Produced Water Quality: The Effects of Different Separation Methods for Water and Chemical Floods

Gravity settling represents the main oil-water separation mechanism. Many separation plants rely only on gravity settling with the aid of demulsifiers (direct or reverse breakers) and other chemicals such as water clarifiers if they are required. Yet, other complementary separation methods exist including filtration, flotation, and centrifugation. In terms of results and more specifically with respect to the separated produced-water, the main threshold on its quality is the dispersed oil content. Even with zero discharge and reinjection into hydrocarbon formations, the presence of residual oil in the aqueous phase represents a concern. High oil content results into formation damage and losses in injectivity which necessitates formation stimulations and hence additional operational expenses. In this work, we investigated the effects of different separation techniques on separated water quality. In addition, we studied the impact of enhanced oil recovery (EOR) chemicals on the different separation techniques in terms of efficiency and water quality. Based on the results, we identified potential improvements to the existing separation process. We used synthetic well-characterized emulsions. The emulsions were prepared at the forecast water: oil ratio using dead crude oil and synthetic representative brines with or without the EOR chemicals. To clearly delineate and distinguish the effectiveness of different separation methods, we exacerbated the conditions by preparing very tight emulsions compared with what is observed on site. With that, we investigated three separation techniques: gravity settling, centrifugation, and filtration. First, we used Jar Tests to study gravity settling, then a benchtop centrifuge at two speeds to evaluate centrifugation potential. Finally, for filtration, we tested two options: membrane and deep-bed filtrations. Concerning the water quality, we performed solvent extraction followed by UV analyses to measure the residual oil content as well as light transmission measurements in order to compare the efficiency of different separation methods. The results of analyses suggest that gravity settling was not efficient in removing oil droplets from water. No separation occurred after 20 minutes in every tested condition. However, note that investigated conditions were severe, tighter emulsions are more difficult to separate compared to those currently observed in the actual separation plant. On the other hand, centrifugation significantly improved light transmission through the separated water. Accordingly, we can conclude that the water quality was largely improved by centrifugation even in the presence of EOR chemicals. In terms of filtration, very good water quality was obtained after membrane filtration. However, significant fouling was observed. In the presence of EOR chemicals, filtration lost its effectiveness due to the low interfacial tension with surfactants and water quality became poor. With deep-bed filtration, produced water quality remained good and fouling was no longer observed. However, the benefits from media filtration were annihilated by the presence of EOR chemicals. Based on these results and at least for our case study, we conclude that centrifugation and deep-bed filtration techniques can significantly improve quality of the separated and eventually reinjected water. In terms of the effects of EOR chemicals, the performance of centrifugation is reduced while filtrations are largely impaired by the presence of EOR chemicals. Thereby, integration of any of the two methods in the separation plant will lead to more efficient produced-water reinjection, eliminating formation damage and frequent stimulations. Yet, it is important to note that economics should be further assessed.

Restoring Well Productivity Through a Fit-for-Purpose Sludge Cleanout Job

Sludge formation could significantly impair well productivity if deposited in the wellbore or surface flow lines. In a field where sludge formation is not common, an oil production well showed a sudden deterioration in well productivity. Thorough investigation of abnormal well performance, from surface and sub-surface perspective, indicated that the deposition of a thick layer of a tight emulsion across the surface choke has resulted in ceasing the oil flow to the gas oil separation plant. Extensive lab analysis indicated that the obstruction material was a sludge deposition promoted by the presence of asphaltene, high amount of iron and low pH brine. It is noteworthy to mention that the analytical results of lab prepared emulsion samples elucidate the rule of low pH aqueous solution, asphaltene and iron ions in inducing tight emulsion formation which helps to understand the root causes of sludge deposition. To come up with a cost-effective remedial treatment considering health, safety and environment (HSE), different emulsion breaking formulations, including different de-emulsifiers and anti-sludge agents, were examined in this study. An effective diesel-based formulation including proper de-emulsifier and anti-sludging agent was used during the execution of the field job. The design of the field job took into consideration a minimal footprint to the environment through the flowback of the well to the neighboring gas oil separation plant. This paper summarizes the joint efforts by production engineers and lab scientists to systemically tackle such major flow assurance issues which could significantly jeopardize wells productivity. The systemic approach starts with problem detection through well intervention and sample collection. It also includes the lab work which was carried out to identify the type and composition of deposition and evaluate/optimize a proper formulation for sludge deposition removal. The paper discusses in detail the design and execution of a successful field treatment, which has resulted in restoring and maintaining the well potential.

Troubleshooting Gas Dehydration Systems Using Data Analysis

The objective of this paper is to showcase the successful and innovative troubleshooting data analysis techniques to operate a TEG dehydration system optimally and reduce glycol loss and to meet the product specifications in one of the gas dehydration systems in an upstream gas oil separation plant (GOSP). The gas dehydration system using Triethylene Glycol (TEG) is the most widely used and reliable gas dehydration system in upstream operation. These proven data analysis techniques were used to tackle major and chronic issues associated with gas dehydration system operation that lead to excessive glycol losses, glycol degradation, and off-specification products. Glycol loss is the most important operating problem in the gas dehydration system and it represents a concern to the operation personnel. Most dehydration units are designed for a loss of less than 1 pound of glycol per million standard cubic feet of natural gas treated, depending on the TEG contactor operating temperature. In this paper, comprehensive data analysis of the potential root causes that aggravate undesired glycol losses degradation and off-specification products will be discussed along with solutions to minimize the expected impact. For example, operating the absorption vessel (contactor) or still column at high temperature will increase the glycol loss by vaporization. Also, the glycol losses occurring in the glycol regenerator section are usually caused by excessive reboiler temperature, which causes vaporization or thermal decomposition of glycol (TEG). In addition, excessive top temperature in the still column allows vaporized glycol to escape from the still column with the water vapor. Excessive contactor operating temperature could be the result of malfunction glycol cooler or high TEG flow rate. This paper will focus on a detailed case study in one of the running TEG systems at a gas-oil separation plant.

Produced Water Quality: the Effects of Different Separation Methods

Gravity settling represents the main oil-water separation mechanism. Many separation plants rely only on gravity settling with the aid of demulsifiers (direct or reverse breakers) and others chemicals such as water clarifiers if they are required. Yet, other complementary separation methods exist including filtration, flotation, and centrifugation. In terms of results and more specifically with respect to the separated produced-water, the main threshold on its quality is the dispersed oil content. Even with zero discharge and reinjection into hydrocarbon formations, the presence of residual oil in the aqueous phase represents a concern. High oil content results into formation damage and losses in injectivity which necessitates formation stimulations and hence additional operational expenses. In this work, we investigated the effects of different separation techniques on separated water quality. Based on the results, we identified potential improvements to the existing separation process. We used synthetic well-characterized emulsions. The emulsions were prepared at the forecast water:oil ratio using dead crude oil and synthetic representative brine. To clearly delineate and distinguish the effectiveness of different separation methods, we exacerbated the conditions by preparing very tight emulsions compared with what is observed on site. With that, we investigated three separation techniques: gravity settling, centrifugation, and filtration. First, we used jar tests to study gravity settling, then a benchtop centrifuge at two speeds to evaluate centrifugation potential. Finally, for filtration, we tested two options: membrane and deep-bed filtrations. Concerning the water quality, we performed solvent extraction followed by UV analyses to measure the residual oil content as well as light transmission measurements in order to compare the efficiency of different separation methods. The results of analyses suggest that gravity settling was not efficient in removing oil droplets from water. No separation occurred after 20 minutes in every tested condition. However, note that investigated conditions were severe, tighter emulsions are more difficult to separate compared to those currently observed in the actual separation plant. On the other hand, centrifugation significantly improved light transmission through the separated water. Accordingly, we can conclude that the water quality was largely improved by centrifugation. In terms of filtration, very good water quality was obtained after membrane filtration. However, significant fouling was observed. With deep-bed filtration, produced water quality remained good and fouling was no longer observed. On the basis of those results, we conclude that for our case study, centrifugation and deep-bed filtration techniques can significantly improve quality of the separated and eventually reinjected water. Thereby, integration of any of the two methods in the separation plant will lead to more efficient produced-water reinjection, eliminating formation damage and frequent stimulations. Yet, it is important to note that economics should be further assessed.

Scientific search under the pressure of high responsibility: development of the technology of electromagnetic isotope separation in the framework of the USSR Atomic project

One of the ways to obtain nuclear explosives for the manufacture of the first atomic bombs was the separation of uranium isotopes by electromagnetic (mass spectrographic) method. The theoretical justification and experimental separation of uranium isotopes by this method was carried out by L. A. Artsimovich in the Laboratory No. 2 of the USSR Academy of Sciences. By the middle of 1945, L. A. Artsimovich had obtained results at the experimental facility indicating the possibility of stable enrichment of uranium with the U-235 isotope using this method. Having the results of the experiments, the Design Bureau at the “Electrosila” plant (D. V. Efremov), with the participation of the Research Vacuum Institute (S. A. Vekshinsky) and the “A” Institute (M. Ardenne), developed a project of an industrial multi-chamber installation for electromagnetic separation of uranium isotopes SU-20. Such an installation was manufactured and put into operation at the newly created plant in the Urals, which allowed in 1951 to obtain the necessary amount of uranium-235 for the RDS-3 atomic bomb. After 1952, the technology of electromagnetic separation was no more used for the separation of uranium isotopes due to the improvement of more productive equipment for gas-diffusion separation of isotopes. The equipment of the electromagnetic isotope separation plant built in the Urals was used to produce lithium-6, needed to equip the first thermonuclear charge, which was successfully tested in 1953. In the next years, the electromagnetic isotope separation plant was involved in the manufacture of isotope products for scientific, technical and medical applications at wide range of utilization in Russia and abroad.