Auswahl der wissenschaftlichen Literatur zum Thema „Pilot-Scale fouling“

There is increasing interest in recycling wastewater effluents for augmentation of existing water supplies. The treatment of wastewater effluents by an integrated membrane system, such as microfiltration pre-treatment followed by reverse osmosis, is the industry standard for groundwater recharge or reservoir augmentation projects. Membrane fouling, especially effluent organic matter fouling, is a major challenge for water reuse applications employing high-pressure membranes. While fouling control through pre-treatment is an important aspect in membrane system design and operation, selecting low fouling membranes is an equally important aspect. Although recent research has begun to elucidate fouling mechanisms, little work has been performed to develop methods to pre-determine the effluent organic matter fouling propensities of high-pressure membranes so that low-fouling membranes can be pre-selected for reuse applications. The purpose of this study was to utilize a bench-scale testing protocol to test the relative effluent organic matter fouling propensities of commercially available NF and RO membranes when treating wastewater effluents. Bench-scale fouling test results were then compared to operational data generated during pilot- and full-scale membrane testing. Pilot- and full-scale testing using recycled water demonstrated that membranes foul at significantly different rates and that the extent of fouling could be estimated utilizing the proposed bench-scale testing protocol.

A pilot-scale study was performed to evaluate a coagulant dose which had been optimized for biopolymer (i.e., foulant) removal on subsequent ultrafiltration (UF) fouling, as well as disinfection by-product (DBP) precursor removal. Polyaluminum chloride (PACl) dosages were selected based on a point of diminishing returns for biopolymer removal (0.5 mg/L) and directly compared to that applied at full-scale (6 mg/L). Membrane fouling (reversible and irreversible) was measured as resistance increase over a 48 hour filtration period. DBP formation potential (total trihalomethanes (TTHMs), haloacetic acids (HAA9) and total adsorbable organic halides (AOX)) were measured in both raw and treated waters. Results of the study indicate that application of a PACl dose optimized for biopolymer reduction (0.5 mg/L) resulted in 65% less irreversible UF fouling when compared to 6 mg/L. The addition of PACl prior to the membrane resulted in up to a 14% reduction in DBP precursors relative to the UF membrane alone. A similar level of DBP precursor reduction was achieved for both 0.5 and 6 mg/L dosages. The results have implications for cost savings, which may be realized due to decreased chemical use, as well as increased membrane life associated with lower irreversible fouling rates.

The formation of inorganic fouling on MF membrane was investigated in membrane bioreactor (MBR) treating industrial wastewater. Membrane autopsy works using microscopic techniques and surface analysis were carried out at the completion of pilot-scale operation to analyze foulant materials extensively. Scaling occurred on the membrane surface significantly in the MBR treating calcium-rich wastewater (LSI > 2.0). Our experiments showed that the coverage of the membrane surface by the inorganic fouling consisted mostly of calcium while the internal fouling within membrane pores due to the scale formation was almost negligible. Most of calcium was rejected on the MF membrane surface as scale formation of calcium carbonate (>90% as rejection). The sequence sodium hypochlorite-citric acid for the removal of membrane scale was more effective than the sequence citric acid-sodium hypochlorite cleaning. It appeared that the structure of organic compounds combined with calcium became loose by the addition of the sodium hypochlorite, thereby releasing calcium more easily from the membrane by applying the acid cleaning agent.

Effects of coagulation/sedimentation as a pre-treatment on the dead-end ultrafiltration (UF) membrane process were studied in terms of membrane fouling and removal efficiency of natural dissolved organic matter, using Chitose River water. Two types of experiment were carried out. One was a bench scale membrane filtration with jar-test and the other was membrane filtration pilot plant combined with the Jet Mixed Separator (JMS) as a pre-coagulation/sedimentation unit. In the bench scale experiment, the effects of coagulant dosage, pH and membrane operating pressure on the membrane fouling and removal efficiency of natural dissolved organic matter were investigated. In the pilot plant experiment, we also investigated the effect of pre-coagulation/sedimentation on the membrane fouling and the removal efficiency of natural dissolved organic matter. Coagulation/sedimentation prior to membrane filtration process controlled the membrane fouling and increased the removal efficiency of natural dissolved organic matter.

Membrane fouling is considered to be the most serious drawback in wastewater treatment when using membrane bioreactors (MBRs), leading to membrane permeability decrease and efficiency deterioration. This work aims to develop an integrated methodology for membrane fouling control, using powdered activated carbon (PAC), which will enhance the adsorption of soluble microbial products (SMP) and improve membrane filterability, by altering the mixed liquor's characteristics. Reversible fouling was assessed in terms of sludge filterability measurements, according to the standard time-to-filter (TTF) method, while irreversible fouling was assessed in terms of SMP removal. Results showed that the addition of PAC at the concentration of 3 g/L in the mixed liquor reduced SMP concentration and enhanced substantially the sludge filterability. Furthermore, the TTFPAC/TTFno PAC ratios were lower, than the corresponding SMPPAC./SMPno PAC ratios, indicating that the batch-mode, short-term addition of PAC promotes the reversible, rather than the irreversible fouling mitigation.

The objective of this study was to develop a new prediction method for evaluating performance of full-scale nanofiltration (NF) pilot plant by using small-scale pilot plants. Operating experiments using both multistage array pilot plant and two small-scale pilot plants in parallel had been conducted for about a year. From this experiment, it was revealed that data obtained from small-scale pilot plants could predict the performance of multistage pilot plant from the viewpoint of flux and rejection. In other words, both permeate water quantity of multistage pilot plant without noticeable fouling caused by aluminium from coagulant and permeate water quality of multistage pilot plant could be estimated.

Membrane contactor technology affords great opportunities for nitrogen recovery from waste streams. This study presents a performance comparison between lab- and pilot-scale membrane contactors using landfill leachate samples. Polypropylene (PP) and polytetrafluoroethylene (PTFE) fibers in different dimensions were compared in terms of ammonia (NH3) recovery on a lab scale using a synthetic ammonium solution. The effect of pre-treating the leachate with tannin coagulation on nitrogen recovery was also evaluated. An ammonia transfer on the lab and pilot scale was scrutinized using landfill leachate as a feed solution. It was found that PTFE fibers performed better than PP fibers. Among PTFE fibers, the most porous one (denoted as M1) had the highest NH3 flux of 19.2 g/m2.h. Tannin pre-treatment reduced fouling and increased NH3, which in turn improved nitrogen recovery. The mass transfer coefficient of the lab-scale reactor was more than double that of the pilot reactor (1.80 × 10−7 m/s vs. 4.45 × 10−7 m/s). This was likely attributed to the difference in reactor design. An analysis of the membrane surface showed that the landfill leachate caused a combination of inorganic and organic fouling. Cleaning with UV and 0.01 M H2O2 was capable of removing the fouling completely and restoring the membrane characteristics.

This study examines the effect of bentonite and zeolite concentration (0.25–5 g/L) on the membrane fouling of a fully automated, pilot-scale membrane bioreactor (MBR) treating high-strength synthetic municipal wastewater. Reversible fouling was estimated by sludge filterability measurements and irreversible fouling was estimated by the reduction of the carbohydrate fraction of soluble microbial products (SMPc), which are considered to be significant MBR foulants. Both minerals were added to biomass samples (during batch-mode experiments) which were obtained from the system’s aeration tank. Results showed that the optimal bentonite and zeolite concentrations were 3.5–4 g/L and 2.5–3.5 g/L, respectively. Interestingly, above these values, the addition of both minerals increased the examined fouling indices, i.e., the measured filterability times and the SMPc concentration, implying that they might act as foulants at high concentrations. Optical microscopy images of the biomass samples showed that the addition of minerals at the optimal concentrations did not affect significantly filamentous microorganisms, since filament index (FI) was practically unaffected (~2). Finally, regarding the system’s treating performance, it was found that the pilot-scale MBR can operate successfully with high-strength synthetic municipal wastewater, since remarkable behaviour was exhibited in terms of organics (BOD5, COD) and ammonium (NH4+-N) removal (>98%).

Abstract Microcoagulation has recently been considered as a promising pretreatment for an ultrafiltration (UF) process from numerous studies. To investigate the effects of microcoagulation on the performance of the UF–reverse osmosis (RO) system treating wastewater with high and fluctuant salinity, different dosages of coagulant (poly-aluminum chloride) were added prior to the UF unit in a pilot-scale UF–RO system for a 10-week period operation. Microcoagulation obviously improved the contaminant removal and cleaning efficiencies, including water backwash, chemical enhanced backwash and cleaning in place processes. Organic fouling was dominated during the initial stage of the RO membrane fouling. The microbial communities of water samples and foulant on the RO membrane were similar to those of seawater and foulant on the RO membranes from seawater RO plants. The microbial community of the foulant on the membrane was similar to that of UF permeate and RO concentrate. These results demonstrated that microcoagulation could improve the performance of the UF–RO system treating the effluent with high and fluctuant salinity from a coastal municipal wastewater treatment plant.

Membrane fouling can be divided into two types: reversible fouling and irreversible fouling. The former can be easily canceled by physical cleaning (e.g., backwashing) while the latter needs chemical cleaning to be mitigated. For more efficient use of membranes, the control of irreversible membrane fouling is of importance. In this study, the effectiveness of pre-coagulation/sedimentation on irreversible membrane fouling was investigated, based on the pilot-scale operation of the membrane unit installed at an existing water purification plant. The membrane employed was a low-pressure ultrafiltration (UF) membrane made of polysulfone and having a molecular weight cut-off of 750,000 daltons. Although pre-coagulation/sedimentation significantly mitigated membrane fouling mainly through the reduction of reversible membrane fouling, the degree of irreversible fouling was not reduced by the pre-treatment. This was because the irreversible fouling observed during this study was mainly attributed to polysaccharides/protein like fractions of organic substances that cannot be efficiently removed by coagulation/sedimentation. Aluminium used as coagulant was thought to cause irreversible fouling to some extent but did not in the pilot operation, which could probable be explained by the fact that coagulation was conducted at relatively high pH (7.0) in this study.

In gas-solid fluidized beds, the generation of electrostatic charges due to continuous contacts between fluidizing particles, and the particles and the fluidization vessel wall, is unavoidable. Industrial operations, such as the production of polyethylene, are susceptible to significant operational challenges caused by electrostatics including reactor wall fouling, a problem known as “sheeting”. The formation of particle sheets can require shutdown periods for clean-up which results in significant economic losses. To gain a better understanding of the underlying mechanisms of electrostatic charging in gas-solid fluidized beds, in an attempt to eliminate or minimize this problem, a pilot-scale pressurized gas-solid fluidization system was designed and built, housing an online electrostatic charge measurement technique consisting of two Faraday cups. The system permits the study of the degree of particle wall fouling at pressures and temperatures up to 2600 kPa and 100°C, respectively, and gas velocities up to 1 m/s (covering a range including turbulent flow regime). The system also allowed, for the first time, the measurement of the fluidizing particles’ mass, net charge and size distribution in various regions of the bed, especially those related to the wall coating under the industrially relevant operating conditions of high pressures and gas velocities. Experimental trials were carried out using polyethylene resin received from commercial reactors to investigate the influence of pressure and gas velocity on the bed hydrodynamics and in turn, the degree of bed electrification. Mechanisms for particle charging, migration and adherence to the column wall were proposed. The size distribution of the gas bubbles shifted towards smaller bubbles as the operating pressure was raised. Thus, higher pressures lead to greater mixing within the bulk of the bed and resulted in a higher degree of particle wall fouling. Moreover, the extent of wall fouling increased linearly with the increase in gas velocity and as the bed transitioned to turbulent regime, due to the increase in particle-wall contacts. Bipolar charging was observed especially within the wall coating with smaller particles being negatively charged. Overall, particle-wall contacts generated negatively charged particles resulting in a net negative charge in the bed, whereas particle-particle contacts generated positively and negatively charged particles resulting in no net charge when entrainment was negligible. The formation of the wall layer and its extent was influenced by the gravitational and drag forces balancing the image force and Coulomb forces (created by the net charge of the bed and the metallic column wall as the attraction between oppositely charged particles).

Le présent travail est une contribution pour mieux comprendre l’influence des micelles de caseine sur l’encrassement de solutions de protéines sériques. En particulier, des approches expérimentales et numériques ont été réalisées, à des tailles laboratoires et pilotes, pour décrire les phénomènes de dénaturation et mieux cerner le rôle du calcium dans les mécanismes d’encrassement. Tout d'abord, l'effet du ratio massique caséine / lactosérum sur les performances d'encrassement des protéines de lactosérum a été étudié dans un échangeur à Plaques à l'échelle pilote. La masse totale du dépôt d'encrassement chute d’abord de manière significative avec l'augmentation de la concentration en caséine, atteignant un minimum quand le ratio vaut 0,2. Au-delà de cette valeur, la masse de dépôt réaugmente. La chute de la masse du dépôt, pour un ratio ≤ 0,2, ne semble pas être corrélée à la dénaturation thermique du BLG mais plus probablement due à la modification des interactions minérales introduites par la caséine. L'augmentation de la masse de dépôt, pour un ratio ≥ 0,2, semble être liée à une co-précipitation du complexe BLG-caséine qui augmente l'encrassement. Il est suggéré que la présence de caséine micellaire modifie profondément l'équilibre calcique en solution et que la teneur en nanocluster de Ca-P modifie fortement les interactions entre les espèces protéiques et les minéraux (calcium ionique, Ca-P) affectant ainsi la dénaturation des protéines et la précipitation des minéraux. Un nouveau modèle cinétique concernant le dépliement thermique et l'agrégation de BLG a été établi. Ce modèle est en mesure de justifier la rupture de pente dans le diagramme d'Arrhenius et de fournir des informations thermodynamiques détaillées pour les processus de dépliement et d'agrégation. Sur la base de ce modèle, il a été confirmé que le calcium ionique avait un rôle protecteur sur le dépliement thermique du BLG à basse température. En revanche, à des températures plus élevées, le calcium favorise l'agrégation et la formation d'espèces BLG dépliées. Un dispositif d'encrassement à l'échelle laboratoire a été construit et tester avec des protéines de lactosérum en régime laminaire. Un modèle CFD 3D réaliste a été implémenté simulant à la fois les réactions au cœur du fluide et en surface. Les résultats ont montré une relation linéaire entre le facteur pré-exponentiel et la concentration de calcium, ce qui suggère que l'encrassement nécessite qu’une seule molécule de calcium soit associée à une protéine de BLG. Il est confirmé que le calcium est essentiel à l'encrassement avec des effets significatifs à la fois sur les processus de dénaturation thermique et sur la croissance du dépôt. Enfin, l'effet du ratio caséine / lactosérum sur l'encrassement a été étudié avec un dispositif d'encrassement de laboratoire. Les résultats laboratoires montrent que la caséine réduit l’aptitude à l’encrassement comme déterminé précédemment avec l’installation pilote. Cependant, dans ce cas, l'encrassement reste à un niveau faible y compris pour des ratios élevés (jusqu'à 4). La présence de caséines individuelles dans la phase sérique a été considérée comme responsable de cette atténuation de l'encrassement, probablement par leurs activités de type chaperon. Cependant, quand le pH de la solution d'encrassement est fixé à 6,6, il est démontré que la caséine perd son effet d'atténuation de l'encrassement pour des ratios plus élevés. Ce comportement est lié à sa faible capacité de micelle de caséine à contrôler le calcium ionique dans la phase sérique à un pH plus bas, entraînant une concentration plus élevée en calcium facilitant la dénaturation de la BLG et l'accumulation de dépôts. Une quantité plus faible de caséines dissociées dans la phase sérique à pH 6,6 pourrait aussi expliquer l'augmentation de la masse d'encrassement car elles ne sont pas en concentration suffisantes pour remplir des fonctions de type chaperon
The present work is a contribution to better understand the influence of casein micelles on the fouling of serum whey protein solutions. In particular, experimental and numerical approaches have been carried out, at laboratory and pilot scales, to describe denaturation phenomena and better understand the role of calcium in fouling mechanisms. First of all, the effect of casein/whey mass ratio on the whey protein fouling performance was investigated in a pilot-scale PHE. The total fouling deposit mass drop significantly with the addition of casein, resulting in a minimum value located at Casein/WPI of 0.2. Exceeding this critical ratio, fouling deposit increased with elevated casein concentrations. The deposit mass drop (Casein/WPI ≤ 0.2) is unlikely to be linked to the thermal denaturation of BLG and is more probably due to the change in mineral interactions introduced by casein. The increased fouling mass (Casein/WPI ≥ 0.2) was attributed to a co-precipitation of BLG-casein complex that enhances the fouling. It is proposed that micellar casein change deeply the calcium balance and the content of CaP nanocluster modifies sharply the interactions which occur between protein species (BLG, caseins) and mineral elements (ionic calcium, Ca-P) thereby affecting the protein denaturation and fouling behavior. A novel kinetic model concerning thermal unfolding and aggregation of BLG was established. This model interprets mathematically the break-slope behavior in the Arrhenius plot and provides detailed thermodynamic information for both unfolding and aggregation processes. Based on this model, it was confirmed that ionic calcium has a protective role on the thermal unfolding of BLG at low temperature. In contrast, at higher temperatures, calcium promotes aggregation and the formation of unfolded BLG species. A bench-scale fouling rig was built to perform whey protein fouling experiments in a laminar regime. A realistic 3D CFD model was achieved to simulate both the bulk and surface reactions. Results showed a linear relationship between the deposition pre-exponential factor and calcium concentration, suggesting the fouling is built in such a pattern that only one calcium ion per BLG molecule is involved. Calcium was confirmed to be essential to fouling growth with significant effects both on the thermal denaturation and deposition processes. Finally, the effect of casein/whey ratio on the whey protein fouling was investigated in the laboratory-scale fouling device. Results revealed a similar effect of casein on fouling mitigation as those found in the pilot plant. However, in this case, the fouling was suppressed and maintained at a low extent even at high Casein/WPI ratios (up to 4). The presence of individual caseins in the serum phase was considered to be responsible for this fouling mitigation probably through their chaperon-like activities. However, when the pH of the fouling solution is set at 6.6, casein is shown to lose its fouling-mitigating effect at higher ratios. This behavior is related to its weak ability of casein micelle to control ionic calcium in the serum phase at lower pH, resulting in higher calcium concentration facilitating BLG denaturation and deposition accumulation. A lower amount of dissociated caseins in the serum phase at pH 6.6 could also explain the increase in fouling mass because they are not in sufficient concentration to perform chaperone-like functions

A 2.4-m³ pilot plant MBR for wastewater treatment was designed and constructed for membrane biofouling studies. Three categories of membrane fouling study were carried out with this MBR pilot plant in order to obtain a better understanding of MBR performance and fouling. Firstly, critical flux assessment based on various defining concepts and influencing parameters was examined. The results showed small variations of critical flux values obtained from different defining concepts. Decline of critical flux as the step change of fouling air flow rate increased was observed, while step length had no obvious effects on the critical flux. A positive relationship between aeration rate and critical flux is observed, while higher sludge concentration caused lower critical flux. Secondly, fouling mechanisms under different sludge composition and different flux regimes were tested. Under supra-critical flux operation, cake resistance accounted for the main fouling contribution, while pore fouling was marginal in both supra-critical flux and sub-critical flux regimes. EPS carbohydrate in soluble and bound forms has greater impact on both pore fouling and cake fouling than protein. Finally, optimization of the MBR pilot plant was carried out. Based on equivalent permeate yield and equivalent energy consumption for each experimental run, three operational variables showed significant influence in membrane fouling rate increase. They were, in the order of importance, filtration mode > scouring frequency > regular aeration intensity. The optimum operating conditions determined by the proposed methodology were 11 L/m².min air intensity with continuous filtration and scouring 24 times per day for the pilot plant MBR.

A pilot scale fluidized bed biomass gasifier developed at Texas A&M University in College Station, Texas was instrumented with thermocouples, pressure transducers and motor controllers for monitoring gasification temperature and pressure, air flow and biomass feeding rates. A process control program was also developed and employed for easier measurement and control. The gasifier was then evaluated in the gasification of sorghum, cotton gin trash (CGT) and manure and predicting the slagging and fouling tendencies of CGT and manure. The expected start-up time, operating temperature and desired fluidization were achieved without any trouble in the instrumented gasifier. The air flow rate was maintained at 1.99 kg/min and the fuel flow rate at 0.95 kg/min. The process control program considerably facilitated its operation which can now be remotely done. The gasification of sorghum, CGT and manure showed that they contained high amounts of volatile component matter and comparable yields of hydrogen, carbon monoxide and methane. Manure showed higher ash content while sorghum yielded lower amount of hydrogen. Their heating values and gas yields did not vary but were considered low ranging from only 4.09 to 4.19 MJ/m3 and from 1.8 to 2.5 m3/kg, respectively. The production of hydrogen and gas calorific values were significantly affected by biomass type but not by the operating temperature. The high values of the alkali index and base-to acid ratio indicated fouling and slagging tendencies of manure and CGT during gasification. The compressive strength profile of pelleted CGT and manure ash showed that the melting (or eutectic point) of these feedstock were around 800 degrees C for CGT and 600 degrees C for manure. Scanning electron microscopy (SEM) images showed relatively uniform bonding behavior and structure of the manure ash while CGT showed agglomeration in its structure as the temperature increased. The instrumentation of the fluidized bed gasifier and employing a process control program made its operation more convenient and safe. Further evaluation showed its application in quantifying the gasification products and predicting the slagging and fouling tendencies of selected biomass. With further development, a full automation of the operation of the gasifier may soon be realized.

The tertiary treatment of resulting water from a conventional biological treatment process is envisaged in the aim to obtain a high quality of water that can be reused for different purposes. This treatment is based on the integration of the membrane-based technologies in the total process of wastewater treatment. The experimental studies are carried out on a small pilot, equipped with different mineral membranes of micro and ultrafiltration. These membranes are used for the different tested processes (MF, MF-UF and cogulation-MF). The results obtained make it possible to attend a complete elimination of the total flora and an additional reduction of the other parameters such as turbidity, suspended matter, COD and BOD. Tests on a large scale are then carried out on a semi-industrial pilot, equipped with the same type of membranes. The optimization of the operating conditions made allow the obtaining under the conditions of transmembrane pressure 0.85 bar, a cross flow velocity of 2.25m/s and with ambient temperature a filtrate flux of about 200 L/hm 2. The coupling of a stage of coagulation in the membrane process allows the reduction of the effect of the membrane fouling and an improvement of 36% of the filtrate flux.

This paper deals with the prediction of ash related problems in fluidized bed boilers during co-firing of various bio-fuels. A study was performed where the slagging and fouling behavior was monitored in three different sized bubbling fluidized bed combustors, a 20 kW semi-pilot reactor, a 2 MW pilot-scale device and a 105 MW full-scale boiler. The aim of the study was to learn about how well slagging and fouling in a small-scale device compares to a full-scale boiler and to see how well the slagging and fouling can be predicted with a small-scale device. Various types of Scandinavian bio-fuels as well as peat were used both separately and mixed. From all three devices ash and deposit samples were collected during as uniform and stable conditions as possible. The fuels used in the three devices during the test campaigns were carefully chosen so that they would be as similar as possible. Bed, furnace and flue gas temperatures were monitored as well as flue gas emissions. The fuels, ashes and deposits were analyzed on their main components and deposition rates were calculated based on the deposit measurements. These data were finally used for assessing the slagging and fouling propensity of the fired fuel. The paper compares and discusses the results from the three different size classes.

Over the past 10-15 years, there has been increasing attention in the development of forward osmosis (FO) technology as a low-energy technical solution to wastewater treatment through the exploitation of the natural osmosis phenomenon across semi-permeable membrane. The significant energy benefit arises in applications where direct recovery of the permeate product from the draw solution (DS) is obviated such as in osmotic concentration (OC) process. In the current research, an OC FO-based pilot-scale unit was applied for wastewater volume reduction from oil and gas processing facilities in Qatar. The pilot unit uses seawater of 40 g/L salinity as a DS and wastewater generated during oil and gas operations as a feed. This feed water is of comparatively low conductivity (2 g/L salinity), making it unusually suited to treatment by OC. Based on FO technology principles, the feed gets concentrated at lower volume with the water permeation through the membrane, meanwhile the water transfer to DS side dilutes it. The diluted DS could be directly discharged into the ocean; so the energy intensive step of DS recovery is entirely eliminated. Two FO membranes (Toyobo and NTU) of hollow fiber configuration were tested to assess their performance and fouling propensity on both synthetic and real wastewaters. Results demonstrated that the membrane-based process can achieve feed water recoveries up to 90% without any scaling issues. Achieved water flux ranges between 1.5 to 12 LMH for feed recoveries between 60 and 90% using a constant dilution rate of the draw solution. Above all, the pilot unit maintained stable water flux of 1.62 and 6 LMH using at 75% feed recovery for over 48 hours of continuous operation Toyobo and NTU membranes respectively.

Co-firing of coal and biomass in existing coal-fired power stations is a cost-effective method to reduce CO2 emissions in energy generation. Nevertheless, the introduction of biomass has to be carefully considered since it could significantly modify combustion and heat transfer phenomena and enhance fouling and corrosion inside the boiler. This paper investigates the effect of substituting a fraction of coal by biomass on the heat transfer and ash deposition rates, by performing pilot tests under different operating conditions in a pulverized fuel combustion rig. Fouling rates have been characterized by means of air-cooled deposition probes installed at one tube bank, reproducing the performance of a large-scale superheater. Heat transfer has been simulated coupling thermal radiation models with semi-empirical approaches for the tube bank behaviour. Ash samples compiled from the wind- and the lee-side of the probe has been collected and analysed by SEM (Scanning Electron Microscopy). Low-to-moderate fouling rates have been typically observed for the tested coal and coal + biomass blends, but with somewhat potassium enrichment at the lee-side deposits when biomass is introduced. As a matter of fact, sootblowing manoeuvres in utility boilers should not be affected when co-firing the tested fuels. Furthermore, chlorine-induced corrosion on heat transfer surfaces is not expected to be significant since the concentration of chlorine in the sampled deposits has been always found to be negligible.

Abstract Sulfate removal in injection water is standard practice to prevent scaling and souring in subsea oil reservoirs. Nanofiltration membranes have been used to this purpose since 1987, when FilmTec™ SR90-400 elements were installed in an offshore platform in the North Sea. The most pressing concern in this type of systems is membrane fouling, with the associated reduction in effective plant operation time and shorten element lifespan caused by the standard Clean-in-Place (CIP) protocols. The object of this research has been to test the latest developments in biofouling-resistant sulfate removal membranes to achieve oil and gas (O&G) industry requirements. Improved chemistry and improved module engineering have enabled the production of new membrane elements that represent the next-generation in sulfate removal nanofiltration. Next-generation sulfate removal membranes have been trial-tested. In pilot testing, target performance was validated in terms of productivity, permeate quality and fouling resistance. The results of this testing indicate that improvements in membrane chemistry and module engineering have resulted in a 63% decrease in pressure drop and a much slower fouling trend over the total of 6 elements. This significant improvement should allow an important reduction in the number of cleanings, which the authors have estimated to be of 50%. Moreover, sulfate rejection values are in the range of 99.9% (below 1 ppm of sulfate in the permeate), providing great injection- quality water. Full-scale testing in a production site in the Atlantic Ocean was done to validate pilot testing results, showing a continued operation of 100 days without any need for a clean-in-place (CIP) procedure. The results obtained in the extensive testing carried out on these new antifouling elements, show that the improvements implemented in its design have the ability to improve the operation of Sulfate Removal Units (SRU). These improvements are the results of reducing maintenance costs and downtime on offshore platforms, resulting in increased operation and improved productivity.

Abstract Kinetic hydrate inhibitors (KHIs) offer an alternative to traditional thermodynamic hydrate inhibitors (THIs) for the prevention of gas hydrates. KHIs have several advantages over THIs, such as lower required volumes, easier logistics and reduced CAPEX. However, KHIs are once through chemicals leading to increased OPEX, are mostly non-biodegradable and therefore cannot be discharged to sea or disposal wells in fear of aquifer pollution. KHIs can also lead to fouling of process equipment, especially at elevated temperatures. To resolve these issues, a new KHI polymer removal method using a solvent extraction-based technique has been developed. In this approach, an immiscible extraction fluid is mixed into the KHI containing aqueous phase where the KHI polymer partitions into the extraction fluid, which can then be separated from the aqueous phase. In some cases, the KHI separated this way can be re-used. This process has the potential to solve problems with KHI produced water treatment/disposal, including where KHI is used in combination with MEG, reducing the costs and process fouling and protecting the environment. A new joint industry project (JIP) is underway with the aim of developing the concept into a commercial process for removal and possible re-use of KHIs upstream of PW treatment or MEG Regeneration systems. The first phase of this project is lab scale evaluation of the solvent extraction method for simulated removal and re-use of two commercial KHI formulations for a real gas-condensate field case. Both the removal efficiency and hydrate inhibition performance of 4 cycles of re-injected/re-used KHI has been successfully demonstrated. Removal of KHI from a real MEG system case was also successfully demonstrated. In the second phase of the JIP, lab scale tests were used to screen extraction and separation equipment and identify optimum process conditions. The upcoming third phase of this JIP is dedicated to demonstrating the selected process concept(s) on pilot scale in a flow loop. In this proceeding we will give highlights of the early laboratory test results from a produced water case where two field qualified KHIs are removed from PW and reused 4 times, still showing adequate hydrate inhibition performance. Successful pilot tests will confirm the operability of this process in the field.

Abstract Fouling of heat exchanger equipment through the formation and attachment of hard scale, microbially induced corrosion (MIC) products, or particulate erosion is a serious challenge to reliable production in the oil and gas industry. Exchangers which become fouled in this way perform 15-30% worse than their rated ability, requiring either constant intervention to clean away biofilms, continuous injection of biocides and corrosion inhibitors, or the regular plugging of tubes to prevent leaks, representing a significant operating expense and billions of dollars in lost production time. When an exchanger is unable to provide sufficient heat due to tube fouling, additional sources of heating must be utilized to make up for this deficit and to ensure that facility processes remain within design allowances. This need for supplemental heating is a significant source of carbon emissions in the industry and represents a significant obstacle towards decarbonization efforts. However, it also represents an economically attractive way to simultaneously lower emissions while also lowering a producer's cost per barrel. This work describes an alternate strategy to control and prevent fouling in heat exchangers, through the one-time application of an omniphobic (water- and oil-repelling) nano-surface treatment. Once applied to a heat exchanger, the extremely smooth and low-surface energy material greatly reduces the ability of MIC-causing bacteria to deposit and adhere to the surface. Because it imparts functionality to the surface itself, rather than simply function as a physical barrier, it enables long lasting protection which was validated under laboratory conditions in a pressurized autoclave, as well as two pilot demonstrations. Results from both the laboratory and field evaluations of the treatment's promise showed that treated surfaces showed a corrosion rate over 36-times lower when compared to untreated surfaces, while also completely arresting the formation of corrosion pitting, tube fouling, and erosion of the tube interior. These field-validated results were then applied to the observed heating deficit of a proposed deployment site, resulting in calculated carbon emissions savings of up to 17,000 Tons CO2 per year.

When moving towards CO2 neutral biofuels, fluidized bed combustion represents a good and flexible combustion technique. Biofuels typically have a high volatile content and varying moisture content. Fluidized bed combustion can provide even combustion conditions regardless of big variations in the fuel quality and fuel properties. However, compared to conventional fuels, biofuels often contain high amounts of chlorine and alkali metals, which set certain challenges for the boiler design. The problems that might occur due to high alkali and chlorine levels in the fuels are mainly slagging, fouling, corrosion and bed sintering. Since the variations in fuel properties between different fuels are big, it is of outmost importance from the boiler manufacturer’s point of view, to be able to predict the behavior of a specific fuel or fuel mixture in a very early stage of boiler design. For this purpose different kinds of calculation and prediction tools are needed. For prediction of slagging and fouling an ash behavior prediction tool has been developed. The prediction routine is based on advanced multi-phase multi-component equilibrium calculations, using the fuel composition and combustion conditions as input. Based on the calculations, the rate of deposit formation, the composition of the deposits and the corrosivity of the deposits at different locations in the boiler can be estimated. The prediction tool can be used in boiler design for defining the optimum arrangement of the superheaters, maximum flue gas temperature in the superheater area and maximum steam temperature. It can also be used for specification of maximum limits of troublesome high alkali, high chlorine fuels in fuel mixtures. In this study the prediction routine has been performed for three biofuels / biofuel mixtures. The calculated results have been evaluated with full scale and pilot scale probe measurements as well as with full scale long term operational experience.

Abstract Accurate level measurement in process vessels is important for safety, production optimization and control as well as for optimization of chemical additives. Most of the level measurement sensors used in oil and gas production today are Differential Pressure (DP) transmitters, displacers and, sometimes, Guided Wave Radar (GWR). More advanced profiler-type sensors are used more rarely and most often only for process analytics. Almost all of the commercially available level measurement instruments are intrusive, meaning that they require a flange or penetration for installation and maintenance. In practice, this implies that installation and maintenance on an existing installation have to be conducted during a turnaround. This makes such a project prohibitively expensive considering the cost of turnaround time and the fact that a turnaround on an offshore platform is only performed once every 1-4 years. This work describes pilot trials with a novel non-intrusive level measurement system that utilizes Guided Elastic Waves (GEW) for attenuation tomography. Pilot experiments were carried out in a model separator with an internal diameter of 1.00 m and length 3.75 m. The pilot separator which was filled to pre-determined levels with tap water, mineral oil and construction sand. Flow of water was induced in some of the experiments. Phase levels were recorded manually through a sight glass and compared to readings generated by the novel measurement system. Experiments showed that the novel level measurement system is able to detect levels of sand and liquid as well as clean water/oil interface levels with very high accuracy. Flow had no significant influence on the measurement results and the sensor output remained stable over the cause of one month. After the successful testing, the system has been qualified for its first trial on an offshore installation. In addition to an offshore pilot, more R&D needs to be conducted in order to develop capabilities to measure emulsion and foam interface layers as well as to determine how fouling by scale, waxes and other impurities present in a full-scale separator influence the measurement.

A numerical model was developed, validated with the aid of pilot evaporator tests, and used to assess practical methods of minimizing scaling observed in a mechanical vapour recompression (MVR) plant at Millar’s Western’s Meadow Lake, Saskatchewan pulp mill. On average, 8,000 m3/day of effluent (approximately 7 m3/Bone Dry Tonne product) resulting from bleached-chemi-thermo-mechanical wood processing, are purified and the recovered water is returned to the plant while the effluent is concentrated to 75% TD&SS in a recovery boiler. The evaporators are used in the first stage of the feed concentration process. The system uses a heat pump principle: steam produced during the boiling of the falling liquid film is mechanically compressed and condensed on the outer surface of a vertical tube evaporator. Most of the condensation and compression heat is recovered. Reducing the rate of scale deposition and increasing the interval between two successive cleaning operations of vertical evaporators used in the MVR scheme was identified as an essential component of operation costs and given special attention. To assist the mill in assessing practical methods for achieving this goal an experimental pilot evaporator and a numerical model were developed and used first at the Alberta Research Council in Edmonton, Canada, and then at the mill location. The mill uses a different model for control and supervision of system parameters. The magnitude of the (critical) temperature difference (CTD) across the laminar sub-layer of boiling liquid film is calculated and is recommended in this paper to be used to quantify the fouling tendency. Further to recommendations resulting from previous experimental investigations [1,2] as well as in this study, the mill introduced additional process control parameters to reduce and maintain the temperature drop across the effluent boiling film to a maximum range of 2–4°C. In addition to CTD, the wall (top-bottom) axial temperature difference (ATD) has been identified as another criteria for assessing potential scale deposition during evaporation-concentration. Calculations and experimental measurements performed with the pilot evaporator [3] suggest that increasing the circulation rate of effluent pumped from the sump to feed the liquid film at the top of evaporator tubes has a positive effect on reducing the CTD and the ATD. During four months of laboratory investigations with a pilot evaporator, non-uniform liquid distribution among vertical evaporator tubes of the evaporator was observed and is discussed separately. This paper will present the model and mill observations and summarize the main results and suggested practical strategies for reducing the rate of scale deposition and improving the system economics.

When moving towards CO2 neutral bio fuels and waste derived fuels, new challenges are set for combustion facilities and technical boiler solutions. A common feature for both bio- and waste fuels is a big variety in composition, often high levels of alkali metals, chlorine and moisture which make these fuels difficult to burn in facilities designed for conventional fuels such as coal, peat and wood. The problems that might occur due to high alkali and chlorine levels in the fuels, are slagging, fouling, corrosion and bed sintering. The Fortum BioMAC BFB boilers are designed especially for difficult, unconventional fuels such as rice husk, olive waste, straw, construction residue, de-inking sludge, etc. The design of each individual boiler is made based on advanced theoretical prediction tools and extensive fuel testing in laboratory and in pilot scale combustion facilities. The theoretical tools consist of a multi-phase multi-component chemical equilibrium model that estimates the slagging/fouling, sintering and corrosion propensity of the fuels/fuel mixtures and of a computational fluid dynamics part. CFD calculations are used to optimize the flow pattern and the temperature of the boiler in order to avoid hot temperatures in the vicinity of refractory linings and cooled surfaces. The chemical equilibrium calculations predict the melting behavior of the fuel ash, which is used as an indicator for the placement of the superheaters. The bottom ash removal is controlled for efficient removal of coarse material, screening and recirculation. The ash related problems of important bio and waste fuels, the analytical procedure of the evaluation of the usability of the fuels and the adaptation of the boiler design are discussed in the paper.