SPE 128609

The Mare’s Tail – The answer to a cost effective produced water

management in deepwater environment?
Oyeneyin, M.B, SPE1; Glen McLellan2; Bhavani Vijayakumar1; Mamdud Hussain1; Roy Bichan2; and Nigel
Weir2
1
The Robert Gordon University, UK 2Opus Plus Limited UK

Copyright 2009, Society of Petroleum Engineers Inc.

The Mare’s Tail works by coalescing small oil
droplets found in produced water, into
This paper was prepared for presentation at the 33rd Annual SPE International
Technical Conference and Exhibition in Abuja, Nigeria, August 3-5, 2009. significantly larger sizes so that the droplets can
This paper was selected for presentation by an SPE Program Committee following
then be separated more efficiently. A spool
review of information contained in an abstract submitted by the author(s). cartridge contains a fibrous coalescer element,
Contents of the paper, as presented, have not been reviewed by the Society of
Petroleum Engineers and are subject to correction by the author(s). The material, which is fixed at the inlet end to facilitate
as presented, does not necessarily reflect any position of the Society of Petroleum
Engineers, its officers, or members. Papers presented at SPE meetings are
inspection and removal. Fluids enter the inlet
subject to publication review by Editorial Committees of the Society of Petroleum nozzle and flow along the spool piece in the
Engineers. Electronic reproduction, distribution, or storage of any part of this paper
for commercial purposes without the written consent of the Society of Petroleum same direction as the coalescer media and then,
Engineers is prohibited. Permission to reproduce in print is restricted to an
abstract of not more than 300 words; illustrations may not be copied. The abstract
as the fluids travel along the oleophilic fibres,
must contain conspicuous acknowledgement of where and by whom the paper small oil droplets are attracted to the surface and
was presented. Write Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-
3836, U.S.A., fax 01-972-952-9435. coalesce with other droplets as they migrate
towards the outlet. The direction of flow along
Abstract the fibres, rather than across it as with more
The deepwater environments form the conventional technologies, means that any solids
cornerstone of future oilfield developments many are passed through the Mare’s Tail rather than
of the hydrocarbon reservoirs of which are building up within the media. The technology has
characterised by High Pressure (HP) and High proved to be particularly suited to FPSO
Temperature (HT). A key feature of HP-HT applications but never tried out for any subsea
reservoirs is the rapid depressurisation in the processing.
early production life of the reservoir. One of the Environmental regulations relating to the
most critical issues associated with the high discharge of oil into the sea continue to tighten
drawdown is early water ingress and sand significantly across the globe. To meet this new
production. Continuous water production is also challenge and improve the efficiency of the
a key phenomenon with mature/depleted Mare’s tail, the development of a second
reservoirs. Keeping production costs to a generation of the system has now been initiated
minimum whilst keeping production targets high, in a collaborative project between RGU & Opus
requires putting in place an effective Plus funded through the UK Knowledge Transfer
management of the produced water either by re- Project Scheme.
injection or by discharge. The challenge is in
nd
meeting the stringent operational requirements In this paper the 2 generation Mare’s Tail
and environmental disposal regulations that development programme is presented. The
define the level of oil in water and solids content paper presents the unique coalescence operating
before re-injection or discharge. In the UK, for mechanism of the 2nd generation Mare’s Tail,
example, legislation is becoming increasingly planned improvements over the 1st generation
strict with the Convention for the Protection of system and its importance/relevance to improved
the Marine Environment of the North-East produced water management in deepwater
Atlantic (OSPAR) commission – which came environment. Potential for application in subsea
into force in 2007 – reducing the total discharge processing compared to FPSO installation is also
tonnage of oil allowed by 15% compared to the highlighted.
st
levels permitted in 2000. The 1 generation of Supporting this optimisation process is a newly
the Mare’s Tail coalescer was initially developed developed support design and optimisation
by Opus Plus through a joint industry project in algorithm the details of which are also presented.
1998 to meet this challenge. Through utilising the Preliminary validation of algorithm predictions
technology, clients have enjoyed a number of key have been carried out using selected field data
benefits, including a greatly improved quality of the results of which have been found to be in
produced water being discharged to the sea – agreement. Stochastic analysis has been carried
without the use of deoiling chemicals. out the results of which are presented to
demonstrate how the algorithm can be utilised in
the optimisation of the design parameters such
2 M.B. Oyeneyin, G. McLellan, B. Vijayakumar, M. Hussain, R. Bichan and N. Weir SPE 128609

that every developed Mare’s Tail is fit for associated and non-associated fines/debris and
purpose. The algorithm can also be utilised to sand grains], inorganic chemicals such as iron,
optimise operational parameters in real time as calcium and magnesium ions and organic
well as any onsite problem diagnosis thus chemicals.
minimising any flat time or loss of production. Produced water is now disposed off either by re-
The paper is concluded with a presentation of the injection for water flooding to improve recovery or
Opus test facility which will be used to test the by discharge. To meet injectivity requirements
Mare’s Tail. the produced water needs extensive treatment to
remove a substantial percentage of the oil
Introduction droplets, suspended solids and inorganic/organic
chemicals. The challenges are in:
The International Energy Agency1 forecasts that 1. The deoiling of the water possibly to
oil demand by 2015 will be about 95 million about 2microns droplet size and 10ppm
barrels/day with a total supply of 85 million concentration
barrels/day of conventional oil whose worldwide 2. Removal of base sediments/suspended
reserve stands at about 1.3 trillion barrels 2. solids
The deepwater environments form the 3. Inorganic iron, calcium and magnesium
cornerstone of future oilfield developments many removal
of the hydrocarbon reservoirs of which are 4. Soluble organic chemical removal
characterised by High Pressure and High
Temperature (HP-HT). A key feature of HP-HT There are now many deoiling, suspended solids
reservoirs is the rapid depressurisation in the and associated organic/inorganic substances
early production life of the reservoir. One of the treatment technologies. The challenges are:
most critical issues associated with the high 1. Which individual or combination of
drawdown across the reservoir sand face is very technologies to use that will be fit-for-
high water ingress and sand production. purpose considering different reservoir
Continuous water production is also a key lithologies and properties as well as
phenomenon with mature/depleted reservoirs produced water characteristics and
with over 98% of water production in mature operating conditions.
fields like Brent and Forties fields in the UKCS for 2. Design optimisation and real time on-site
example. Keeping production costs to a process optimisation
minimum whilst keeping production targets high,
requires putting in place an effective Produced Water Management Technologies
management of the produced water either by re- The produced water management technologies
4
injection or by discharge. In the challenging and can be divided into four main groups :
environmentally sensitive Arctic and ultra
deepwater regions, regulations for the discharge 1. The Deoiling Technologies
of oil to sea are tightening considerably across 2. The Suspended Solids Removal Technologies
the globe and resulting in an ever expanding 3. The Inorganic Chemical Removal
market for water clean up technologies. The Technologies
challenge is in meeting the stringent operational 4. The Soluble Organic Substance Removal
requirements and environmental disposal Technologies
regulations that define the level of oil in water
and solids content before re-injection or A. Deoiling Technologies
discharge. In Europe, for example, legislation is There is a number of separation technologies for
becoming increasingly strict with the OSPAR the deoiling of base water produced with oil.
3
commission – which came into force in 2007 – The most popular deoiling technologies include:
reducing the total discharge tonnage of oil • Centrifugation – In this method the settling
allowed by 15% compared to the levels permitted rate of the oil droplets can be enhanced by
in 20003. increasing the acceleration the droplets are
Due to tightening legislative targets for oil in subjected to using a centrifuge. The system
water discharge to the marine environment, the is only efficient in removing droplets over
worldwide market for water clean up technology 2microns.
is huge. This trend is continuing across the • Membrane Ultra Filtration – The use of a
industry worldwide especially for ultra deepwater suitable membrane can yield low produced
operations and subsea developments. water oil concentration. The technology lacks

the ability to handle large flow rates and can

Challenges of Produced Water
readily clog necessitating high degree of
Produced water from oil/gas reservoirs usually
replacement maintenance. Surfactant
contain in various concentrations oil droplets,
dissolved gas, suspended solids [mainly
3 The Mare’s Tail – The Answer to a Cost Effective Water Management in Deepwater Environment? SPE 128609
addition can improve the separation where the soluble ferrous iron can be
efficiency. oxidised into a ferric hydroxide precipitate
• Plate Separation – The separation system is that settles out in the tank
made up of a packet of parallel plates • Lime soda ash softening – This is a water
through which produced water can be softening process in which added hydrated
diverted. Presence of the corrugated plates lime or caustic soda is used to adjust the pH
leads to a reduction in settling distance of the to above 10 resulting in the formation of
oil droplets. It is a relatively simple system to calcium carbonate that precipitates and can
produce and needs little maintenance. It is be filtered out.
however incapable of handling very small • Cation Exchange – Resin additive can
droplets. promote the exchange of sodium ion for
• Hydrocyclone Separator – This is a conical calcium or magnesium ion in the hard water.
device wherein the produced mixture of oil
and water is separated out by centrifugal D. Soluble organic removal – Treatment includes
forces. The produced water enters the biological and activation processes involving the
cyclone tangentially with centrifugal use of activated carbon, reverse osmosis,
4
acceleration promoting gravitational electrodialysis methods to name a few .
separation. The hydrocyclone is very good in Many of the separation systems are used
separating the large droplets but lacks the individually or packaged with other units. A
ability to handle very small droplets. typical example of such systems is the Compact
• Induced Gas Flotation – In this case the Floatation Unit (CFU) that has found wide
rising velocity of oil droplets is enhanced application in deepwater environments5. The
through the injection of gas bubbles to CFU is a combination of gas floatation and
suspended droplets creating a lighter and centrifugal separation.
bigger droplet size enhanced by the gas
expansion. The suspended droplets form a
froth layer which can be skimmed off. The Mare’s Tail® [MT]
• API Separator – This is a well established
separator usually designed to promote The Mare’s Tail [Figure 1] works by coalescing
quiescent separation of water and free oil. It small oil droplets found in produced water, into
is usually good with high oil concentration significantly larger sizes so that the droplets can
only. then be separated more efficiently. The 1st
• Coalescence – The process of coalescence generation of the Mare’s Tail coalescer was
involves the aggregation of small droplets initially developed by Opus Plus through a joint
into bigger particles which can then readily industry project (JIP) in 19986 to meet this
separate out the oil from the produced water challenge. A spool piece within the technology
mixture. contains a fibrous coalescer element, which is
Of all the above separation techniques only the fixed at the inlet end to facilitate inspection and
coalescence process has the ability to remove removal. Fluids enter the inlet nozzle and flow
very small droplets below 2microns. along the spool piece in the same direction as
The Mare’s Tail, the subject of this paper, the coalescer media and then, as the fluids travel
operates on the coalescence principle. along the oleophilic fibres, small oil droplets are
attracted to the surface and coalesce with other
B. Suspended Solids Removal droplets as they migrate towards the outlet. The
This technique includes: direction of flow along the fibres, rather than
• Sedimentation – Process involves long across it as with more conventional technologies,
retention time in a tank designed to establish means that any solids are passed through the
quiescent condition Mare’s Tail rather than building up within the
• Cartridge Strainer Unit – This is a tube media.
support system that holds sized filter The coalescing action occurs within two seconds
cartridges for solids filtration in the bundle, making a very compact device.
• Hydrocyclone – Process similar to deoiling The combination of flow along the fibres, rather
hydrocyclone, but designed to remove solids than across it, as in many conventional
particles from the flow stream into an coalescers, results in a self cleaning operation
accumulation vessel. because solids pass through the coalescer.
The system can be installed upstream of any
other deoiling separation technology previously
C. Inorganic Chemical Removal described where droplet size can have an effect
This is made up of the following processes: on performance. The Mare’s Tail has the
• Aeration and Sedimentation – This is competitive advantage of delivering greatly
primarily for iron removal. In the process, improved quality of produced water without the
water is aerated in a sedimentation tank use of chemicals [Figure 2].
4 M.B. Oyeneyin, G. McLellan, B. Vijayakumar, M. Hussain, R. Bichan and N. Weir SPE 128609

There are many configuration options including:

• Units spooled into existing pipe work
[Figure 3]
• Installed parallel to existing pipe work
facilitating by-pass[Figure 4]
• Horizontal, inclined or vertical orientation
• Can be supplied packaged with other
deoiling equipment[Figure 4]

Figure 4: Mare’s Tail Unit with other facilities

Spool

Figure 1: The Mare’s Tail

Cartridge

Figure 5: Mare’s Tail showing the separated

Cartridge and Spool

The technology has proved to be particularly

suited to fixed platform and FPSO applications
but never tried out for any subsea processing.
As a unit that can readily be spooled into existing
pipe works, the MT has the potential for
application in subsea production system [SPS]
modules. The challenges are in the ability to
Figure 2: Produced Water Quality develop and utilise a spool material that can
meet the harsh deepwater environmental
conditions in terms of seawater corrosion effect
and prevailing high pressure and temperature.

Specifically The Mare’s Tail is made up of the

following key components [Figure 5]:
1. A spool
2. Fibre cartridge

To date 2’’, 4’’ and 6’’ nominal spool sizes with

designated pipe schedule numbers [Table 1]
Figure 3: Spooled Mare’s Tail have been developed and utilised for the initial
6, 7
JIP studies . These same schedules will be
utilised for the ongoing studies.

Eighteen successful field trials have been

conducted for 13 different leading oil companies
worldwide and 20 units of 4’’, 6’’, 10’’ and 18’’ MT
full-scale installations have been executed.
5 The Mare’s Tail – The Answer to a Cost Effective Water Management in Deepwater Environment? SPE 128609
Table 1: Mare’s Tale Pipe Schedules of the operating parameters, absolute knowledge
of the operating envelope, capabilities and
Nom. O.D Schedule Wall Wt, limitations of the Mare’s Tail.
Size No Thick kg/m The key challenges in the new KTP project are
ness, in:
mm 1. The provision of a detailed understanding
2.375’’ 10 2.77 3.93 of why the Mare’s Tail works
2’’ (60.3mm) 40 3.91 5.44 2. The development of a second generation
of a stand alone Mare’s Tail that is fit for
80 5.54 7.48
purpose and meets the customer’s needs.
4.5’’ 10 3.05 8.36
This requires adopting appropriate design
4’’ (114.3mm) 40 6.02 16.07
optimisation strategy
80 8.56 22.32 3. Developing the strategy for laboratory and
6’’ 6.625 40 7.11 28.26 on-site performance and process
(168.3mm) 160 18.26 67.56 optimisation
During the JIP, tests were conducted initially with The background JIP results to date confirm there
different type of fibres to test their surface area, is a complex relationship between the
availability and affinity towards coalescing oil parameters that affect coalescence. The
droplets of different sizes used[Figure 6] and to underlying umbrella strategy adopted therefore is
confirm which type of fibre is the most to develop a semi-empirical model that:
appropriate to be used as the Mare’s Tail fibre. (i) clearly defines the coalescence efficiency
The materials tested were horse hair, hemp rope of the Mare’s Tail (MT)
and fibres, poly propylene rope, poly propylene (ii) identifies the key parameters and
mop, sobaide, sysal string, cotton string and combined effects of all the parameters on the
nylon rope. From the tests it was confirmed that coalescence efficiency.
polypropylene mop showed the better results. It The model supported by selective experiments
was also identified during the JIP that length has form the foundation of any design and on-site
a major impact on the efficiency of the Mare’s process optimisation envisaged for the 2
nd

Tail, which states that the efficiency increases generation MT.

along with the length, but beyond a certain
length, there is no significant improvement in the Table 2: Mare’s Tail Coalescer Status Update
efficiency of the Mare’s Tail [Figure 7]. and Reference
Current Mare’s Tail development solely comes Company
from performance feedback from offshore trials Title/Subject Platform/Terminal
Name
or full scale installations [See Table 2]. This has
proved to be unreliable as units can either not be 6’’, 10’’ and 18’’ Haewener Brim
Shell
on-line for specific platform reasons or the Mare’s Tail Units FPSO
installation itself does not support the resource to 2 x 10’’ Mare's
Schlumberger Offshore Brazil
provide adequate feedback. This has restricted Tail Units
any Mare’s Tail related work to design and ExxonMobil 4” Mare’s Tail NSO platform
fabrication for full scale applications. The 2 x 21” Mare’s
requirement is to have the knowledge of the Hess Triton FPSO
Tail units
technologies operating limits given the vast array
BP America
of production conditions both in national and 14” Mare’s Tail Na Kika Platform
Inc
global oil fields.
Environmental regulations relating to the E.ON Ruhrgas 6” Mare’s Tail Ravenspurn North
discharge of oil into the sea continue to tighten UK North Sea Units platform
significantly across the globe. To meet this new Murphy
West Patricia
challenge and improve the efficiency of the Sarawak Oil 6” Mare’s Tail
Platform
Mare’s Tail, the development of a second Co Ltd
generation of the system has now been initiated 20” unit is being
in a collaborative project between The Robert Lundin Britain supplied as part Heather platform.
Gordon University and Opus Plus funded through Limited of a 50,000 BPD
the UK Knowledge Transfer Project Scheme CFU unit
(KTP). This partnership allows further research Total 2 x 20” (60,000 BAP and ESP1
and development to gain a better understanding Cameroon BPD) units platforms
6 M.B. Oyeneyin, G. McLellan, B. Vijayakumar, M. Hussain, R. Bichan and N. Weir SPE 128609

The Coalescence Efficiency Model Definition of Mare’s Tale Coalescence

Efficiency
Review of MT Coalescence Mechanism The coalescence efficiency of the Mare’s Tail is
Coalescence in the Mare’s Tail can be defined as here defined as the measure of the concentration
the aggregation of small oil droplets due to of the coalesced oil droplets as a function of the
electrostatic forces of attraction between the oil total concentration of the inlet droplets.
droplets particles and operating fibre medium. Expressed mathematically,
The oleophilic fibres used in the Mare’s Tail help C − C oo
to coalesce smaller oil droplets into bigger η c = oi …1
C oi
droplets. This is achieved by several forces like
Where:
interfacial surface tension, dispersion and dipolar
Coi = Concentration of oil droplet of size di at inlet
effect, cohesive attraction, drag, kinetic and
Coo= Concentration of effluent oil droplet of
gravity forces acting between oil droplets and the
diameter di
fibres. Coalescence is also affected by zeta
potential in the oil droplet.
The Coalescence Efficiency Model
An oil droplet has an uneven charge distribution,
8 The stability and coalescence efficiency of the
also known as the London Dispersion Effect .
Mare’s are a complex physical and chemical
This uneven distribution can lead to the dipolar
phenomena influenced by the following key
effect i.e. change in the shape of the molecule
parameters:
due to the presence of an external electrical field
when it comes into close proximity with the
Mare’s Tail media. This mechanism promotes an • Flow rate, q
initial attraction of the droplets to the Mare’s Tail • Spool diameter, Ds
fibre media. This primary coalescence is followed • Cartridge diameter, Dc
by cohesive attraction or intermolecular attraction • Fluid density, ρfluid
between like molecules. Cohesive attraction can • Fluid viscosity, μfluid.
then lead to a weak boundary layer condition, • Cumulative volume of produced water, Q
which aggregates the oil droplets further. • Production time, t
The size of an oil droplet plays a vital role in • Length of the Spool, Ls
coalescence due to cohesion. If the size of the oil • Porosity, φ
droplet is bigger the charge distribution will be • Inlet oil diameter, di
higher, and there will be little or no zeta potential • Inlet oil concentration, Co
i.e. voltage difference between the inner and the • Density of polypropylene, ρpp
outer layer of the droplet which leads to a weak • Differential pressure across the
boundary layer condition. Capillary forces i.e. the Spool/cartridge, ΔP
ability of a substance to draw another substance • Specific surface area of the media, Spp
into it and the surface tension properties of the
• Specific surface area of the oil droplet, Soil
Mare’s Tail media promote further coalescence.
• Pack structure, B
These are forces that occur due to the surface
energy of the media towards the oil droplets. The • Interfacial surface tension, γ
droplets are attracted to and encapsulate the • Production time, t
fibre media surface. Drag, gravity and kinetic
energy of the oil droplet entering the Mare’s Tail Expressed mathematically, the coalescence
system act on the big droplets i.e. droplets that efficiency of the Mare’s Tail is given as:
have already coated the media, and break their
⎡q , D , D , ρ ⎤
fluid , μ fluid , Q , ⎥
boundary layer to form a bigger droplet. The
force due to gravity helps in increasing the ⎢ s c
residence time of the droplet, and the drag and η c = f ⎢ L s , φ , d i , C o , ρ pp , Δ P , ⎥
kinetic energy helps the droplet to collide with ⎢ ⎥
media surface. Thus as the produced water ⎢⎣ S pp , S oil , B , γ , t ⎥⎦
travels along the oleophilic fibres, small oil ….2
droplets are attracted to the surface and ηc = Coalescence Efficiency of Mare’s Tail
coalesce with other droplets as they migrate A correlation between the coalescence efficiency
towards the outlet. The direction of flow along and the average coalesced oil droplet size will
the fibres, rather than across it means that any subsequently be established as part of the
solids are passed through the Mare’s Tail rather project objectives.
than building up within the media.
The coalescence efficiency model for the Mare’s
Tail can be derived as:
7 The Mare’s Tail – The Answer to a Cost Effective Water Management in Deepwater Environment? SPE 128609

⎛ D a ⎡(D − D ) ⎤ b ⎞ Effect of Spool Length and Diameter

⎜⎡ c ⎤ s c ⎟ [Figures 9 to 13]
⎜⎢ L ⎥ * ⎢ D ⎥ ⎟
⎜⎣ ⎦ ⎣ c ⎦ ⎟ The coalescence efficiency appears to increase
⎜ c ⎟ with increase in length in a power law
⎜ ⎡ φ ⎤ ⎟ relationship the magnitude of which is inversely
⎜* ⎢ ⎥ ⎟
⎜ ⎣⎢ s pp
L * S * (1 − φ) * B ⎦⎥ ⎟ proportional to the spool diameter [Figure 9].
⎜ d e
⎟ The smaller the diameter the higher the efficiency
⎜ ⎡ C ⎤ ⎡S ⎤ ⎡ ΔP * D ⎤ f ⎟ ….3 as depicted by the 2’’ and 4’’ spools relative to
o oil c ⎟
ηc = K * ⎜* ⎢1 − ⎥ *⎢ ⎥ *⎢ ⎥
⎜ ⎢⎣ ρpp ⎥⎦ ⎢⎣Spp ⎥⎦ ⎣ γ ⎦ ⎟ the 6’’ spool [Figure 11]. Overall the efficiency
⎜ ⎟ plateaus at some critical lengths as illustrated by
⎜ ⎡ ρ ⎤
g h ⎟ the Efficiency versus Dc/L relationships [See
⎛ ⎞
⎜* ⎢⎜ pp − 1⎟ * pp ⎥ * ⎡ Dc ⎤
D ⎟
⎜ ⎢⎜ ρ ⎟ ⎢ ⎥ ⎟ Figures 12 and 13].
⎜ ⎣⎝ fluid ⎠
D c ⎥⎦ ⎣ i⎦
d
⎟ These results substantially validate the initial
⎜ i j ⎟ findings from the JIP studies [See Figure 7]
⎜ ⎡ Dc * μfluid⎤ ⎡ Q ⎤ ⎟
⎜* ⎢ ⎥ *⎢ ⎥ ⎟
⎜ ⎣ ρfluid * q ⎦ ⎣q * t ⎦ ⎟ Effect of Oil droplet Viscosity and
⎝ ⎠
Concentration
K, a, b, c, d, e, f, g, h, I, j are empirical constants Detailed comparative analysis carried out on light
which have been evaluated from experimental and heavy crude oil with viscosities of 3cp and
test data. 250cp respectively confirms that the Mare’s Tail
performs better in the presence of heavy oil
droplets with the coalescence efficiency
Results and Discussions
increasing with increase in viscosity [Figure 13].
This same trend of increase is also prevalent
Highlights of the JIP Studies 6, 7
when reviewing the effect of oil droplet
Highlights of results from the JIP studies are
concentration [Figure 14]. A possible exception
presented in Figures 6-7.
would be oil-water emulsion [which is usually
more viscous than its equivalent individual
Highlights of Model Predictions
phases] the analysis of which will be carried out
The selected experimental data generated from
as part of planned further experimental studies.
the JIP studies were compiled to set up a
development database and test database. The
development database was used to derive the
empirical constants which were subsequently Future Work
tested. The model prediction showed a basic
accuracy level of 90% with a regression Future work will focus on but not limited to the
coefficient of 57%. following:
• Further experimental validation of the MT
The preliminary studies to date based on the performance
analysis of both the original JIP data and ongoing • Comparative analysis of the efficiency of
model predictions have confirmed that the major woven fibres versus MT mop
parameters affecting the Mare’s Tail coalescence • Condensate and heavy oil separation
efficiency are: analysis
• CFD analysis of the different flow
1. Produced Water Flow rate, q[ Figure 8] phenomena including the entry and exit
2. Mare’s Tail Length , Ls[ Figure 9] effects.
3. Mare’s Tail Spool/Cartridge Diameter, Ds, • Finite Element Analysis of the stress
Dc [ Figure10] mechanics as a precursor towards
4. The Cartridge Diameter to Length ratio, evaluating the potential of the MT for
Dc/Ls [ Figure 11] subsea processing.
5. The Oil droplet concentration, Co [ Figure
13] The Opus Plus Test Facility
6. The Oil droplet viscosity, μoil [ Figure 14] The test facility at Opus Plus Limited was
originally opened in 1988 to support the
Effect of Flow Rate [Figure 8] development and testing of full scale offshore
The Mare’s Tail model prediction indicates that water treatment equipment. Initially known as the
the coalescence efficiency is hyperbolically Orkney Water Test Centre (OWTC), the
proportional to the produced water flow rate company is established as an internationally
which is possibly enhanced by the prevailing recognised facility specialising in effluent
turbulent flow regime in the spool. treatment and water handling.

A wide range of industry projects has been

conducted since the centre’s opening covering
8 M.B. Oyeneyin, G. McLellan, B. Vijayakumar, M. Hussain, R. Bichan and N. Weir SPE 128609

numerous onshore and offshore effluent 5.Preliminary testing of the Mare’s Tail
treatments and separation technologies. Work Coalescence efficiency model shows good
has been carried out for oil and gas operators, agreement with the preceding JIP experimental
equipment vendors, research sponsors as well data.
as consortiums of companies on a Joint Industry 6.Analysis carried out to date, has confirmed that
Project basis. the Mare’s Tail Coalescence Efficiency is
The unique facility provides an extension to substantially affected by flow rate, flow regime,
Operators and suppliers resource for validation spool length to diameter ratio, oil droplet
and R&D, with the following capabilities: concentration and viscosity.
7.This new model will form the foundation of the
nd
• Testing at actual or near field conditions to 2 Generation Mare’s Tail development as part
provide high confidence levels. of the KTP project study.
• Safe, trouble free discharge of effluent from
testing, allowing once through flow, Nomenclature
• Maintaining consistent operating parameters.
• The opportunity to verify performance and B = Cartridge Fibre Pack Structure
operating envelopes. Co = Inlet oil Concentration, mg/lt
• A cost effective way of gaining comparative di = Inlet oil diameter, m
data on available technologies prior Dc = Cartridge diameter, m
• On site heavy and medium crude oil ensures Ds = Spool diameter, m
valid operating conditions Ls = Spool Length, m
• Confidentiality and security in results ΔP = Spool Pressure Drop, N/m2
demanded by the Oil and Gas industry. q = Flow rate, m3/hr
• Expertise of the Opus team provides a Q = Cumulative Production, m3
versatile service for performance validation, Soil = Specific surface area of the oil droplet,
product research or product development. m-1
• Extensive support facilities including Spp = Specific surface area of the media
analytical laboratories and equipment, t = Production time, hr
fabrication workshop and mechanical μfluid = Produced water viscosity, Ns/m2
handling ρfluid = Produced water density, kg/m3
ρpp = Polypropylene fibre density, kg/m3
φ = Cartridge porosity
Conclusions γ = Interfacial tension, mN/m
ηc = Coalescence Efficiency
1.The development and especially the field
application of the Mare’s Tail for de-oiling Acknowledgement
produced water have confirmed that the Mare’s
The authors wish to express their sincere
Tail has a highly competitive advantage over
appreciation to the management of the sponsors
other conventional produced water management
of the Mare’s Tail project, Opus Plus Ltd and
technologies in delivering greatly improved
KTP-TSB UK, for their financial support and
quality of produced water without the use of
permission to publish this paper.
chemical.
2.The Mare’s Tail which operates on
coalescence principle is the original product of a References
st
joint industry project initiated in 1998. The 1 1. International Energy Agency: World Energy
generation of the Mare’s Tail is now being utilised Outlook ISBN No. 978-92-64-04560-6, Paris,
in different parts of the world. 2008
3.To improve its performance further especially
with respect to achieving a design optimisation 2. Penwell Corporation: World’s Proved
that is fit-for-purpose and real-time process Reserves of oil and natural gas, Oil & Gas
optimisation onsite a new support semi-empirical Journal, v.106.48, Dec. 2008
model which can be used in real-time has been 3. www.ospar.com
developed, tested and in the process of being 4. Hayes, Tom and Dan Arthur: ‘’Overview of
validated as part of the collaborative programme emerging produced water treatment
between The Robert Gordon University and technologies’’, Paper presented at the 11th
Opus Plus under the Knowledge Transfer Annual International Environmental Conference,
Partnership in the UK. Albuquerque, Oct. 12-15, 2004.
4.The new model can be used to evaluate the
coalescence efficiency of the Mare’s Tail under 5. Franklewicz, Ted, Chang-Ming, Lee and Kevin
different operating conditions. Juniel: ‘’ Compact induced Gas Floatation as
an effective water treatment technology on
9 The Mare’s Tail – The Answer to a Cost Effective Water Management in Deepwater Environment? SPE 128609
deepwater platforms’’, OTC Paper No. 17612,
2005. 60

6. Environmental Resource Ltd: Droplet growth

systems for improved oil-water separation, JIP
Project Report No. ERT F98/259, February 50

2000.
7.Opus Plus Ltd; MT Project Development

Efficiency, %
Reports, 2005. 40

8. Jingquan Li, Yongan Gu : ‘’Coalescence of oil- 4" Schedule 10

4" Schedule 40

in-water emulsions in fibrous and granular 30

2" Schedule 10

beds’’, Separation and Purification

Technology, 42, [1], pp1-13, March,2005.
20
0 0.2 0.4 0.6 0.8 1 1.2 1.4
q (m3/hr)

100
Figure 8: Effect of Flow rate on Mare’s Tail
90 Coalescence Efficiency
80

100
70

Inlet1109 90
60 Outlet1109
C u m . W eig h t, %

Inlet1117
Outlet1117 80
50

70
40

60
E ffic ie n c y , %
30

50
20

10 40
Schedule 10

0 30 Schedule 80
0.1 1 10 100
Oil Droplet Size, microns 20

10

Figure 6: Mare’s Tail Oil droplet size

0
distribution at inlet and outlet - Result of JIP 0.5 1 1.5 2 2.5 3 3.5

Studies 6, 7 Mare's Tail Length, m

Figure 9: Effect of Spool length and Schedule

on Coalescence Efficiency [2’’ Spool]
Varying Mop Lenght
100

90

80 100

70
Cyclone % Removal

90
60 No Tail
3T 500 ppm 80
50
3T 250 ppm
40 70
4.5T 500 ppm
30 4.5T 250 ppm
60
E ffic ie n c y , %

20
50 2'' Spool
10
4'' Spool
6'' Spool
0 40
0.9 1.3 1.6 2.0
30

20

Figure 7: Effect of Mare’s Tail Length on 10

Coalescence Efficiency-Result of JIP Studies6,

7 0
0.5 1 1.5 2 2.5 3 3.5
Mare's Tail Length, m

Figure 10: Effect of Spool length and

Diameter on Coalescence Efficiency
10 M.B. Oyeneyin, G. McLellan, B. Vijayakumar, M. Hussain, R. Bichan and N. Weir SPE 128609

70 90

80
60

70

50
60
SCHEDULE 10

SCHEDULE 40

Efficiency, %
40
Efficiency, %

50
SCHEDULE 80

40
30

30 4" schedule 10
4" Schedule 40
20
2" Schedule 10
20

10
10

0 0
0 20 40 60 80 100 120 140 160
0 0.1 0.2 0.3 0.4 0.5 0.6
Ci (mg/l)
Dc/L

Figure 11: Effect of Dc/L on Coalescence Figure 14: Effect of Oil Droplet Concentration
Efficiency on Coalescence Efficiency

70

60

50

40
E ffic ie n c y , %

30

20
SCHEDULE 10
SCHEDULE 40

10 SCHEDULE 80

0
0 20 40 60 80 100 120
L/Dc

Figure 12: Coalescence Efficiency versus Figure 15: Opus Test Facility
L/DC

100

90

80

70

60
E ff ic ie n c y , %

50

40

Viscosity = 250cp
30
Viscosity = 3cp

20

10

0
0 0.5 1 1.5 2 2.5 3 3.5
Length, m

Figure 13: Effect of Viscosity on Coalescence

Efficiency
 11 The Mare’s Tail – The Answer to a Cost Effective Water Management in Deepwater Environment? SPE 128609

Figure 16: Schematic of Opus Test Facility