SAGD (De-Oiling) Solutions

SAGD Produced Fluid Separation requirements: Sand Removal: continuous, batch process, in tank separators Oil Removal: cyclones, induced gas flotation, filtration Gas Removal: cyclones, large vessels, high pressure cyclones Question #1 – What level of water quality is required? (How Clean is Clean?) Question #2 – What does it cost to get the water quality required? Question #3 – What level of water quality can I get within the allotted budget? Produced Water Treatment Equipment

WATER TREATMENT APPLICATIONS General Data Sheet Information Temperature Pressure Water flow rate Inlet oil in water concentration (ppm-mg/L) Inlet TSS Suspended solids conc. (ppm-mg/L) Outlet oil in water concentration (ppm-mg/L) Outlet TSS Suspended solids conc. (ppm-mg/L) Redundancy Applicable codes and manufacturing specifications Materials of construction Controls and automation Coatings Safety in design standards Off shore certification, foreign standards Defining Water Treatment Options

Technology Offered By APSI & PS Filter General Process Fluids Overview

OWS EQPT- IGF & NSF (ORF) UNITS HERE OWS EQPT- NSF (AF) UNITS HERE SAGD Flow Chart

Produced Water Separation Capabilities Gravity Separation Two Phase/Three Phase Separators: 1000’s of ppm oil in water, % oil in water CPI/API Separators: inlet 5, ,000 ppm - removal efficiency 90% ppm outlet Cyclonic Separation De-oiling Hydrocyclones: 2,000-5,000 ppm inlet – removal efficiency 90% ppm outlet Pressurized Oil/Water Separation Induced Gas Flotation: ppm inlet – removal efficiency 90% ppm outlet Pressure Filtration – Granular Media/Depth Filtration and Surface Filtration Nut Shell Filter: ppm inlet – removal efficiency 90% ppm outlet Cartridge/Bag filter: 2-5 ppm inlet – removal efficiency 90% - less than 1 ppm – or absolute micron cut off

Produced Fluid Separation Requirements Off Shore Disposal or Injection Disposal: GOM 29 mg/L (ppm), spikes to 40 mg/L (ppm) – everywhere else in the world – 15 ppm and lower On Shore Water Management Disposal Wells: what is required to make sure they do not plug the injection well – completely dependent on the injection formation – 50 ppm? – 20 ppm? Less for tighter formations. Water Flood for Oil Recovery: again water quality to assure the injection well does not get plugged such that long term oil production is affected – 20 ppm or less usually required Steam Flood for Enhanced Oil Recovery: pressure and temperature for enhanced oil recovery – protecting softeners and steam generators – 2 ppm or less usually required

Single Cell IGF Package

30,000 BWPD Single Cell IGF P&ID

Single Cell IGF 3D Model 100,000 BWPD

IGF & Nut Shell Filter Package

Horizontal Quad Cell IGF 3D Model

Horizontal Quad Cell IGF Package

Horizontal Quad Cell IGF P&ID

Horizontal IGF “Mechanical Agitation”

Filtration in a Nut Shell!

Crushed Walnut Shells

Typical Flow Scheme

Typical Oil Removal Efficiency

Typical Solids Removal Efficiency

Backwash Assembly Schematic The backwash continues up the shaft sleeve and out the backwash exit ports Backwash water exits through the screen and the walnut shells are retained in the vessel The mixer scrubber assembly rotates preventing plugging of the basket

Internal Backwash Assembly Rotating Backwash Basket Agitator Blades

NSF Backwash Outlet Samples

Typical Walnut Shell Filter Designs

Mixer Design vs Pump Design

NSF Design w/ External Pump

NSF Design #2 w/ External Pump

NSF Design w/ Internal Mixer

CFD Study of Mixing in Cylindrical Tanks Performed for R & D 1057 Dr. Binxin Wu Sr. CFD Research Engineer Philadelphia Mixing Solutions 1221E. Main St., Palmyra, PA Phone: Fax: Mar. 13, 2013

Objectives The objectives of this CFD analysis are to: 1. Develop a CFD model to predict the mixing flow patterns in cylindrical tanks mixed by a mechanical impeller and a pump, respectively, and 2. Qualitatively and quantitatively identify the flow patterns.

Pump Mixing Model Inputs Liquid Height:17’ Tank Diameter:12’ Fluid Properties:viscosity: 1 cPdensity: 1.3 SG Pump Diameter: 10” Pumping Rate: 800 usgpm per each inlet

Pump Mixing Design Outlet Inlet

Velocity Contours (Front View) m/s y = 0 (central-plane) m/s

Velocity Contours (Top View) m/s z = 30”

Velocity Vectors (Front View) m/s y = 0 (central-plane)

Velocity Vectors (Top View) m/s z = 30”

Mechanical Mixing Model Inputs Liquid Height:91” Tank Diameter:144” Fluid Properties:viscosity: 1 cPdensity: 1.3 SG Impeller Type:LS 3/39 Impeller Diameter:58” Impeller Off the Bottom:56” Impeller Rotational Speed:125 rpm

Mechanical Mixing Design

Velocity Contours (Front View) m/s y = 0 (central-plane)

Velocity Contours (Front View) m/s y = 0 (central-plane)

NSF Filter Package 3D Model

APSI Nut Shell Filter Pilot Site Test

APSI Nut Shell Filter Pilot Skid – 3,500 BWPD

Nut Shell Filter Package for ConocoPhillips Canada

NSF & IGF Package – 30,000 BWPD

Horizontal IGF & 2 NSF Units

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