Technical Advancements in SAGD Evaporative Produced Water Treatment

Abstract

Abstract There has been a shift away from the use of warm lime softening (WLS) and weak acid cation (WAC) ion exchange for produced water treatment to the use of mechanical vapour compression (MVC) evaporation followed by high pressure drum-type boilers. Approximately 18 steam assisted gravity drainage (SAGD) produced water evaporators are operating or are in various stages of construction in Alberta and overseas. Since the commissioning of the first such evaporators in 2002, many technical advancements have occurred which have resulted in reduced operating costs, improved reliability, reduced scaling and fouling potential, improved distillate quality and improved boiler feed quality for steam generation. This paper provides details of the technical advancements in evaporative produced water treatment based on full-scale operating data and lessons learned. It also presents improved evaporator configurations, discusses improvements in contaminant reduction and scale prevention systems, demonstrates how capital and operating costs can be drastically reduced as compared to earlier evaporator system designs, and provides recent advancements in modularization, evaporator disposal treatment, deoiling, membrane preconcentration, and zero discharge solids drying techniques. Introduction Over the past few years, there has been a rapid shift away from the use of traditional produced water treatment methods using WLS for silica reduction and WAC ion exchange for hardness removal, to the use of evaporative produced water treatment methods at SAGD facilities. With the use of evaporative produced water treatment, standard drum boilers are utilized for steam generation in lieu of once through steam generators (OTSG) and vapour liquid separators. This shift has occurred because of technical, economic and reliability factors, resulting in markedly improved life cycle costs for SAGD facilities. A simplified block flow diagram of the traditional approach to produced water treatment and steam generation is provided in Figure 1. A block flow diagram for the evaporative approach is provided in Figure 2.