Resources Recovery Plant
Team India: Lynette Hernandez, Hsin Ting Hsieh, Alexander Palmas, and Jose Ortiz
Mentor: Patrick H. Shannon, Middough
1
Table of Contents
Executive Summary……………………………………………………………………………...3
Discussion………………………………………………………………………………………...4
Introduction………………………………………………………………………………4
Description of Process……………………………………………………………………6
Process Control…………………………………………………………………………..7
Environmental Safety Concerns and Their Mitigation………………………………..8
Economics……………………………………………………………………………….11
Recommendations………………………………………………………………………………11
Appendices………………………………………………………………………………………12
1. Design Basis…….………………………………………………………………..….12
2. Block Flow Diagrams……………………………………………………………….13
3. Process Flow Diagrams Showing Major Equipment …………………………….15
4. Material and Energy Balance………………………………………………...……18
5. Calculations…………………………………………………………………………21
6. Annotated Equipment List…………………………………………………………23
7. Economic Evaluation Factored from Equipment Cost ………………………….27
8. Utilities………………………………………………………………………………29
9. Conceptual Control Scheme…………………………………………………….…30
10. General Arrangement – Major equipment Layout………………………………31
11. Distribution and End-use Review…………………………………………….……32
12. Constraints Review…………………………………………………………………33
13. Applicable Standards………………………………………………………………34
14. Project Communications File………………………………………………………34
15. Information Sources and References ……………………………………………..38
2
Executive Summary
Greenhouse gases and water treatment have been a concern to all of those who want to minimize
environmental impact. It is even a major concern when designing an industrial shale gas complex.
As the name suggests, the industrial shale gas complex has a main focus: to integrate the
production of various chemicals and iron by use of natural gas from shale oil. In order to achieve
this goal, nine separate units have been created, each serving a specific purpose. It will be
located in Williston, ND.
The Resources Recovery Plant is made to treat the process waste water to recycle for use in the
Combined Heat and Power (CHP) Plant and in the Fertilizer Plant. Carbon dioxide that comes
out of other plants in the complex is sent here to be purified to at least 95% and be sold for
enhanced oil recovery (EOR) to the Dakota Gasification Company.
The process waste water comes from the Gas Treatment Plant (3,000 lb/day), Fischer-Tropsch
Plant (1,086,652 lb/day), CHP Plant (766,800 lb/day), Gas/Liquids Plant (23,856 lb/day),
flowback water (353,386 lb/day), and produced water (124,468 lb/day). The flowback water will
only be present for the first 30 days. However, the produced water will continue to be present
throughout the life of the plant. In order to clean the process waste water, an API Oil-Water
Separator, a dissolved air flotation (DAF) unit, an Ultra-Filtration (UF) Unit, and a Reverse
Osmosis (RO) Unit are used. All the waste streams are collected to be hauled away.
The effluent CO2 stream comes from the Gas Treatment Plant (5,464 lbmol/day) and the
Gas/Liquids Plant (913 lbmol/day). A clean stream comes from the Iron Reduction Plant
(148,000 lbmol/day) and this is just compressed and not cleaned. For the treatment of carbon
dioxide, a PSA unit is used to purify it to 95%. The waste stream from PSA is sent to the CHP
plant so that they can dispose of it by incinerating it. The clean stream is sent through a
compressor to achieve a 2,200 psi stream that can be sold to the Dakota Gasification Company
for EOR Purposes.
Equipment sizing and energy sinks/loads were calculated mainly from ASPEN Cost Simulator.
The sizing and the energy load for the CO2 compressor has been done by hand using several
equations and a chart. Taking this into consideration, an economic analysis was made. This
includes cost for equipment, raw materials, labor, maintenance, loans, and depreciations.
Assuming this plant is to last for 20 years, an NPV value of -$111,272,066 can be found. Since
this value is negative, the plant loses money overall. However, transfer prices have not been
taken into consideration, so an accurate economic analysis cannot be done. Also, this plant was
not meant to make money. As a cleanup plant necessary in the shale gas complex to maintain
environmental standards, it is not required that the Resource Recovery Plant have a positive NPV
3
value. If the complex is built, it is necessary to build the Resources Recovery Plant in order to
comply with EPA regulations.
Discussion
1 Introduction
The Resources Recovery Plant is essential to the integrated shale gas complex. There are two
purposes for this plant:
1 Clean up carbon dioxide coming from three other plants in the complex to sell to the
Dakota Gasification Company for EOR (enhanced oil recovery).
2 Clean frac and process waste water to feed back to the Combined Heat and Power Plant
and the Fertilizer Plant.
The design basis for this can be found in Appendix I. Cleaning frac water is necessary for several
reasons. One reason is because we reduce the amount of fresh water taken from local rivers or
other sources of water to the community by recovering the flowback and produced frac water for
reuse. Another reason is to prevent this highly contaminated water to run down to the nearby
sewers and rivers since this can potentially devastate a community. Finally, cleaning the frac
water will satisfy EPA regulations of water released to municipal city water treatment plants.
This plant will be located near Williston, ND. Within the shale gas complex, this plant will be
located in the Southeast part of the complex. This will facilitate the transfer of water and CO2
streams to the plant since it collaborates with 6 out of the other 8 plants in the complex. Different
methods for water purification and for CO2 cleanup are described below.
There are three main processes used commercially to purify carbon dioxide: membrane
separation, PSA (pressure swing adsorption), and cryogenic distillation. Membrane separation
works by separating molecules based on their permeabilities and sizes. It can be as pure as PSA.
It has a low capital cost and is very easy to install. However, it is uneconomical for high purity
requirements and large outputs. PSA uses high and low pressure to separate molecules. It has a
low to moderate capital cost and also a relatively simple installation and start-up. However, it
doesn’t provide high purity for very large flowrates. Cryogenic distillation uses a distillation
column at very cold temperatures. It produces very high purity gases and uses a low amount of
electricity. However it needs a large space and has a long start-up and shut-down. It also has very
high capital costs. Cryogenic distillation is the best process to use when operating at high
flowrates and a >99% purity level is required. However, given that there isn’t such a high flow
rate and purity of only 95% is necessary, PSA is the best method to use. This is due to economics
given the design basis specific to this process (refer to Appendix I for details). Figure 1 below
4
shows how it was determined that PSA was the best process to use given the purity requirements
and total amount of flowrate.
Figure 1: Determination of Best Process Depending on Flowrate and Percent Purity[69]
As previously mentioned, Pressure Swing Adsorption (PSA) will be used to clean up the carbon
dioxide. Then, the CO2 will be compressed to achieve the necessary pressure requirements to sell
to the Dakota Gasification Company. A total of 129,378 lbmol/day at 2,200 psi will be sold to
this company.
For water treatment, a crystallizer can be incorporated. It was not used since, due to the time
constraint, there was not enough time to fully research how it would impact our process.
Originally, a sand trap was going to be used to get rid of large solids in the frac water. However,
due to the amount of TSS (total suspended solids) in the frac water, an API separator can do that
job. Therefore, using a sand trap was not economically effective.
Another process design that could have been used is green completions. In green completions, oil
is removed from water and added to pipe lines to be processed. This is more environmentally
friendly since there is no flaring. However, using this process would require a rental cost. This
would cost approximately $1,000/day, which is not economically feasible either. LPG, or gelled
liquified petroleum gas, is also used for water cleanup. It is beneficial because nearly all of the
water is recovered after fracturing and no salts are brought up. However, it is not beneficial in
this specific process. This is because there are carboxylic acids and alcohols in the process waste
water that comes from the Fischer-Tropsch and Gas/Liquids Plant that need to be cleaned up
accordingly. Therefore, a three-stage purification process was designed in order to make the frac
and waste water cleaning as beneficial as possible, both to comply with the environmental
regulations and be economically feasible.
5
Water treatment will consist of several purification stages to get the water pure enough to be
used as process plant water. A total of 690,428 lb/day will be supplied to the Fertilizer Plant and
a total of 444,273 lb/day will be supplied to the CHP Plant. The purification stages consist of an
API Separator, dissolved air flotation unit (DAF), ultra-filtration unit, and a reverse osmosis unit.
In order to achieve the necessary purification for both the carbon dioxide and the water, it is
necessary to take economics into consideration. Sizing and energy sinks/loads were calculated
either by ASPEN, hand calculations, or contacting companies for pricing/sizing information
given parameters specific to our needs.
2
Description of Process
a CO2 Cleanup
Carbon dioxide will come from three different plants: Gas Treatment, Gas/Liquids, and Iron
Reduction. In order for CO2 to be sold for EOR (enhanced oil recovery) purposes to the Dakota
Gasification Company, it is necessary that the stream be at least 95% pure and at a pressure of
2,200 psi. The Gas Treatment and Gas/Liquids Plants have CO2 streams that need purification.
Therefore, the streams will be combined and enter a PSA Adsorber Unit. Here, low and high
pressure (10% and 90% of total pressure, respectively) will be used to separate the CO2 from the
rest of the contaminants, which include water, methane, ethane, and carbon monoxide. Inside the
PSA Adsorber, there is an internal compressor, which allows for such high pressure changes.
The higher the pressure, the more gas that will be absorbed. Once the pressure is reduced, the
adsorbed gas will be released out of the PSA unit. In order for adsorption to take place, different
types of adsorbents can be used. These adsorbents are usually very porous materials chosen
because of their large surface areas. In this case, zeolite will be used as the adsorbent. The PSA
Adsorber has a recovery rate of 85%. This ensures that the outlet CO2 stream is at least 95% pure.
The remaining impure stream is directed to the CHP plant so that they can incinerate it. The CO2
stream from the Iron Reduction Plant will be combined with the outlet stream from the PSA
Adsorber. Since this stream is already dry and 95% pure, it fits the purity requirement for the
Dakota Gasification Company. Therefore, cleaning is not necessary. In order to increase the
pressure of CO2 to 2,200 psi, a compressor will be used. Finally, the outlet stream from the
compressor will be at least 95% pure and at a final pressure of 2,200 psi to be sold for EOR.
b
Water Treatment
Initially, waste water coming from the Gas Treatment Plant and the Fischer-Tropsch Plant and
the Flowback Water will be combined in an equalizer pond at the beginning to go through the
entire cleanup process since there is a high concentration of TDS. Doing this will avoid problems
in the DAF unit. After 30 minutes of residence time, it will be pumped out to go into the API
6
Separator. Here, with the aid of baffles, it will be possible to agglomerate the oil particles
together so they can be separated by gravity. The API Separator uses gravity and the density of
the molecules for separation. Since the oils are less dense than the water, the water will go to the
bottom and the oil will float on the top. A skimmer at the surface and a conveyer belt at the
bottom will remove these contaminants and pump them out as sludge. An oil retention baffle
near the exit of the API Separator will be used to prevent the floating excess oil to be pumped
out with the cleaner stream of water. An adjustable overflow weir will be used across the end of
the API Separator to control the outlet water flow. The API Separator will be constructed several
feet above the ground to allow for gravity to take the outlet water stream into a dissolved air
flotation unit (DAF), which will be located below the API Separator.
Water will be further treated in the DAF unit. This unit is composed of three tanks divided by
walls, each with their own mixer for the add-in pre-treatment chemicals. The first tank in this
series will control the water pH. pH needs to always be between 6-9. This is because the ferric
chloride, anionic polymer, and the UF-RO system work better between this pH range. Given that
the entering water stream is always acidic, NaOH will be added for the water to be within the
necessary guidelines. Once the correct pH is achieved, it will flow into the second tank. Ferric
chloride will be added in the second tank. This will precipitate out the salt and minerals. These
salts and minerals will be collected in a waste tank. The water will flow out of the second tank
and into the third tank. Here, PAM (anionic polymer) will be added to coagulate emulsified oils.
These emulsified oils will also be collected in a waste tank. Finally, water will flow into the DAF
Unit, where it will use dissolved air in water to enhance flotation of the remaining oils and
suspended solids that have not yet been removed. A skimmer at the top of the DAF Unit will
skim off the top sludge to be collected in a waste tank. Some of the water that comes out of the
DAF Unit will be recycled back into the DAF Unit to enhance oil and solid separation to the top.
The oil-free water enters a second equalizer tank. Here, water coming from the Gas/Liquids Plant
and CHP Plant get added in since they have low contents of salts and minerals. The mixed water
gets pumped into the Ultra-Filtration Unit (UF) to remove, for the most part, the alcohols,
carboxylic acids, salts, and minerals. The exiting stream is pumped to the Reverse Osmosis Unit
(RO) to get a 99.9% pure water stream. Everything that is rejected from both the UF and RO
Units is placed in a waste tank. The exiting clean water is the process plant water sent out to
CHP and the Fertilizer Plants. The remaining water is placed in a storage tank. All the waste in
the tanks will be hauled away so that it can be disposed of appropriately.
Process Control
The general overall process control for water treatment system will be dictated by the incoming
flowrates of frac flowback water and contaminated water that’s contaminated with by products
from the other plants of the overall shale gas integrated plant. Initially, flowback frac water will
be pumped to the first equalizer tank. This water flowrate stream will be controlled by a valve
that will control the flowrate to the equalizer tank. Fischer-Tropsch and gas treatment water will
3
7
flow via separate water pipes to the initial equalizer pond also be controlled by separate flowrate
valves to the pond. The equalizer tank must receive all the waste water generated by the
respective plants and flow control will control the feed to the API separator and to the UF unit.
A centrifugal pump with variable frequency drive will be used to pump the water in the equalizer
pond to the API separator. Level indicator controls will be placed in API separator to monitor
level to prevent overflow and a flowrate control to increase the inlet water stream to enhance oil
and water separation as it hits the baffles (separation, oil/water) or reduced to maintain the output
water at constant rate to the secondary treatment DAF.
After all solids and oils are removed, water (after one hour residence time in an equalizer tank
with contaminated water from gas/liquid and CHP boiler blow down/cooling tower blowdown
plants) will enter a single pipe through a pump and be pressurized to at least 150 psig to enter the
series of UF filters. A pressure sensor will be integrated within the Ultra-Filtration unit so as not
to exceed maximum pressure in the unit and will be transmitted back to pressure valve to
decrease/increase accordingly. The permeate water containing mostly dissolved salts will be sent
to the ultrafiltration and reverse osmosis unit and pressurized to at least 150psig and 300psig,
respectively. Again, a pressure transmitter will be placed within RO unit and be sent to control
panel to adjust pressure inlet flowrate and decrease/increase according to the output quality of
final process water and be sent to CHP. Reject streams from UF-RO and API-DAF units will be
pumped out to waste tanks to be hauled out to landfill.
The general overall process control for CO2 purification will be dictated by the pressure of the
incoming streams. Flow control valves will be placed in the PSA adsorber system so that once
one adsorber becomes saturated, the flow will be directed to the other adsorber. There will also
be pressure control valves so that the system does not get over-pressurized. This will be done by
having a purge valve between the two adsorbers. This purge valve will allow the pressures to
change. By changing the pressures between the two adsorbers, the CO2 gas and the waste stream
will be released to go to the appropriate place (CO2 will go to the compressor and the waste
stream will be directed to CHP Plant for incinerations).
4
Environmental safety concerns and their mitigation
The major environmental safety concern of the Resources Recovery plant is within the process of
purifying frac water/produced water, water from other plants, and effluent vapor, in this case,
carbon dioxide. Different processes can be hazardous for workers. The necessity of purification
taken place in the Resources Recovery plant is to allow site to reach all EPA requirements.
While working at the Resources Recovery plant, all workers must wear Personal Protective
Equipment at all times. Training will be provided for workers, so they are aware of which PPE
applies to the type of work they are doing.
The whole water treatment plant contains a very large amount of water where during the process
of transforming water, water might drain out and create water puddles around the treatment
plants where slips, trips, or falls are a main safety concern for workers. Mops and other cleaning
8
equipments will be provide at each section for workers to clean up water puddles. Areas with
puddles will be mark. Leaks of tanks or other equipments will be fix promptly. Floors of the
working area will use surfaces that provide traction. Workers must wear shoes that has non-slip
soles. [57] As an additional precaution, drains will collect water so that there is no pool on the
floor.
The first part of the water treatment process involves an API separator and a DAF unit where
most of the emulsified oils from the water are removed and sent into a waste tank. The second
part of the process involves an UF-RO unit where salts will be removed and sent to waste tank.
The waste tanks will then be hauled out to landfill at a cost of 18 cents per gallon. Engulfment
and/or drowning into treatment tanks or waste tanks are hazards to workers. Guard rails will be
place on all open water sources around the treatment plant. Rescue equipments such as floats and
hooks will be available at each section. Warning signs will be posted around areas where
accidental falls might happen to prevent accidents from happening. [57]
“Water treatment plants have pumps and valves for moving water and many moving parts such
as screens, belt presses, and conveyors remove debris and move sludge. This equipment can
cause caught/crush hazards if you place a hand, arm, or foot too near a moving part.” [57] Guard
all moving machinery and watch for these hazards while working. Make sure the pressure for the
pump does not exceed 1000 psi. While operating pumps in a wet environment, it requires
maintenance and repair work so make sure to check the equipments every month. Also, while
operating, be careful of being electrocuted. Also, workers must follow lockout/tagout procedures
to guard against accidental equipment startup while operating. [57]
In the DAF unit, ferric chloride, sodium hydroxide, and polymer are used. These chemicals can
be aggressive to human bodies. Personal Protective Equipment such as masks, gloves, bodysuits,
aprons, and working boots must be worn at all times while working with these chemicals. Local
safety showers, eyewash, and fire extinguisher will be provided at each work section. All
operators are trained on handling these chemicals.
Ferric chloride is a non-flammable chemical. In the case of ingestion, ferric chloride is very
hazardous. It is also hazardous in case of skin-contact, eye contact, and inhalation. Ferric
chloride is corrosive to eyes and skin. When experiencing eye contact with ferric chloride,
immediately remove all contact lenses and flush eyes with water for at least 15 minutes keeping
eyelids open and do not use any eye ointment. Also, seek medical attention immediately. When
experiencing skin contact, immediately remove all contaminated clothes and wash them before
using it. Then, place the victim under the shower. If the chemical got on the victim’s exposed
skin such as hands, wash the contaminated skin thoroughly with running water and non-abrasive
soap. If there is any irritation, seek medical attention immediately. If there is inhalation, allow
the workers to rest at a well ventilated area and seek medical attention immediately. If
experiencing ingestion, do not induce vomit and seek medical attention immediately. If the
victim is not breathing due to ingestion, perform CPR immediately. When spilling occurs, use
water spray to prevent vapors and call assistant on disposal. Ferric chloride is a corrosive
material where it needs to be locked up and stored in container at a separate safety cabinet or
room. The container needs to be dry and away from heat, sources of ignition and sunlight. While
9
working with ferric chloride, splash goggles, synthetic aprons, vapor and dust respirator, boots
and gloves must be worn at all times. [58]
Sodium Hydroxide is non-flammable chemical yet it is very corrosive. In case of skin contact,
eye contact, and ingestion, it is very hazardous. "Liquid or spray mist may produce tissue
damage particularly on mucous membranes of eyes, mouth and respiratory tract. Skin contact
may produce burns. Inhalation of the spray mist may produce severe irritation of respiratory tract,
characterized by coughing, choking, or shortness of breath. Severe over-exposure can result in
death. Inflammation of the eye is characterized by redness, watering, and itching. Skin
inflammation is characterized by itching, scaling, reddening, or, occasionally, blistering." [59]
When experiencing eye contact, immediately remove all contact lenses and flush eyes with water
for at least 15 minutes keeping eyelids open and do not use any eye ointment. Also, seek medical
attention immediately. When experiencing skin contact, immediately remove all contaminated
clothes and wash clothes before reuse. Then, flush skin with plenty of water for at least 15
minutes and seek medical attention immediately. If there is inhalation, move to a fresh air area
and seek medical attention immediately. Oxygen will be available if breathing is difficult. If
swallowed, do not induce vomit and seek medical attention immediately. Sodium hydroxide is a
highly corrosive and poisonous liquid, so absorb with DRY earth, sand or other non-combustible
material and do not touch spilled material. Then, use water spray to reduce vapors and prevent
entry into sewers, basements or confined areas. Also, call for assistance on disposal. While
working with sodium hydroxide, splash goggles, full suit, vapor respirator, boots, and gloves
must be worn at all times. [59]
The polymer used in the DAF unit is Polyacrylamide. Acrylamide is combustible but it has a
very high flash point, therefore, it is consider as slight fire hazard when exposed to heat, sparks
or flames. However, Acrylamide is flammable liquid when it is dissolved in solvents. It is also
hazardous in case of skin-contact, eye contact, and inhalation. When experiencing eye contact,
immediately remove all contact lenses and flush eyes with large amount of water. When
experiencing skin contact, immediately remove all contaminated clothes and wash them before
using it. Then, wash the contaminated skin thoroughly with running water and non-abrasive soap.
If there is any irritation, seek medical attention immediately. If there is inhalation, move to fresh
air area immediately and have victim blow his/her nose. If the victim is not breathing, perform
CPR immediately and seek medical attention. If experiencing ingestion, have victim rinse the
contaminated mouth with water, drink about 8oz water, and induce vomit by giving syrup of
ipecac as directed on package. However, do not force an unconscious victim to drink water or
vomit. Acrylamide should be stored in a dark, dry, well-ventilated refrigerated area in a tightly
sealed container that are labeled with OSHA’s hazard communication standard. [60]
When spilling occurs, use water spray to prevent vapors and call assistant on disposal. Ferric
chloride is a corrosive material where it needs to be locked up and stored in container at a
separate safety cabinet or room. The container needs to be dry and away from heat, sources of
ignition and sunlight. While working with ferric chloride, splash goggles, synthetic aprons, vapor
and dust respirator, boots and gloves must be worn at all times.
Besides the water treatment plant, Resources Recovery plant also has the pressure swing
adsorption system (PSA) that is used to purify carbon dioxide to a purity of 95% and a
10
compressor to compress the carbon dioxide from 1,125 psi to 2,200 psi in order to sell for EOR.
While working with PSA, workers must monitor the pressure swing adsorption system at all
times to avoid invalid input or outlet temperatures or pressures. When carbon dioxide is under
pressure, it can potentially cause damage or injury. Workers must also monitor the compressor at
all times to avoid damage. Therefore, while working with the carbon dioxide compressor, make
sure pressure does not exceed 2,500 psi. Also, make sure the temperature of the PSA unit and
compressor doesn’t not exceed 2000C as carbon dioxide will decompose and producing toxic
carbon monoxide. [61]
Carbon dioxide is heavier than air. Instead of rising, it will go downward. Since it is an
asphyxiant, care must be taken. Carbon dioxide is not combustible. However, fire extinguisher
will still be provided at each working area in case of fire. In case of inhalation and eye contact, it
is hazardous. When experiencing inhalation, immediately move to fresh air area and rest.
Artificial respiration are provided if needed. If experiencing eye contact, rinse with plenty of
warm water for several minutes (remove contact lenses if easily possible), then seek medical
attention. Carbon dioxide needs to be stored in a fireproof and cool place. While working with
carbon dioxide, gloves, protective clothing, safety goggles, and face shield must be worn at all
times. [61]
5
Economics
In order to determine the equipment cost, the ASPEN Cost Simulator program was used.
However, not all the equipment needed was found there. For the remaining of the equipment,
companies were contacted to determine both pricing and sizing. This gave a total of $32,087,082
for capital cost. More details on the exact numbers of the equipment cost can be found in
Appendix 7. The amount of workers totals to 15, 12 workers and 3 managers. Some of the
workers and managers will be shared between the other plants in the complex. Therefore, all the
salaries don’t necessarily need to be supplied by the Resources Recovery Plant. Using the help of
Jerry Palmer (one of the mentors for the design of this shale gas complex), it was possible to
account for variations in prices during the 20 year life of the plant. Overall, the NPV Value is
negative. Therefore, this plant loses money. However, it is necessary to be built since without
this plant, the complex would not be able to comply with the EPA standards and regulations.
After having a general economic analysis for the entire complex, it is found that there is a
positive NPV value of about $1.8 billion/year. This shows that as an integrated shale gas
complex, this is a good design, even when the Resource Recovery plant loses money.
Recommendations
Given the overall economic for the shale gas complex, this is the desirable project. The Resource
Recovery plant is needed in order to comply with EPA and Environmental standards regardless if
this plant is profitable or not.
11
The waste streams from the API/DAF and UF-RO are highly salinized reject streams which are
set to be hauled out to landfill. However, there are alternative ways to reuse the waste sludge and
oils instead of disposing it. It is possible to recover water from the TSS/sludge by pumping this
sludge to a filter press and recycle the water back to API for further treatment or be used as a
make up for DAF unit. Oils can also be recovered from the waste streams by separating the oils
from the waste and reuse the oils being recovered as a fuel source.
Another major recommendation would be to use mechanical vapor recompression evaporators in
series to evaporate water and concentrating the brine with the use of low pressure steam that is
circulating within the integrated shale gas complex. Further, a crystallizer will allow production
of crystalline salts, which could be sold as merchant products. This will essentially be referred as
a zero liquid discharge where only solids would be sent out to landfill.
Appendices
Appendix 1: Design Basis
Table 1-1: Design Basis for CO2 Cleanup
Compon
ents
Gas
Treatment
(lbmol/day)
Gas/Liquids
(lbmol/day)
Iron Reduction
(lbmol/day)
CO2
4,317
387
140,600
Water
0
0
0
Methane
812
0
1,480
Nitrogen
74
0
0
Oxygen
0
0
0
Ethane
261
0
0
Hydrogen 0
82
2,960
CO
0
444
2,960
Total
5,464
913
148,000
12
Table 1-2: Design Basis for Water Treatment
Components
Flowback
(lb/day)
Fischer-Tropsch
(lb/day)
Gas
Treatment
(lb/day)
CHP
(lb/day)
Gas/Liquids
(lb/day)
Water
333,986
987,466
3,000
766,800
23,232
TDS
81,473
0
0
0
0
TSS
541
0
0
0
0
Oil
500
0
0
0
0
Alcohols
0
93,000
0
0
624
Carboxylic
Acids
0
6,186
0
0
0
Total
416,500
1,086,652
3,000
766,800
23,856
Appendix 2: Block Flow Diagrams
Figure 2-1: Block Flow Diagram for CO2 Cleanup
13
Figure 2-2: Block Flow Diagram for Waste Water Treatment
14
Appendix 3: Process Flow Diagrams Showing Major Equipment
Figure 3-1: Process Flow Diagram for CO2 Cleanup Showing Major Equipment
Table 3-1: Equipment Quick Information
Unit
Description
PSA Adsorber
Purifies and dries CO2 from incoming streams
Compressor
Changes pressure of CO2 stream to 2,200 psi
(pressure necessary to sell for EOR)
15
Figure 3-2: Process Flow Diagram for Water Treatment Showing Major Equipment
16
Table 3-2: Equipment Quick Information
Unit
Description
Equalizer Pond
Adds in the water
streams from
Flowback, FischerTropsch, and Gas
Treatment
API Oil-Water
Separator
Remove big oil
particles and minerals
DAF (Dissolved Air
Flotation)
Precipitates minerals,
coagulates emulsified
oils and solids,
adjusts pH, and
removes traces of
suspended solids
Air Drum
Dissolved air in water
recycle to DAF unit
Tank
Equalizer tank used to
add in water from
gas/liquids and CHP
Plants
Waste Tanks
Stores waste from UF
and RO unit to be
hauled away
Ultra-filtration Unit
Removes most salts
Reverse Osmosis
Unit
Further purifies water
for plant use
Storage Tank
Stores small amount
of water that is not
sent to any plant for
their process
17
Appendix 4: Material and Energy Balance
Refer to Figure 3-1 to determine stream numbers.
Table 4-1: Mass Balance for CO2 Cleanup Process
Streams
CO2 Flow
Rate
(lbmol/day)
Waste Flow
Rate
(lbmol/day)
Total Flow
Rate
(lbmol/day)
Pressure
(psi)
Temperature
(ºF)
1
4,317
1,147
5,464
550
150
2
387
526
913
87
93
3
4,704
1,673
6,377
637
297
4
706
1,463
2,168
701
68
5
3,999
210
4,209
1,210
68
6
140,600
7,400
148,000
15
77
7
144,599
7,610
152,209
1,225
77
8
122,909
6,469
129,378
2,200
268
Please refer to Figure 3-2 to determine the stream numbers.
Table 4-2: Streams Entering the Equalizer Pond (all units in lb/day)
Streams
Water
TDS
TSS
Oil
Alcohols
Carboxylic
Acids
Total
Flowrate
1
333,986
81,473
541
500
0
0
416,500
2
987,466
0
0
0
93,000
6,186
1,086,652
3
3,000
0
0
0
0
0
3,000
18
Table 4-3: Streams Around the API Separator
Streams
Water
TDS
TSS
Oil
Alcohols
Carboxylic
Acids
Total
Flowrate
4
1,324,452
81,473
541
500
93,000
6,186
1,506,152
5
66,223
0
271
230
0
0
66,724
6
1,258,229
81,473
270
270
93,000
6,186
1,439,428
Table 4-4: pH Control and Addition of Ferric Chloride
Streams Water
TDS
TSS
Oil
Alcohols
Carbo
Acids
NaOH
Ferric
Chloride
Total
Flowrate
0
0
0
0
0
4,080
0
8,160
90
90
31,000
2,062
0
0
481,169
0
0
0
0
0
200
200
7
4,080
8
420,77 27,158
0
9
0
0
Table 4-5: Addition of Polymer
Streams
Water
TDS
TSS
Oil
Alcohols
Carboxylic
Acids
Polymer
Total
Flowrate
10
420,770
27,158
90
90
31,000
2,062
0
481,169
11
0
0
0
0
0
0
11,000
11,000
12
420,770
27,158
90
90
31,000
2,062
0
481,169
Table 4-6a: Emulsified Oil Removal
Streams
Water
TDS
TSS
Oil
Alcohols
Carbo-acids
13
1,266,389
81,473
270
270
93,000
6,186
14
12,664
5,681
270
270
0
0
15
1,253,726
75,792
0
0
93,000
6,186
19
Table 4-6b:Solids Removal
Streams
NaOH
Polymer
Ferric
Chloride
Salt
precipitation
Air
Total
Flowrate
13
4,080
11,000
200
0
0
1,462,868
14
0
270
200
5,681
25
25,061
15
4,080
10,730
0
0
0
1,443,514
Table 4-7: Recycled Streams
Streams
Water
TDS
Alcohols
Carbo
Acids
NaOH
Polymer
Air
Total
Flowrate
16
376,118
22,738
27,900
1,856
1,224
3,219
0
433,054
17
0
0
0
0
0
0
25
25
16+17
376,118
22,738
27,900
1,856
1,224
3,219
25
433,079
Table 4-8: Equailizer
Streams
Water
TDS
Alcohols
Carbo
Acids
NaOH
Polymer
Total
Flowrate
18
877,608
53,054
65,100
4,330
2,856
7,511
1,010,459
19
766,800
0
0
0
0
0
766,800
20
23,232
0
624
0
0
0
23,856
Table 4-9: Ultrafiltration
Streams
Water
TDS
Alcohols
Carbo
Acids
NaOH
Polymer
Total
Flowrate
21
1,667,640
53,054
65,724
4,330
2,856
7,511
1,801,115
22
250,146
52,134
66,348
4,330
2,713
7,135
382,807
23
1,417,494
920
0
0
143
376
1,418,932
20
Table 4-10: Reverse Osmosis
Streams
Water
TDS
NaOH
Polymer
Total Flowrate
23
1,417,494
920
143
376
1,418,932
24
343,034
785
143
376
344,337
25
1,074,460
135
0
0
1,074,595
Table 4-11: Process Plant Water
Water
Waste
Total Flowrate
To Fertilizer Plant
690,346
87
690,433
To CHP
384,114
48
384,163
Appendix 5: Calculations
It was first necessary to convert the lbmol/day of CO2 to lb/hr in order to use equation (1)
to get the flow rate in ACFM.
æ152,209lbmol öæ 1day öæ 44.01lb ö
֍
÷ = 279,113lb /hr
ç
֍
day
è
øè 24hrs øè 1lbmol ø
ACFM =
lb /hr (T,°R)(0.1787)
(1)
(P, psia) MW , lb lbmol
(
)
Using equation (1), the flow rate in ACFM is found.
ACFM =
279,113 · 537 · 0.1787
= 496.8
1225 · 44.01
Equation (2) is needed in order to get the Compression Ratio.
CR =
Pin
(2)
Pout
CR =
1, 225psia
= 0.613
2, 200 psia
Equation (3) is used to get volume efficiency. Here, n is defined as the number of stages in
the compressor.
21
(
VE% = 93 - CR - 8 CR
1
n
)
-1 (3)
Since this is a single-stage compressor, n=1 and the volumetric efficiency can be found.
VE% = 93- 0.613-8*(0.6131/1 -1) = 86.7%
Since the volumetric efficiency and the flow rate in ACFM is known, it is possible to use
equation (4) to get the piston displacement.
PD =
ACFM
(4)
VE%
Once the piston displacement is found, a chart is used to determine the area of the
compressor.
PD =
496.8
= 5.73 Þ A = 161 ft 2
86.7
In order to find the energy requirement needed to run the compressor, several equations
were taken into consideration.
k -1
é
ù
æ
ö
P
ê 2 k
ú
H AD =
RT ç ÷ -1ú (5)
k -1 1 êè P1 ø
êë
úû
Equation (5) gives the adiabatic head for the compressor. (It is given in units of J/kg, so
some conversions need to be done to get it in HP.) However, another equation is needed to
find out what is the actual horsepower required by the compressor to run. That equation is
shown below.
k
HP =
w · H AD
(6)
e A · 33,000
The variables for these equations are as follows:
k=
CP 0.037kJ /molK
=
=1.3
CV 0.028kJ /molK
R = Specific Gas Constant = R =
T1 = Inlet Temperature
P1 = Inlet Pressure
P2 = Outlet Pressure
εA = Compressor Efficiency
R
MWCO2
22
With these known parameters, it is now possible to first calculate the adiabatic head.
H AD
1.3-1
é
ù
1.3
æ
ö
1.3 æ188.9J ö
2,200
psi
ê
=
-1ú = 35,404.8J /kg
ç
÷(297.9K ) êç
÷
ú
1.3 -1 è kgK ø
1,225
psi
è
ø
ë
û
In order to use equation (6), it is necessary that the adiabatic head be in HP and that the
flow rate be in CFM. Converting the 35,404.8 J/kg to HP and the flow rate in lbmol/day to
CFM, equation (6) can be used to find the total amount of horsepower required to run the
compressor.
æ 35,404.8J öæ152,209lbmol öæ 1day öæ 1hr öæ1min öæ 44.01lb öæ 0.4535kg öæ 1HP
ö
֍
֍
֍
֍
֍
÷ = 1,670HP
ç
֍
֍
kg
day
è
øè
øè 24hr øè 60min øè 60s øè 1lbmol øè 1lb øè 745.699J /s ø
æ152,209lbmol öæ 1day öæ 1hr öæ 44.01lb öæ 0.4535kg öæ m 3 öæ 35.31 ft 3 ö
֍
֍
֍
֍
֍
÷ = 37,622CFM
ç
֍
3
day
è
øè 24hr øè 60min øè 1lbmol øè 1lb øè1.98kg øè 1m ø
HP =
( 37,622CFM ) · ( 35,404.8J /kg)
= 2,339HP
(.85) · 33,000
Appendix 6: Annotated Equipment List
The following is a list of the total equipment used to purify water and carbon dioxide.
1
2
3
4
5
6
Equipment Needed to Purify Water
Extra Piping
Equalizer Pond, Equalizer Tank, Storage Tank, and Waste Water Tank
Pumps
API separator
DAF unit
Ultra-Filtration and Reverse Osmosis Units
7
8
Equipment Needed to Purify Carbon Dioxide
CO2 PSA Generator
Compressor
23
The following tables provide detailed information of each piece of equipment, in the order
mentioned above.
Table 6-1: Extra Piping (Carbon Steel)
Parameter
Value
Units
Pipe Length
1,000
FEET
Pipe Diameter
6
INCHES
Table 6-2: Equalizer Pond, Equalizer Tank, Storage Tank, and Waste Tank
Parameter
Equalizer
Pond
Equalizer
Tank
Storage
Tank
Waste
Tank
Units
Liquid Volume
300,000
600,000
800,000
1,000,000
GALLONS
Design Temperature
68
68
68
68
F
Vessel Diameter
40
32
21
66
FT
Vessel Height
32
32
32
40
FT
Weld Efficiency
85
85
85
85
PERCENT
Thickness Average
0.241
.252
0.27
0.36
INCHES
Corrosion Allowance
0.125
0.125
0.125
0.125
INCHES
24
Table 6-3: Pumps to be Used Throughout the Plant
Parameter
Pump Before and
After the API
Recycle
Pump
UF Pump
RO Pump
Units
Design
Temperature
120
120
120
120
F
Design Gauge
Pressure
30
30
150
300
PSIG
Fluid Head
225
200
200
75
FEET
Driver Power
15
5
15
15
HP
Speed
3,600
1,800
1,800
1,800
RPM
Pump Efficiency
65
50
65
50
PERCENT
Liquid Flow
Stream
117
30
180
150
GPM
Table 6-4: API Separator
Parameter
Value
Units
Liquid Flow
Rate
117.5
GPM
Diameter
5.0
FEET
Length
23.3
FEET
25
Table 6-5: DAF Unit
Parameter
Value
Volume per
Cell
1,500
Number of
Cells
15
Power Drive
100
Units
FT3
HP
Table 6-6: Ultra-Filtration and Reverse Osmosis Units
Parameter
UF Unit
RO Unit
Capacity
403,000
360,000
Efficiency
85
75
Units
GALLONS/DAY
Table 6-7: CO2 PSA Generator
Parameter
Value
Units
Capacity
59 - 1,765
CFM
Low End Pressure
10
PERCENT OF TOTAL
High End Pressure
90
PERCENT OF TOTAL
Energy Requirement
2,200
HP
26
Table 6-8: CO2 Compressor
Parameter
Value for Compressor
Units
Capacity
6.2
CFM
Inlet Pressure
1,225
PSIG
Outlet Pressure
2,200
PSIG
Inlet Temperature
77
F
Outlet Temperature
268
F
Energy Requirement
2,339
HP
Size
161
FT2
Efficiency
85
Appendix 7: Economic Evaluation Factored from Equipment Costs
Everything needed in order to make this plant work was taken into economical consideration.
Choices were made based on what is better for plant, both to achieve the necessary goal and to
be as economical as possible. The tables below show the individual prices for what is required in
the plant.
Table 7-1: Prices for the extra materials used for water purification.
Material
Price
Ferric Chloride
(solid)
$423 per ton
(includes
transportation)
PAM (emulsion)
$3-$6 per pound
NaOH (50 wt%
solution)
$125 per ton
27
Table 7-2: Prices and specifications for selling Carbon Dioxide for EOR Purpose
Gas
Bulk Price
Carbon Dioxide
(>95% purity)
$50 per ton
Table 7-3: Water treatment equipment pricing
Equipment
Price
Extra Piping
$21,923
Equalizer Pond
$223,041
Equalizer Tank
$351,362
API Pump
$38,801
API separator
$107,441
DAF Unit
$1,580,023
UF Pump
$25,572
Recycle Pump
$19,123
Ro Pump
$26,304
Waste Water Tank
$505,685
Storage Water Tank
$143,253
UF Pump
$250,000
RO Pump
$180,000
Table 7-4: Carbon Dioxide Cleanup Equipment Pricing
Equipment
Price
PSA Carbon Dioxide Generator
$321,642
Compressor
$25,039,166
Given this information, an overall economic evaluation on the resources recovery plant was
calculated. The information collected was assuming that this plant has a 20-year life. The values
for capital cost, revenue, and total expenses are shown in Table 7-6. The revenue comes from
selling CO2 to the Dakota Gasification Company. Total expenses are based on salaries and
28
fringes, water treatment costs (NaOH, PAM, FeCl3, and landfill waste), loan expense,
maintenance, and depreciation. From this information, the NPV value is -$111,272,066. Since
it’s negative, this plant loses money overall. However, transfer prices were not taken into
consideration. If transfer prices had been available, a more detailed and accurate plant economic
evaluation could be completed.
Table 7-6: Overall economic Evaluation
Capital Cost
$32,087,082
Revenue
$129,456,086
Total Expenses
$463,623,521
Appendix 8: Utilities
The only utilities that this plant will require is electricity and instrumental air. Electricity is
required to power all of the units and pumps within the water and gas cleaning plant. The total
horsepower requirements of both plants is 29,415 HP, meaning that the plant will require
526,434 kilowatt-hours. The air will be used in the Dissolved Air flotation unit. It will be
bubbled from the bottom of the DAF unit and it will separate the dissolved oil from the water.
29
Appendix 9: Conceptual Control Scheme
The controls for the DAF unit as shown above are specific to the level within the system, the pH
and pressure in the vessel that is used for the dissolved air in water. A pH control loop is
necessary for the outflow water from the DAF as the units that follows (ultrafiltration and
reverse osmosis) are sensitive to extremely low pH fluid. The pH transmitter will send a signal to
to the solution control panel and open the valve to increase the quantity of inlet NaOH when the
pH is low. The dissolved air and recycled water vessel has a level control where if water level
exceeds set point level, a transmitter signal will be sent to an outlet control valve from DAF to
decrease the flow rate of recycled water and therefore lower water level to air-water vessel. This
vessel is to be maintained at 70 psig. In the case that this pressure is increased, a pressure
sensor/transmitter will send a signal to the indicator panel/control to open the pressure relief
valve to partially depressurize the vessel. Though not shown, in the case of overflow of water
from DAF unit, the under-over weir will be adjusted to decrease the over flow of water and a
transmitter flow rate signal will be sent to control flow control panel and adjust the inlet DAF
valve to prevent overflow of water from overall DAF unit.
30
Appendix 10: General Arrangement - Major Equipment Layout
The overall plant layout for wastewater treatment and carbon dioxide purification is shown
above. We are located in Williston, North Dakota. The pipe rack will have dimensions of 12 feet
wide and 22 feet high and will provide us with the raw water material to be cleaned up. An
incoming pipe will contain flowback frac water from the well, second waste water will come
from the gas treatment plant, and third pipe will contain waste water from the Fischer-Tropsch
plant. This contaminated water will be collected in the first equalizer pond as shown on the plant
layout.
After an hour of residence time it will be pumped out to the API separator, which is about 200
feet away. After an hour of resonance time and partial water/oil and suspended solid separation,
collected sludge will be pumped out to sludge tank via pipe as shown on plant layout. Effluent
water will then flow and be pumped to secondary separation treatment or DAF (dissolved air
floatation unit). An incoming stream of NaOH and Polymer adjust pH and enhance emulsified
31
oil to be coagulated to be carried with incoming air dissolved stream and be skimmed off as
sludge solid waste. This waste will also be pumped out to same tank as that of API waste.
Addition of ferric chloride will help partially precipitate dissolve salts and to be sent to sludge
waste tank as mentioned previously. A 30wt% of effluent water from DAF unit will be recycled
back and used as the medium of the dissolved air for flotation of solids and remaining oils to be
separated from water.
The effluent water from the DAF unit will be pumped out to a second equalizer tank 200 feet
away and allowed to equalize with an incoming stream from boiler blowdown/cooling tower
blowdown from CHP and gas/liquids. After an hour of mixing of these three water sources,
contaminated water will be pumped into the ultrafiltration unit 100 feet away via single pipe. The
rejected stream will be pumped to waste tank as shown on plant layout. Permeate water will be
pumped to the Reverse Osmosis unit to filter out dissolved salts. Again, concentrated salt reject
will be pumped to same tank as Ultrafiltration. Clean process water will be pumped to holding
tank 300 feet away via single pipe to be used as process water for Fertilizer plant and CHP plant
to produce steam and energy.
Another process treatment is that of carbon dioxide purifying. Three separate pipes will pump
CO2 and its contaminants to a Pressure Swing Adsorption system to get adsorbed contaminants
while CO2 will permeate and be sent to a compressor to ultimately be sold for enhanced oil
recovery. In this plant layout, there is also a building for lab/quality control and road way for
incoming trucks to empty waste tanks to be sent off to landfill and replenish NaOH, polymer,
and ferric chloride to raw material tanks.
Appendix 11: Distribution and End-use Issues Review
The Water cleaning plant will receive water from numerous sources. It will be getting water
from Fischer-Tropsch, gas treatment, flowback, gas-liquids, and CHP plant. The water inputs
are added into two different areas of the plant, depending on what the water is contaminated with.
If the water contains any oils, the stream will enter at the beginning to the first equalizer pond. If
it does not contain any oil, it will be inserted after the dissolved air flotation unit. Therefore, the
flowback, Fischer-Tropsch, and the gas treatment water will enter through the beginning of the
plant into the equalizer pond; and gas-liquids and CHP water will be enter right after the DAF
unit since they contain no oil. The clean water will then be sent to the CHP and the fertilizer
plant. Unfortunately due to the amount of water the plant is receiving, it is unable to fulfill CHP
water demands. This means that CHP will have to purchase more water from another source.
Also, CHP requires a higher purity than what is required of normal process water, meaning that
they will have to further clean the water that is going to be sent to their plant. The plant will also
be producing a lot of waste water consisting mainly of salts and oils. The waste water will be
32
collected in a tank after the unit that is removing the waste. The tanks will be emptied out every
week and will be transported by trucks to a landfill.
The only gas that requires purification in the whole complex is CO2. The CO2 is coming in from
the gas/liquids plant, the gas treatment plant, and the iron reduction plant. The purified CO2 will
have a purity of at least 95% and a pressure of 2,200 psi; it will be sold for EOR (enhanced oil
recovery) to the Dakota Gasification Company. The waste gas will be sent to the CHP plant.
Appendix 12: Constraints Review
There were many constraints with our design that had to be worked around. One of the major
constraints was that in order for EOR to accept our cleaned CO2, we had to have it at a 95%
purity and make it have a pressure of 2,200 psi. In order to abide by these constraints, we had to
add a compressor after the PSA unit in order to significantly increase the pressure of the CO2.
Also, in order for the CO2 to reach a purity of 95% we had to find a PSA packed with zeolite as
the adsorbent. Zeolite is specifically used to separate CO2, and it is the only packing material
that could economically purify the CO2 to the specifications that EOR demands.
Additionally, the flow rate of the flow back water is not continuous. The flow rate of the flow
back water decreases exponentially as time increases. In order to assure that the frac water
cleaning plant has a consistent and reliable flow rate at all times, we made all the water inputs to
go into an equalizer tank. This equalizer tank will combine all of the incoming water streams
from the various plants and make it homogeneous. This is also why there is an equalizer tank in
the end of our process, to ensure that the plants that are receiving the now clean process water
acquire it at the same flow rate all the time.
After the initial 30 days of the plant operation the flow back water will turn into produced water.
Produced water has a significantly lower flow rate that the flow back water, but it contains a
tremendous amount of salt and oil in it. We did not have to design an entirely new process from
this phenomena due to the fact that the water cleaning system was designed to handle significant
water with significant amounts of salt and oil. We did have to redesign an entirely new balance
though, and take that into account when giving the CHP and the fertilizer group the specific
number on how much water they are receiving.
Lastly, for both the flow back water and the produced water mass balances, the percentage of salt
in the water is very small. This is due to the fact that the flowback/produced water is being
diluted by all the other process waste water. Due to this, the only type of cleaning system able to
remove the salts from the water was a reverse osmosis system. Chemical and distillation salt
removal treatment require a much higher salt concentration for the water going into it for it to be
33
effective at cleaning the water. The total salt concentration of the total water that we are
cleaning fit well within the tolerances of the reverse osmosis system though. Additionally,
reverse osmosis can clean the water to concentrations as low as 10 ppm of salt. This was also a
huge deciding factor for reverse osmosis since the CHP plant requires extremely pure water for
their process.
Appendix 13: Applicable Standards
●
●
●
●
●
●
●
●
●
●
●
●
No water can be taken from local rivers
No water can be dispose to local rivers
All PPE must follow OSHA CFR 1910[66], which is the code that explains all the PPE
that needs to be used depending on the type of work done
All Hazmat Emergency Procedures must follow the Emergency Response Guidebook
(ERG)[67]
All of the disposal of emissions must follow the Guidance of EPA Halon Emission
Reduction Rule (40 CFR Part 82, Subpart H) [68]
Pressure vessel must be designed and fabricated per ASME Codes [69]
All pumps and compressors design must follow ANSI Standards [70]
All rotating equipments design must follow ANSI Standards [71]
The use of Sodium Hydroxide in water treatment plant must follow AWWA B200-12Revised [72]
The use of Polyacrylamide in water treatment plant must follow AWWA B453-06 [72]
The use of Steel pipe in water treatment plant must follow AWWA C200-12-Revised [72]
All underground service line valves and fittings must follow AWWA C800-12-Revised
[72]
●
●
●
●
●
●
●
●
All PVC must follow AWWA C900-07 [72]
All storage tanks for water treatment plant must follow AWWA D102-11 [72]
Water Treatment Plant Operation and Management must follow AWWA G100-11 [72]
Utility Management System must follow AWWA G400-09 [72]
Security Practices for Operation and Management must follow AWWA G430-09 [72]
Emergency Preparedness Practices must follow AWWA G440-11[72]
Communications and Customer Relations must follow AWWA G420-09 [72]
Source Water Protection must follow AWWA G300-07 [72]
Appendix 14: Project Communications File
Meetings with the team mentor were held weekly. General questions and other concerns were
handled via email. General notes on what was discussed each meeting are found below and are
arranged chronologically.
01/18/2013 Meeting - Telecon (42 minutes)
34
●
●
●
●
●
●
●
Cryogenic distillation
Membrane separation
Adsorption
Water desalting/sun vaporization
How to reuse all water to be put back into the system
Discharge water rules/safety in Williston, ND
Hydrocarbons - Pressure, composition, and temperature coming in from other streams
01/25/2013 Meeting - Telecon (50 minutes)
● Block flow diagram for each gas and one for water treatment
● Overall material balance
● Order for water treatment steps
● Need to contact other plants to see how much is incoming and how much should be
provided to each plant
● Membrane Separation vs. PSA vs. Cryogenic Distillation
● Goal for CO2 is to sell as dry ice or for EOR (Enhanced Oil Recovery)
02/02/2013 Meeting - In person (from 11am to 2:15pm)
● Guidelines for presentation
● EPA rules and regulations
● In detail steps for water treatment
● David Field - Contact from Salt Creek Technologies who is willing to help with waste
water treatment inquiries
● Try for a zero-discharge plant
● Assumptions for flow of water and gases to be treated based on general material balance
02/08/2013 Meeting - Telecon (1 hour)
● Discuss rough economics for what to use for gas treatment
○ Membrane, PSA, Cryogenic Distillation, Puraspec
● See if we are allowed to contact vendors for pricing
○ CO2, N2, O2, etc.
○ Units, sizing, energy requirements
● Specifications on purity of gases to sell
● Begin having recordings of each meeting available
● How to develop a good spreadsheet
● Set up time to speak with David Field
● Reminder on what needs to be available on the wiki and how it should be
presented/updated
02/12/2013 Meeting - Telecon with David Field (1 hour, 16 minutes)
35
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●
●
●
●
●
●
●
●
●
All the meeting was related to water treatment
Need to remove oil, grease, heavy metals, TDS, minerals, salts, etc.
Need an equalization basin
Will have flow-back, boiler blowdown, and cooling tower blowdown water
Only Fischer-Tropsch, gas treatment, and flow back water will be pretreated, the rest of
the water will be desalted (enter at the UF-RO unit)
UF-RO is more economical than evaporation/crystallization
Steps are primary treatment, chemical conditioning, and UF-RO
○ From there into a storage tank
Cheaper to have waste taken ($0.18/gal cost) than to treat waste in a crystallizer
Reject from RO unit will be placed in a tank and that will be hauled away about once a
month
General cost information based on assumed flow rates
02/15/2013 Meeting - Telecon (48 minutes)
● Purify standards to the lowest amount allowed
● Find more information to see if there is a membrane separator we could use since it’s
probably cheaper
● Follow David Field’s advice on water treatment and feel free to contact him for any
questions
02/22/2013 Meeting - Telecon (55 minutes)
● Speak to the class, not to the screen or wall
● Overall good presentation
● Need to focus on getting more detailed information for water treatment
● Can’t slow down, need to keep busy to get the project done on time
03/01/2013 Meeting - Telecon (55 minutes)
● Economic Evaluation
○ RO vs. Evaporator
○ Reject tank vs. Crystallizer
● Flowsheeting
● Call vendors to get pricing/sizing for equipment
● ASPEN may not be the best program for getting equipment pricing and sizing
● Need to find horsepower
● Assume total installed costs are about 3-4 times the cost of equipment (as a general rule)
● Contact David Fields for more information regarding equipment sizing and general
pricing for waste water treatment
● Make sure no other plant requires process plant water and get rough estimates of how
much is required per plant
36
○
Need to figure out size of storage tank or specifications for discharge into a local
river
3/8/2013 Meeting - Telecon (1 hour)
● Catalytically oxidize waste from CO2
● Membrane and operating pressure for UF and RO
● Need to know what the CHP water needs are
● Say 30 psig for all pumps
● UF ahs 150 psig
● RO has 300 psig
● Discuss questions not answered in this meeting
● Contact David Field for pricing of UF and RO unit
● Get estimates in ASPEN Cost Estimator
3/22/2013 Meeting - Telecon (32 minutes)
● Get parallel compressor so that we can lower cost and hp requirement
● Speak to David Field about stream input (technical explanation)
● Tell everyone our design basis is complete
● Need to show the loops for the flow control
● Mat balance and sizing calculations
○ Probably pick the compressor since it’s something we need to make sure we have
anyways (hand calculations necessary, no ASPEN)
● Next meeting cancelled unless we need help
● Total reject water from membrane - need enough steam to evaporate (1000 BTU/lb)
○ such a good crystallizer that we can get: 1 lb steam/1lb water
○ CHP will send us the steam required
○ Need to haul away solid garbage (conveyer belt needed)
○ Other reject is for landfill for sure (hazardous landfill)
4/5/2013 - Meeting Telecon (27 minutes)
● Fix the general plant layout to include places where trucks can come in to load/unload
and add in pipes
● Mentor won’t be able to come for the 4th meeting presentation
● Need to send everything done to him by Monday night
● A negative NPV and IRR value are okay since many things are not taken into
consideration
○ Make sure to explain what was taken into consideration
● Pick only one thing to focus on for control scheme
37
4/26/2013 - Meeting Telecon (1 hour)
● Discuss final report
● Edit several parts to make more sense
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42