Pengolahan Air (TK-3231)

Pengolahan Air Terproduksi (Produced

Water)

What is Produced Water?

Produced water is water trapped in underground formations that is
brought to the surface during oil and gas exploration and
production.
Three-phase separator / Knock-out drum
Gas

Water
Up to 80 90%

Oil

GasOil Separation
Oil and Gas Wells
Field processing
of natural gas
- Compression
- Sulfur recovery
- Sweetening
- Dehydration
- Fractionation
- Recovery of NGL

Separation
of Fluid
Water
Water Processing
- Oil/water
separation
- Treatment
- Utilization

Crude oil
processing
Desalting
Sweetening
Dehydration
Stabilization

Clasification of PW based on the source

Natural Gas Produced Water
Oilfield Produced Water
Coalbed methane (CBM) produced water

Global onshore and offshore water production

Note: 1 US bbl oil= 158,9873 Liters

http://prosep.com/

Chemical Composition of Produced Water

Salinity and Inorganic Ions
Total Organic Carbon
Organic Acids
Petroleum Hydrocarbons
(BTEX, Polycyclic Aromatic Hydrocarbons (PAHs),
Phenols)
Heavy metals and radioactive (Toxic)
Production Chemicals (from chemical treatment)
Corrosion inhibitor, Biocide, Gas treatment
chemicals

Salinity and Inorganic Ions

Concentration ratios of
many of these ions are
different in seawater and
produced water, possibly
contributing to the aquatic
toxicity of produced water

Total Organic Carbon

BTEX
BTEX may be present in
untreated produced
water from different
sources at
concentrations as high
as 600 mg/L

Treatment trends

Electrocoagulation
TSS

Oil & Grease

Sock Filter

Metals (Ba,
Sr)

Chemical Precipitation
(Sodium-Sulfate, Lime,
etc.)

Clarifier

Ozone

Dissolved Air Floatation

Electrocoagulation

Induced Air Floatation

Hardness

Lime and soda ash

Iron (Fe)

Precipitation with NaOH

Sulfate

Precipitation with
BaChloride
Membrane
(Nanofiltration)

Walnut Filter
Chlorine disinfection
Bacteria

UV disinfection
Ozone disinfection

Produced Water Management

Injection into oil wells

Direct discharge

Reuse in oil and gas operation

Consumed in beneficial use (irrigation, Managed

wetlands)

Conventional Treatment Methods for Disposal Purpose

gravitational
separation and
skimming
dissolved air
floatation
de-emulsification
coagulation and
flocculation

Produced Water Treating Equipment

Solids Separation
Wellhead Solids/Liquid Hydrocyclone
Primary Produced Water
Separation
Corrugated Plate Separators (CPS)
API Separators
Solid/Liquid Hydrocyclone
Liquid/Liquid Hydrocyclone
Secondary Produced Water
Separation
Induced Gas Flotation Separators
Dissolved Gas Flotation Separators

Tertiary Produced Water

Separation
Walnut Shell Filters
Media Filters
Cartridge Filters
Activated Carbon Filters
Advanced Treatment
Biological Treatment
Membranes
Solids Handling
Gravity Thickeners
Filter Press
Belt Filter Press

duced Water Treating Equipment

Oil/Water Separator

API oilwater separator

Dissolved Air Flotation (DAF)

Wastewater is fed into a DAF system and hit
with a stream of whitewater, which is
recirculated clarified water from the DAF thats
super saturated with dissolved air. As these two
mixtures blend together, microscopic bubbles
attach to solid particulates, giving them
enough buoyancy to surface in the DAF tank.
As solids accumulate in a floating layer on the
top of the DAF tank, a skimmer gently nudges
the sludge toward a discharge hopper.
Any solids that dont float will sink to the V
bottom of the DAF tank. Settled solids are
concentrated and discharged by an
automatically controlled pneumatic drain valve.
The clarified water flows out via an under-over
weir on either side of the DAF unit. Some of this
water is used in the recirculation loop while the
rest flows out of the vessel.

Produced Water Treatment For Injection/Reinjection

General purposes:
Oil & grease removal
Suspended solids removal
Organics removal
Controlling microbial growth
Controlling corrosion rate
Controlling oxygen concentration
REINJECTION:
Suitability of produced water with formation
Presence of particulate formation clogging, equipment damage, heat insulation
Controlled excess supended solids, dissolved oil, corrosion, chemical reaction,
microbial growth removal of oil & grease, suspended solid, organic

Quality Standard for Re-injection Purposes

Parameter
Oil content(mg/L)
SS conc. (mg/L)
Medium diameter (m)
Total Fe (mg/L)
Sulfide
SBR (n/ml)
TGB (n/ml)
IB (n/ml)
pH

Re-injection
Standard
<0.1
<0.1
<0.5
<0.5
<0.05
0
<102
<102
6-9

Water Injection/Reinjection Process Map (SIEMENS)

Produced Water Treating Equipment

Coarse Screening
Back Flushing Strainers
Traveling Water Screens

Fine Solids
Separation/Filtration
Media Filters
Gravity Clarifiers
Solids Contact Clarifiers
Absorption Clarifiers
Microfiltration Filters

Deaeration

Vacuum Dearators
Degasifiers

Sulfate Removal
Sulfate Removal Systems

Softening Systems
Brine Softeners
Weak Acid Cation Softeners

Solids Handling
Gravity Thickeners
Filter Press
Belt Filter Press
Centrifuges

Chemical Feed Systems

Chemical Feed Systems

Chlorine Generation/Feed
Systems
Electro-Chlorination Systems

Steam Assisted Gravity Drainage (SAGD)

Produced Water Treatment for Process Water

Produced Water Treatment for Process Water

Dissolved Solids Removal
Hot and cold softeners
Demineralization
Continuous Deionization
Reverse Osmosis
Suspended Solids Removal Condensate Polishers
Solids Contact Clarifiers
Dissolved Gas Removal
Absorption Clarifiers
Degasifiers
Circular and Rectangular Gravity
Deaerators
Clarifiers
Solids Handling
Gravity Filters
Belt Filter Press
Pressure Filters
Filter Press
Microfiltration
Gravity Thickener
Screening/Grit Removal
Bar Screens
Trash Rakes
Traveling Water Screens

Chibunna Onyems Igwe, 2013

Filtration Technology
Catridge filter
Membrane filter
Media filter Walnut filter
Cartridge filter :
Non- backwash able
Routine replacement, high cost
Complex maintenance
Membrane filter :
Backwashable
High selectivity, particle removal up to 0,01 m
Continuous operation
Walnut filter :
Backwashable
Lower selectivity compare with membrane
Continuous operation

Process Equipment

Separated
particle sizes
(m)

API gravity separator

150

Corrugated plate
separator

40

Induced gas flotation

without chemical adiition

25

Induced gas flotation

with chemical addition

35

Hydrocyclone

10 -15

Mesh coalescer

Media filter

Sentrifuge

Membrane filter

0.01
[Argonne National Laboratory]

Power Clean ORF- Walnut Shell oil removal filter

Power CleanNutshell
filters adalah hak paten
teknologi dari
Perusahaan Veolia
Water.
Power CleanNutshell
filters sangat ampuh
untuk memisahkan
padatan tersuspensi
dan kandungan
hidrokarbon dari
produced water.

Power Clean ORF- Walnut Shell oil removal filter

Prinsip kerjanya adalah
menggunakan proses fluidisasi
yang dengan mudah dapat
memisahkan kontaminan dan
minyak dari media, serta
menggunakan volume air
backwash yang sangat sedikit
tanpa adanya penggunaan
surfaktan.
Keseluruhan proses backwash
dan scrubbing berlangsung
selama 12 menit.

Membrane Technology for Produced Water Treatment

PRODUCED
WATER

REUSE

MBR - RO

DISCHARGE

MBR

RE-INJECTION

UF

State of the art of membrane tech. (1)

Topic

Results

Reference

Oil removal

UF Crossflow: oil conc. in permeate = 15 mg/l, flux = 25 LMH

Farnand & Krug

(1989)

Organic
removal

NF: oil rejection =72 89%, oil conc. in permeate = 48 mg/l.

Dyke & Bartels

(1990)

Oil, grease, and Ceramic MF: dispersed oil & grease conc. in permeate <5 mg/l; Chen, et al. (1991)
suspended solid suspended solid < 1 mg/l
removal
Oil &
UF bench scale: flux 217 321 LMH; recovery 90%
suspended solid
removal

Zaidi, et al. (1991)

Oil &
MF/UF: oil conc. in permeate 10 mg/l, TSS conc.15 26 mg/l; Zaidi, et al. (1992)
suspended solid average flux 1250 LMH.
removal
Produced water
treatment

Crossflow UF: oil & grease conc. in permeate 14 mg/l

Santos (1993)

State of the art of membrane tech. (2)

Topic

Results

Reference

Water
treatment

MF, UF: BTEX reduction 54%, Cu & Zn removal: 95%

Bilstad & Espedal

(1996)

Water
treatment
(model
solution)

MF (ceramic, PAN): hydrocarbon conc. in permeate < 6 ppm. Fouling layer Mueller, et al.
was affacted by membrane material and morphology
(1997)

Water
treatment

UF bench scale: produce permeate with high quality (meets regulation Santos & Weisner
standard); flux were affected by varied feed
(1997)

Water
treatment for
irrigation
purposes or
discharge

Hybrid RO-constructed wet land; reduce conductivity up to 95% & TDS Murray-Gulde, et
94%
al, (2003)

State of the art of membrane tech. (3)

Topic

Results

Reference

Salt removal

ED: TDS removal increased linearly with increased voltage

Water treatment

UF, NF, RO: system recovery more than 80% (UF concentrate Osmonics [Arthur
recycle konsentrat UF and utilization of RO concentrate)
(2005)]

Oil and
suspended solid
removal

Sirivedhin, et al.
(2004)

RO

Arthur (2005)

MF, RO

Newpark [Arthur
(2005)]

UF: turbidity removal 95.75 99.87 %; oil removal 47.32 Beech (2006)
94.31% by using three different membrane material. The best
performance was PVDF membrane with MWCO of 30.000 and
operating pressure 10-150 psi (oil in permeate < 10 ppm)

Salt Removal and Recovery in Water

Fouling in membrane
Produced water:
Prevention of
membrane
fouling by waxes
and asphaltenes
Oil emulsion
adsorption, cake
layer

Membrane Cleaning
Removal of foreign material from the surface and body of the
membrane and associated equipment
Cleaning frequency economics, membrane lifetime
Clean membrane [Cheryan (1998)]:
Physically Chemically Biologically clean membrane
Flux recovery to initial flux of a new membrane after cleaning
can be used as indication of clean membrane
Cleaning methods:
hydraulic cleaning,
Module configuration
mechanical cleaning,
Membranes type
chemical cleaning,
Chemical resistance
Type of foulant
electrical cleaning

Membrane Cleaning
Chemicals used for cleaning:
Acids: dissolving calcium salts and metal oxides
Alkalis: removing silica, inorganic colloids and
many biological/organic foulants,
Surfactants: displacing foulants, emulsifying
oils, dissolving hydrophobic foulants,
Oxidants: oxidizing organic material and
bacteria (disinfection),
Sequestrates (chelating agents): removing
metal cations from a solution,
Enzymes: degrading foulants.
Alkaline-acidic-alkaline wash cycle
Micellar solution

Flux versus time graph for Devecatagi produced water

[Cakmakci, et al., 2008]

Case Study 1: Produced Water Treatment Plant

(Tambun Plant)

Oil & Gas Production

Produced water !

Oil & Gas

Lab. scale to full scale

UF Membrane System

Tambun Plant, Bekasi, Indonesia

Case Study 1: Produced Water Treatment Plant

(Tambun Plant)

Lab. Scale Apparatus

Pilot Scale UF Membrane System

Product
Flux and Rejection Performance

Feed

Case Study 1: Produced Water Treatment Plant

(Tambun Plant)

Current production capacity: 1.5 MLD of produced water

Process units:
Oil catcher
Skim tank
CPI
Automatic screen filter
UF system
De-aerator

The UF facility has been operational since 2008

The effluent meets reinjection requirement

Full-scale system

Methane Produced Water with a Pall

Integrated Membrane System at Origin
Energy, cont.
Provide almost 90% of the total gas market in
Coal Seam Methane

Quensland, Australia

Water must be pumped from the coal

seams to reduce the pressure & allow
the large volumes of gas to flow

Produced water !

Gas

Origin Energy & Pall Corporation

The Spring Gully Gas Plant, Central Queensland

Integrated Membrane System (IMS): MF/RO

[Pall Corporation , 2008]

Methane Produced Water with a Pall

Integrated Membrane System at Origin
Energy, cont.
An IMS consist of:
4 MF racks, each
containing 56 x 0.1
micron Microza modules
1 RO system
Pre-strainer
Chemical dosing &
compressed air systems
Interconnecting pipe
work
Motor control centers

Produced Water
with a Pall Integrated Membrane System at Origin
Energy, cont.
Current production capacity: 9 MLD of
CSM produced water, and the IMS can be
expanded to support up to 15 MLD
Process units:
- Prestrainer
- MF system
- RO systems
- Chemical cleaning and flushing systems
- Chemical dosing systems
- Compressed air systems
- Motor control centers
- Interconnecting pipework

Key advantage to the Pall IMS

system:
adaptability of RO systems to
variations in feedwater
(periodic alga blooms)
minimum power requirements
through use of an inter-stage
boosting capability that
balance flux
High degree of instrumentation
to enable ongoing remote
monitoring and full automatic
sequencing of all processes

The IMS facility has been operational since December 2007

The effluent meets discharge limits prescribed by the Queensland EPA

COMPARISON of PRODUCED WATER

TREATMENT PLANT
The Spring Gully Gas
Plant

The Tambun Plant

Source of
Coal seam methane
produced water production

Oil and gas production

Capacity

9-15 MLD

1.5 MLD

System

MF/RO

UF

Treatment
objective

Discharge

Reinjection

Operated since

December 2007

Oct. 2007

CASE STUDY 3: WTP MEMBRANE BASED WIP

CAPACITY 50.000 BPD
Gravity separation Skimmer Tanks
Plate coalescence CPI Separator
Gas flotation Dissolved Air Flotation (DAF)
Filtration
Media filter (multi media: antrachite dan garnet )
Membrane filter
Deaeration Vacuum Deaerator
Solid Handling Coagulation/Flocculation-Dewatering-Incinerator
Chemical Feed System Coagulany/flocculant, biocide, ph adjusment, oxygen
scavenger

CASE STUDY : WTP MEMBRANE BASED WIP

CAPACITY 50.000 BPD