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    18 views16 pages

    Water Softener Regeneration

    Uploaded by

    José Helí Vallejos Coronado

    Copyright:

    © All Rights Reserved
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    2) United States Patent (10) Patent No: US 8,663,476 B2 Boodoo (45) Date of Patent: Mar. 4, 2014 (Si) WATER SOFTENER REGENERATION exon me 92m en (75) Imentor: Francs Daodoo,KingofProsa,PA EDOLTSS. AL 128002 Chen (us) 200710199900 AL $2007. Zimmerman (73) Assignee: The Purolite Company, Bala Cynwyd, OTHER PUBLICATIONS PAcus) Downy, Don “High Toa Dislel Salis (TDS) Proved (2) Notice: Sebjettomy dims hemo in YAH Sting Wh iS Shet Thy Ra patent is extended or adjusted under 35 Fanart etal, “Review of Once-Through Steam Generators” Jour U.S.C. 154(b) by 728 days. ‘nal of Petroleum Technology, 1968, vol. 17, No. 4, pp. 409-416." vlc SSTWDL Pot Daa. Skat”) Srp (21) Appl. Nos 12368886 oe Sys tal “Chena Water an Wate Taine Pots eo Sus CHC mesic 2) Fie: eee Downey, Don, Chemical Process Engineering Report, High Total sor Pub Desnbed Sate (TDS Poel Wt Sieg ith ae © Prior Publication Data Stu Sel Testoly Resi Pui Can, 9 aes Us 20100199448 AL Aug 5,210 eee aa ees si) mc, pees. Bois 304 (200601) * city ‘BOLI 3916 (2006.01) hho! Bors avn (200601) Primary Examiner —Keshnan § Menon ‘BOLD 15/04 (2006.01) " ns cnr ia (00801) (14) torn Agent o Firm — Fish & Richardson PC. (2) USC - USS amet: zoca.aieraioasy 6) atsmact: ry eareripee Anew proces for ion exchange sofening of water wed in (59) ik of CicatenSenrch i Rag eea Gone (Sty orcad ss) References ted the cost for commercial regenerants the woud cherie be neded Further the very bigh pry ofthe salt covered US. PATENT DOCUMENTS inite Blowdown heey rsa in the prodactiono sa uray a eoie pana ned water wi hares leakage eves tht ate a ont of 0 . vine ‘magnitude lower than can be attained using commercial sat, SER A+ 41997 Sinn 20310 urredicing sae depot petal andinpeving operating pee ee ae efeieny ately ofthe OTS. estan Bz 122m03 Chen SEB01T BD 102007 Renata 20 Clans, 6 Drawing Shets 7 Aa S oF FX awa | oat wes | Vane] aC | wa potter, LL Lda] ie hos |e Sie 5 é\ ‘ “ne one 2 US. Patent Mar. 4, 2014 Sheet 1 of 6 US 8,663,476 B2 ? ob ment: Oi Hot or eae Produced _| removal, ‘Wa After Polisher Water ——>] Clarification |—>} Lime >| biker High Ds | /Fiter Softener le Blowdown \oe_ [E™ Stam bole Downhole | inecen steam FIG. 1 US. Patent Mar. 4, 2014 Sheet 2 of 6 US 8,663,476 B2 2 J POOF Roa F 3 op 6 F «pe, Pretreat- ‘meat: Oil, Hot or lsimmry Produced —_| removal, ‘Warm RS ISAC wac Waer-—>| Clarificaion |] Lime —] Fier | —>) =e High ts | Filter Softener | 5 52 J 4 | Bat Becager a Once Thea a ‘Steam | Biter = Downhole «af Injection FIG. 2 US. Patent Mar. 4, 2014 Sheet 3 of 6 US 8,663,476 B2 4 4 CO, H,S, oO 12 Aj 7 40 Produced oil After Water >| removal -—») Filter High TDs Degasser 52 Heat Exchanger Blowdown 4 Steam Downhole <—— 46 Injection FIG. 3 US. Patent Mar. 4, 2014 Sheet 4 of 6 US 8,663,476 B2 SACI + 12 Water from 36 Profiler, Oil == ——) % ‘Water to Polisher, Separator, ete * wac, oroTsB SAC2 ste Brine from Wass <—______ + biowdown * x 6 24 FIG. 4 US. Patent Mar.4,2014 Sheet Sof 6 US 8,663,476 B2 é z 2 3 26 6 8 : i =e Ss Brine Concentration % FIG. 5 US. Patent Mar.4,2014 Sheet 6 of 6 US 8,663,476 B2 FIG. 6 US 8,663,476 B2 1 WATER SOFTENER REGENERATION FIELD OF THE INVENTION ‘The present invention relates generally to regeneration of $ atersolieners and mare particularly tsofener regeneration in Steam Assistod Gravity Drainage (SAGD) systems using ‘onoe-thra steam generator (OTSG) boiler Blowdowa, BACKGROUND OF THE INVENTION ‘Steam generation is used in hea ol recovery operations since, in onder to recover heavy oil from some geoloyicl Tocation, steam is neessary to inerease the mobifty ofthe oil before it ean be pumped tothe surface, Oil producersoften 15 use once-tzough (or once-try) steam generators (OTSG), as they are an essential part ofthe Steam Assisted Gravity Drainage (SAGD) processes for enhanced oil recovery of heavy cil deposits, such as from the tar sands region of Alberta, Canada. SAGD processes consist of a par of hori zontal wells drilled into the ol reservoir. Steam is injected imtooneof the wellbore to heat and reduce the viscosity ofthe cil: the oil is then collected in the second wellbore and brought tothe surface. Approximately 3 barrels of water are noeded for every barel of oil produced. 'SAGD processes typically make use of avilable brackish water the cary stages ofthe pect to makesteum, Laterin the process, “produced water” (ie, water obtained from a mixture of ol and water) is used to make steam. The OTSG uses this water aftr proper pretreatment to proce a mixture 30 ‘of seam and water whichis then separate by’ steam-water separator vessels before the stam is injcted downhole into tho oil reserve, OTSGs generally produce steam and waterat a ratio of approximately 80% steam and 20% water. SAGD projects require 100% steam quality for efficient operation so itis important to separate the water fom the steam, ‘OTSGs typically generate steam at presses of §,000 to 15,000 KPs aad therefore require excellent pretreatment of the water to avoid scaling and deposit problems on the heat transfer surfaces. Asa result, feodwater to these boilers must typically have no more 02 ppm total hardness (TH) as CaCO, @ maxizaum of 10 ppen of hydrocarbons, preferably less than 50 ppm of silica and less than 12,000 ppm total «dissolved solids (TDS) Silica ean complex wih alum, ion ‘and other multivalent cations (eg. barium, strontium and sluminum) to form hard enersted deposits on te boiler heat transfer surfaces, thereby reducing heat transfer efficiency ‘and inereasing the potential for rupture and failure of the boiler: The lower the concentration of hardness and other rltivalent cation inthe biler water, the lower the likeli hoo of formation ofthese complex deposits, In SAGD processes, water pretreatment can include, for ‘example, an oil removal proces, hot or warm lime softeners, and one or more jon exchange processes, often operated in series a primary and polisher vessels or as a strong acid ‘cation resin and a weak acid cation resin vessel, Dissolved calcium, magnesium, ion, barium, strontium and aluminum areexchaaged onto the strong acid cation (SAC)rsia with an ‘equivaleat amount of sodium released into the treated water Upon exhaustion (breakthrough of hardness into the treated water, gui brine soution i used to regenerate the SAC resin, Large quantities of salt are generally consumed inthe softeaiagof high TDS water, equiringsmuchas Sbarelsof _watero produce | barrel of el. Therefore operating costs for salt can be substantial, Large amounts of dey salt must be purchased and delivered io remote locations in many cases, Lane facilites for salt storage and brine solution makeup Fa 2 rust be installed and operated. Additionally, labor for ban- Atng ofsatcanbe significant. For example, typical salt usage can range frem 6 10 15 Ibs of salt per 1000 gallons of water softened, depending onthe hardness content of the produced water and the design ofthe softener system. For producing 33,000 barrels of oil per day; itis necessary to solen about 100,000 barelsper day of produce or brackish water, reauir- ing between 20,0000 50,000 pound of salt per day; or about 9,000 tons of salt per year. Atthe same time dschargeof such Tange quantities of spent sat brine represents a substantial burden oa the environment 1s thus desirable to provide ways to minimize the pure chase and use of such large quantities of salt for regeneration While maintaining or even reducing hardness leakage from the softeners. ‘SUMMARY OF THE INVENTION A new softener regeneration method is now provided. ‘One embodiment provides a method of regenerating resin in an jon exchange Water softener in a system containing a Once-Tirough Steam Generstor (OTSG) and an ion exchange water softener comprising: ‘recovering water concentrated asa blowdown steam fom. the OTSG, and regenerating theresin in theion exchange water softenerby ‘ovving the blowdovsn stream through the fon exchange ‘water softener, In one embodiment, the ion exchange water softener is @ sodium cycle water softener. Since the blowdown stream coming fom te boiler is heated, the invention also comprise reducing the temperature ofthe blowdowsn steam using & heat exchanger. In one embodiment, the temperature is reduced wo less than 95°C. ‘The system may contain any of a variety of apparatus for filtering or otherwise cleasing the produced or brackish water. none embodiment, the system contains nol moval apparatus, a Hot Lime Softener (HLS), an after fie, anion exchange apparatus, and a polisher. In one embodiment, the system does not include lime softener (ithe HLS. WLS, ‘orany other lime soflener. In this embodiment, the addition of a lime softener is unnecessary due to the advantageous properties ofthe presently claimed invention Tn one embodiment, the resin in the ion exchange water softener comprises a standard strong acid cation resin. This resin may be, for example a shallow shell resin (such as Purlite SSTSODL), a macroporous polystyrene resin croslinked with dvinylbenzene having sulphonic acid fune- tional groups, ora gel polystyrene resin crosslinked with, divinylbenzene having sulphonic acid functional yroups Tn one embodiment, the ion exchange resin bas lest than 1.0 ppm hardness leakage after regenerating the resi in the jon exchange water softener, In another embodiment, the resin has less than 200 ppb hardaess leakage and in yet ‘nother embodimeat, the resi has less than $0 ppb hardness Teakage. In one embodiment, regenerating the resin comprises regenerating in counter. made and in another embodi- iment, regenerating the resin comprises regenerating ina o- flow mode none embodiment, the system comprise atleast two water sofeaer vessels, wherein he Water softener vessels are oper- ated in analtomating mode. In an embodiment of the present invention, a method of regenerating resin in an ion exchange water soften is pro- vided. This method comprises: US 8,663,476 B2 3 recovering water concentrated asa lowdown stream from 4 Once-Throgh Steam Generator (OTSG); and regenerating th resin in theion exchange water softener by loving the blowdown steam through theion exchange ‘water salener. s ‘This embodiment may be such that an jon exchange water softener isnot cectly oF indirectly connected to the Once “Through Steam Generator. Another embodiment includes a method for reducing the amount of salt additives and wastewater ina steam-basod ‘enhanced ol recovery proces, wherein the process includes tn jon exchange water softener and 8 Once-Thmough Steam Generator (GIS) comprising: recovering water concentrated asa lowdown stream from the OTSG, and regenerating the resin in theion exchange water softener by flowing the blowdown stream through the ion exchange ‘water sotener, wherein regenerant brine containing an effective amount of purchased salt snot add tothe system for regeneration of 20 the srong ail cation resin ‘Yet another embodiment includes a system comprising: (@) produced or brackish water having total dissolved so: its of between 1000-250.00 pp (})av ion exchange apparatus for reducing wate hardness ‘of the produced or brackish water containing aa ion ‘exchange resin; (6) Once-Through Steam Generator (OTSG); (@) 8 separator apparatus that separates the output of the ‘OTSG into stam and a blowedlown stream: (6) a heat exchanger that reduces the temperature of the ‘lowdown steam; (a plurality of flow contol valves operatively connected to the ion exchange apparatus and the heat exchanger, ‘wherein he flow contol valvesare configured to contr. the flow of the Blowdown steam through the ion exchange apparatus to regenerate the jon exchange The blowdown steam ofthis system may flow through the jon exchange apparatus ina direction opposite fom the How ‘of the produced or brackish water. The system may also be adapted to regenerate the ion exchange resin to havea bard- ness leakage of less than 208 pp, » BRIEF DESCRIPTION OF THEDRAWINGS 4s Non-limiting and non exhaustive embodiments of the present invention are described with reference to the follow ing drawings. Inthe drawings, like reference numerals refer to like pars throughout the various figures unless etherise specif For a beter understanding of the present invention, refer ‘ence will be made to the following Detail Description, ‘which isto be readin association with the secompanying drawings, wherein FIG. 1 shows a typical high TDS treatment scheme for steam proaution FIG. 2 shows a high TDS treatment scheme according 10 the present iaveatioa, FIG. 3 showsa second high TDS treatment scheme aceon! ing to the present invention, FIG. 4 shows an embodiment having two SAC resins FIG. S shows four SAC type ion exchange resin (Puroite ‘C100, C100E, SST60, SST80) (sodium cycle) and the effect ‘of bine concentration on exchange capacity FIG. 6 shows the predicted breakthrough of total hardness for standard SAC in virgin condition (influent TDS 12000 s 4 ppmssCaCO,,THot300ppmasC=CO, predicted onanion «exchange simulation program (IX-SIMULATOR, Puro). DETAILED DES CRIPTION ‘The present invention makes use of the sat naturally present in the brackish or produced water, allowing operators of softening systems (1) reduce and preferably eliminate the cost assovated with the purchase and handing of large amounts of blk sl for regeneration ofthe softeners, (2) achieve lower levels of hardness leakage previously con- sidered unatsinable for sat regenerate stenes, anor (3) minimize and preferably eliminate ational burden on ‘the envionment fom discharge of commercial salt Ina typical SAGD process, as shown in FIG. 1, pretreat ment ofthe high TDS water forthe OTSG (12) wl tyra ineludeancil removal process (14 follawedby aot orwam. lime softener (HLS or WLS) (23) forslica removal andsome partial removal ofhadness. The wateristhen pssed through after ier 24 to remove any cayover shag fom HLS ‘or WLS, This is fllowed by at east one ionexchange process (26) and (28)oreduce total harness (TH) olessthan the 02 pm target. Typically two om exchange vessels using strong acid cation (SAC) resins operating on a sodium eyele, ae ‘operated in series as primary (26) and polisher (28) vessels ensure that the hardness target is met. ‘Nor-timiting examples of suitable SAC resins include Purolite® C100 and Purlite® SSTSODL shallow shell resin, Inorder to obtain ow hardness leakage witha SAC softenet operating om high TDS water itis necessary to use high dosages of sodium chloride (sl), tpically ranging fom 15, 10 30 bs salt per cubic fot of resin (240 to 480 gi), “The presence ofeach ofthe HLS (2), after fer (24), and polisher (28) or optionally other ites such as a WAC in the system independently depen on the content ofthe produce high TDS water or brine (12) entering the boiler. Additional filters or soeners, ether the same or diferent from those described in FIG, 1 may aso be used, For waters with higher ‘TDS (generally higher than $000 ppm, the second polisher ‘esl is typicilly replaced bya weak acd eation (WAC) resin (28) operating in the sum form in onder to achieve the ‘maximum tage of 0.2 ppm TH. In preparation for repeneration of SAC resins i the meth- cdsin the priory, guid rin solution (32)s usually made up onsite fom dry sodium chloride purchased ether in the form of rock or solar salt, The accepted practice isto use a brine concentrationof HPéorhighe,orsalt dosage of usually 15.25 ft of resin. On passewe ofthe brine though tersin bea, calcium, magnesium and ater divalent cation are dis- placed from the resin exchange for sodium. SAC resins can either be operate in co-flow move, with the water and brine entering and exiting the ion exchange vessel inthe same direction, or in counterfiow mode, with water and brine entering the vessel in opposite directions. Ina prefered embodiment, counterfow is prefered for achieving the lowest hardness leakage asthe freshest brine makes first contact with the volume of esin atthe end ofthe ‘esel om which the softened water exits when the vessel is next placed into service. Tis means thatthe resin where the brine enters gets maximum regeneration efficiency and residual hardness ions leftover inthe resin wll beat a mini- ‘mum. When the vessel s put ino service the softened water Jeaving the vessel makes last contact with ths highly rezen- erated resin andthus desorption of hardness (ie leakage) ino te water during the next service cycles kept a minimum, Counter-low operation can therefore use a lower dosage of US 8,663,476 B2 5 salt compared to co-low operation and is widely used for high TDS applications inthe oil ild. Regeneration ofthe WAC units more complicated, rogue ing the use of increasingly more af the following: expensive ‘acids and caustic, costly specially lined vessel intemal ‘operator attention, and a generally increased complexity of ‘operation The interstices of oil or gas producing formations usually ‘contin hgh TDS water or brine in ation to the ol andor as. The pressure gradient created by the production of anol ‘or gas wel causes the bine to also flow tothe well boee, Ia systems using an OTSG th brine can be used as a source for producing the steam used to inject into the wellbore to heat and reduce the viscosity ofthe heavy ol ‘The TDS of brackish and produced water generally ranges from 2.00010 8,000 ppm and even higher. For purposes ofthis invention, it should be recognized that this TDS is largely sodium chloride, along with a few hundred ppm of caleium, ‘magnesium and silica, SAC resins used in sotenig remove dissolved divalent cations such as calcium, magnesium, barium, iro, and manganese fom the waterand replace them, ‘with sodium, Thus the water after softening, apart from the small amount of hardness leakage, is comprised largely sodium salts (.gclorde, sulfate, bicarbonate) with sodium, chloride being the major fraction, Regeneration of SAC resis eoquire sodinm chloride brine ‘concentrations that areanuch higher than the TDS of the water that has been softened ast is necessary to have high enough ‘chemical driving force to reverse the ion exchange process of| clisplacing divalent cations by monovalent sodium, Under «iluebrine conditions the sotiening resin hs higher selec- tivity or attraction fr divalent cations (eg caleium and mag nesium) compared to sodium, Selectivity of the resin for divalent cations reverses as the TDS concentration of the brine increases. Fortis reason the accepted practice isto use brine concentrations of 10% orhigher. Compared totheinthu- ‘ent TDS of 2,000 08.000 ppm, 10% brine equates to 100,000 pm, thus providing the necessary driving fore considered necessary to properly regenerate the resin while uilizing ‘minimum quantity of brine Adequate quantities of salt are preseat in high TDS water ‘once this salt is concentrated it can be eliciently used for regenerating the sodium cycle SAC resin used to pre-soften the water used in the OTSG boilers. The salt concentrating ‘mechanism inherent inthe design and operation of the Once ‘Through Steam Generator (OTSG) boiler used in SAGD ‘operations can be used to provide a sulliciemtly concentrated salt solution for eegeneration ofthe SAC resi, An essential feature of the SAGD proces i the require ment for steam quality to be close to 100% for efficient ‘operation, meaning that (guid) water content of the steam ‘ust be as low as practical, OTSG boilersby design produce mixture of team and water at atypical ratio of 8% 10 20% respectively Iti therefore necessary to separate the steam from the water before it can be injected into the il reservoirs. “This separation is done via the sieam- water separator vessels located downstream ofthe boiler. These steam separator ves- sels bring the steam to near 100% quality by separating out the water into what is eferred to as a bloidown steam, This blowdovin stream comprises approximately 20% ofthe total ‘water originally fed tothe boiler. Essentially all ofthe dis- solved solids (TDS) originally present in the feed water tothe ‘OTSG boiler ends up ithe 20% faction that comprises the blowdown water. This amounts to 2 concentration factor of § times the TDS present in the feedwater othe boiler. Forexample, the TDS oftypical produced water may range from 2.000 ppm to 8000 ppm, ot approximately 0.2% to Fa » 6 (0.8% (1% equates to 10,000 ppm). Such a water typically conains 100 ppm to 300 ppm total harness (expressed as CaCO) while the majority ofthe remaining eation content willbe sodium. On passage ofthis water through a regenee- ated cation exchange water softener, the total hardness is Picked up bythe softener and an equivalent amount of sodium is released in tothe water. Thus, the cation content ofthe ater leaving the water softener inthis example isessentaly sodium. Fora feedwater TDS of 5,000 ppm the five times concentrating mechanism of the OTSG results na concen tration of 25,000 pp TDS inthe boiler blowdowa (or 2.5% concentration), essentially all of whichis sodium chloride. ‘When the above 2.5% brine concentration is compared 0 the industry standard of using @ 10P6 sodium chloride brine sclution (100,000 ppm) it can be seen that the industry stan- dard is 4 times higher. However, this common industry prac- tice of using 10% oF higher brine concentration does not strictly apply when salts freely available, as isthe case with the solutious of the present iawention. When salt is frely available, itis practical to use much loser concentrations of brine and to stil achieve quite satisfactory regeneration effi- ciency. The freely available salt found in the blowdown is sufficient to compensate fr the expected ossin efficiency at Jower brine concentrations, The excess of salt available for regeneration ofthe softeners by concentrating an recovering the salt via the blowdown mechanism from the OTSG boiler js sufficient to regenerate the SAC. Eventhough the concen tration of satin the blowdostas low by current standards, the «quantity of salt eailable in the boiler blowdown effetively represents a much larger quantity and dosage (usually about times higher) than sed in curreat practice. “The high purity of the salt solution available fom the blowdown from the OTSG and its postive impact on the process pre-softening the water usd in the oiler with SAC softeners compared to commercially available sal is par= ticularly usefil benefit inthe presen invention, Fr example, 10% brine made from commercial salt may contain hardness ranging from 200 to 2000 pp whereas the haedness content ofthe brine available in the blowdowa from the OTSG will generally be 1 ppm. Using the moch higher purity OTSG. brine to regenerate the softener will resul in very low levels of hardness leakage, ia fict, much lower than what ean be oblained when regenerating the sollenee with commercial sources of salt. For example, hardness leakage of 40 ppb or lower is possible with te invention compared to 1 10 8 ppm with various grades of commercial sal. FIG. Loutines typical conventional treatment train anda ‘modified treatment rain ofthe present invention, showing the recovery and reuse ofthe blow down from the OTSG boiler for softer regeneration, Produced water or brackish water (12) is typically subjectod to a number of unit operations for cleanup of the water before itis used in the boiler, including deviling (14), warm lime softening (22), filuation (24), sodium eyele softening (26) using brine as regenerant and then weak acid eaton softening for inal plishing (30) before entering the OTSG boiler (42) and then the seam -water sepa ‘ator (44) Although a weak acid cation polisher is shown for vessel (30), this ean be replaced by a second sodium eycle softener for polishing in cases where the TDS is onthe lower end ofthe 2,000 10 15,000 ppm TDS range such as would be the case for brackish water (or example, 2,000t0 5,000 pps). Tn the warm lime softener (22) showen, ime, magnesium and a polymer flocculent may be added to rede silica, suspended solids residual oi and partially softenthe water by precipitation of any temporary hardness that may be US 8,663,476 B2 1 present. A simple filter dvsnstream ofthe cafe serves to enue any residual suspended solids that may get carried ‘over fom clarifier. Remaining hardness after the warm lime softener, typically ‘out 20 10 300 pp. is largely remeved by a sodium cycles ‘water softener (26), with average leakage of hardness from the unit typically ranging from about 5 to 15 ppm total ard nessas CaCO, Operating capacity sgenerally about 20t0 30 kilograms of hardaess per eubie of resin (or about 0.910 Lt ‘equivalent of handness per liter of resin). On exhaustion, the softeners taken offline and a 10% brie solution (or higher) is passed though the resin at total volumes that comespoads to dosage of 151025 Ibs of sodium chloride sal per cubic foot ‘of ion exchange resin (240 to 400 grams NaCl por liter of| resin), ether in co-low but more preferably in countess ‘mode of operation. For an iafluent toa hardness of 200 ppm as CaCO, and a salt dosage of 15 Ibs (240 grams NaCl per literof resin) this would coreespond toa service eyelevolume ‘of treated water of approximately 275 bed volumes of water based onthe volume of resin in the softener, or removal of 1-1 ‘equivalents of ardnes per liter of resin. (Note 1 bed volume ‘equals a volume of water equals tothe volume of resin i the vessel) For example | lite of resin would teat 275 liters of water before hardness leakage rises 10 the defined break through point at which time itis taken ofline and regenerated ‘wit brine, Fora salt dosage of 15 Ibs/t of resin (240 grams NaCUiter of esin, thiscorresponds ta dosageof 4.1 chemi- ‘al equivalents of NaCl per liter of resin. Thus the equivalent usage rato of sodium chloride to total hardness removed is 4.1/1.1, of 3.7/1 Once the brine solution is used, the spent brine is removed as waste (32) FIG. 2 further exemplifies the regeneration process of one ‘embodiment of the present invention showing the rcovery of| the boiler blowdown (48), fist cooling vi a heat exchanger (62). aheat exchanger used for pre-heatng the feedwater 5 before i enters the boiler) toa temperature close to typical ‘operating temperatures of the softener at about 8010 95° C. then passage of the blowidown water (84) contining the sodium chloride through the resin to regenerate it In the ‘example shown, the brine concentration inthe blowdown will ‘ypically range from 1%t03.5% depending onthe TDSin the influent water. Inthe emmbodiment wherein a second sodium ‘cycle softeners used asthe polisher (28) (instead ofthe weak ‘cid cation resin), the brine can be used to regenerate this sodium eycle softeneras well. In oae embodiment, the brine is passed through the polisher vessel first in counter-fow mode and is then routed tothe primary softener, in wht is. ‘known as thoroughfare regeneration. “This higher available salt amounts to “fre regenerant” that ‘canbe used to further improve the performance of the sot- ‘ener and hence provide even loser leakages than would be ‘coontmically feasible if salt had to be purchased, By use of| this exces free rogenorant, itis expected thatthe hardness leakage from the primary softener willbe reduced to values ‘hata a small faction ofthat obiainable from softeners tha rely on purchased salts, Commercial salts typically have impurities of calcium at levels upto about 1.5%. This im rity essentially determines the lowest calcium leakage that ‘canbe obtained from asoftener-Fr example, one study using brackish water at about 9,000 ppm showed that using pure salt (no calcium impurities) for counter-fow regeneration would sive a hardness leakage of 0.2 ppm. Predicted leakage based ‘on commercial salt with 0.5% caleium impurity wes 5 ppm total hardness. Field results showed average leakage was -sctually close o 6 t 7 ppm hardness leakage Use of salt recovered from the blawdowan of the OTSG boiler does not sulfer from this limit on hardness leakage s 8 since th hardness in the blown sintaly dictated the purity ofthe egenerant salt usd animal bythe equi- lieium conditions between the esi, sodium and hardness ions that ae present inthe wate. The hardness content ofthe Dowdown brine in ft dictate bythe lenkageofhanlness from the softeners. But the harass leakage fom the resin bedisdependenton he trace level of calcium and magnesium, thatarelef onthe portion of th resin tht makes las contact withthe water leaving the ion exchange vessel Residual hardoes onthe resin in tur depends on the hardness inthe brine ise With commercial sores brine (ck sallte) éontsning abou 1% of 15000 ppm of calcium (or aout 1500 ppt fora 10%brine soluon, a signiiant amount of calc is lef on the resin, and this dicts the bandos leakage. This is atthe case, however, with rine recovered fron the OTSG boiler hs bine will contain o more ian 1 ppm of calcium hardness once the system is operating vin spesificatons, Tis is easy to ee since the hardness in the softened waters contol 0 gretr tan 0.2 ppm of hardves,Aferthe Sines concentration effet ha occurs in the OTSG boiler (with 80% steam, 20% water produced), the hardaess concentration wll be no more tan ppm once the soflene is well called. Even with upsets in contol the hades content ofthe lowdown rinsed or regeneration willbea mane faction of the typical 1500 pan that ound inbrine made from commercials In esance, wse of biowdown salt 1 reyenerte the upstream sofleter can represent an onder of magnitude improvement in harness reduction efciency that cannot be achieved with commercial sat FIG, 3 exemplifies another embodiment ofthe preset invention showing either produced water oF brackish water (42) subjected wo a umber of unl operations for leap of ‘hewaterbeforeitisused inthe boiler (42) including deoiing (04, tation (24), desing (36) and sodium eee soften- ing (26). The degassing step (36) generally removes CO,, HSand0, 40) fom he water. Thecleaned vate enters the ISG boiler 42) and then the seams separator (4) ‘where steam (46) is produced for use it the downhole injec- toa ite. The separatr (48) also produces boiler blowdown (4B), whichseeoverdand cole va abeat exchanger (52) and then passage ofthe blow down water (54 tthe SAC (26) torepenerte the SAC. ‘Additonal components or modieations used in OTSG ot related stems may also be used. Forexample, the rection Of divalent and eaten cation concentrations to reduce ‘leased compound scaling andor the removal of fine foflener may be aocoplisbe, for example, by using the method as deseibod in US. Pa. App Pub. No, 20071 (095789, heren ncosporaed by reference. In one embadiment ofthe preseat avention, 28 showa in FIG. 4a minimum of primary sodium eyce softener units (24) are operated inp, with one inservice andthe other on standby or bing repented. While uit (SAC 1) sn secviee, unit 2 (SAC 2) can be regenerate wit the recovered blowers from the boiler (84), essentially amounting to a Aipsop switching ofthe two uni from sevice o regenera tion an back, with the appropriate valving and conto (36) Jn one paricular embodiment, counter-ow regeneration (down-flow service and upflow regeneration, or vice versa) is thepreferedamettodotrepeneraionasitwilyield the west tans: leakage. Co-flow regeneration (ia which both ser- ‘ice flow and regencant passthrough the vessel inthe same diretion) can work but not secon as counte-ow, bt does offer amore simplified ese design ands spat of anoherenbodment of the present invention. US 8,663,476 B2 9 In one embodiment ofthe present invention, where efl- ciency is optimized, the hardness removed is largely loaded ‘onthe portion ofthe resin volume tats close tothe influent point ofthe vessel. Regeneration is perfommed fequenly ‘enough to avoid loading hardness on the portion of resin

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