The Offshore Produced Water Gamechanger Report 2010-2014
Douglas-Westwood, February 2010, Pages: 111
The first edition of “The Offshore Produced Water Gamechanger Report,” explores the options available for managing produced water from offshore oil and gas production streams.
Water Management
Produced water is the largest waste stream from hydrocarbon production. In fact, daily water production volumes significantly exceed that of oil volumes, to the extent that 211 million barrels of water are produced by the industry daily compared to around 85 million barrels of oil over the same timeframe. The report identifies a range of new and emerging technologies that can help operators deal successfully with produced water – including treatment, minimisation, separation and re-injection.
Market Opportunities & Growth Potential
“The Offshore Produced Water Gamechanger Report,” also report provides detailed forecasts on market opportunities and growth potential for key produced water treatment equipment and technologies. It highlights that the total size of the market opportunity for final stage produced water treatment systems is estimated to be around $4.3 billion for the next five years – and predicts that the size of market opportunity for topside produced water re-injection systems is around $9.8 billion over the same period.
Case Studies & Operator Opinion
Case specific information is provided on the application of modern produced water management technologies such as Chevron’s application of compact flotation units at its Alba field, and ConocoPhillips’ adoption of condensate based extraction technology at the Ekofisk field. Significantly, the results of a global survey are provided, based on responses from 16 operator companies with a total of 21 respondents covering most of the major oil producing regions of the world. The survey includes opinions from companies such as Shell, BP, ExxonMobil, Total and Saudi Aramco.
Document Contents:
- Executive Summary & Conclusions– the produced water management challenge
- Drivers for Innovation– regulations, cost of water management, waterflooding for improved oil recovery and process de-bottlenecking
- Produced Water Treatment– technology overview – including Hydrocyclone, flotation, adsorption, macro porous polymer-based hydrocarbon extraction, biological treatment of produced water, walnut shell filtration and condensate enhanced separation technology. This chapter also covers the latest treatment technologies such as use of surfactant modified zeolite (SMZ), AltelaRainSM system, gas hydrate formation, novel centrifugal separation, electroflotation, WaterCatox, inline separation and electrostatic dehydration
- Produced Water Minimisation– mechanical blocking devices, chemical shut-off, intelligent well technology inflow control valves, passive inflow control devices, ICD screen technology, bright water polymer, squeeze cementing technology, zonal isolation, membrane wells and fracturing horizontal wells
- Downhole Oil Water Separation– technology overview and industry acceptance and major advances
- Subsea Separation– introduction, technology overview and the unique features of subsea separation
- Produced Water Re-injection– injection for enhanced oil recovery, role of intelligent completions etc
- Operator Opinions on Produced Water Management– the results of a new and exclusive industry survey regarding produced water management. Key results include opinion on drivers for new technology, impact of current and pending produced water treatment regulations and insight into the way in which operators decide on an optimal produced water management solution
- Offshore Produced Water Market– size of market for topside treatment final stage equipments and topside re-injection equipments split by georgraphy and by segment
- Appendix– assumptions used for market forecast
1 Executive Summary
1.1 Introduction
1.2 The global produced water management challenge
2 Drivers for Innovation
2.1 Regulations
2.2 Cost of water management
2.3 Waterflooding for Improved Oil Recovery (IOR)
2.4 Process de-bottlenecking
3 Produced Water Treatment
3.1 Introduction
3.2 Technology overview
3.3 Latest treatment technologies
4 Produced Water Minimisation
4.1 Mechanical blocking devices
4.2 Chemical water shut-off
4.3 Intelligent Well Technology (IWT) & Inflow Control Valves (ICV)
4.4 Passive Inflow Control Devices (ICD)
4.5 ICD screen technology
4.6 Fracturing horizontal wells to offset water production
4.7 Concept of membrane wells
4.8 Squeeze cementing technology
4.9 Use of “Bright Water Polymer®” (BP)
4.10 Use of expandable tubular technology for zonal isolation
5 Downhole Oil Water Separation (DOWS)
6 Subsea Separation
6.1 Introduction
6.2 Unique features of subsea separation
6.3 Technology overview
6.4 Separation technologies
6.5 Technology trends
7 Produced Water Re-Injection
7.1 Produced water injection for Enhanced Oil Recovery
7.2 Modern technologies for optimal waterflood performance
7.3 Produced water injection as the preferred management approach
8 Operators’ Opinions on Produced Water Management
8.1 Drivers for new technology
8.2 Produced water re-injection
8.3 Downhole oil/water separation
8.4 Deciding on an optimal produced water management solution
9 Produced Water Treatment Market
9.1 Introduction
9.2 Overview
9.3 The forecasting process
9.4 Offshore produced water market by market type
9.5 Offshore produced water market by region
9.6 Conclusions
10 Appendices
10.1 General Assumptions
10.2 Key assumptions for treatment systems in existing installations
10.3 Key assumptions for treatment systems in new installations
10.4 Key assumptions for re-injection systems in existing installations
10.5 Key assumptions for re-injection systems in new installations
Figures:
Figure 1: Produced water management cost distribution
Figure 2: Average abatement cost
Figure 3: PWRI cost variation of filtering up to 2 micron particulate size
Figure 4: Relative cost of re-injection as a reference (Ekofisk Case)
Figure 5: Relative cost efficiency of the CTour process as a reference (Ekofisk Case)
Figure 6: Produced Water Constituents
Figure 7: Oilspin AV Liquid/ Liquid Hydrocyclone
Figure 8: Schematic – Hydrocyclone
Figure 9: Produced Water Treatment skid
Figure 10: Hydrocyclone
Figure 11: IGF unit (Hydraulic Tridair™) suitable for offshore application
Figure 12: IGF unit (Hydraulic Tridair™) sectional drawing
Figure 13: EPCON CFU sectional view
Figure 14: Opus compact flotation technology
Figure 15: CrudeSorb® process description
Figure 16: CETCO’s RFV2000 CrudeSorb® Adsorption Skid
Figure 17: TORR™ Separation System
Figure 18: MPPE extraction process system layout
Figure 19: Membrane Bio-Reactor Process diagram
Figure 20: Depiction of a membrane module of DHV MBR system
Figure 21: Typical CTour process layout
Figure 22: Historical and forecast water production rate (BPWD)
Figure 23: AltelaRainSM System sectional view
Figure 24: AquaPurge® System
Figure 25: Process description of produced water treatment using hydrates
Figure 26: Enviro Voraxial® Separator
Figure 27: Process description of treatment using modulated high voltage DC field
Figure 28: Process description of treatment using bimodal field modulation
Figure 29: WaterCatox Process sectional view
Figure 30: WaterCatox Process sectional view
Figure 31: WaterCatox equipment
Figure 32: GLCC sectional view
Figure 33: Large diameter monolith membrane element with permeate conduits
Figure 34: Effect of fluid gel solutions on the oil zone
Figure 35: Flow distribution variables
Figure 36: EQUALIZER™ Inflow Control Device
Figure 37: Fracturing technique to help offset water production
Figure 38: Expandable tubular open hole cladding solution-schematic
Figure 39: Schematic – Typical DOWS System
Figure 40 : Typical layout of a subsea O/W separation system
Figure 41: Tordis subsea unit
Figure 42: Typical produced water re-injection system layout
Figure 43: Minox De-oxygenation process
Figure 44: Factors that influence Produced Water Re-injection Performance
Figure 45: Typical well production profile and value added by waterflood operations
Figure 46: Drivers for new technology
Figure 47: Breakdown of environmental and regulatory drivers
Figure 48: Cost/performance drivers for innovation in produced water treatment
Figure 49: Drivers for PWRI
Figure 50: Environmental drivers for PWRI
Figure 51: Cost/production drivers for PWRI
Figure 52: Impact of PWRI on produced water treatment
Figure 53: Main problems associated with PWRI
Figure 54: Breakdown of issues related to formation damage
Figure 55: Breakdown of operational problems with PWRI
Figure 56: Breakdown of Cost related PWRI problems
Figure 57: Breakdown of PWRI corrosion issues
Figure 58: PWRI - other prominent issues
Figure 59: DOWS key concerns
Figure 60: Breakdown of operational issues with downhole oil-water separation
Figure 61: Factors that contribute to produced water management decision
Figure 62: Breakdown of reservoir considerations
Figure 63: Breakdown of macro factors
Figure 64: Stages of produced water separation
Figure 65: Flowchart for produced water market model for new installations
Figure 66: Flowchart for produced water market model for existing installations
Figure 67: Produced water management option decision tree for existing installations
Figure 68: Produced water market forecast summary
Figure 69: Forecast of average number of final stage treatment units sold per year
Figure 70: Global produced water market split by market type
Figure 71: Global produced water treatment market for new installations
Figure 72: Regional share of treatment market for new installations in 2009
Figure 73: Global re-injection market for new installations
Figure 74: Regional share of re-injection equipment for new installations in 2009
Figure 75: Global market for produced water treatment for existing installations
Figure 76: Regional share of treatment equipment for existing installations in 2009
Figure 77: Global market for Produced water re-injection for existing installations
Figure 79: Gulf of Mexico produced water market
Figure 80: Middle East produced water market
Figure 81: North Sea produced water market
Figure 82: South East Asia produced water market
Figure 83: South America produced water market
Figure 84: Africa produced water market
Figure 85: Australasia produced water market
Figure 86: Regional share of the offshore produced water market
Figure 87: PW treatment probability distribution for existing installations
Figure 88: PW re-injection probability distribution for existing installations
Tables:
Table 1: Improved separation efficiency with oils of different densities
Table 2: Comparison of flotation processes for treating oily waste/ produced water
Table 3: Water treatment technologies and their providers
Table 4: Leading vendors of ICD equipment and their products
Table 5: BP funded research on low salinity water injection on waterflood programme
Table 6: Operator Technology Wish List
Table 7: Emerging Technologies
Table 8: Representative age of platforms going for treatment system upgrade
Table 9: Produced water market summary ($million)
Table 10: Top three operators of offshore processing facilities between 10-25 years
Table 11: Offshore installations with processing facilities between 10-25 years
Table 12: Probability of opting for conventional treatment systems
Table 13: Probability for produced water treatment (new installation)
Table 14: Probability for reinjection (new installation)
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