Abstract: Many processes generate wastewater streams rich in sulfate and chloride. These salt components are traditionally not recovered and are discharged to the environment. The invention recovers pure water for recycle/reuse and simultaneously generates valuable pure salts of NaCl and Na2SO4 for beneficial reuse, eliminating the waste stream. Process consists of the sequential crystallization of salt products with an intermediate purification step in which a chemical reactant is added to elevate levels of purity. The process is configured to simultaneously achieve zero liquid discharge.

Abstract: A sodium chloride recovery method for upgrading a mixed salt stream from lower sodium chloride purity to an increased sodium chloride purity is provided. The salt recovery method utilizes the solubility properties of the impurities in the mixed salt to preferentially dissolve them over sodium chloride. As the impurities are removed from the solid phase using a salt stripper, sodium chloride rich slurry is generated. The rich salt slurry is processed by an upgrader to remove the remaining impurities. The upgraded sodium chloride slurry is dewatered and washed in the phase separator to generate sodium chloride salt at a higher purity.

Abstract: We provide an evaporation based method for water recovery from gasification wastewater to achieve zero liquid discharge. Grey water from a gasification system is processed by an evaporation system which recovers >99% of the influent water and generates a solid phase in a crystallizing reactor. The crystallizing reactor converts dissolved solids present as highly soluble species into alternative chemical forms that are amenable to precipitation and removal from the liquid phase to achieve zero liquid discharge.

Abstract: Many processes generate wastewater streams rich in sulfate and chloride. These salt components are traditionally not recovered and are discharged to the environment. The invention recovers pure water for recycle/reuse and simultaneously generates valuable pure salts of NaCl and Na2SO4 for beneficial reuse, eliminating the waste stream. Process consists of the sequential crystallization of salt products with an intermediate purification step in which a chemical reactant is added to elevate levels of purity. The process is configured to simultaneously achieve zero liquid discharge.

Abstract: A method for treatment of produced water, particularly deoiled water, by evaporation. Methods use a vertical tube heat exchanger bundle where the brine is distributed in a falling film along the inside of the tube wall. Condensing steam causes a portion of the deoiled water to evaporate; this water vapor travels upward in a counterflow direction relative to the deoiled water. Evaporator sump volume is minimized, and evaporators may have a multi-piece construction to lower the center of gravity of an evaporator installation. This technology provides several advantages over conventional vertical tube co-current flow evaporators (where the vapor flows downward with the falling film). These advantages include a minimal total installed cost (TIC) and enhanced water chemistry management.

Abstract: We provide an evaporation based zero-liquid discharge method for generation of steam for enhanced oil recovery (EOR) processes utilizing once-through steam generators (OTSGs). The method includes feeding the OTSG(s) with produced water, vaporizing a fraction of this water for steam injection and blowing down the balance of the water. This water, referred to as OTSG blowdown, can be flashed to produce a vapor stream and a liquid that is fed to a mechanical vapor compression (MVC) evaporative process. The latent energy contained in the vapor stream generated by the upstream flash is beneficially recycled to substantially reduce or eliminate the energy consumption of the MVC process. The evaporative process can be used to reduce the liquid waste for disposal or eliminate the need for liquid disposal by achieving zero liquid discharge.

Abstract: We provide an evaporation based zero-liquid discharge method for generation of steam for enhanced oil recovery (EOR) processes utilizing once-through steam generators (OTSGs). The method includes feeding the OTSG(s) with produced water, vaporizing a fraction of this water for steam injection and blowing down the balance of the water. This water, referred to as OTSG blowdown, can be flashed to produce a vapor stream and a liquid that is fed to a mechanical vapor compression (MVC) evaporative process. The latent energy contained in the vapor stream generated by the upstream flash is beneficially recycled to substantially reduce or eliminate the energy consumption of the MVC process. The evaporative process can be used to reduce the liquid waste for disposal or eliminate the need for liquid disposal by achieving zero liquid discharge.

Abstract: Embodiments presented herein provide an evaporation based zero liquid discharge method for generation of up to 100% quality high pressure steam from produced water in the heavy oil production industry. De-oiled water is processed in an evaporation system producing a distillate that allows steam to be generated with either drum-type boilers operating at higher pressures or once-through steam generators (OTSGs) operating at higher vaporization rates. Evaporator blowdown is treated in a forced-circulation evaporator to provide a zero liquid discharge system that could recycle >98% of the deoiled water for industrial use. Exemplary embodiments of the invention provide at least one “straight sump” evaporator and at least one hybrid external mist eliminator. Embodiments of the evaporation method operate at a higher overall efficiency than those of the prior art by producing distillate at a higher enthalpy which minimizes the high pressure boiler preheating requirement.

Abstract: Embodiments presented herein provide an evaporation based zero liquid discharge method for generation of up to 100% quality high pressure steam from produced water in the heavy oil production industry. De-oiled water is processed in an evaporation system producing a distillate that allows steam to be generated with either drum-type boilers operating at higher pressures or once-through steam generators (OTSGs) operating at higher vaporization rates. Evaporator blowdown is treated in a forced-circulation evaporator to provide a zero liquid discharge system that could recycle >98% of the deoiled water for industrial use. Exemplary embodiments of the invention provide at least one “straight sump” evaporator and at least one hybrid external mist eliminator. Embodiments of the evaporation method operate at a higher overall efficiency than those of the prior art by producing distillate at a higher enthalpy which minimizes the high pressure boiler preheating requirement.

Abstract: Evaporation technology is commonly used to to treat process waters that contain low solubility salts. The technology typically used is a brine boncentrator which uses seeded slurry techniques internal to the falling film evaporator which allows these scaling salts to co-precipitate with the seed crystals instead of scaling on the heat transfer surface. Such systems often employ hydroclones to recover and recycle seed crystals that would otherwise leave the process with the brine blowdown stream. These hydroclones (or other separation devices) often have regions of tight clearance that are susceptible to plugging which can lead to suboptimal process availability and greater maintenance obligations. The inventors have developed an apparatus called a “settling chamber” for separating large solid particles from the feed stream to the hydroclone to eliminate plugging, improve availability and reduce maintenance requirements.

Abstract: Embodiments presented herein provide an evaporation based zero liquid discharge method for generation of up to 100% quality high pressure steam from produced water in the heavy oil production industry. De-oiled water is processed in an evaporation system producing a distillate that allows steam to be generated with either drum-type boilers operating at higher pressures or once-through steam generators (OTSGs) operating at higher vaporization rates. Evaporator blowdown is treated in a forced-circulation evaporator to provide a zero liquid discharge system that could recycle >98% of the deoiled water for industrial use. Exemplary embodiments of the invention provide at least one “straight sump” evaporator and at least one hybrid external mist eliminator. Embodiments of the evaporation method operate at a higher overall efficiency than those of the prior art by producing distillate at a higher enthalpy which minimizes the high pressure boiler preheating requirement.

Abstract: We provide an evaporator technology for treatment of produced water that may be deoiled water. Systems described herein utilize a vertical tube heat exchanger bundle where the brine is distributed in a falling film along the inside of the tube wall. Condensing steam causes a portion of the deoiled water to evaporate; this water vapor travels upward in a counterflow direction relative to the deoiled water. This evaporator technology provides several design advantages over the conventional vertical tube co-current flow evaporators (where the vapor flows downward with the falling film). These advantages include a minimal total installed cost (TIC) as well as offering optimal design features for water chemistry management.

Abstract: Embodiments presented herein provide an evaporation based zero liquid discharge method for generation of up to 100% quality high pressure steam from produced water in the heavy oil production industry. De-oiled water is processed in an evaporation system producing a distillate that allows steam to be generated with either drum-type boilers operating at higher pressures or once-through steam generators (OTSGs) operating at higher vaporization rates. Evaporator blowdown is treated in a forced-circulation evaporator to provide a zero liquid discharge system that could recycle>98% of the deoiled water for industrial use. Exemplary embodiments of the invention provide at least one “straight sump” evaporator and at least one hybrid external mist eliminator. Embodiments of the evaporation method operate at a higher overall efficiency than those of the prior art by producing distillate at a higher enthalpy which minimizes the high pressure boiler preheating requirement.