SPE SPE 19759 A New Caustic Process for Softening Produced Water for Steam Generation II R.J. Jan and T.G. Reed Jr., Mobil E&P U.S. Copyright 1989. Society of Petroleum Engineers, Inc. this paper was prepared for presentation at the 64th Annual Technlcsl Conference and Exhibition of the Society of Petroleum Engineers held In San Antonio, TX, October 8-11.1989. This paper was selected for presentation by an SPE Program Committee following review of Information contained In an abstract submitted by the author(s). Contents of the paper as presented. have not been reviewed by the Society 01 Petroleum Engineers and are aubJect to correction by the author(.). The material. as presented. does not necaasartly any position 01 the Society 01 Petroleum Engineers. Its officers. or members. Papers presented at SPE meetings are aubJect to publication review by Editorial Commln_ 01 the Society 01 Petroleum Engineers. Permlsaion to copy I. _rieled to an abatreel 01 not more than 300 word•• 1lluatr>Jlion. may not be copied. Tho abstrac1 should contain conaptcuous acknowledgment 01 where and by whom tho paper la pre.ented. Write Publications Manager, SPE, P.O. Bo. 833836, Richardson. TX 75083-3836. rele•• 730989 SPEOAL. raneci ABSTRACT Oilfield produced water containing a high concentration of total dissolved solids (TDS) and hardness can successfully be softened for use as oilfield ~team generator feedwater. At the Belridge field in Kern County, California, the combination of caustic softening and weak acid cation exchange have been used to soften produced water containing 11,000 TDS and 550 ppm hardness to less than 1 ppm hardness. The resultant sludge containing calcium carbonate and magnesium hydroxide is concentrated by centrifuging and is disposed of in a land fill. Compared to the use of conventional strong acid ion exchange followed by weak acid or weak acid followed by weak acid ion exchange systems, the process offers the benefits of lower capital and chemical costs, partial silica removal and the elimination of liquid waste discharge. This paper gives design parameters, operating conditions, and discusses future applications in thermal recovery projects. pressure to drive the oil toward producing wells. A review of steam drive dynamics and project descriptions are given by Ali(2)(3) and Chu.(4) In California typically 0.2 to 0,5 barrel of oil is produced for each water equivalent barrel of steam injected. Therefore for a field producing 40,000 B/D of heavy oil, steam injection is 80,000 to ,(,4" 200,000 B/D. The availability of a large quantity of suitable feed water is imperative. In a conventiont<l boiler 100 , quality steam is produced from WL\ter having a very low salt content. The steam is used (or indirect heating or driving turbines, and the condensate is returned to the boiler for reuse. The only makeup water required i~ to replace the boiler blowdown which controls both the suspended and dissolved solids content of the boiler water. Hence, a large boiler requires only a very small water treating plant. For heavy oil recovery, steam is normally produced in steam generators(5,6) , These generators are horizontal fired heaters with a single pass tube arrangement which produce only 70 - 80 , quality steam. The steam together with the 20 - 30 , water that stays in liquid phase are injected into the oil formation. Since no condensate is returned for reuse, full steam makeup of water are required to feed the generators. INTRODUCTION The injection of steam for heavy oil recovery started in the late 1950s and has become the principal enhanced oil recovery method. In Kern County, California, where the major U.S. efforts have taken place, cyclic steam and steam drive operations accounted for over 400,000 B/D(l) of production. Thermal methods are also being used in the heavy oils and tar sands of Canada and Venezuela, with each country expecting 500,000 B/D by the year 2000.(1) This feed water must be free of calcium and magnesium to prevent scale formation in the steam generator tubes or in the oil formation. Silica at high concentration can also pose a precipitation problem. Since fresh water is not always available or cannot be consumed for environmental reasons, the softening of higher saline water produced in the oil recovery process becomes In a typical recovery process, high pressure steam is injected at a rate sufficient to heat the formaation to reduce the oil viscosity and to provide necessary. A new process for softening of produced water for steam generation has been developed and commerci- References and illustrations at end of paper. alized at the Mobil Oil South Belridge field. 519 The SPEl A NEW CAUSTIC PROCESS FOR SOFTENING PRODUCED WATER FOR STEAM GENERATION Ion Exchange - Weak Acid FollOwed by Weak Asid process is a variation of the hot lime process used widely for boiler feedwater purposes. .w.tmD COMMERCIAL WATER TREATING SYSTEMS Ion Exchange - Strong Acid Followed by Strong Mid ~ Ion exchange techniques have been extensively used and documented in several California alkaline floods and steamflood operations(7,8,9,lO). Most common systems consist of two beds of strong acid ion exchange resin in series with the first bed removing the bulk of the hardness and the second acting as a polisher to remove the last traces of calcium and magnesium. The chemical structure of the strong acid cation exchange resins is usually a sulfonated copolymer of styrene and divinybenzene. The resin functions by exchanging sodium ions for calcium and magnesium ions. It is regenerated with sodium chloride brine. The low cost of brine regenerant makes the system economically attractive. The system works well on oil free water with total dissolved solids (TDS) of less than 5000 ppm. In cases where the TDS of the water is higher, sodium in the produced water competes for sites on the resin with the calcium and magnesium. This makes the softening of water to less than the required 1 ppm hardness very difficult. Further, brine regenerant waste usually amounts to 10-15 % of of the total soft water produced. Disposal of this quantity of waste brine poses additional problems. In the event that the TDS of the in excess of 8,000 ppm, strong acid resin i. effective in hardness removal. The use of a strong acid followed by a weak acid system be,co.e,. impractical. An alternative is to employ a weak acid followed by weak acid system(7,8,9). This technique can reduce the hardness of a high TDS produced water to less than 1 ppm. However, the regeneration costs are high. To soften a large volume of water with a significant hardness say 350 ppm or higher, by this technique would be economically practical. While ion exchange processes work well to remova the calcium and magnesium values from water, neither strong acid resins nor weak acid resins have any noticeable effect on removing scalecausing silica from the water. Further. when ion exchange resins are regenerated, the calcium and magnesium ions from the resins are entrained in the regenerative liquid, (e.g., brine or acid) which, is routinely disposed of by injection into a subterranean formation. Unfortunately, the calcium and magnesium iona in the spent regenerative liquid can plug the formation th.!re,by severely restricting the injection of the waste liquid into the formation. In strong acid resin systems, as much as 10-15 , of the treated water, and in weak acid resin systems, 5-10 , of the product water, may be lost due to regenerant make-up, backwashing, and rinsing of the resin. Lime-Soda process followed by Ion Exchange Ion Exchange '- Strong Acid Followed by Weak Acid System One of the oldest methods of water softening is lime-soda softening. (11,12,13,14) The calcium and magnesium salts constituting the hardness content of a water are chemically precipitated and removed through the use of lime (calcium hydroxide) to raise the pH and soda ash (sodium carbonate) to supply the carbonate ion. This process may be carried out at normal raw water temperatures, in which case it is referred to as "cold lime process" or at temperatures near or above the boiling point, referred to as "hot lime process" . The principal difference between these two processes is the faster reaction rate and the reduced solubility of calcium and magnesium salts at elevated temperatures, which result in the hot process having a higher efficiency than the cold Because of the limitation stated above, the strong acid followed by weak acid system is used for produced water with TDS between 5000 - 8000 ppm. The chemical structure of the weak acid cation exchange resins is usually a carboxylic acid group within an acrylic divinylbenzene matrix. This type of resin exhibits a very strong selectivity for calcium and magnesium ions. Hence, it can effectively remove the hardness in a system where the strong acid resin cannot. The resin is considerable more costly to purchase, and requires two steps in regeneration; first, it is treated with hydrochloric acid to remove the calcium and magnesium and then with caustic soda to convert the resin back to the sodium form. Compared to the cost of brine regenerant (for strong acid resin), the cost of acid and caustic (for weak acid resin) is several times higher. process. The hot process can reduce the hardness of the water down to 15-25 ppm. The cold process is limited to 30-50 ppm. Since by itself, neither process can meet the requirements of less than 1 This system utilizes strong acid resin as primary softener to remove majority of the hardness and minimize the regenerant cost. It is followed with ppm hardness, ion exchange softeners are used for final polishing. The polishing softener could be a strong acid resin or a weak acid ion exchange resin depending on the TDS of the water. a weak acid resin as polisher to ensure the final softness of the product water meets the 1 ppm specification. The lime processes reduce bicarbonate and silica in feedwater in addition to the hardness. For softening of large volumes of water With high hardness and high TDS, it is an economically Several operators in Kern County have chosen this option. attractive process, however, it requires handling/storage facilities for lime, 520 produc~s SPE 19759 RAYMOND J. JAN large volumes of sludge for disposal snd is susceptible to operating upsets due to lime scale or plugging. Further, in most processes using lime, the feed water is routinely heated to above its boiling point (212 - 220 F) to enhance the chemical reactions between the lime and the hardness ions. These high temperature "hot lime" processes require expensive pressure vessels, additional energy for heating, and present delicate handling and safety problems, all of which add substantially to the overall costs of the water softening operation. Esso in Canada is operating several large hot lime softening units with weak acid polishing. No producers in the heavy oil field of Kern County, California are utilizing this process at this time. Ihermosoft/Ihermosludge Process If water containing significant quantities of bicarbonate is heated under pressure to above 400 F, the bicarbonate will decompose, liberating C02 and causing the pH to increase. This increase in pH will precipitate the calcium and magnesium. The sludge thus produced will absorb some of the silica content as well. At this high temperature the hardness can be reduced to less than 1 ppm and some silica is removed in the sludge. A number of years ago, "thermosludge" boilers which use a related process, were built which generated 100 , steam from produced water(15). Both softening and steam generation took placa in the same equipment. The high cost of the equipment and operating difficulties restricted its use. Work is continuing, primarily in Canada, to develop a commercial process "Thermosoft" utilizing this chemistry to soften produced water for feed to steam generators. 3 given in Table 1. Because of its high TDS (10,500 ppm), one could not expect the existing strong acid softeners to be able to soften the produced water to less than I ppm hardness. One of the first options considered was to install new weak acid softeners which would function as polishers and remove any hardness leakage from the existing strong acid softeners. Such a system is schematically shown in Figure 1. A second option investigated was lime softening followed by weak acid resin. Laboratory tests confirmed that lime process would be about two cents per barrel lower in operating costs when compared to the strong acid followed by weak acid system. Howeyer, the quantity of solid prd'duced by the precipitation of the calcium and magnesium would present a significant disposal problem. It was therefore decided to investigate the use of caustic soda instead of lime to effect the precipitation of calcium and magnesium. CAUSTIC PRECIPITATION PROCESS AT BELRIDGE Chemistry Caustic (NaOH) is known to elevate the pH of a solution and when carbonate in sufficient quantity is present will cause the calcium and magnesium hardness to precipitate just as the lime (Ca(OH)2) does. However, the cost of caustic versus lime, on an equivalent hydroxyl ion ( OH- ) basis is at least six times higher. For this rea~on, lime has been commonly used for large scale commercial water softening purpose. There is not another known water softening plant which uses the caustic precipitation process. The chemical reactions that take place for a lime and a caustic precipitation reaction are as follows: Ca(OH)2 SOUTH BELRIDGE FIELD The South Belridge field is located in western Kern County, California approximately 50 miles west of Bakersfield. The overall structure of the field is a broad southeasterly plunging anticline, about nine miles long and two miles wide. Mobil has for years, operated a steam drive at the south end of the field. Current steam injection rate is about 110,000 BID or about 1,650,000 pounds per hour. Ca(OH)2 + 2 NaHC03'" CaC03# + 2 H20 + Na2C03 Caustic Soda For many years, steam generator feed water was prepared by blending produced water with fresh water from the California Aqueduct in about a 50-50 ratio. The blend resulted in a water of about 4000 - 5000 ppm TDS and was softened in a strong acid resin system which consisted of eight trains of primary and polishing vessels. The use of the fresh water meant that significant quantities of produced water had to be disposed of each day. With ever increasing difficulties in produced water disposal, and potential restrictions on fresh water supply, a decision was made in 1987 to convert the generator feed water system to 100 % produced water. NaOH + Ca( HC0 3) 2 .. CaC03+ + H20 + NaHC03 2 NaOH + Mg( HC0 3) 2 .. Mg(OH) 2+ + H20 + Na2C03 NaOH + NaHC03 -- Na2C03 + H2 0 The chemical reactions show that a). To precipitate each mole of calcium ion, two moles of hydroxyl ion are required with lime while only one mole is needed with caustic. In preCipitating each mole of calcium hardness, two moles of calcite (CaC03) sludge are formed with lime, while only one mole is formed with caustic. A typical Belridge produced water analysis is 521 4 b). A NEW CAUSTIC PROCESS FOR SOFTENING PRODUCED WATER FOR STEAM GENERATION To precipitate each mole of magnesium hardness, four moles of hydroxyl ions are required with lime while only two moles are needed with caustic. In precipitating each mole of magnesium hardness, two mol~s The treated water from the reactor/clarifier, with its hardness reduced from 514 ppm to about 10 - SO ppm, is processed in sand filters where any entrained solids are removed from the water. of calcite and After filtration, the water enters the ion exchange polisher vessels. Weak acid resin having a carboxylic functional group is used in this step where substantially all of the remaining hardness ions, i.e., calcium and magnesium, are removed from the produced water. The soft water, having a final hardness of less than 1 ppm is supplied as feed one mole of magnesium hydroxide sludge are formed with lime, while only one mole of magnesium hydroxide is generated with the caustic process. c). SPE 19759 Neutralizatio~of sodium bicarbonate, which is required in order to raise the pH. consumes hydroxyl ions. The neutralization generates calcite sludge for the lime process but no solid precipitant is formed for the caustic water to steam generators. process. Further, lime has such a low solubility in water that a significant portion of it is not dissolved and thus not used in the precipitation process. The undissolved lime is included in the resultant sludge. These theoretical observations were confirmed in laboratory tests conducted with Belridge produced water. The sludge formed in a caustic process is five times less than for the lime reaction. The operating cost is less than one cent per barrel of soft water higher than for the lime system. The precipitate from the reactor/clarifier is dewatered in a centrifuge and these solids, which constitute the only substantial waste in the operation, are removed as a sludge and are ready for disposal as landfill materials. Liquid wastes due to filter backwashing and ion exchange regeneration are recycled to the reactor/ clarifier where they are processed along with the produced water. This results in no liquid waste which must be injected or otherwise be disposed of. BELRIDGE OPERATING RESULTS Caustic soda had additional advantages. First it could be added to the system as a liquid which made control easy as opposed to metering solid lime. Second, caustic is used for weak acid resin regeneration, its supply and storage are needed anyway. Third, lime sludge is very susceptible to scaling and plugging which makes lime based softeners less reliable. Caustic sludge is fluffy and flows like a thick paint. Conceptual design of the Belridge water plant started in July, 1987. Detailed engineering, equipment procurement and construction were completed in October, 1988 and the new water plant was placed in service one month later. The plant has a design capacity of 120,000 BID with feed of only produced water. Typical operating data is given in Table 2. The reactor/clarifier effectively reduces the produced water hardness from about 500 ppm down to about 35 ppm at a pH of 9.3. Over half of the silica is also removed, possibly as magnesium silicate. This is an added benefit for the precipitation process as conventional ion exchange alone woulc not have reduced any of the silica Based on these factors. a decision was made to develop a caustic precipitation system followed by weak acid ion exchange to soften the produced water at Belridge. The rate of reaction between the caustic and the dissolved hardness ions in the water is strongly dependent upon time, temperature, pH and the sludge recirculation. At Belridge, the water being treated is produced as part of the production of a steam recovery operation and is already at a temperature of 160 - 180 F. This relatively high temperature greatly benefits the caustic precipitation reactions. The clarifier was sized, based on laboratory tests. to give a 1 gpm/sq. ft. for reaction and settling. A pH of 9.3 was found to be content. Also, heavy metals such as barium. iron, manganese and strontium are practically all removed at the clarifier. Overall quality of the feed water to the steam generators improved significantly compared to the original strong acid ion exchange system. Because over 90 , of the hardness is removed in the reactor/clarifier, the weak acid ion exchange columns are able to operate without needing a regeneration step for five to seven days. In the absence of a clarifier, the ion exchange system would need to be regenerated at about once every twelve hours. Significant chemical savings and ease of operations are realized. optimum. Process Block Diagram The process block diagram developed for the Belridge water plant is given in Figure 2. OPERATING PROBLEHS AND SOLUTIONS In operation, the produced water enters a reactor/ clarifier where it is mixed with an aqueous solution of caustic. In the reactor/clarifier, a large volume of dense slurry of previously precipitated solids is recirculated and mixed with the incoming produced water. This sludge recirculation provides The new water plant has been in service for over six months treating all produced water. The efficiency and smoothness of operation have exceeded the original expectations. Over this period, there were two shut downs related to the reactor/clarifier. Deflection of the rake shaft seed crystals and encourages the completion of the precipitation reactions. 522 SPE 19759 RAYMOND J. JAN 5 caused the rake arms to cateh the sample line in one instanee and eon tact with the tank floor in other instanee. Corrective action is underway to add a lower support member to restrain the shaft from moving. his valuable advice and test work on ion exchange system and to E. R. Fieler, Mobil Exploration and Producing Serviee Inc. for her review and valuable comments of the manuscript. Scaling and plugging problems which eommonly occur in a lime proeess have not been observed even when sludge is left standing for over a week. REFERENCES The centrifuge is eoncentrating the elarifier sludge to over 50 , solids, whieh were subjected to the State of California "Criteria for Identifieation of Hazardous and Extremely Hazardous Waste" tests and deemed not hazardous. 1. Kuuskraa, V.A.: "The Status and Potential of Enhanced Oil Recovery". SPE/DOE No. 14951, Paper presented at the SPE/DOE Fifth Symposium on Enhanced Oil Recovery, Tulsa, OK., April 20-23, 1986. For produced waters with even higher hardness and TDS than those of Belridge, the proeess would be even more attractive. The higher capital and operating eosts of ion exchange systems make them impractical. 2. Farouq Ali, S.M.: "Current Status of Steam Injection as a Heavy Oil Recovery Method". J. Cdn. Pet. Tech., Jan-March, 1974, pp. 1-15. 3. Farouq Ali, S.M. and Meldau, R.F.: "Current Steamflood Technology". J. Pet. Tech., Oct., 1979, pp. 1332-1342. 4. Chu, C.: "State-of-the-Art Review of Steamflood Field Projects". SPE No. 11733, Paper presented the 1983 California Regional Meeting, Ventura, California, April 23-25, 1983. 5. Bradley, B.Y. and Gatzke, L.R.: "Steamflood Heater Scale and Corrosion". J. Pet. Tech., Feb., 1975, pp. 171-178. 6. Burns, W.C.: "Water Treatment for Once-Through Steam Generators". J. Pet. Tech., April, 1965, pp.417-421. 7. Reyes, R.B.: "Softening of Oilfield Produced Water by Ion Exchange for Alkaline Flooding and Steamflooding", SPE 11706, presented at 53rd Annual California Regional Meeting of SPE, Ventura, CA., 1983. 8. Hart, R.A. and Thomas, S.A.: "Design and Implementation of Softening Process for High TDS Oil Field Produced Water", International Water Conference, IWC-86-9, 1986, pp. 72-80. 9. Lange, P.M., Martinola F.B. and Soest H.K.: "New Technology in the Softening of Produced Water in Enhanced Oil Recovery Systems", International Water Conference, Pittsburg, Penn., IWC-87-36, 1987. 10. Bradley, B.W.: "Influence of Salt Dosage and Hardness on Series Softener Performance", SPE 1951, Presented at 42nd Annual Fall Meeting of SPE, Houston, Tx., Oct., 1967. 11. Harden, J.E. and Hull, G.R.: "Operating Experiences with a Large Hot Lime-Zeolite System for 1500 PSI boilers'", Proceedings, Am. Power Conf., Vol. XIX, 1957, pp. 672-684. 12. Lane, M. and Duff, J.H.: "Some Chemical Aspects of Hot Process-Hot Zeolite Plant Performance", . With ever increasing limitations on produeed water disposal and fresh water supply, other existing water plants are under study for conversion. CONCLUSIONS 1. 2. 3. A new process for softening of high TDS produced water for steam generation using caustic has been developed and commercially demonstrated. The use of caustic preeipitation redueed the calcium and magnesium hardness from about 500 ppm to less than 50 ppm. Residual hardness was polished to less than 1 ppm by weak acid ion exchange resins. For. high TDS and high hardness produced water, this process offers a signifieant operating cost reduction over the conventional weak acid ion exchange systems with the additional benefit of psrtial silica removal. 4. 5. This process concentrates the calcium and magnesium hardness from the produced water as calcite and magnesium hydroxide solids and generates no liquid waste. Compared to the lime system, this process is cost competitive, operationaly more reliable and produces only about 20 , of the solid sludge volumes. Caustic precipitation sludge is fluffy and not susceptible to scaling and plugging as does the lime process sludge. ACKNOWLEDGEHENTS The authors wish to thank Mobil Exploration and Producing U.S. for permission to publish this paper. Thanks are due R. B. Reyes, Dow Chemical U.S.A. for 523 A NEW CAUSTIC PROCESS FOR SOFTENING PRODUCED WATER FOR STEAM GENERATION 6 Presented before the 16th Annual Meeting of the Am. Power Conf., Mar. 24-26, 1954. 13. Liang, L.S., Wei, I.W. and Siderrpou10s H.G.: "Simulation of Lime-Soda Softening", J. Envir. Eng. Div., Oct., 1980, pp. 935-945. 14. Owen, T.E. and Humenick, M.J.: "The Effect of Water Treatment Alternatives on Water Demands for In Situ Production of Bitumen", University of Wyoming, Dept. of Civil Eng., 1985. 15. Hull, R.J.: "The Thermos1udge Water Treating and Steam Generation Process", J. Pet. Tech., Dec., 1967, pp. 1537-1540. TABLE 2 TABLE 1 OPERATING RESULTS OF THE BELRIDGE CAUSTIC SOFTENING PLANT (12/6/88) TYPICAL BELRIDGE PRODUCED WATER ANALYSIS CONSTITUENTS CALCIUM, AS Ca AS CaC03 MAGNESIUM, AS Mg AS CaC03 TOTAL HARDNESS, AS CaC03 CONSTITUENTS PPM CONCENTRATION, PPM PRODUCED WATER CLARIFIER OVERFLOW SOFT . WATER 103 pH, unit 7.0 9.3 9.3 257 HARDNESS, AS CaC03 407 35.4 0.6 SILICA, AS Si02 202 88 78 257 IRON, AS Fe 0.5 0.1 0.1 514 BARIUM, AS Ba 2 0.5 0.5 MANGANESE, AS Mn 0.2 0.05 0.05 STRONTIUM, AS Sr 3.1 0.1 0.1 63 SODIUM, AS Na 3,900 BICARBONATE, AS HC03 1,362 CHLORIDE, AS Cl 5,300 SULFATE, AS S04 76 SILICA, AS Si02 242 TDS SP! 19759 ... _.----------------_ ..... _---------_._._-_._---_._.-- 10,500 pH, unit 7.0 TEMPERATURE, F 170 524 . SPE 197 C; 9 , FILTERED WATER ElCISTINel mONel ACID SOFTENERS ,., NEW WEAK ACID SOF'TENERS REGENERATED WITH .. " HCL AND .. " NaOH SOLUTIONS . TO SOFT WATER TANK FIGURE 1: SCHEMATIC DIAGRAM or A STRONG ACID rOLLOWED BY A WEAK ACID SYSTEt.I I'IIODUCED WATER II _ SOUDS , SOUII/UGUID SEPAIIA)'ION _SUJDOE ...- UQUIDS NaOH IN IlEACTOR CUIUFIER • BACKWASH IN ~ ~ OVERF\.OW FILTERS fw:t;ASH OUT ~ 1IlIIOIERA11ON WEAK ACID CHtII1CALS IN IX IIEGOIEIWITS OUT 1 SOFT WATER FIGURE 2: BELRIDGE WATER PLANT BLOCK DIAGRAM 525
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