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Seminar Report Nasif New
Seminar Report Nasif New
Seminar Report Nasif New
SEMINAR REPORT
Submitted by
AL NASIF NOUSHAD
TEC19ME004
to
of
Bachelor of Technology
In
Mechanical Engineering
SEMINAR REPORT
Submitted in partial fulfilment of the requirements for the award of the degree of
Bachelor of Technology
by
AL NASIF NOUSHAD
Reg. No.: TEC19ME004
Mrs.LEKSHMI.R.S
DECEMBER 2022
DEPARTMENT OF MECHANICAL ENGINEERING
TRAVANCORE ENGINEERING COLLEGE
CERTIFICATE
This is to certify that the seminar report entitled “Waste Management Approaches to Boost
Sustainable Value Of Waste From Oil And Gas Industry” Was submitted by AL NASIF
NOUSHAD (TEC19ME004) Of the Seventh semester Mechanical Engineering Department to
the APJ Abdul Kalam Technological University in partial fulfilment of the requirements for the
award of the Degree of Bachelor of Technology in Mechanical Engineering during the year
2022-23 is a bonafide record of the seminar work carried out by him/her under my/our
supervision and guidance.
I am also indebted to all the teaching and non-teaching staff of the Department of
Mechanical Engineering for their cooperation and suggestions, which is the spirit behind
this report.
Words are few but feelings are more to appreciate our family and friends for the
constant support and encouragement provided for the seminar and also for reviewing
this document and for giving me valuable suggestions.
AL NASIF NOUSHAD
Dec 2022
Travancore Engineering College, Oyoor
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ABSTRACT
Any matter in any physical form generated in such a large quantity that affects or alter
the natural ecosystem falls under the category of waste. Globally, the oil and gas industry
produces a large volume of waste. Any petroleum-based or synthetic oil that, through
contamination, has become unsuitable for its original purpose due to the presence of
impurities or loss of original properties. Basic three types of wastes streams, including solid
waste (oil sludge), flue gases (CO2 and SO2), and liquids (produced water) originating from
the oil and gas industry. Several techniques have been developed for the treatment and
handling of waste. For sustainable treatment and management of waste it should be coupled
with resource recovery and re-utilization concepts. The study shows the characterization and
respective treatment technologies, challenges and possible opportunities. The choice of
treatment technology depends on several factors including the characteristic of the influent
waste stream, purpose of treatment, the final use of the product & the treatment cost. In this
seminar we discuss about the above mentioned types of waste generation, their treatment
technologies in different types of wastes in oil and gas industry their challenge etc.
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CONTENTS
ACKNOWLEDGEMENT i
ABSTRACT ii
LIST OF FIGURES iv
LIST OF TABLES v
NOMENCLATURE vi
1. INTRODUCTION 1
2. LITERATURE REVIEW 8
Introduction 8
5. CONCLUSION 28
6 FURURE SCOPE 29
REFERENCE 30
LIST OF FIGURES
iv
LIST OF TABLES
TABLE NO TITLE PAGE NO
V
NOMENCLATURE
NOTATION
C Celsius
R Reaction
ABBREVIATIONS
V
CHAPTER 1
INTRODUCTION
Increasing growth of the petroleum industry has resulted in huge amounts of various
waste materials, which need proper disposal and valorization. A major challenge throughout
the O&G sector is that many waste streams can become contaminated by oily or hazardous
fluids, and radioactivity requiring careful handling, treatment and disposal. Generated wastes
at terminals may include tank bottom sludge; this must be periodically removed to maintain
product quality or tank storage capacity; as well as spill cleanup materials and soils
contaminated with oil. Typically, sludge is composed of water, residual product, and various
solids including sand, scale, and rust. Tank sludge and spill cleanup materials should be dealt
via re-processing for product recovery or as a waste at a licensed facility handling this kind of
material in an environmentally sound manner. To identify the challenges facing the oil
industry in achieving sustainable management of all wastes from inshore or offshore
production facilities , and to compare and contrast the most important factors that affects
waste management in developed oil areas with those in less developed.
Globally, the oil and gas industry produces a large volume of waste in the form of
produced water, oil sludge, and flue gases that can pose a negative impact on environment. As
such there is a need for the treatment and safe handling of this waste. Although, several
techniques have been developed for the treatment of oil and gas industry waste, recent
research trends have highlighted that for the sustainable treatment and management of oil and
gas industry waste, it should be coupled with resource recovery and re-utilization concepts in
line with circular economy perspectives. Essentially, converting waste into economic value
added products, reducing environmental impacts and supporting sustainability within the oil
and gas industry is of paramount importance. The characterization and respective treatment
technologies, challenges, and possible emerging opportunities. An insight into the resource
recovery and reuse potential for all three type of wastes considered.
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A holistic approach should be adopted by considering these points to handle and
manage the waste, including:
Oil and gas waste generation depends on the level of industry activity, which in turn
varies with petroleum prices. Thus, oil and gas waste generation can vary considerably from
year to year; also varies geographically. Petroleum products are known for the hydrocarbon
materials obtained from the well, which occur in either the form of crude oil or crude gas. In a
crude oil well, the crude oil is mainstream.
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1.1 OIL AND GAS INDUSTRY WASTE GENERATION
Petroleum products are known for the hydrocarbon materials obtained from the
well, which occur in either the form of crude oil or crude gas. The life cycle of various
processes (extraction from well to petroleum products) within the oil and gas sector
produce various types of wastes, which require disposal and/or recycling. The handling
of these wastes is important as they are contaminated with oily and hazardous material.
Non-hazardous waste is mostly composed of plastic, wood, metal cuts, drilling fluids,
and sand muds. All wastes are generated at various points during oil and gas operations,
which include drilling, transportation, refining, and gas production operations in the oil
and gas industry. The most important wastes are oil debris, lubricating oils and sands,
used oils hydraulic, board and plastic residue, metal scraps and drilling fluid wastes
(soda ash, magnesium, emulsifiers, etc). From enhanced oil recovery systems (EOR),
wastes include unused chemicals, polymers, SOx and metal contained emissions and
SOx liquor . From gas production operations, SO2 and CO2 flue gases are emitted
during the gas sweetening operation.vvxdvdvdvggggg
Three types of wastes are mainly produced in oil and gas industry
1) Produced water.
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1.2 PRODUCED WATER
The largest waste stream in the oil and gas industry exploration activities is the
produced water (PW), representing 70–80 % of the total wastewater and contains organic and
inorganic compounds. Produced water is a mixture of formation water, saline water already
existing in the aquifer and brought to the surface during exploration and injected water used to
facilitate oil recovery. Minerals are present in PW in the form of heavy metals, radioactive
chemicals and other anions and cations such as sodium, ferric, chlorine, sulphate, sulphite, and
carbonate . The quality of PW largely depends on the geological formation, location, reservoir
life span, and production techniques.It is the naturally occurring water that comes out of
ground along with oil and gas.
Produced waters are waters pumped from wells and separated from the oil and gas
produced. The radioactivity levels in produced waters from unconventional drilling can be
significant and the volumes are large. The ratio of produced water to oil in conventional well
was approximately 10 barrels of produced water per barrel of oil. According to the American
Petroleum Institute (API), more than 18 billion barrels of waste fluids from oil and gas
production are generated annually in the United States. Produced waters contain levels of
radium and its decay products that are concentrated, but the concentrations vary from site to
site. In general, produced waters are re-injected into deep wells or are treated for reuse.
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Fig 1.2 Produced water
The improper disposal of petroleum sludge to the environment, create a major threat
such as significant modifications in the chemical and physical properties of the surrounding
soils, resulting in morphological change. The efficient remediation of oil sludge is a major
issue facing all petroleum industries worldwide due to the presence of hazards and corrosive
materials. OS management is driven by three basic concepts, the first is the possible
reduction of OS waste during operation, and the other two are in practice and include: the
disposal and recovery of oil before disposal or conversion into value-added products.
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Fig 1.3 Solid hydrocarbon waste
The waste gases are generally produced from the petroleum refinery . These waste
gases are also termed as flue gases which include gases such as nitrogen, sulfur dioxide,
and carbon dioxide, among others typically. Natural gas (NG) is the gaseous form of
hydrocarbon located in oil-fields, coal beds, and gas fields. It mainly consists of
hydrocarbons (methane) and non-hydrocarbon gases such as H2S, CO2 (acid gases), O2
and N2, which are generated during thermogenic, biogenic, acidogenesis, and
methanogenesis processes in the conversion of organic matter and other elements present
from inside the earth . The variation of these elements in conventional gas (rock or earth
from a well) and non-conventional gas (shale gas, coal bed) depends on the geographical
location. NG is considered a clean fuel compared to other fossil fuels such as crude oil
and coal. CO2 and H2S should be within a specific limit before their use in energy and
other applications. NG is also classified based on sulphur species content, such as sweet
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gas (S negligible) and sour gas (H2S content >5 mg/Nm3). Sweet gas does not require
treatment for sulphur removal. The other important elements that should be considered for
energy application, include N2, water arsenic, and mercury content. The most important
waste stream is the acid gas (SOx and COX), which is the primary stream of
the gas industry.
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1.5 REPORT OUTLINE
The chapter 1 deals with the oil and gas industry waste generation as follows. Initially
chapter 3 deals with treatment technologies for produced water , Emerging methods for oil
sludge treatment and acid gas removal technologies. In chapter 4 deals with the result and
analysis showing the resource recovery from produced water. Chapter 5 deals with the
application of oil and gas industry waste generation. In chapter 6 deals with the challenges and
future scopes of oil and gas industry waste generation.FFFFFFFFFFFFFFFFFFFFFFFFFFF
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CHAPTER 2
LITERATURE REVIEW
The purpose of this chapter is to provide a literature survey of past research effort such
as journals or articles related to application of waste management approaches to boost
sustainable value of waste from oil and gas industry Moreover review of other relevant
research studies made to provide more information in order to understand more on this
research Current and previous research related to waste management will be discussed in the
Literature review
Literature provides some operations for treatment of oily sludges, such as landfilling,
incineration, co-processing in clinkerization furnaces, microwave liquefaction, centrifugation,
destructive distillation, thermal plasma, low-temperature conversion, incorporation in ceramic
materials, development of impermeable materials, encapsulation and biodegradation in land
farming, biopiles and bioreactors. The management of the technology to be applied for the
treatment of oily wastes is essential to promote proper environmental management, and
provide alternative methods to reduce, reuse and recycle the wastes. Nowadays both the
treatment and management of these waste materials is essential to promote sustainable
management of exploration and exploitation of natural resources. Biological, physical and
chemical processes can be used to reduce environmental contamination by petroleum
hydrocarbons to acceptable levels. The choice of treatment method depends on the physical
and chemical properties of the waste as well as the availability of facilities to process these
wastes.
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Produced water is currently treated in conventional trains that include phase
separators, decanters, cyclones and coarse filters in order to comply with existing
regulation for discharge. These treatment trains do not achieve more restrictive
limitations related to the reuse of the effluent (reinjection into extraction wells) or other
beneficial uses (e.g., irrigation). This review tries to provide an overview of different
treatments that are being applied to polish this type of effluents. These technologies
include membranes, physical, biological, thermal or chemical treatments, where special
emphasis has been made on advanced oxidation processes due to the advantages offered
by these processes.
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CHAPTER 3
EXPERIMENTAL SET UP
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3.2 PHYSIOCHEMICAL TREATMENT
3.2.1 HYDROCYCLONE
Hydrocyclones are used to separate suspended solids and dispersed oil particles that
have a lower density than the water. They remove solids from the bulk fluid based on the
difference in gravity. PW is fed into the hydrocyclone under a certain pressure that creates a
centrifugal movement; it aids in increasing the diameter of the particles and separating them
from the bulk fluid. The solid particles are discharged from the bottom and clean fluid is
discharged through the overflow outlet. Hydro-cyclones are very effective in removing sus-
pended particles; however, they cannot remove dissolved solids. They are compact, less
energy-intensive, have a long life span, and are easy to use. They are favourable for use in
offshore installations due to smaller space requirements. They are widely used on an industrial
scale for the treatment of PW. It has been reported that the use of a hydrocylone in an offshore
facility is used PW flow rate of 250 m3h− 1. It resulted in 75 % removal of dispersed oil, 47
% of PAHs, and 33 % of phenol. However, scale formation, relatively fast wear of operating
parts, and clogging of solids at apex are the major issues with their use.
Thermal technologies are useful for the treatment of PW. In this technology, water is
converted to steam by heating and is then condensed to relatively high-quality water . Hybrid
thermal desalination plants, such as MED–VCD, have been used to achieve higher efficiency .
Although membrane technologies are typically preferred to thermal technologies, recent
innovations in thermal process engineering make thermal process more attractive and
competitive in treating highly contaminated water. Based on temperature and pressure
variations, thermal technologies are classified as
MSF distillation process is a mature and robust technology for brackish and sea water
desalination. Its operation is based on evaporation of water by reducing the pressure instead of
raising the temperature. Feed water is pre-heated and flows into a chamber with lower
pressure where it immediately flashes into steam. Water recovery from MSF treatment is
∼20% and often requires post-treatment because it typically contains 2–10 mg/l of TDS . A
major setback in operating MSF is scale formation on heat transfer surfaces which often
makes this process require the use of scale inhibitors and acids. Overall costs vary depending
on the size, site location and materials of construction . Its energy requirement is between 3.35
and 4.70 kWh/bbl .Globally, MSF market share has significantly decreased due to
competition of membrane technologies, but it is a relatively cost-effective treatment method
with plant life expectancy of more than 20 years, and can be employed for produced water
treatment.
3.3.2 MULTI-EFFECT DISTILLATION (MED)
MED process involves application of sufficient energy that converts saline water to
steam, which is condensed and recovered as pure water. Multiple effects are employed in
order to improve the efficiency and minimize energy consumption . A major advantage
of this system is the energy efficiency gained through the combination of several
evaporator systems. Product water recovery from MED systems are in the range of 20–
67% depending on the type of the evaporator design employed . Despite the high water
recovery from MED systems, it has not been extensively used for water production like
MSF because of scaling problem associated with old designs. Recently, falling film
evaporators have been introduced to improve heat transfer rates and reduce the rate of
scale formation.
3.5.1 PYROLYSIS
This process is the thermal decomposition at high temperature in the range of 700–
1000 ◦C under an inert environment. It produces low molecular weight hydrocarbons in liquid
form, non-condensable gases, and a solid char. The pyrolysis process is carried out in the inert
atmosphere, which provides some benefits such as lower emissions of Sox and Nox, swift and
easy storage and transposition of pyrolysis products, and the fixing of metals in char, provides
a clean and environment-friendly option. The product type and yield depend on the pyrolysis
techniques, in which solid char and oil are the main products of slow and fast pyrolysis. The
conversion of oil sludge into valuable products (oil, char, and gas) is widely investigated by
various researchers . The pyrolysis characteristics of tank oil sludge of Shanghai Oil Field,
China, and noticed that 80 % conversion of an organic component of OS into pyrolysis
products. The higher oil recovery from the OS is also indicated in another study for laboratory
and pilot-scale pyrolysis processing, which can be 70–84 % at a higher temperature of 450–
650 ◦C. A pilot scale pyrolysis study shows that char production decreases from 30 to 18 %
and gas production from 35 to 32 % with the increase in temperature from 600 to 800 ◦C,
whereas oil production increases from 32 to 52 % . The fraction or array of product yield
depends highly on the components present in the oil sludge. It widely varies and depends on
the collection point, oil separation process, sedimentation, etc.
Fig.3.5.1 Pyrolysis
3.5.2 GASIFICATION
Gasification is very promising technique, which is used to convert organic
hydrocarbon into syngas at elevated temperature in the presence of oxidizing agent known as
a gasifying medium in a reactor known as a gasifier. The conversion of hydrocarbon to the
syngas is due to the propagation of reactions (R1-R8) . Some researchers consider the
gasification of OS for the production of syngas and other related products . performed the
steam gasification of OS at a higher temperature of 600–900 ◦C, and noticed the higher H2-
rich syngas of about 48.50 ml/ min. g, with a high percentage of char of more than
50%.developed a simulation model using Aspen plus for the steam gasification of OS and
biomass and their blends to investigate the H2 potential. The oil sludge has a good quantity of
C, 89.3 %, H2, 6.9 %, and the volatile matter is 16 % with a fixed C of 54.1 %. Gasification of
OS is performed by varying the parameter of steam/OS of 0.2–1.5, 0.25–0.37 Eq air/oil sludge
at 1300 ◦C produced a gas yield of 2.28 Nm3/kg OS, with 1.84 Nm3/H2/kg OS. With the
integration of biomass, H2 yield increased up to 3.51 Nm3 H2/kg OS. The syngas produced
from gasification or pyrolysis can be used for electricity generation, a potential revenue
stream.
3.6 ACID GAS REMOVAL TECHNOLOGIES
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CHAPTER 4
RESULT &
ANALYSIS
4.1 WATER
Water recovery and its reuse is crucial to establishing the economic sustainability of
PW treatment. Due to the scarcity of water in many areas around the world, the reuse of PW
can improve water and environmental footprints. It is reported that the PW can be reused for
irrigation, livestock watering, aquaculture growth, and in industries for various processes such
as cooling towers, fire extinction, and fracturing operations. The purpose of re-using PW
determines the level of treatment. For instance, a low or mild level treatment is required to
reuse PW for industrial processes and irrigation, whereas relatively strict treatment would be
required for its reuse for aquaculture growth, livestock watering. US-EPA and US Department
of Agriculture Natural Resources Conservation Service have developed different standards for
the reuse of wastewater. All reported that Coal Bed Methane (CBM) PW could be used for
livestock as the water contains a TDS 1000–7000 mg.L-1, which is suitable for livestock
drinking. Another study reported a successful application of PW for the cultivation of
tomatoes . Several projects have been carried out in the US to demonstrate the use of PW to
irrigate various crops including grass concentration of TDS, sodium, alkalinity, and trace
elements in produced water its reuse for irrigation purposes is challenging.
4.3 INORGANICS
PW contains several elements that can be recovered and sold in the market to offset the
cost of treatment. Major elements present in PW are Ca, Mg, Cl, K, Ba, Sr, Na, Ba, Sr, Li, Br,
and . Their concentrations in PW are not consistently reported in the literature. These elements
can be used for various commercial applications. Calcium is widely used in construction and
chemical industries. The recovery of calcium from oil and gas wastewater, although the
economic assessment demonstrated that it was not cost-effective. Mg is used as a reducing
agent in the synthesis of titanium and alloys. In 2016, global production of Mg was estimated
at 1.01 million tonnes . Cl is used in the pulp, and paper industry. Sodium chloride is a
common salt used in the food industry and chemical industry. An estimate in 2016 showed
that the world market for Cl was 255 million tonnes. K is commonly used in fertilizers, rubber
synthesis, food preservatives, and batteries. World potash production is estimated to be 39
million tonnes (as K2O equivalent) per year .Ba is used as a filler in paints, paper, metal
costing, and plastics. Global Ba production is estimated at 7,140, 000 tonnes for year 2016.
Unfortunately, commercial production of Ba from PW has been rarely reported. Li is the most
useful metal that can be recovered from PW. It is a rare metal that is used for various
applications such as ceramic and polymer products, metallurgical, and pharmaceutical
industries. Recently, interest is growing to use Li in energy storage, batteries, and nuclear
fusion. Li recovery from the PW could be considered as a sustainable source.
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CHAPTER 5
CONCLUSION
Sustainable and safe handling of oil and gas industry waste is a global concern. This
study identified three major types of waste in the form of produced water, oil sludge, and flue
gases, generated from the oil and gas industry. Treatment technologies corresponding to each
type of waste are thoroughly discussed. It is found that the choice of treatment technology
depends on several factors including the characteristics of the influent waste stream, purpose
of treatment, the final use of the product, and the treatment cost. An integrated approach that
couples several treatment technologies is often suitable for cost-effectiveness, high treatment
efficiency, low energy intensive, and is environment friendly. Recovery of water, organic and
inorganic materials, nutrients, flue gases, and their re-utilization may not only compensate the
treatment costs, it can also potentially provide a net economic gain. The conversion of solid
wastes such as OS into energy and valuable products such as syngas, char, oil, and electricity
draws additional benefits and provides a holistic waste management approach. The sustainable
conversion of waste can be a source of environmentally friendly products with added
economic benefits. The recovered water can be used for irrigation, municipal and industrial
purposes. Metals such as Sr, Li, Br, and Ca present a high market value. The organic carbon
and nutrients can be fed to the microorganisms to generate a variety of biorefinery products.
Sulphur can be reutilized in the fertilizer and construction industry. Similarly, the recovered
CO2 can be used for various purposes in chemical and biochemical industries. These will
bring economic and environmental cushion for this industry. However, despite numerous
potentials for resource recovery from oil and gas industry waste, its practical application has
been rarely demonstrated yet. Transformation of “treatment” to resource recovery” concept
would require large scale changes in the existing infrastructure. It is important to note that
further detailing of waste reutilisation options and feasibility studies are required to calculate
key economic indicators.
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CHAPTER 6
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Despite the availability of efficient treatment techniques, it has been demonstrated that
as of yet, none of the technologies is economically sustainable. To ensure the economic
sustainability of oil and gas industry waste management, the transition from “only treatment”
to “resource recovery” is inevitable. The implementation of the resource recovery concept
requires modification in the existing treatment facilities. Going forward, there is a need to
conduct comprehensive and detailed feasibility analysis in order to determine capital and
operating costs required to implement the concepts highlighted, which will thus enable the
computation of accurate economic forecasts in terms of pay back period and net present value.
A further limitation of this study, is perhaps related to the technology readiness level of
certain processes computed, which are based on theoretical assessments that consider input
from reported literature. Furthermore, to implement such ambitious programs, strategic
management and support from the relevant stake holders are also required. Finally, the
mobilization of policy-makers, R & D institutions, industries, and funding agencies is
recommended to advocate for the benefits of resource recovery
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REFERENCE
[1] Gardas BB, Raut RD, Narkhede B. Determinants of sustainable supply chain
management: A case study from the oil and gas supply chain. Sustainable Prod
Consum 2019;17:241–53.
analysis and optimization for the catalytic air gasification of palm kernel shell
co-gasification and co-pyrolysis for gas production. Renew Sustain Energy Rev
2022;161:112349.
technologies integrated with CO2 capture and utilisation within BECCS networks.
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