22nd Joint GCC-Japan Environment Symposium
“Sustainable GCC Environment - Challenge for Our Future”
March 3-5, 2014, Saudi Arabia
Application of
Ultrafiltration Membrane System to
Water Recycle System for the Oil Industry
参考（装置）
HISATO AOYAMA
Professional Engineer (Chemical)
Manager, Heavy Oil Project
Application of Ultrafiltration Membrane System
to Water Recycle System for the Oil Industry
Contents
(*)
1.
Integration UF Membrane System with SAGD
2.
UF membrane Bench Test Performance
3.
Application to Water Recycle System
4.
Summary
(*) UF: Ultrafiltration
Copyright 2014 JGC all rights reserved
2
Water Treating System for SAGD
High Fumic
Substance
Off Gas
Water/
Bitumen
Well Head
Separator
Steam
Steam
Separator
Separator
(Boiler)
BFW
Condensate
Water
After
Filter
Bitumen
WAC
Oil Separator
Copyright 2014 JGC all rights reserved
Recovered
Water
X
WLS
BFW
Evaporator /
Crystallizer
Waste Water
(Discharged to
Environment)
Water Recycle
Ratio: 90%
Make up
Water
Note
(*1) WLS: Warm Lime Softener
(*2) UF: Ultrafiltration Membrane
(*3) WAC: Weak Acid Cation
(*4) BFW: Boiler Feed Water
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Water Treating System for SAGD (UF Membrane)
Off Gas
Lower Fumic
Substance
Water/
Bitumen
Well Head
Separator
Steam
Steam
Separator
Separator
(Boiler)
BFW
•Reduced Coking
Condensate
Water
After
Filter
Bitumen
WAC
Oil Separator
Copyright 2014 JGC all rights reserved
Recovered
Water
WLS
BFW
Evaporator /
Crystallizer
UF
•Eliminating Humic
substances
Zero Liquid
Discharge
Smaller
Make up
Water
Note
(*1) WLS: Warm Lime Softener
(*2) UF: Ultrafiltration Membrane
(*3) WAC: Weak Acid Cation
(*4) BFW: Boiler Feed Water
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Contents
1.
Integration UF Membrane System with SAGD
2.
UF membrane Bench Test Performance
3.
Application to Water Recycle System
4.
Summary
Copyright 2014 JGC all rights reserved
5
UF Membrane for Removing Macro Molecular
Feed
Water
Cross Section of
UF Membrane
Concent-rated
Water
1.3mm
0.8mm
Permeated
Water
Pore Size 0.01μm
Macro Molecular (TOC, etc.)
Pore Size
Molecule
Size
Ion, Low Molecular
Na+,Cl-,Ca2+
Copyright 2014 JGC all rights reserved
Membrane
Type
1Å
0.001μm
Ion, Low Molecular
0.01μm
Macro Molecular
Na+,Cl-,Ca2+
RO
NF
UF
6
Stable Permeation Flux
3.5
(*1) MWCO:
Molecular
Weight
Cut Off
分画分子量1
MWCO(*1) 0 , 0 0 0 PES - UF 6 5 ℃
(*2)
分画分子量1
0 , 0 0 0 PES - UF 2 5 ℃
MWCO
3.0
MWCO
分画分子量3
0 , 0 0 0 PES - UF 6 5 ℃
2.5
(*2) PES:
Polyether
Sulfone
2.0
3
2
Flux [m /m ･day･0.05MPa]
4.0
1.5
1.0
0.5
0.0
0
50
100
150
200
Time [min]
It is estimated that a stable permeation flux would be approximately 1.3 1.5 m3/(m2 day) at any of these molecular weight cutoffs under a filtration
pressure of 0.05 MPa.
Copyright 2014 JGC all rights reserved
7
Humic Substance Removal Rate
フミン質除去率
Humic substance
Removal[％]
Rate [%]
100
90% of
Removal
at MWCO
10,000
90
80
70
60
50
40
MWCO:
分画分子量1
0,000 25℃
30
MWCO:
分画分子量1
0,000 65℃
20
MWCO:
分画分子量3
0,000 65℃
MWCO:
分画分子量1
50,000 25℃
10
0
0
50
100
150
Time [min]
Humic substances removal rate:
R = ( 1 - 465 nm absorbance of permeating water / 465 nm absorbance of feed water ) x 100
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8
Picture of UF Module Permeated Water
Feed Water
Concentrated
Water
Permeated
Water
(MWCO:10,000）
Copyright 2014 JGC all rights reserved
Permeated
Water
（MWCO:150,000）
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Contents
1.
Integration UF Membrane System with SAGD
2.
UF membrane Bench Test Performance
3.
Application to Water Recycle System
4.
Summary
Copyright 2014 JGC all rights reserved
10
UF Membrane Module Operation
UF membrane for SAGD Water
RO for Sea Water
(for reference)
•Filtration speed: 1.0 m3/(m2・day) ……….. 0.01m3/(m2・day)
•Filtration pressure: 0.1 Mpa ………………. 5 MPa
•Back washing frequency: 1 min./60 min. …. n/a.
•Recovery rate: 90% ……………………….. 30%
Recycled Water
(100vol%)
Feed Tank
Feed
(200vol%)
Permeated
(100vol%)
Back
wash
SAGD Water
From after filter
(100vol%)
モジュール
UF
Permeated
Water (90vol %)
Permeate Tank
Rejected Water
(10%)
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11
Case Study: OPEX of UF Membrane System 1,000 m3 /day
Equipment cost:
• 790,000 USD
(incl. UF Membrane: 590,000 USD)
参考（装置）
Depreciation cost：
• 158,000 USD/year
= 42￠/m3 of water
(five-year straight-line)
Running costs:
• Membrane: 160,000 USD/year
(replacement once a year)
• Electricity : 29,000 USD/year
• Other: 26,000 USD/year
• Total: 213,000USD/year
= 58￠/m3 of water
Total OPEX :
 $1.00 /m3 of water
Copyright 2014 JGC all rights reserved
12
Contents
1.
Integration UF Membrane System with SAGD
2.
UF membrane Bench Test Performance
3.
Application to Water Recycle System
4.
Summary
Copyright 2014 JGC all rights reserved
13
UF Membrane System
to Water Recycle System
1.
Integration of UF Membrane System with SAGD:


2.
Ultra Filtration Bench Test Performance:


3.
Reduction of Humic Substance content would be a key to higher
reliability and lower maintenance costs of SAGD Boiler.
Minimizing of discharge waste water to environment and saving
of intake water are expected.
Stable permeation flux of 1.3 - 1.5 m3/(m2 day) is confirmed
using JGC/Daicen’s Ultrafiltration Membrane
Removal rate of humic substances of about 90% is attained.
Application to Water Recycle System:


Cost effective compared to Sea Water RO system
OPEX of US$1.00 / M3 - water is estimated at a SAGD site in
Canada.
Contact: Hisato Aoyama ([email protected])
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