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REDUCED DISPOSAL COST OF PRODUCED AND FLOWBACK WATER
- 1. Applying thermal processing to the oil patch A case study in collaboration that has the potential to address the produced water challenge. Jonathan Matthews, P.E. Magpie Consulting, Inc
- 2. Shale Water Conference – The Potential in Thermal Processing © 2022 Bepex International LLC What you’ll hear from us Our preliminary understanding of the need Our experience in a similar situation Our proposed solution and preliminary economics Proposed next steps toward evaluation Who is Bepex International?
- 3. Shale Water Conference – The Potential in Thermal Processing © 2022 Bepex International LLC Our Preliminary Understanding Ratio of produced water to oil is 3-4 : 1 Disposal rates of 15-20 MMB/Day increasing to 20/28 MMB/Day by 2026 70-90% of this is currently injected into deep disposal wells Increasing hydraulic pressure in these wells has increased seismic activity Earthquakes greater than 3 (Richter) have increased from 9 to 176 in 2 years Resulted in increased regulations and more are anticipated Produced Water in the Permian Basin
- 4. Shale Water Conference – The Potential in Thermal Processing © 2022 Bepex International LLC Drawing from Experience We were approached by the members of COSIA (Canada’s Oil Sands Innovation Alliance) to h address accumulating tailings volume requirements Began a collaborative study to determine what treatment options may exist Preliminary assessment of the tailings on the bench level Pilot testing of an adaptation of an existing thermal technology Demonstration and scale-up to meet the estimated capacity of 200 tonnes/hr sludge per train Canadian Oil Sands
- 5. Shale Water Conference – The Potential in Thermal Processing © 2022 Bepex International LLC Drawing from Experience Fluid Fines Thermal Drying (FTTD)™ Demonstrated ability to concentrate a sludge from 30% solids to between 70-95% solids Product range provides flexibility to the operator for site-specific requirements The results? Dried solids are immediately trafficable Strong potential for heat recovery and integration (90%) Strong potential for H2O recovery from the vapor stream Reduction of fugitive methane emissions from tailings ponds A simplified version of the FTTD™ process could provide a significant reduction in overall cost Canadian Oil Sands Process
- 6. Shale Water Conference – The Potential in Thermal Processing © 2022 Bepex International LLC FTTD™ Process Fluid Fine Tailings, Concentrated to 50% Solids Mixer Dryer Natural Gas Air Heater Natural Gas Fresh Air (Combustion) Cyclone Separator System Blower Trafficable Deposits @ 80% Solids Dried Fluid Fine Tailings Fluid Fine Tailings (Dryer Bypass) @ 50% Solids Water Recovery Canadian Oil Sands FTTD™ Process Fluid fine tailings concentrated to 50% solids. 25% bypasses the dryer and is mixed into the dried tailings. Final composition is immediately trafficable at 80% solids. Recycle Water to Process
- 7. Shale Water Conference – The Potential in Thermal Processing © 2022 Bepex International LLC Conceptual Process Flow Dryer Natural Gas Air Heater System Blower Water 1101 B/D ~2-3% Solids Clean Water 974 B/D Concentrated Brine to Disposal Wells 37 B/D Water to Frack 89 B/D Economizer Pre-Heater Air Cooler Settlers From Well Gas Oil 200 B/D Produced Water Produced Water Process Flow 30% of the water used for fracking Dryer waste stream at 50% solids Potential to integrate natural gas to be flared Outputs are variable based on site-specific requirements Natural Gas Fresh Air (Combustion)
- 8. Shale Water Conference – The Potential in Thermal Processing © 2022 Bepex International LLC What are the alternatives? Drill where produced water is very limited Trucking all water to an acceptable disposal site Recycle produced water for re-use in fracking Reduce the volume of water by evaporation with dry air Reduce the volume of water by means of mechanical separation Reduce the volume of water by thermal evaporation Alternatives Do Exist, with Limitations Bepex is at this conference to learn more about your specific operating challenges in order to help drive down water management costs. Based on our experience in a similar space, we recommend investigation of mechanical separation and thermal evaporation, along with heat recovery and integration.
- 9. Shale Water Conference – The Potential in Thermal Processing © 2022 Bepex International LLC Key Cost Bases Economic Estimates Natural Gas $5/MBTU Electricity $0.07/kWh Water Disposal $2.5/B of water Trucking $2.80/B of water Fresh Water $1/B Assumptions Electricity cost escalated up based on gas cost 50% of water trucked to disposal wells Thermal process heat recovery is limited to 16% This is a conservative estimate. We’ve demonstrated 90%+recovery in FTTD™ Process The vaporized water is cost neutral Preliminary estimates based on available information. Site-specific costs would be necessary to more appropriately examine the scenarios.
- 10. Shale Water Conference – The Potential in Thermal Processing © 2022 Bepex International LLC Water/Disposal and Utility Cost Estimates ($/B Oil) Economic Estimates Expense Base Case Dry Air (2) Thermal Drying Natural Gas - 3 8 Electricity - 18 2 Disposal Cost (3) 20 1 1 Fresh Water 1 1 1 Total (est.) 21 23 12 (1) All scenarios include 30% recycle back to fracking water (2) Assumes preheating air and water to 200°F (3) Includes trucking of 50% of the water 50 miles in 5000-gallon trucks One of many potential scenarios. The estimates will depend on site-specific costs.
- 11. Shale Water Conference – The Potential in Thermal Processing © 2022 Bepex International LLC Drawing on our experience Proposed Next Steps To better evaluate the potential economic benefit, site-specific investigation is necessary. 1. Bench Testing Preliminary technical feasibility Design of experiment for pilot scale trials 3. Pilot Testing Demonstration at pilot scale of a thermal process system 2. Site-Specific Investigation Heat recovery/integration Condensed water recovery Maximum evaporation Disposition of fracking chemicals Investment cost
- 12. Who is Bepex? Process Technology and Systems Provider Thermal & Separation Agglomeration/Particle Enlargement Size Reduction/Micronizing Solids product and process development Over 125 years in business 25,000 ft2 Pilot Plant Over 5,000 installations globally Over 500 in Texas alone, primarily in the petrochemical industry
- 13. Shale Water Conference – The Potential in Thermal Processing © 2022 Bepex International LLC Thermal Technologies and Process Development 10 different proprietary thermal technologies Indirect or Direct Heat Transfer Vacuum or Atmospheric Environment Match the drying technology to the application rather than forcing an imperfect solution
- 14. Shale Water Conference – The Potential in Thermal Processing © 2022 Bepex International LLC Collaborative development of a thermal evaporation process has the potential to significantly reduce expense tied to produced water disposal in the Permian Basin. Take Home Message