclone vessel to a fully
integrated package with our deoilingand polishing equipment. Alderley
has demonstrated track record
of delivering total solutions to the
customer needs.
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 uid as it ows through. Because of the
difference in density between the oil and water, the induced centrifugal forcepushes the oil into a central core. Careful differential pressure control is used to
remove the oily core in a countercurrent ow.
• Low investment and running costs
• Ideal for retrotting/upgrading
existing produced water treatment
systems
• Compact and efcient
• High turndown
• High erosion resistance
• Low fouling
Oily water
reject Inlet
Clean water
outlet
Hydrocyclone Package
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Secondary Treatment for Produced Water Efcient complementary technologies to further reduce oil-in-water levels
At Alderley we have vast experiencein complete produced water treatment
solutions to meet even the most
demanding requirements. Secondary
treatment conditions produced waterand solids in preparation for discharge
or further polishing. Hydrocyclonesprovide 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.
Alderley’s IGF and CFU systems may
also be used as the primary stage of
treatment where low pressure drop
combined with efcient oil removal is
required.
Alderley can provide a range of
secondary separation processes
along with project management and
customer support to deliver a fully-integrated 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-sandconcentration. A guaranteed level of oil on the solids can thus be achieved.
Alderley’s 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 oat to the top of the vessel where they
are skimmed off. The IGF vessels operate a controlled residence time system foreach cell to maximise the efciency 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
t 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 residualoil requirements and ensure maximum hydrocable recovery.
Compact Flotation Units (CFU)
Alderley’s 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 oatation gas. With our multi step pressure drop inlet wemaximise the efciency while reducing chemical usage.
We are world experts in
meeting even the most
demanding of produced
water treatment
requirements.
Hydraulic induced gas
oatation unit 1 x 4 cell mechanical induced gas oatation vessel
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Tertiary Produced Water TreatmentWhere stringent standards are required for reinjection or environmental discharge
Nutshell Filters
Alderley’s range of polishing ltersusing nutshell media are typically
used onshore to remove the nal free
oil and suspended solids entrained inthe produced water.
Our superior design of media
management minimises backwash
duration while stimulating media
attrition typically caused by othermechanical machinery.
Adsorption Fil ters
Our advanced adsorption lters utilise
a range of cartridges and bulk media
to treat dissolved oils and organicssuch as BTEX (Benzene, toluene,
Ethyl Benzene and Xylene) as well
as free oil to achieve the highest
environmental standard required.
Cartridge Filters
Alderley’s cartridge based technologies
cover both particulate and oil removal
for polishing prior to water injection.
Based around a range of bothcartridge and inline proprietary
designs our coalescing technology are
used to maximise and enhance the
performance of traditional separation
equipment, or the stand polishingstage or simply as a guard lter to
protect downstream equipment.
Alderley provide a range of polishingtechnologies including nutshell media
lters, cartridge lters and adsorption
lters. These systems remove the
very ne suspended solids and oildroplets, and the adsorption lters
treat dissolved oils and organics suchas BTEX (Benzene, Toluene, Ethyl
Benzene and Xylene).
Supplied as either stand-alone or fully
integrated skid-mounted systems,
these units can be manufactured at anumber of international locations within
Alderley’s global fabrication network,
as appropriate to the project build
location and schedule needs.
Nutshell lter vessel
Oil adsorption media vessel
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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
Produced Water Treatment Systems Brochure Rev. 3
Registered Ofce Alder ley plc
Alderley House Arnolds Field Estate
The Downs, Wickwar
Gloucestershire, UKGL12 8JDTel: +44 (0) 1454 294556
Alder ley FZE
Dubai, UAE
Tel: +971 4804 2777
Alder ley ICDDammam, Saudi ArabiaTel: +966 1 3810 0262
Regional Facilities Alder ley Process Technologies
Wickwar, UKTel: +44 (0) 1454 294556
Aberdeen, UKTel: +44 (0) 1224 300451
Alder ley East Asia
SingaporeTel: +65 6408 0151