Draft

Dewatering Manual

Alan Gilmour

Senior Technical Advisor

Drilling Waste Management

Dewatering Manual v 1.0 1

 Table of Contents
Page
1. Introduction 9
1.1 Wastewater Treatment 9
1.2 Water Re-use, Pollution Prevention and Waste Minimization 9
1.3 Dewatering 10
1.4 Dewatering Applications 11
1.5 Dewatering and Drilling Operations 12
1.6 Optimal Use of Dewatering Systems 13
1.7 Water treatment 14
1.8 Pre-job Planning 14
1.9 Dewatering procedures 15
1.9.1 Pilot Testing 15
1.9.2 Complete Removal of Turbidity 16
1.9.3 Removal of Oil 16
1.9.4 Process Rates 16

2. Stability of Colloidal Fluids 19

2.1 Colloids 19
2.2 Particle Charge 20
2.2.1 Partial Solubility 20
2.2.2 Adsorption of Dissolved Ionic Species 21
2.3 Electrical Repulsion of Colloidal Particles 22
2.4 Zeta Potential 23
2.5 The Tendency of Colloids to Agglomerate or Remain as Discrete Particles 24
2.6 Van der Waals Attractive Forces 25
2.7 Coagulation and Flocculation of Colloidal Particles 25
2.7.1 Double Layer Compression 25
2.7.2 Charge neutralization 26
2.7.3 Bridging 26
2.7.4 Colloid Entrapment 26
3. Coagulation of Colloidal Particles 29
3.1 Common Coagulants 29
3.1.1 Inorganic metal Salts 29
3.1.2 Al+3 and Fe+3 Hydrolyzing Metal Salts 33
3.1.3 The Effect of Concentration of Hydrolyzing Salts 35
3.1.4 Coagulation Reactions and Alkalinity 36
3.1.5 Polynuclear Species 36
3.1.6 Polyaluminum Chloride 38
3.1.7 Advantages and Disadvantages of Inorganic Coagulants 38
3.1 3.2 Action of Hydrolyzing Metal Coagulants 39
3.2.1 Phase 1. Very Low Coagulant Dose 39
3.2.2 Phase 2. Dosage Sufficient for Charge Neutralization 39
3.2.3 Phase 3. Additions above the Electrostatic neutral Point 39
3.2.4 Phase 4. High Excess Concentration. 40
3.2 3.3 Charge Neutralization versus Enmeshment with Hydrolyzing Metal Salts 41
3.3 3.4 Polymeric Coagulants 42
3.4.1 Epi-DMA 42
3.4.2 PolyDADMAC 43
3.4.3 Advantages of Polymeric Coagulants 43
3.4.4 Disadvantages OF Polymeric Coagulants 44
3.4 3.5 Factors Influencing Coagulation 44
3.5.1 Drilling Fluid Type 44
3.5.2 Dilution 45

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 3.5.3 pH 45
3.5.4 Salts 45
3.5.5 Concentration of Colloidal particles 45
3.5.6 Water Temperature 45
3.5.7 Mixing Effects 45
3.5.8 Choice of Coagulant 46

4. Flocculation of Colloidal Particles 49

4.1 Synthetic Bridging Polymers 49
4.2 The Mechanism of Flocculation 50
4.2.1 Adsorption of Polymer Flocculant onto Colloidal particles 51
4.2.2 The Formation of Aggregates 52
4.3 Factors Influencing Flocculation 53
4.3.1 Polymer Dosage 53
4.3.2 pH 53
4.3.3 Salts 53
4.3.4 Concentration of Colloidal Particles 53
4.3.5 Particle Size 53
4.3.6 Molecular Weight 53
4.3.7 Mixing or Shear Effects 54
4.3.8 Location of Polymer Addition Point 54
4.4 Characterizing Polymers 54
4.4.1 Molecular Weight 54
4.4.2 Structure 55
4.4.3 Charge density 55
4.4.4 Charge Type of Polymer 55
4.5 Flocculation of Oil-Based Drilling Fluids 56
4.5.1 Oil-Based Drilling Fluids 56
4.5.2 Mechanism of Flocculation in Oil-Based Drilling Fluids 57
4.5.3 The Use of Surfactants to Improve Flocculation of Oil-Based or Synthetic Fluids 58

5. Removal of the Flocculated Solids using Decanting Centrifuges 61

5.1 Centrifuge Performance Factors 62
5.1.1 G-Force 62
5.1.2 Viscosity 63
5.1.3 Cake Dryness 63
5.1.4 Pond Depth and Processing Capacity 63
5.1.5 Bowl-Conveyor Differential RPM and Torque 64
5.2 Centrifuging Unweighted Drilling Fluids 65
5.3 Centrifuging Hydrocyclone Underflow 65
5.4 Centrifuging Weighted Muds 66
5.5 Two-Stage Centrifuging 66
5.6 Treatment of recovered Centrate Fluid 67
5.6.1 Compatibility Requirements of the Recycled Fluids 67

6. Dewatering Systems 71
6.1 Dewatering System Set Up 71
6.2 The Mixing System 72
6.3 Polymer Packaging and Application 74
6.3.1 Dry Polymer Powders 74
6.3.2 Liquid Polymers 75
6.3.3 Emulsion Polymers 75
6.3.4 Emulsion Polymers and flocculation of Oil-based or Synthetic Drilling Fluids 77
6.3.5 Mannich Polymers 78
6.4 The Delivery System 79
6.4.2 Progressive Cavity Pumps 79
6.4.3 Flocculant Addition Points 80

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 6.5 The Separation Equipment 81
6.5.1 Physical Properties of the Flocked Solids 81
6.5.2 Centrifuge Geometry 82
6.5.3 Bowl Speed 82
6.5.4 Conveyor Speed 82
6.5.5 Pool Depth 82
6.5.6 Feed Rate 83
6.5.7 Polymers 83
6.6 Dewatering Layouts 84
7 Economics of Dewatering 93
7.1 Establishing Cost Comparisons for Dewatering versus Normal Practices 94
7.2 The Waste Management Plan 95
7.3 Monitoring Dewatering Costs and Efficiency 96
8 Water Treatment 101
8.1 Introduction 101
8.2 The Water Treatment Process 102
8.3 Flocculation and Chemical Precipitation 102
8.3.1 Metals Removal 103
8.3.2 Heavy Metal Hydroxide Precipitation 105
8.3.3 Sulfide Precipitation 109
8.3.4 Carbonate Precipitation 112
8.3.5 Metals Removal with Ferric Chloride 113
8.4 Removal of Fats, Oils and Greases 114
8.5 Phosphorus Removal 114
8.6 Nominal Organic Material Removal 115
8.6.1 Biological Oxygen Demand 116
8.6.2 Chemical Oxygen Demand 116
8.7 Nutrients 117
8.8 Water Treatment Systems 117
8.8.1 The Three Pits/Tanks System 119
8.8.2 The First Flush System 121
8.8.3 Fluids Handling Recommendations 122
8.9 Laboratory Equipment and Testing procedures 122
8.10 Sampling Methods 123
8.11 Alternative Systems 124
8.11.1 Water treatment Plants 124
8.11.2 Purtification (or Depuration) Plant 124
8.11.3 Water Treatment Tank 127
8.11.4 Enhanced Offshore Water Treatment System 129

9 Dewatering Procedures 133

9.1 Selecting the Most Efficient Polymer 133
9.1.1 Summary of the Dewatering process 133
9.1.2 Coagulation 134
9.1.3 Flocculation 136
9.1.4 Factors Effecting Coagulation and Flocculation 137
9.2 Pilot testing Procedures 138
9.3 The Jar Test 138
9.4 Equipment and Laboratory Space 140
9.5 Testing in the Laboratory 141
9.5.1 Preparation 141
9.5.2 Dilute the Test Fluid 141
9.5.3 Choice of Working Solution Concentrations 141
9.5.4 Determine the Optimum Coagulant Dose 142

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 9.5.5 Determine the Optimum Flocculant Polymer Dose 142
9.5.6 Fine Tuning the Optimum Doses and Dilution Requirement 143
9.6 Field testing 143
9.7 Field testing –The“ Qu ickandDir
ty”
,“Bu
cke
tCh
emi
st
ry”Me
thod 144
9.8 Standard Field Test Procedures 145
9.8.1 Step 1: Dilution of Mud Sample 145
9.8.2 Step 2: Choice of Working Solution Concentration 145
9.8.3 Step 3; Determine if pH Adjustment is Necessary 145
9.8.4 Step 4: pH Adjustment 146
9.8.5 Step 5: Flocculation of pH Adjusted Drilling Fluid Sample 146
9.8.6 Step 6: Flocculation of Mud Sample Requiring Coagulation 146
9.9 Preparation of Coagulant and Flocculant Stock Solutions 147
9.9.1 Recommended Pilot Testing Equipment Required 147
9.9.2 Preparation of Inorganic Coagulants 147
9.9.3 Preparation of Powder Polymer 148
9.9.4 Preparation of High Molecular Weight Liquid Solution and Emulsion Polymers 149
9.10Pilot test Example` 151
9.11Field Preparation of Polymer Solution Tanks with Solid Grade Polymers 152
9.11.1 Determine the Number of Usable Gallons in the Polymer Mixing Tank 152
9.11.2 Determine how many lbs of Water is in the Tank 152
9.11.3 Determine Polymer Dosage to Add a 1% by Weight Solution 152
9.11.4 Tank Preparation 152
9.12 Field Preparation of Polymer Solution tanks with Liquid Grade Polymers 152
9.13 Application Rate of Polymers 153
9.14 Guide for Dewatering Spreadsheet 154
9.15 Laboratory procedures for Oil-Based or Synthetic Drilling Fluids 156
9.15.1 Required Equipment 156
9.15.2 Laboratory procedure 156

10 Coagulants and Flocculants 161

10.1Inorganic Coagulants 161
10.2Cross Reference : Cationic Polymeric Coagulants 162
10.2.1 Polyamines 162
10.2.2 PolyDADMACs 162
10.2.3 Resin Amines 162
10.3 Cross reference ; Cationic Polymeric Flocculants 163
10.3.1 Cationic Solid Grade Flocculants 163
10.3.2 Cationic Liquid Dispersion/Emulsion Flocculants 163
10.4 Cross reference ; Non-ionic/Anionic Polymeric Flocculants 164
10.4.1 Non-ionic/Anionic Solid Grade Flocculants 164
10.4.2 Non-ionic/Anionic Liquid Dispersion/Emulsion Flocculants 164

11 Guidelines for Dewatering treatment of Drilling Fluids 167

10.1 Drilling Fluid System Treatments 168
10.2 Cross Reference Chart 170
12 Field Applications 175
12.1 Closed Loop Systems and Reserve Pit Minimization 177
12.2 Dry Location Survey, Agip Monte Enoc, Italy 183
12.3 Dry Location Report, OMV Austria 193
12.4 Dewatering Recommendations, Berkin Basin, Algeria 199
12.5 Dewatering and Water Treatment Procedures, Dorood Project, Kharg Island 209
12.6 Performance Report: Water treatment Features and Benefits 227
12.7 Floc Water Drilling (Utilizing a Sump) 233
12.7.1 Utilizing a Sump 235
12.7.2 Closed System, No Sump 236

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13 Appendices

Appendix 1: Testing Equipment and Equipment Specific Tests

Appendix 1.1 OFI Testing Equipment
App 1.1.1 Pol yPr e p“N”Fl ocTe stKi t
App.1.1.2 Water Analysis Kit in Stainless Steel Case
Appendix 1.2: Hach Colorimeters and Portable Laboratory Equipment
Appendix 1.3; Hach Colorimeter Chemical Analysis Procedures
Appendix 1.4: Jar Test Equipment

Appendix 2: Equipment Manuals

Appendix 2.1 Midcofloc 15, Installation and Field Service Manual
Appendix 2.2 Dewatering Unit DWU 18 (1), Installation and Field Service Manual
Appendix 2.3 MV Dewatering Unit: Installation Manual
Appendix 2.4 Offshore Envirounit
Appendix 2.5 RECLAIM Technology and Operations Manual
Appendix 2.6 Winterized Dewatering Unit

Appendix 3: Dewatering Pre-Planning Survey

14 References

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