Device for Processing Water, System, and Methods

Abstract

Apparatus and methods for use in water processing include housing sections that house in their interiors water treating membranes, the respective interiors being separate from one another. A distributor chamber for containing a flow of water to be treated conveys water to be treated from a feed inlet and distributes the water to be treated into the interiors of the housing sections. A collector chamber for collecting treated water from the interiors of the housing sections is provided to communicate a merged flow of the treated water to an extraction outlet. The device may be employed in subsea systems or in a topside water processing system

Claims

1. A device for water processing, the device comprising: a plurality of housing sections for housing filter membranes for treating the water by filtration in the interiors of the housing sections, wherein the interiors of the housing sections are separate from one another; a feed inlet for supplying the device with water to be treated; an extraction outlet for extracting treated water from the device; a distributor chamber for containing a flow of water to be treated from the feed inlet and distributing the water to be treated into the interiors of the housing sections; and a collector chamber for collecting treated water from the interiors of the housing sections and communicating a merged flow of the treated water to the extraction outlet.

2. A device as claimed in claim 1, wherein the housing sections comprise tubular sections, wherein ends of the tubular sections comprise openings through which treated water can pass from the interiors of the tubular housing sections into the collector chamber.

3. A device as claimed in claim 1, further comprising at least one filter membrane in the interior of each housing section.

4. A device as claimed in claim 3, wherein the filter membranes are ultrafiltration membranes or microfiltration membranes.

5. A device as claimed in claim 1, further comprising walling or casing configured to form: the housing sections; the distributor chamber; and the collector chamber.

6. A device as claimed in claim 5, wherein the walling or casing includes at least one bonded joint.

7. A device as claimed in claim 5, wherein at least one of the housing sections is joined to a section of the walling or casing by at least one bonded joint.

8. A device as claimed in claim 6, wherein the bonded joint comprises a resin bond.

9. A device as claimed in claim 5, wherein the walling or casing includes either or both of: a cover which is removable for accessing at least one of the housing sections through an interior of the collector chamber; and a cover which is removable for accessing at least one of the housing sections through an interior of the distributor chamber.

10. A device as claimed in claim 1, wherein the housing sections comprise elongate tubulars having first and second ends.

11. A device as claimed in claim 10, wherein the extraction outlet is arranged to extract the treated fluid from the collector chamber in a radial direction with respect to a longitudinal axis of the housing sections.

12. A device as claimed in claim 10, wherein the feed inlet is arranged to enter the water to be treated into the distributor chamber in a radial direction with respect to a longitudinal axis of the housing sections.

13. A device as claimed in claim 11, wherein either or both of the feed inlet and extraction outlet are arranged in a section of walling or casing radially offset from the housing sections.

14. A device as claimed in claim 1, wherein the distributor chamber has a cross-sectional extent which tapers away from the feed inlet.

15. A device as claimed in claim 1, wherein the collector chamber has a cross-sectional extent which tapers away from the extraction outlet.

16. A device as claimed in claim 1, wherein the housing sections comprise tubulars having first and second ends, the tubulars arranged in parallel and spaced apart relationship.

17. A device as claimed in claim 16, wherein the walling or casing comprises a first end which forms a structure emcompassing the first ends of the tubulars to provide the distributor chamber, the distributor chamber reaching across the first ends of the tubulars.

18. A device as claimed in claim 16, wherein the walling or casing comprising a first end which forms a structure comprising the distributor chamber, the distributor chamber reaching across the first ends of the tubulars, wherein the first ends section is connected to the first ends of the tubulars by annular joints formed on the outsides of the respective tubulars at or near the first ends of the tubulars.

19. A device as claimed in claim 17, wherein the first ends section of walling or casing includes at least one sleeve adapted to fit around an outer diameter of at least one of the tubulars, wherein a portion of the tubular is received in the sleeve and bonded thereto.

20. A device as claimed in claim 16, wherein the walling or casing comprises a second end which forms a structure encompassing the second ends of the tubulars to provide the collector chamber, the collector chamber reaching across the second ends of the tubulars.

21. A device as claimed in claim 19, wherein the walling or casing comprises a second end which forms a structure to provide the collector chamber, the collector chamber reaching across the second ends of the tubulars, wherein the second ends section is connected to the second ends of the tubulars by annular joints formed on the outsides of the respective tubulars.

22. A device as claimed in claim 20, wherein the second ends section of walling or casing includes at least one sleeve adapted to fit around an outer diameter of at least one of the tubulars, and wherein a portion of the tubular is received in the sleeve and bonded thereto.

23. A method of constructing the device as claimed in claim 1.

24. A method of constructing the device as claimed in claim 1, the method comprising the steps of: providing elongate tubular sections of casing for housing filter membranes therein; and either or both of: bonding a first ends section of casing or walling to the first ends of the tubular sections to the distributor chamber; and bonding a second ends section of casing or walling to the second ends of the tubular sections to form the collector chamber.

25. A method as claimed in claim 24, further comprising inserting the first end of at least one of the tubular sections into a sleeve, and bonding an outer surface of the tubular section to at least one surface of the sleeve.

26. A method as claimed in claim 23, further comprising inserting the second end of at least one of the tubular sections into a sleeve, and bonding an outer surface of the tubular section to at least one surface of the sleeve.

27. A method of treating seawater subsea, the method comprising the steps of: providing the device of claims 1, in a system to produce treated seawater; operating the system to treat the seawater, feeding the seawater to be treated through the feed inlet into the distributor chamber and from the distributor chamber into the housing sections, using the filter membranes to treat respective water streams by filtration in the respective housing sections; and further operating the system to extract the treated seawater from the cylindrical sections through the extraction outlet from the collector chamber.

28. A method as claimed in claim 27, wherein the step of providing the device comprises immersing the device sub sea.

29. A method as claimed in claim 27, wherein the housing sections comprise tubular sections of casing or walling, outer surfaces of which are in contact with and surrounded by the sea, the tubular sections comprising pressure vessels in which the interior of the casings are isolated from pressure applied from the sea in the surrounding environment against the outer surfaces.

30. A method as claimed in claim 27, wherein the treated water comprises injection water for injection into at least one wellbore.

31. A method as claimed in claim 27, wherein the device is applied to treat the water by filtration by using the filter membranes to remove solids from the water.

32. A system for treating seawater subsea, the system comprising: a device as claimed in claim 1; a pump wherein the suction side of the pump is connected to the extraction outlet of the device.

33. A system as claimed in claim 32 wherein the pump is configured to pump water from the device, and for obtaining a pressure of water being processed by the device that is lower than that of treated water to be supplied to a further treatment stage downstream from the pump.

34. A system as claimed in claim 32, wherein the pump is configured to pump water from the device for obtaining a pressure of water being processed in the device that is lower than a pressure of sea exerted on the device at depths up to 300 meters.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0048] There will now be described, by way of example only, exemplary embodiments of the invention, with reference to the accompanying drawings, in which:

[0049] FIG. 1 is a side-on representation of a device for water processing according to an embodiment of the disclosure;

[0050] FIG. 2 is a sectional representation on line AA in the inset frame I of FIG. 1, in larger and exaggerated non-uniform scale;

[0051] FIG. 3 is a top view representation of the device of FIG. 1;

[0052] FIG. 4 is a side-on, part sectional representation of a device for water processing according to another embodiment of the disclosure;

[0053] FIG. 5 is a perspective representation of a bank of water processing devices according to another embodiment; and

[0054] FIG. 6 is a contour plot of flow velocity from flow modelling results based on the device of FIG. 4;

[0055] FIG. 7 is a schematic diagram of a system for processing water at the seabed in which devices for water processing may be employed; and

[0056] FIG. 8 is a prior art representation of an end portion of a membrane casing.

DETAILED DESCRIPTION OF THE DISCLOSED EXEMPLARY EMBODIMENTS

[0057] Turning first to consider FIG. 1, a device 1 for use in processing water is generally depicted. The device 1 has two cylindrical housings 12, 14. The housings 12, 14 are spaced apart by a distance D and arranged in parallel relationship.

[0058] The device 1 is illustrated in an orientation for operational use, where the cylindrical housings are vertical. In practice, the device 1 may be supported in this orientation in a frame on the seabed, and immersed such that exterior surfaces 12s, 14s of the walls of the housings 12, 14 contact the surrounding seawater. In other variants, the housings 12, 14 could be installed in other orientations, e.g. horizontally.

[0059] The cylindrical housings 12, 14 comprise tubulars of equal lengths, and are arranged so that the first, upper ends 12t, 14t of the housings are aligned side-by-side, and the second, lower ends 12b, 14b of the housings are aligned at the same height as each other side-by-side.

[0060] Filter membranes 77 such as microfiltration (MF) or ultrafiltration (UF) membranes are contained inside the housings 12, 14. The filter membranes 77 are typically mounted to an interior ring on an inner wall of the housings, so as to facilitate supporting the membranes in operational position. The membranes mounted inside the housings are used for filtration treating water, e.g. seawater. The cylindrical housings 12, 14 isolate the interior, including the membranes 77 from effects of pressure of the seawater environment against the outer surfaces 12s, 14s of the housings.

[0061] The device provides in effect a pressure tight unit of casing and/or walling that is formed to provide a connected interior flow space with a flow path for water to be treated to be fed in, treated by the membranes, and extracted from the device.

[0062] At the lower end, the device 1 has a distributor chamber 20. The walling and/or casing 21 (i.e. a first section of casing and/or walling) is adapted and formed to produce a structure encompassing the lower ends 12b, 14b of the housings, so as to provide the distributor chamber 20 which allows the water to be treated to be distributed into the two cylindrical housings 12, 14. The ends 12b, 14b of the cylindrical housings 12, 14 are received in sleeves 22, 24 and bonded in place.

[0063] At the upper end, the device 1 has a collector chamber 30. The walling or casing 31 (i.e. a second section of casing and/or walling) is adapted and formed to obtain a structure that encompasses the upper ends 12t, 14t of the housings, so as to obtain the collector chamber 30 which allows the treated water from the housings 12, 14 to be collected and merged together. In this regard, the ends 12t, 14t are received in corresponding sleeves 32, 34 and bonded in place to obtain a bonded joints 50 using suitable bonding material between the surfaces of the sleeves and an outer surface of the walls of the housings 12, 14. The distributor chamber 20 reaches across the first ends and the collector chamber 30 reaches across the second ends of the cylindrical housings 12, 14.

[0064] As indicated by arrows F, the device 1 provides in its interior a flow path by which seawater is fed through the device and treated. Seawater enters the distributor chamber 20 in a common flow, and is distributed between the cylindrical casings 12, 14. The seawater passes through the cylindrical housings and is treated by the membranes. The treated seawater then enters into the collector chamber 30 where the treated seawater is collected and merged together into flow of treated water which is extracted.

[0065] In more detail now, it can thus be seen in FIG. 1 that the device includes a feed inlet 25 into which the seawater to be treated enters into the distributor chamber 20. The water to be treated flows into the distributor chamber 20 and into the lower ends 12b, 14b of the housings 12, 14. The feed inlet 25 is arranged to direct water radially into the distributor chamber 20 with respect to the longitudinal axes L of the cylindrical housings 12, 14. The bottom ends 12b, 14b of the housings 12, 14 define entrances to the interiors of the cylindrical casings 12, 14. It can be appreciated that the entrances to the interiors of the cylindrical housings are spaced apart at different distances away from the feed inlet 25, and the seawater is supplied and distributed into the entrances into the respective cylindrical housings 12, 14 where part of the water is processed separately in one housing 12 and another part of the supplied water is processed separately by the membranes in the other housing 14. The feed inlet 25 is disposed in a part of the walling and/or casing 21 where it is offset radially away from the housings 12 with respect to the axes L.

[0066] The device 1 also has an extraction outlet 35 from which water that has been treated is removed from the collector chamber 30 through the extraction outlet 35. The treated water arrives in the interior of the collector chamber 30 from the upper ends 12t, 14t of the casings. The extraction outlet 35 is arranged to direct the treated water in direction radially with respect to the axes L. The upper ends 12t, 14t of the casings define exits from the interiors of the cylindrical housings 12, 14. The exits from the interiors of the cylindrical housings are spaced apart at different distances from the extraction outlet 35, so that the treated fluid is drawn laterally through the chamber 30 from both far and near exits toward the extraction outlet 35. The extraction inlet 35 is disposed in a part of the walling and/or casing 31 where it is radially offset away from the housings 12, 14 with respect to the axes L.

[0067] It can be noted that the collector chamber 30 has casing and/or walling 31 which extends in a direction along the axes L beyond the upper ends of the cylindrical housings 12, 14 to create chamber 30 which is spacious and can give favourable flow characteristics such as to minimise pressure drop effects and maximise distribution effectiveness amongst housings 12, 14. Indeed preferably, the interiors of the housings 12, 14 and the interiors of the collector chamber 30 and distributor chamber 20 do not impose any restrictions to the flow through of seawater aside from the necessary effects of the membranes. The configuration of the distributor chamber 20 is similar. With casing and/or walling 21 extending in the direction along the axes L beyond lower ends of the cylindrical housings 12, 14.

[0068] The walling and/or casing 31 defining the collection chamber 30 also includes a removable lid 37 which is secured in place against a circumferential lip 36 of the walling. The lid 37 is sealably fastened, e.g. screwed into part of the walling and/or casing 31. A gasket or other, e.g. elastomer seal is provided on the lid 27 or lip 36 to obtain the seal when the lid is 37 fastened and the device is in use. The lid 37 is removable, e.g. by unscrewing, to allow direct vertical axial access to the interior of the casings 12, 14 through an interior region of the collector chamber 30, e.g. for servicing or replacement of membranes at the due time. Thus, membranes and supporting rings and/or fastening brackets may be readily pulled out from or inserted their location in the interiors of housings 12, 14. The bonded joint 50, arrangement of the ends 12t, 14t, the casing and/or walling 31, and the chamber 30, allow open access through the lid 37 to the full internal diameter of the walls of the housings 12, 14 is provided. The interiors of the device are free from restrictions in the region above the location of the housings and the ends 12t, 14t of the housings 12, 14. This not only may facilitate replacement, but may also provide an open flow path.

[0069] The lower, distributor chamber 20 is arranged similarly, where the walling and/or casing 21 includes a removable lid 27, allowing access in the same way as for the collector chamber 30 except from the other ends of the housings 12, 14.

[0070] It may also be noted that the distributor chamber 20 is tapered in depth extent away from the feed inlet 25. Conversely, the collection chamber 30 is tapered away from the extraction outlet 35. The tapers can facilitate channelling water through the device 1.

[0071] In FIG. 2, part of the structure encompassing the ends 12t, 14t of the cylindrical sections is illustrated. It depicts in particular the bonded joint 50 between the upper end 12t of the housing 12 and the sleeve 32. FIG. 2 gives a schematic representation of the relationships and are not to scale, and the scale also does not correspond with that of FIG. 1.

[0072] The housing 12 has an opening 12x from the interior of the casing 12 through which treated water passes into the collection chamber 30 in use. Flow of treated water is contained at the end of the housing by the full internal diameter M of the space between wall portions of the cylindrical housing 12. The space for the flow of treated water exiting the housing 12 is unrestricted. Typically, the diameter M and indicated cross section of the housing is substantially constant the entire top-to-bottom length of the housing 12.

[0073] Any of and/or preferably each of the housings 12 is fluidly connected to the collector chamber 30 substantially as depicted in FIG. 2. The interior space 30i of the collector chamber 30 provides a channel 44 for flow of the treated water toward the extraction outlet. The width W of the channel 44 is greater than the diameter M of interior of the tubular housing for flow therealong. The interior extends beyond the end 12t of the housings 12 by depth extent T, which also is greater than the diameter M for flow in the interior of the tubular housings 12.

[0074] The housing 12 defines an opening 12x which is in effect also an opening of or in the chamber 30 through which the fluid passes into the chamber.

[0075] The converse arrangement is applicable for the distributor chamber 20 where any or preferably each of the housings 12, 14 are connected at their bottom ends to the distributor chamber 20 in the same manner as indicated in FIG. 2.

[0076] The collar 32 in this example is an integrated formation of the walling and/or casing 31 of the chamber 30. The upper portion of the wall 12w is received in the collar. The collar 32 provides a 360 degree circumferential wall around the outside of the cylindrical casing 12. Bonding material 51 is disposed in an annular region 52 between the collar 32 and an outer surface of the wall 12w of the casing, and forms a fluid tight, e.g. water tight, bond between the surface of the casing 12 and the sleeve. The join 50 is also pressure tight so that the pathway for treated water into the chamber 30 through the joined section is isolated from seawater pressure due to seawater contacting the exterior of the join when immersed.

[0077] The bonding material 51 is selected to be compatible with the material of the sleeve 32 and that of the housing 12. Typically, the materials of the sleeve 32 and the housing 12 are the same, but not necessarily so. For purposes of this example, the material of the housing 12 and sleeve 32 subjected to the bonding material is glass reinforced epoxy (GRE) or glass reinforced plastics (GRP) or similar, and the bonding material is a resin that is compatible, e.g. epoxy resin. In order to form the bond 50, the end of the tubular cylindrical housing 12 is arranged in the sleeve 12 and epoxy resin is poured into the annular region 52 and left to set.

[0078] FIG. 3 illustrates the lid 37 in closer detail. The lid is in the form of a covering plate that reaches across the ends of both cylindrical sections. The lid 37 fits onto a circumferential lip and allows functionality as described above.

[0079] In FIG. 4, a device 101 for water processing is depicted in another example. The device 101 functions similarly to that of FIGS. 1 to 3. However, this device 101 has nine cylindrical housings 112 mounted in parallel, each of which houses filter membranes for treating water. Thus, water is treated separately in separate housings 112. The housings 112 are individually bonded at the upper ends to a first section of casings and/or walling providing a collection chamber 130, and at the lower ends to another, second section of casings and/or walling providing a distributor chamber 120. The walling and/or casing at the top end is fitted with a lid 137, and has collars 132 in which upper ends of the cylindrical housings 112 are received and bonded. Treated water exits from the housings 112 and enters the combined region of the chamber 130, and exits laterally through an extraction outlet 135. Water to be treated enters through inlet 125 into the distributor chamber 120 and is distributed into the housings 112 and is treated by the filter membranes, e.g. by microfiltration. Since a greater number of cylindrical casings are available for the membranes, the amount of fluid that can be treated can be increased in the device of 101 compared with that of the device 1. The flow paths for water through the device 101 is marked by arrows F.

[0080] With reference to FIG. 5, a bank 200 of devices 201 for water processing can be used for treating still greater volumes of seawater. Each device 201 in FIG. 5 is similar to that shown in FIG. 3, except that the feed inlets are arranged differently to supply water through an underside. The feed inlets 225 may be connected together to a common supply of seawater. The extraction outlets 235 may be connected together to a common extraction pipe, and a pump can be operated downstream from the outlets 235 to help to draw the seawater through the bank of devices 201 in use.

[0081] In FIG. 6, results from modelling provides a map of the flow rate of water fed through the casings from the feed inlet 325 to the extraction outlet 335 in an nine housing device such as the devices 101 or 201 of FIG. 4 or 5.

[0082] In FIG. 7, an example system 500 for processing seawater and performing water treatment for producing water for injection into a wellbore. The device 1, 101, 201 can be used to implement the parallel feedthrough filtering as indicated by filters A,B,C,D. Filters A, B, C and D may be implemented in one device, by filter membranes in respective separate housing sections fluidly connected to the collector chamber and distributor chambers such as in the devices described above. Thus, one housing section of the device may provide filter A, the next housing section filter B, etc. The membranes may be ultra filtration or micro filtration membranes, so as to apply the same processing to water streams in parallel. Operating the system 500 includes using the pump 508 which is connected on its suction side to the extraction outlet 35, 135, 235 to facilitate drawing seawater through the devices 1, 101, 201. Raw/untreated seawater is fed into the feed inlet, into the distributor chamber where disinfection or electrolytic treatment is conducted and then into the respective housings for filtering. The feed inlet is typically an open inlet open to water, with no pump placed upstream of the feed inlet. The pressure of water treated in the device on the suction side of the pump 508 is lower than of the ambient seawater at or near the seabed, e.g. pressure of the sea exerted on the exterior of the device 1, 101, 201. Downstream processing of the seawater takes place at positive pressure differentials and may include a defusion process for the purpose of removing dissolved (ionic / molecular) materials, where the filtered water from the device is driven through by the pump.

[0083] In the processing of water at the seabed, it can be appreciated that embodiments disclosed herein are directed to overcoming challenges where the conventional approach for connecting the membrane elements involves multiple connection points, each requiring compliance to high tolerance and certification levels. In high throughput applications, the challenges associated with the conventional connection technique can be exacerbated, as simply adding elements to cope with demand can be associated with further fittings and connections. Yet further, it can be noted that fluid supplied through individual branches pipes can restrict flow and place requirements for further elements even higher.

[0084] The injected water may be injected through the wellbore into a subsurface formation for example to stimulate the recovery of oil and gas from the formation. The water may also need to be of a particular quality to avoid potential difficulties when introducing it to the wellbore. This may be to avoid effects of deposits, corrosion, wear or the like on equipment of the wellbore.

[0085] Various modifications and improvements may be made without departing from the scope of the invention as defined by the claims below and their equivalents. Although bonded joints are utilised in various examples, and can be an efficient and convenient manner of construction, it may be appreciated that the device may also be embodied by a one-piece casing and/or walling that has a similar form to that illustrated in the various figures but which avoids bonded joints or connections altogether. Although the use of the device is described in the above with reference to the drawings as taking place subsea, it may in other variants be installed topsides instead, e.g. on a platform or rig, and used in a topsides water processing system, e.g. on the platform or rig.