Presentation about: Disk stack centrifuge technology for the oil-water separation of heavy crude oil emulsions

GEA Westfalia Separator Systems GmbH Business Unit Oilfield Michael Miedek Thomas Fislage Mechanical Separation / Westfalia Separator

GEA Westfalia Separator Norway AS

Jarle Richter Flaata

Mechanical Separation / Westfalia Separator

content
1.0 Basics of GEA Westfalia Separator disc stack centrifuges 2.0 Disc stack centrifuges used for heavy crude oil de-hydration - Performance limitation

3.0 Disc Stack Centrifuges integrated in the crude oil process incl. status of actually activities
4.0 Conclusion - Strength and Weakness of disc stack centrifuges Discussion
2

Mechanical Separation / Westfalia Separator

basic function

1.0 Basics of GEA Westfalia Separator disc stack centrifuges

Mechanical Separation / Westfalia Separator

basic function
To be successful in the separation/de-hydration of heavy crude oil emulsions is mainly determent by the following influence able parameters: - g-force (created by centrifugal acceleration)

- settling path

Extreme high g-force influence the velocity/settling time of water droplets and the coalescence force effect positive.
4

Mechanical Separation / Westfalia Separator

basic function
The stokes law is the basic calculation of the settling velocity for water droplets

Slightly controlable by the selection of low share force equipment.

v
v

Controlable parameters via the centrifugal technology. Controlable parameters via the separation temperature.

Mechanical Separation / Westfalia Separator

basic function
Disc Stack Centrifuges provides highest g-force and lowest settling path
Untreated Product Inlet Treated Water Outlet Sludge Outlet Treated Oil Outlet

Disc Stack Centrifuges multiply will provide 5,000 10,000 x g The settling path will be 0.35 0.5 mm only. The extremely high clarification area (up to 260,000 m) provided by the hundreds of separation discs can offer very low foot print requirements for this technology

Mechanical Separation / Westfalia Separator

basic function
The optimal solution for the crude oil de-hydration will be provided with disc stack centrifugal technology as nozzle design Continues operation Higher solid load can be handle Biggest heavy crude oil centrifuge on the market Centrifuge housing suitable for inert gas blanketing up to 2 bar g Separation temperature up to 130 C

Direct drive with coupling

Symbolic Sketch. Not To Scale!

Mechanical Separation / Westfalia Separator

basic function
Operating Principles: Production
After pre-filling the bowl with make-up water product can be introduced into the rotating bowl.
Animation, click on buttons:

Start Make Up Water Production

Symbolic Sketch. Not To Scale! 8

Mechanical Separation / Westfalia Separator

2.0 Disc stack centrifuges used for oil-water separation of heavy crude oil emulsions

Mechanical Separation / Westfalia Separator

disc stack centrifuges for heavy crude oil Disc stack separator performance figures o Water Droplets with a size of approximately 5-15 micron and bigger will be separated from the heavy crude oil
This water drops will be separted from the crude oil This water drop let will be present in the treated crude oil

d (s f ) Vst r 18
To improve the separation result it might be necessary to: - Increase the retention time of the product in the centrifuge -> reduce the throughput - Adding of demulsifier -> break emulsion more easily and create bigger water droplets
10

Mechanical Separation / Westfalia Separator

disc stack centrifuges for heavy crude oil Disc stack separator performance figures o Sediments with a size of approximately 3-10 micron and a density bigger than 1.4 g/ml and bigger shall be separated from the crude oil.
This sediment particles will be separated from the crude oil This sediment particle will be present in the treated crude oil

d (s f ) Vst r 18
To improve the separation result it might be necessary to: - Increase the retention time of the product in the centrifuge -> reduce the throughput - Adding of demulsifier -> break emulsion more easily and create sediment agglomeration
11

Mechanical Separation / Westfalia Separator

disc stack centrifuges for heavy crude oil Separation of water droplets inside A disc gap
Clarified Liquid Out
VC = Centrifugal Velocity VF = Main Flow Velocity VR = Resulting Velocity
Animation, click on buttons:

Start
Start Big Droplet

vF vR vC

Start Stokes Droplet

Start To Small Droplet

Ri

Main Feed Flow In

w Ro
12
Symbolic Sketch. Not To Scale!

Mechanical Separation / Westfalia Separator

disc stack centrifuges for heavy crude oil Disc stack centrifuges for crude oil desalting/dewatering! Why? o The extremely high g-force provide the best achievable BS&W content within the treated product (between 0.5% 1%) .

o Increased requirement of the water cut and can be handle with the same technology with out major adjustments.
o The disc stack centrifuge reduce the content of ultra fine sediments to excellent levels (3-Phase Separation). o For higher sediment load of the pre-treated crude oil (> 0.2-0.3%) our nozzle centrifuges provide the optimum solution. o This technology can handle heavy crude oil up to API 12.5 (approximately 0.935 kg/m @ 95 C). With high separation temperature up to 130 C even lower (API 10 -11 ) !!! o With the support of a demulsifier even stable emulsions are breakable and separable (temperature stable - does not influence process).
13

Mechanical Separation / Westfalia Separator

disc stack centrifuges for heavy crude oil Capacity limitation of single centrifuges
o The capacity of centrifuges will be mainly influenced by: - Viscosity of the crude oil - Density of the crude oil (Can influence by separation temperature) o Further points are extremely important: - Emulsions - Particle sizes - Water droplet sizes The biggest single centrifuge systems Westfalia can provided are: - The WSD 200 is the actual biggest self cleaning centrifuge Max. capacity up to 15000 bpd (100 m/h ) For Heavy Crude Oil needs to reduce to 6000 9000 bpd (40-60 m/h) - The ODB 260 is the actual biggest nozzle centrifuge Max. capacity up to 37500 bpd (250 m/h ) For Heavy Crude Oil needs to reduce to 15000 22500 bpd (100 150 m/h)
14

Mechanical Separation / Westfalia Separator

3.0 Heavy Crude oil process for the oil-water separation of heavy crude oil emulsions

15

Mechanical Separation / Westfalia Separator

Heavy crude oil treatment process

16

Mechanical Separation / Westfalia Separator

Heavy crude oil treatment process The pressure drop create emulsions

Crude Oil Stream

Produced Water Stream

17

Mechanical Separation / Westfalia Separator

Heavy crude oil treatment process

18

Mechanical Separation / Westfalia Separator

crude oil treatment process Pictures as example of our nozzle centrifuge ODB 260 system

19

Mechanical Separation / Westfalia Separator

Heavy crude oil treatment process The ODB 260 systems on the test bench

20

Mechanical Separation / Westfalia Separator

Heavy crude oil treatment process The FPSO where our ODB 260 system are installed

21

Mechanical Separation / Westfalia Separator

Heavy crude oil treatment process

22

Mechanical Separation / Westfalia Separator

crude oil treatment process

23

Mechanical Separation / Westfalia Separator

crude oil treatment process

24

Mechanical Separation / Westfalia Separator

Heavy crude oil treatment process A view inside the building with 30 ODB 260 systems Total Capacity for 17 centrifuges for heavy crude oil: 255,000 300,000 bpd

25

Mechanical Separation / Westfalia Separator

Heavy crude oil treatment process

26

Mechanical Separation / Westfalia Separator

4.0 Conclusion

Strength Best achievable performance results Minimal footprint requirements Less chemical consumption Less operation temperature Centrifuges can be converted from crude oil centrifuges into produced water centrifuges for de-oiling Separation of water and sediments in one step

Weakness Rotating equipment is that really a weakness? Investment may appear higher Knowledge and well trained operator Crude Oil needs to be degassed

27

Mechanical Separation / Westfalia Separator

Produced Water
Produced Water De-Oiling ODB 260-71-107 Conversion Kit for Produced Water Deoiling Feed & Discharge Assembly centripetal pump for oil - centripetal pump for water Ringulating ring Centripetal pump chamber cover Disc stack Distributor

Conversion can be done on site!

Mechanical Separation / Westfalia Separator

Systems overview
Our Systems for upstream and downstream oilfield applications

Upstream

Downstream

On- and Offshore Installations Oil & Gas Production

Production Crude Oil Produced Water Drain Water Drilling Drain Water Drilling mud Slop Water Solids Control Tank Cleaning Brine Utilities Bilge Water Fuel Oil Hydraulic Oil Lube Oil

Oil Refineries Gas Treatment Plant Tank Terminal

Oil Management
Cat fines MEG (Mono Ethylene Glycol) Slop Oil Slop Water Tank Bottoms

29

Mechanical Separation / Westfalia Separator

30 Add text using "Insert -> Header & Footer"

Mechanical Separation / Westfalia Separator

5.0 Disc stack centrifuges used for produced water treatment applications

31

Mechanical Separation / Westfalia Separator

disc stack centrifuges for produced water The Following Parameter influence the Separator Type
Parameter 1.) Limitation of oil content in treated produced water in relation of the oil content in the feed Criteria < 40 ppm < 30 ppm < 15 ppm - Self Cleaning Centrifuge - Nozzle Centrifuge - Duplex Material or - Super Duplex Material

2.) Maximum Solid content in the feed

3.) Maximum Salt content in the feed under influence of the product temperature

Comments: Item 1.) A lower level of hydrocarbons in the treated produced water requested a throughput reduction of the centrifuge. The same effect for an higher feed level. Item 2.) In case of solid content will be above approx 0.1% a nozzle centrifuge could be selected. Item 3.) WS recommend a separation temperature of 50 C to max. 70 C. In case of chloride content will be above 8000 ppm super duplex material shall be selected.
32

Mechanical Separation / Westfalia Separator

disc stack centrifuges for produced water WS offered a weight range of Centrifugal Separators for the Produced Water Treatment application
Centrifuge Type Disc Stack Self Cleaning Centrifuges WSD 8 WSD 18 WSD 35 WSD 60 WSD 200 Disc Stack Nozzle Centrifuges ODC 45 ODB 260 Treatment Capacity* up to 3,000 l/h or 450 BPD up to 6,000 l/h or 900 BPD up to 16,000 l/h or 2,400 BPD up to 28,000 l/h or 4,200 BPD up to 100,000 l/h or 15,000 BPD

up to 25,000 l/h or 3,750 BPD up to 200,000 l/h or 30,000 BPD

* This is an optimum capacity and is calculated for an oil content in the feed produce water below 1,000 mg/l and a oil content in the treated produced water of 40 mg/l. Higher oil content in the feed and lower oil content in the treated product required a throughput reduction. Real throughput for individual projects will be checked case by case by WS with real product data.
33

Mechanical Separation / Westfalia Separator

disc stack centrifuges for produced water Biggest self cleaning centrifuge from Westfalia Separator
Centrifuge type WSD 200-01-573 Design for use: De-watering of crude oil / De-oiling of water

Max. capacities of up to 100 m/h

Suitable for installation in Ex-Zone 1 - Electrical component in Ex-design - Hood and sludge catcher equipped with inert gas blanketing Material selection - Hood: - Frame: - Bowl:

stainless steel ductile cast iron super duplex stainless steel

4300 rpm 70 Litre

Technical Data WSD 200 - Bowl Speed: - Bowl Volume:

Drive: 110 kW electrical motor operated via frequency converter

34

Mechanical Separation / Westfalia Separator

6.0 Produced water treatment process

35

Mechanical Separation / Westfalia Separator

Produced water treatment process

36

Mechanical Separation / Westfalia Separator

Produced water treatment process Produced Water Treatment Systems Example: Double Centrifuge System WSC 50-01-506 for Chevron Alba FSU
SCOPE OF SUPPLY: 2 Centrifuges WSC 50 1 Duplex Filter 2 Feed Pumps 3 Base frames 2 Sludge Pumps 1 - Control Panel DESIGN FEATURE: - Capacity: 2 x 20 m/h - Fluid: Produced Water - Ex- design - N2 blanketing EXPECTED PERFORMANCE: - Oil content in feed: up to 1000 ppm - Oil content outlet: < 40 ppm
37

Mechanical Separation / Westfalia Separator

produced water treatment process Produced Water Treatment Systems Example: Double Centrifuge System WSC 50-01-506 for Chevron Alba FSU

Performance Separation temperature 20 - 50 C Oil content in feed up to 1000 ppm Oil content in treated PW Min. : 8 ppm Cumulative Average : 16 ppm Max. : 29 ppm

Outlet Results WSC-50 PW Unit

35 30 25 20 15 10 5 0

29

Oil Content (ppm)

16 8

38

Mechanical Separation / Westfalia Separator

produced water treatment process Produced Water Treatment System Conversion TI Asia / TI Africa 3 x Triple unit WSD 200 For a TOTAL of 800m/h oily water

39

Mechanical Separation / Westfalia Separator