• HYDRA-CLAIM™ Water Treatment System

    Until now, the upstream oil and gas industry has not had a viable and cost-effective solution for removing high salt concentrations from frac flowback and produced water. NOV Water Services has effectively closed that solutions gap with the addition of the HYDRA-CLAIM Water Treatment System to its industry-leading and award-winning suite of water services technologies. NOV brings the patented HYDRA-CLAIM desalination technology to the upstream sector, giving operators the first membrane-based solution capable of removing salt concentrations many times higher than seawater. For operators, that means E&P waste waters can be converted to fresh water quality, fully treated for reuse in new drilling and completion fluids or for surface discharge in remote areas where disposal options have traditionally been limited and expensive. The scalable, continuous cycle technology has a designed treatment capacity of 4,000 bbl/day. In addition, the companion ClearFlo* pretreatment system can be used alone or in conjunction with the HYDRA-CLAIM system to remove scaling ions prior to the final treatment.

     

    Description

    GAME-CHANGING SOLUTION FOR TREATING SALTY E&P WATER

    Until now, the upstream oil and gas industry has not had a viable and cost-effective solution for removing high salt concentrations from frac flowback and produced water. Water Services has effectively closed that solutions gap with the addition of the HYDRA-CLAIM Water Treatment System to its industry-leading and award-winning suite of water services technologies.

    NOV brings the patented HYDRA-CLAIM desalination technology to the upstream sector, giving operators the first membrane-based solution capable of removing salt concentrations up to five times higher than seawater. For operators, that means E&P waste waters can be converted to fresh water quality, fully treated for reuse in new drilling and completion fluids or for surface discharge in remote areas where disposal options have traditionally been limited and expensive. As an added bonus, the HYDRA-CLAIM system can achieve an exceptionally high water recovery rate, and does so under a low temperature/pressure regime while using half the energy required of many thermal evaporative systems.

    The new generation HYDRA-CLAIM system relies on proprietary forward osmosis (FO) technologies to treat water up to 150,000 ppm of total dissolved solids (TDS), four times the maximum capacity of conventional reverse osmosis (RO) and produces drinking quality water. The residual brine streams contain up to 25% salt sufficiently conditioned for use in new drilling, drill-in and frac fluids.

    The scalable, continuous cycle technology has a designed treatment capacity of 4,000 bbl/day and operates within a 30% smaller footprint than conventional thermal treatment systems. Unlike mechanical evaporation units, the robust membrane technology of the HYDRA-CLAIM system also requires significantly less maintenance and less downtime. In addition, the companion ClearFlo* pretreatment system can be used alone or in conjunction with the HYDRA-CLAIM system to remove scaling ions prior to the final treatment.

    Application 

     • Onshore unconventional shale plays

    High Capacity, Less Energy: The FO Advantage

    Conventional water treatment systems relying on pressure-driven reverse osmosis are largely ineffective in removing the high salt concentrations typical in frac flowback and produced waters. Even the most highly-efficient RO system can only remove a maximum of 65,000 ppm TDS, which represents the low end of salt concentrations in oilfield production. A thermal distillation unit, while effective at removing high levels of dissolved solids, requires a tremendous amount of energy that when combined with its larger footprint and higher costs to build and maintain, makes it an impractical and uneconomic solution for onshore production operations.

    The state-of-the-art HYDRA-CLAIM system, on the other hand, utilizes a patented process that capitalizes on natural Forward Osmosis, which uses a patented high-concentration draw solution as the driving osmotic pressure gradient to equalize the salinity of two liquid streams. The process begins with water being osmotically driven from the produced water feed stream through the salt-rejecting semi-permeable membrane and into the draw solution.  This produces a reduced volume, high TDS waste stream and a diluted draw solution stream.

    Once the water is drawn through the membrane, the diluted draw solution goes through the recovery system where it is heated to its low vaporization point. There, the draw solution is separated, condensed and reused continuously in the closed-loop process. The low-temperature vaporization of the draw solution allows for continual reconstitution with considerably less energy required. 

    All this is carried out in a system that operates at extremely low pressure and at considerably lower temperatures than conventional thermal systems. The capacity of the draw solution to handle extremely high TDS is a function of equally high osmotic forces that deliver higher treatment capacity, with less energy and in a footprint appreciably smaller than conventional thermal units. Since it operates with low pressures and temperatures, the HYDRA-CLAIM system does not require the titanium plates and other premium metals of thermal units, significantly reducing up-front and operational costs.

    At the end of the process, you are left with produced water that meets US Environmental Protection Agency (EPA) freshwater standards, as well as 10-lb brine that is sufficiently conditioned for continual reuse in building new fluid systems.

    HYDRA-CLAIM Rounds Out Water Management Solution Suite

    The HYDRA-CLAIM system augments the industry-leading Water Services technology portfolio that also comprises a full range of water transfer, storage and treatment technologies.

    The water services offering includes the innovative AQUA-VES™ mobile water-treatment system that employs novel membrane separation technology relying on vibration, rather than high flow rates, to remove total suspended solids (TSS), oil and grease, and bacteria from flowback and produced waters for reuse in active frac systems. The HYDRA-CLAIM system represents the end of the water treatment puzzle by removing the TDS to deliver both freshwater and reusable brine.

    The AQUA-VES mobile water-treatment system won the 2013 World Oil “Best Health, Safety, Environment / Sustainable Development – Onshore” award.

    *ClearFlo is a registered trademark of Oasys Water.

    Features/Benefits

    Features

    • Removes salt and other contaminants from frac flowback and produced water

    • Proprietary forward osmosis (FO) technology

    • 4,000 bbl/day treating capacity

    • Achieves exceptionally high water recovery rate

    • Concentrates up to 250,000 ppm TDS

    • Smaller footprint

    • Half the energy consumption of comparable thermal evaporative systems

    • Requires no exotic metals

    • Companion ClearFlo scaling ion pretreatment system


    Benefits

    • Delivers fresh water that meets EPA Standards as well as a clean, softened reusable brine

    • Eliminates regulatory risk of storing and moving water with high chlorides

    • Reduces disposal volumes and costs

    • Conserves freshwater resources

    • State of the art technology that delivers improved performance over competition

    • Capable of handling water requirements from multiple wells

    • Lower overall operational costs

    • Able to process variable produced water feed and enables treatment of water containing various contaminants

    • Can treat waters with up to four times the concentrate of feed to a standard RO system

    • Elevates HSE profile

    • No hydraulic pressure on the FO membrane surface, nearly eliminating the potential for membrane fouling

    Other

    Case Study - Permian

    Extended operations

    > 1,200 hours and 400,000 litre

    Challenging Saline Feed

    > 100,000 ppm TDS intake

    Exceeded Brine spec

    > 240,000 ppm TDS concentrate

    Exceeded Product quality

    < 500 ppm TDS fresh water

    Low pretreatment cost

     


    To learn more about how the HYDRA-CLAIM water treatment system can help meet your onshore upstream water management objectives, contact your NOV FluidControl representative.

    Case study courtesy of Oasys Water.

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