Treatment of Crude Oil-Brine Emulsions with Ceramic Membranes

Rubinstein Technical Corporation
Industrial Water Consulting

Ian Rubinstein Ph.D. P.Chem.

PO Box 1382,

Station M,

Calgary,

Alberta T2P 2L6, E-mail:

Canada

Phone/Fax: (403) 281-8259

rubinsti@telus.net

RTC 21 Jun 2006 1

startup events Minimize maintenance events Minimize chemical stockage and disposal Minimize capital and operating expenses RTC 21 Jun 2006 2 . temperatures Variable levels of oil. solids. shutdown. contaminants Harsh operating environment Upset. pressures.PRODUCED WATER DEOILING CHALLENGES Variable feed rate.

OBJECTIVES Remove solids and oil droplets to <0. stripper or softener Continuous process Mechanically and chemically robust Long life.1μ. expandable concept Lower cost than current processes RTC 21 Jun 2006 3 . low maintenance Modular. 10 mg/L Feed to biox.

OIL SANDS PRODUCED WATER DEOILING Oil Recycle Emulsion 90°C Skim Tank Gas Flotation Coalescer ORF Water CURRENT PROCESS Oil Recycle Emulsion 140°C Membrane Bank Water MEMBRANE PROCESS RTC 21 Jun 2006 4 .

CROSSFLOW MEMBRANE PROCESS Forward Flush CONCENTRATE E L E M E N T S gross PERMEATE net Perm Tank EMULSION FEED Feed Pump Backpulse Pump RTC 21 Jun 2006 5 .

OPERATING ISSUES AND RESPONSES Coalescing of oil droplets in gel layer Turbulent crossflow through feed channels Droplet deformation and squeeze through High shear to create rigid charged oil droplets Droplet and bubble blockage of pores Permeate backpulse Deposition of scales Non-chemical cleaning regimes RTC 21 Jun 2006 6 .

95°C With cleaning regime RTC 21 Jun 2006 7 .FIELD TESTS IN CSS OIL SANDS PLANT First Generation Bench Scale Elements Primary Separator Emulsion 60 Flux (m3/m2. 1.5 metres/sec.day) 50 40 30 20 10 0 0 100 200 300 400 Hours 500 600 700 Feed: 400 KPa.

10% oil in feed Fouling overcome Membrane surface modification. no detectable solids Thermomechanical stability Withstands 100°C temperature. cleaning regimes RTC 21 Jun 2006 8 . 1% sand.PILOT PERFORMANCE SUMMARY Good efficiency Net flux > 10m3/m2.day High quality of treated water < 30 mg/L hydrocarbon spillover (mainly dissolved organics).

POTENTIAL OILY WATER APPLICATIONS Emulsion Free Oil/ Feed Water Separator Oil out UF Bank Chemicals/ Heat Demin/ Soften Plant Processes High Oil Separator Evaporator/ Crystallizer Solids disposal Salt disposal RTC 21 Jun 2006 9 .

High temperature capability .2nd GENERATION CeraMem MEMBRANES .Low-cost. 1500 mm length RTC 21 Jun 2006 10 .Chemically durable. backflushable . abrasion and solventresistant . long life Current: 142 mm diameter.Silicon carbide supports eliminate durability problems of 1st generation .High process flux . 864 mm length Future: Up to 200 mm diameter.Easy cleaning.

Δp 1034 KPa = 15 HP Membranes: 5 Trains of 2 elements (142 mm diam. Δp 276 KPa = 45 HP total Backpulse Pump: 545 m3/d.1000 m3/DAY MEMBRANE SYSTEM Backpulse PERMEATE 987 m3/d 0 KPa FEED 1036 m3/d 0 KPa 49 m3/d 414 KPa CONCENTRATE 1090 m3/d 689 KPa Recycle 5451 m3/d. 864 mm long) per train RTC 21 Jun 2006 11 . Δp 414 KPa = 10 HP Recycle Pumps: 5724 m3/d. 414 KPa Feed Pump: 1090 m3/d.

Filters) CAPEX. Square metres 14.000 Can $0. ISF. Membranes) $22.000 bopd Facility. Total Installed Cost OPEX.949. (Surge Tank.122.000 Can $0.DE-OILING COST COMPARISON 40. SOR = 2.250 RTC 21 Jun 2006 12 .056 Can (power + membrane replacement every 3 years) 6.400 $28.165 Can (power + chemicals) FOOTPRINT. (Skim Tank.5 Conventional Deoiling.000 m3/d Produced Water 100. Per m3 water treated Ceramic Membrane Deoiling.

RESULTS AND CONCLUSIONS Accepts % levels of oil and solids in water Permeate has no visible oil or solids Membrane surface and cleaning regimes tailored for oil sands produced water deoiling Flux maintained above economic target level 18% lower Capex. lifespan. 66% lower Opex than conventional process Next step: Full sized demonstration Evaluate stability. process economics RTC 21 Jun 2006 13 .