Produced Water Bypass Control for Steam Generation

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Solution Overview

Problem

In oil or bitumen extraction operations, produced water contains contaminants like oil, grease, and silica that can foul steam generating equipment, and its varying quality poses challenges for treatment and reuse, requiring an economical and reliable method to manage contaminant concentrations for efficient steam generation.

Innovation Solution

A process and apparatus that allows a portion of produced water to bypass certain treatment units, adjusting contaminant concentrations by monitoring and controlling the flow through a series of treatment units, including oil-water separation, water treatment, and steam generation units, using sensors and chemical adjustments to maintain optimal contaminant levels for steam generation, and incorporating a by-pass line to enhance throughput and reduce equipment costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If all produced water flows through the complete treatment train, then contaminant removal is maximized, but treatment cost and energy consumption increase unnecessarily

Engineering Contradiction:

Improvecontaminant removal effectivenessVSAvoidtreatment energy consumption

Core Design Contradiction:

Manufacturing precisionVSLoss of energy

Solution Approach 1:

The system applies partial treatment action by allowing a portion of produced water to bypass certain treatment units when contaminant levels are already acceptable. This prevents unnecessary energy consumption while maintaining sufficient contaminant removal effectiveness for steam generation requirements.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The system dynamically changes operational parameters (flow distribution ratios) based on real-time contaminant concentration measurements. When contaminant levels are low, more water bypasses treatment; when levels are high, more water receives treatment, optimizing the balance between removal effectiveness and energy consumption.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If produced water treatment train is oversized to handle upset conditions, then reliability is improved, but capital cost and operating cost increase

Engineering Contradiction:

Improvetreatment system reliabilityVSAvoidtreatment train size

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system uses dynamic flow control to adjust treatment capacity in real-time based on actual contaminant loads. During upset conditions with high contaminant concentrations, the control system increases treatment throughput. During normal conditions, it reduces treatment throughput. This dynamic adjustment provides reliability during upsets without requiring permanent oversized equipment.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system extracts only the necessary treatment capacity needed at any given moment based on real-time monitoring. Instead of having fixed oversized capacity, the system dynamically activates only the treatment capacity required for current conditions, reducing both capital and operating costs while maintaining reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If produced water is treated to very low contaminant concentrations, then steam generation reliability is improved, but treatment cost increases

Engineering Contradiction:

Improvesteam generation reliabilityVSAvoidtreatment cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The system changes the target contaminant concentration parameter dynamically based on actual water quality and steam generation requirements. Instead of always treating to a fixed low concentration, the system adjusts the target concentration to match actual needs, reducing treatment cost while maintaining sufficient steam generation reliability.

Inventive Principle:

Principle #35Parameter changes

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 approach allows for stable contaminant concentrations in produced water entering steam generation units, reducing equipment costs and energy consumption by optimizing treatment processes, enabling efficient reuse of produced water without over-sizing treatment trains, and effectively managing upset conditions.

Implementation Method 1

an oil-water separation unit

Methodology Applied

Scientific EffectGravity separation: Gravitation

Implementation Method 2

oil-water separation

Methodology Applied

Scientific EffectDensity difference: Density Gradient

Implementation Method 3

steam generating unit

Methodology Applied

Scientific EffectSteam generation: Boiling

Data Source

PatentUS10501353B2Monitoring and control of unit operations for generating steam from produced water

Publication Date: 2019.12.10 BL TECHNOLOGY INC

AI summary

In a process and apparatus for treating produced water, the produced water flows through a series of treatment units. A portion of the produced water may by-pass one or more of the treatment units but the by-pass portion may be such that the treated water is still acceptable, for example for discharge or reuse. Concentrations of oil and grease, organic carbon, silica, pH or related parameters in the produced water may be monitored and used to control the process or apparatus. Control of the process may involve one or more of altering a by-pass portion, altering the addition of chemicals, and altering the operation of a unit process. The process may be controlled to respond to upset conditions, or such that the concentration of one or more limiting contaminants is near, but not over, a specified maximum for re-use or discharge.