Iron Removal from Waste Water via Spray Atomization
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Solution Overview
Problem
Current methods for removing iron from flowback and produced water in the oil and gas industry are expensive, complex, and pose safety risks due to the need for air injection, leading to inefficient processing and potential explosions.
Innovation Solution
The system employs oxidizers and self-generating, self-sustaining active sludge layers in treatment tanks, where the water is spray-atomized to increase surface area and facilitate oxidation, reducing the need for air injection and enhancing iron removal through a self-sustaining filtration process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aeration is used to remove iron from waste water, then iron removal is achieved, but the risk of explosions increases and the system becomes more complex
Solution Approach 1:
The patent uses strong oxidants such as hydrogen peroxide, ozone, or permanganate to accelerate the oxidation of ferrous iron to ferric iron, eliminating the need for prolonged aeration and reducing explosion risks associated with air injection systems
2Reliability
If membrane filtration is used to remove iron, then iron removal is achieved, but the system becomes expensive and prone to membrane fouling
Solution Approach 1:
The patent performs preliminary oxidation of iron to form precipitates before filtration, removing iron in a more economical manner and preventing membrane fouling by eliminating the need for expensive membrane filtration systems
3Reliability
If ion exchange is used to remove iron, then iron removal is achieved, but the system becomes overly complicated and difficult to operate
Solution Approach 1:
The patent extracts iron from waste water through oxidation and precipitation, separating it from the water stream in a simple, easily operated process that eliminates the complexity of ion exchange systems
4Reliability
If current iron removal techniques are used, then iron is removed, but adequate flow-through is not maintained for efficient processing
Solution Approach 1:
The patent changes the oxidation state of iron from ferrous to ferric, causing precipitation that can be easily separated while maintaining high flow-through rates and efficient processing capacity
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
This method provides an affordable, efficient, and safe means to remove iron from contaminated water, reducing equipment corrosion and membrane fouling, while maintaining efficient flow-through and minimizing regulatory compliance issues.
Implementation Method 1
The systems and methods employ one or more oxidizers... mixed with the one or more oxidizers and pumped into the one or more treatment tanks
Implementation Method 2
The one or more dispersion devices spray-atomize the mixture into minute globules (e.g. a fog, a mist or the like) inside the one or more treatment tanks
Implementation Method 3
additional mixtures of flowback fracturing water or produced water may then be atomized into the one or more treatment tanks where they interact with the active sludge layer... thereby removing various iron species from the additional mixtures
Implementation Method 4
The atomized mixtures settle and form a layer of active sludge and a treated solution in each the one or more treatment tanks
Data Source
AI summary
Systems and methods for removing iron from waste water employ one or more oxidizers, one or more treatment tanks having one or more self-generating and self-sustaining active sludge layers, and one or more spray-atomizing devices. A mixture of flowback fracturing water, or produced water, and the one or more oxidizers is spray-atomized by the spray-atomizing device inside the one or more treatment tanks. The atomized mixture settles in the one or more treatment tanks resulting in one or more self-generating and self-sustaining active sludge layers and one or more treated solutions. Additional mixtures of the flowback fracturing water, or produced water, and the one or more oxidizers may be continually spray-atomized into the one or more treatment tanks and filtered by the one or more sludge layer(s) so as to remove precipitated iron species from accumulated distillates and produce additional treated solutions for collection in one or more finish tanks.