Ceramic Membrane Filtration for Polymer Recovery in Produced Water
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Solution Overview
Problem
Current methods for treating produced water from chemically enhanced oil recovery processes are inadequate in separating water from suspended solids, free oil, and emulsified oil, and fail to recycle viscosity-increasing polymers effectively, leading to limited polymer reuse and increased chemical addition in reinjection.
Innovation Solution
A treatment process using a microfiltration ceramic membrane with a cut-off ranging from 2 μm to 10 μm to separate viscosity-increasing polymeric compounds from suspended solids and emulsified oil, allowing for the recycling of polymers and reducing the need for additional chemicals in the permeate before re-injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional treatment processes are used for produced water from polymer flooding, then oil separation is achieved, but polymer recovery is insufficient and membrane fouling increases
Solution Approach 1:
The patent changes the membrane cut-off parameter from conventional smaller values to specifically 2-10 μm, and adjusts operating parameters like transmembrane pressure (0.5-5 bar) and temperature (25-110°C) to optimize polymer passage while retaining oil and solids, resolving the contradiction between polymer recovery and membrane fouling
Solution Approach 2:
The patent employs ceramic membranes with specific porosity and pore size distribution (cut-off 2-10 μm) that allow polymer molecules to pass through while blocking oil and suspended solids, achieving simultaneous polymer recovery and fouling prevention through material selection
2Manufacturing precision
If smaller membrane cut-off is used to separate emulsified oil, then oil separation improves, but polymer loss increases
Solution Approach 1:
The patent optimizes the membrane cut-off parameter to 2-10 μm, which is larger than conventional ultrafiltration membranes, allowing polymer molecules to pass through while still effectively separating emulsified oil droplets, thus resolving the trade-off between oil separation efficiency and polymer loss
3Loss of substance
If multiple treatment steps are added to improve polymer recovery, then polymer recycling improves, but process complexity increases
Solution Approach 1:
The patent makes the ceramic membrane filtration step perform multiple functions simultaneously: separating oil, removing suspended solids, and recovering polymers in a single operation, eliminating the need for multiple separate treatment steps and reducing overall process complexity while improving polymer recycling
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process effectively recycles viscosity-increasing polymeric compounds, reduces membrane fouling, and allows for the reuse of polymers in oil-bearing formations, enhancing oil recovery while minimizing the addition of new polymers and chemicals.
Implementation Method 1
directing the produced water to a filtration device, and subjecting the produced water to filtration, for obtaining a retentate stream and a permeate stream, wherein the filtration device comprises a microfiltration ceramic membrane unit having a cut-off of from about 2 μm to about 10 μm
Data Source
AI summary
The present invention is concerned with the treatment of produced water, that may be obtained from a chemically enhanced oil recovery process using viscosity-increasing polymeric compounds. Said treatment comprises particularly the steps of obtaining a produced water, such as from an oil-water mixture recovered from an oil-bearing formation, wherein the produced water comprises the viscosity-increasing polymeric compounds; and, of directing the produced water to a specific filtration device, and subjecting the produced water to filtration, for obtaining a retentate stream and a permeate stream. Said process allows particularly obtaining a permeate comprising the viscosity-increasing polymeric compounds, said permeate being substantially free of suspended solids, free oil and emulsified oil.