Aibel Technology

Advanced Methods for Dehydration of Heavy Oils

Jarle MichaelsenManager, Separation Business UnitVera Cruz: 19 March 2009 www.aibel.com

Outline

Introduction to Produced Water SeparationWhat is electrocoalesence ?What is VIEC (Vessel Internal Electrostatic Coalescer) ?How does it work ?What are the benefits ?

2

Where does the water come from?

3

WATER

GAS

OIL

Produced Water Separation

4

Main reasons for VIEC

RejectGas

Water

Oil ExportEL.COALESCER (Dehydrator)

LP GasHP Gas

HeatHeat

Advantages :

•Increase production •Improve level control•Reduce chemical consumption•Reduce fluid heating •Less fresh water for desalting

•Improve BS&W•Improve water quality before discharge •Compact Separation

©20

08

6

The electric field creates an attractive force between water droplets. This forces them to coalesce, and thereby the settling velocity increases.

What is electrocoalescence ?

- ++ -

Water droplets

Electrodes

Laboratory test with VIEC

7

VIEC feasibility tests are used to find the potential of the VIEC for a specific process and to optimize chemicals.Emulsions are mixed, exposed to demulsifier, and treated/not treated with the electric field. Droplet size distributions are always measured. The amount of free water separated with time is recorded.

100 ml

HV AC

100 ml

HV AC

100 ml100 ml

HV AC

VIEC Performance

0

10

20

30

40

50

60

70

80

90

100

0 20 40 60 80 100 120

Atmospheric viscosity (cP)

Sep

arat

ion

durin

g no

rmal

resi

denc

e tim

e (%

)

WITH VIECNO VIEC

VIEC will provide efficient bulk water removal in normal ranges of operational conditions.

When normal gravitational separation gives some separation, the VIEC will provide more than 70% separation, usually even much better.

For production separators in operation, a performance in the range from 2-8% BS&W in the oil outlet is usually achived.

Figure: Separation results of different crude oils as a function of the crude oil viscosity. Normal residence time, normal dosage of demulsifier, small droplets

©20

08

9

Typical VIEC System

VIEC wall VIEC Block Control room

Details of one VIEC wall

Spring loaded brake shoes

VIEC wall complete with tubing

12

The High Temperature VIEC (HTVIEC) has the same function as the epoxy VIEC™

Made to withstand high temperatures so that it may be installed in separators where high temperatures are required i.e for heavy and viscous oils

The HTVIEC is designed to withstand 150ºC, and the material in the main components are stainless steel and ceramics

Pilot installation will be july 2009 on Teekay Petrojarl’s FPSO for Petrobras’ Siri project for oil with API grade 12

HTVIEC – High Temperature VIEC

HT VIEC Block

13

High Temperature VIEC – Piloting on SIRI (Brasil)

HT-VIECILMS

©20

08

14

Modification of separator internals

Aibel’s Computional Model for Wave Simulations in Separators

15

LOWACC™ – Low Water Content Coalescer

LOWACC™

The LOWACC™ is designed to operate downstream of the VIEC™ to knock out the last traces of water. Combined with the VIEC™, this may enable one-stage separation and/or enhance heavy oil separation

The LOWACC™ is particularly good for separatorswith difficult separation or heavy emulsions Due to longer retention time in the electrostatic field , LOWACC™ can in several cases provide export quality of oil (BS&W 0.5%) without any further treatmentThe LOWACC™ is planned to be released to the market this year (Piloting)

LOWACC Wall

©20

08

16

Example - 80.000 BLPD separation moduleCompact Separation Conv. Separation Module

Size 9,3m x 16,3m (151 m2) 16m x 28m (448 m2)Weight 280 ton 520 ton• Piping 30 ton 140 ton• Structure 126 ton 230 tonEquipment• Pumps 0 6 (crude trans, pw trans, coal. trans)• Vessels 2 3• Valves 50 % 100%• Instrument 40 % 100%

©20

08

17

VIEC Installations1. StatoilHydro, Troll C - Reduced chemical cons.and increased production API 29

2. Bluewater, FPSO Munin - Increased production API 26

3. StatoilHydro, Research Center - Improved separation API 17 - 32

4. Maersk Oil Qatar, Al Shaheen - Improved separation API 22 - 28

5. StatoilHydro, Grane - Improved separation, increased production API 19

6. Petrobras, P-34 - Improved separation of heavy oil API 17

7. Petrobras, P-35 - Cleaner Produced Water from heavy oiland reduced heating API 20

8. StatoilHydro, Volve - Improved separation, salt removal API 39

9. StatoilHydro, Fram East - Increased production API 29

10. Petrobras, P-37 – Improved separation API 22

11. Woodside, Vincent - Improved separation, reduced

residence time API 19-21

12. StatoilHydro, Heidrun - Improved separation, Naphtenates API 25

13. StatoilHydro, Gjøa - Expected emulsion problems API 50

14. BP, Valhall - Emulsion problems API 39

15. BP, Schiehallion - Emulsion problems, Production restrictions API 27

16. Total, Ofon – Emulsion problems, API 45

©20

08

18

Summary of potential VIEC benefits

•Increased production•Increased process uptime•Reduced weight & space •Reduced chemical consumption•Reduced emissions to sea•Reduced consumption of energy

Test Separator used at Cantarel field

19

Advanced Electrostatic Coalescers

VIEC Vessel Internal Electrostatic CoalescerBulk Water Removal 2 – 6 % Water in Oil

LOWACCLOw WAter Content CoalescerPolishing unit. Export Oil Quality< 0,5 % Water in Oil

High Efficiency Compact Separation©

2008

21

LP Crude Degasser/PW Degasser

HP separator

Produced Water Treatment

Interstage Heater

16. Total, Ofon – Emulsion problems©

2008

22

Motivation: The process design basis anticipates that stable oil/water emulsions will occur in the production separators. In addition Aromatic Rich Naphtha is present in the oil. This may cause deposits in the presence of emulsion making the emulsion more stable.

The design of the process system has to take no separation in the MP separator into account. Therefore installation of the VIEC® in the LP separator is required as a minimum to meet the design basis.

Result/Status:VIEC improves the separation significantly for all conditions tested

At 60 degC and no chemicals, VIEC® increase the free water knock out by a factor of ten, from 7% to 70% after 5 min.

VIEC® installed in LP Separator. Brackets installed in MP separator. To be in operation in 2010

Settling curves for OFON Oil, 60 deg C

VIEC batch test for Ofon30% WC, 60degC, with demulsifier

0

10

20

30

40

50

60

70

80

90

100

0 5 10 15 20

Time (min)

VIEC OFF

VIEC ON

VIEC batch test for Ofon30% WC, 60degC, no chemicals

0

10

20

30

40

50

60

70

80

90

0 10 20 30 40 50Time (min)

VIEC OFF

VIEC ON

VIEC batch test for Ofon30% WC, 60degC, with demulsifier and acid

0

10

20

30

40

50

60

70

80

90

100

0 5 10 15 20 25

Time (min)

Sepa

rate

d w

ater

(%)

VIEC OFF, w/demulsifier and acid

VIEC ON, w/demulsifier and acid

Sep

arat

ed w

ater

(%)

23

VIEC™– Vessel Internal Electrostatic Coalescer

The VIEC™ is designed to solve emulsion and water in oil problems and provide efficient bulk water removal

The VIEC™ can be installed inside the first- or second-stage separator, and thereby enhance speed and efficiency of the separation process

Specifically designed to tolerate 100% water and gas, VIEC™ will contribute to more cost-effective and environmentally friendly production

Increased production capacityReduced heat requirements and chemical consumptionImproved produced water quality

Features:Tested oil range API 11-40Suitable for both retrofit and new buildsOpen slots to prevent cloggingLow voltage installationFully insulated electrodes

LOWACC™ – Low Water Content Coalescer

24

IP Position

Covered by own patents

Technology status

Pilot Technology, Installed in StatoilHydro’s test loop in Porgrunn (Norway)Ready for field piloting in 2009

Competitive position

Unique technology, but competes with alternative solutions:Conventional electrostatic coalescers

Marked potentialAny installation new or retrofit where there are space or weight limitations

25

ILMS - Inductive Level Measurement System

The Inductive Level Measurement System (ILMS) is a unique level profiler

Gives a profile of oil in water in addition to detecting sand depositionsAble to detect rapidly moving oil/water interfaceThe ILMS can measure both vertically and horizontally, and it can be installed in several places throughout the vessel, using the same 2” nozzles to penetrate the pressure vessel with cablesVery robust to phenomena such as scaling

Water

Crude OilOil continuousemulsionWater continuousemulsion

Electronics

Sensor elements

Conductivity profile

Wat

er c

ont.

Oil

cont

.

Signal/Conductivity

Easiest todetect

ILMS - Inductive Level Measurement System

26

IP Position

License agreement with GE (Vetco Gray)Technology status

Allready Piloted technology, installed subsea on Troll CWill be Installed medio 2009 on Teekay Petrojarl’s FPSO for Petrobras’ Siri project for oil with API grade 12

Competitive position

competes with alternative solutions:Nucleonic density profilersCondictive level profilersRadar/ultrasound

Marked potential

Cheap and robust none nucleonic level (Oil Water) interfaceAll separators with oil/water interface control

27

HECS – High Efficiency Compact Separation

80.000 BLPD example Conv Sep. module HECSSize 16m x 28m (448m2) 9m x 16 m (144 m2)Total weight 520 ton 280 tonPiping 140 ton 30 tonStructure 230 ton 126 tonPumps 6 0Vessels 4 2

The HECS concept combines T&P's technology such as VIEC™, LOWACC™ and ILMS, and will offer more efficient and compact separators requiring fewer stages compared to a conventional system

Additional advantagesCleaner oilCleaner produced waterLes chemical consumptionLess heatingSmaller supports on deck

©20

09

28

ILMS - Description of the system

ILMS rodFerrite sensors/gas tight feedthrough for each sensorInstalled during shut-down or from 4’’ flange (future product)

Penetrator

Junction boxStandard Eex e junction box Certified Ex certificate: ”DNV-2001-OSL-ATEX-0176”

CableBFOU cable 1.5 mm2 twisted pairs, individually screenedFire and flame retardant, halogen-free, <90 oC, <250 VCables up to 70 meter has been qualified

ElectronicsAll electronics in cabinet in safe areaCommunication over TCP/IP (analog output)

Competitive advantages for increased production, while reducing emissions to sea and air:

Technology for improving the Topside designs

Technology for a

global future

• Gas technology:• Flare Gas Recovery

• Flare Gas Ignition

• HC Blanketing

• VOC Recovery

• LP Gas Compression

• Operational support, studies, and troubleshooting

• Computational Fluid Dynamics

• Laboratory services

• Separation technology:• Vessel Internal Electrostatic

Coalescer (VIEC)

• Low Water Content Coalescer

(LOWACC)

• Inductive Level Measurement System (ILMS)

• Separators w/ internals

• Sand Management

• Produced Water Treatment

• Sea Water Filtration technology:• PuriTech Fine Filter

HECS – High Efficiency Compact Separation

30

IP Position

Covered by own patents for products (Viec ,Lowacc, Combined Sep/Degasser)Technology status

Conceptual technology based on patented products.Depends on successful Lowacc piloting

Competitive position

Unique IP protected compact separationHighly competitive where size, weight and transportability are important issues

Marked potential

All process module installations where size and weight are important

Portable unitsRetrofit units

LOWACC platesPlanar insulated electrodes (similar materials as qualified for the VIEC)Planar non-insulated electrodesTransformer is similar to the VIEC

Internal tubing and external junction boxSimilar as qualified for the VIEC230 V

Power supply and softwareSimilar as qualified for the VIEC

LOWACC – current design

32

VIEC™/HTVIEC

Separation Technology Products

ILMS

PuriTech

HECS – High Efficiency Compact Separation Separators

LOWACC™

©20

08

33

Typical Size and Weights

80.000 blpd 30.000 blpdW x L 9300 x 16300 W x L 8500 x 14000280 tonnes 210 tonnes EL UPPER/LOWER DECK 7400 EL U./L DECK 6900

©20

08

34

The Vessel Internal Electrostatic Coalescer (VIEC) solves problems with emulsion and water in oil.

Fully insulated electrodes. Tolerate 100% water/gasInstallation in 1st or 2nd stage separatorSuitable for both retrofit and new buildsLow voltage installation. (220 – 230 V)Unit Power use: 10-30 kW/wallInstalled for oil range API 17- 40Tested oil range API 11- 40Temperature max 90 ºC

VIEC – Vessel Internal Electrostatic Coalescer