Oil and Gas Produced Water Management: A Review of Treatment Technologies, Challenges, and Opportunities

Environmental trade-offs in energy production: A review of the produced water life cycle and environmental footprint

Produced water, a major by-product of oil and gas production, represents the most significant amount of waste by volume in the oil and gas industry. Focusing on the hydrocarbon's lifecycle, this review delves into the composition and global variations of produced water. It assesses the current treatment methods for their effectiveness and their potential for reuse in sectors beyond oil and gas, such as agriculture. The review highlights the environmental trade-offs in maximising energy production, analysing the ecological implications of produced water disposal in marine environments and the potential risks to marine biodiversity. Regional regulatory frameworks and their role in mitigating these environmental impacts are examined, alongside the challenges faced in standardising treatment solutions due to the complex nature of produced water. The conclusion underscores the need for continuous research to develop innovative and effective treatment technologies and advocates for a balanced approach to energy production that prioritises environmental stewardship.

Treated water from oil and gas extraction as an unconventional water resource for agriculture in the Anadarko Basin

The energy industry generates large volumes of produced water (PW) as a byproduct of oil and gas extraction. In the central United States, PW disposal occurs through deep well injection, which can increase seismic activity. The treatment of PW for use in agriculture is an alternative to current disposal practices that can also provide supplemental water in regions where limited freshwater sources can affect agricultural production. This paper assesses the potential for developing PW as a water source for agriculture in the Anadarko basin, a major oil and gas field spanning parts of Kansas, Oklahoma, Colorado, and Texas. From 2011 to 2019, assessment of state oil and gas databases indicated that PW generation in the Anadarko Basin averaged 428 million m3/yr. A techno-economic analysis of PW treatment was combined with geographical information on PW availability and composition to assess the costs and energy requirements to recover this PW as a non-conventional water resource for agriculture. The volume of freshwater economically extractable from PW was estimated to be between 58 million m3 per year using reverse osmosis (RO) treatment only and 82 million m3 per year using a combination of RO and mechanical vapor compression to treat higher salinity waters. These volumes could meet 1-2 % and 49-70 % of the irrigation and livestock water demands in the basin, respectively. PW recovery could also modestly contribute to mitigating the decline of the Ogallala aquifer by ~2 %. RO treatment costs and energy requirements, 0.3-1.5 $/m3 and 1.01-2.65 kWh/m3, respectively, are similar to those for deep well injection. Treatment of higher salinity waters increases costs and energy requirements substantially and is likely not economically feasible in most cases. The approach presented here provides a valuable framework for assessing PW as a supplemental water source in regions facing similar challenges.

Electrochemical-based processes for produced water and oily wastewater treatment: A review

The greatest volume of by-products produced in oil and gas recovery operations is referred to as produced water and increasing environmental concerns and strict legislations on discharging it into the environment cause to more attention for focusing on degradation methods for treatment of produced water especially electrochemical technologies. This article provides an overview of electrochemical technologies for treating oily wastewater and produced water, including: electro-coagulation, electro-Fenton, electrochemical oxidation and electrochemical membrane reactor as a single stage and combination of these technologies as multi-stage treatment process. Many researchers have carried out experiments to examine the impact of various factors such as material (i.e, electrode material) and operational conditions (i.e., potential, current density, pH, electrode distance, and other factors) for organic elimination to obtain the high efficiency. Results of each method are reviewed and discussed according to these studies, comprehensively. Furthermore, several challenges need to be overcome and perspectives for future study are proposed for each method.

The Acute Toxicity of Salinity in Onshore Unconventional Gas Waters to Freshwater Invertebrates in Receiving Environments: A Systematic Review

Industries such as unconventional natural gas have seen increased global expansion to meet the increasing energy needs of our increasing global population. Unconventional gas uses hydraulic fracturing that produces significant volumes of produced waters, which can be highly saline and pose a toxic threat to freshwater invertebrates if exposure via discharges, spills, leaks, or runoff were to occur. The primary aim of the present review was to determine the sodium (Na⁺ ) and chloride (Cl^- ) content of these waters as an approximate measure of salinity and how these values compare to the NaCl or synthetic marine salt acute toxicity values of freshwater invertebrate taxa. Shale gas produced waters are much more saline with 78 900 ± 10 200 NaCl mg/L and total dissolved solids (TDS) of 83 200 ± 12 200 mg/L compared to coal bed methane (CBM) produced waters with 4300 ± 1100 NaCl mg/L and TDS of 5900 ± 1300 mg/L and pose a far greater toxicity risk from NaCl to freshwater invertebrates. In addition, the toxicity of other major ions (Ca²⁺ , K⁺ , Mg²⁺ , CO 3 2 - , HCO₃ ^- , and SO 4 2 - ) and their influence on the toxicity of Na⁺ and Cl^- were evaluated. Exposure of untreated and undiluted shale gas produced waters to freshwater invertebrates is likely to result in significant or complete mortality. Shale gas produced waters have higher concentrations of various metals compared with CBM produced waters and are more acidic. We recommend future research to increase the reporting and consistency of water quality parameters, metals, and particularly organics of produced waters to provide a better baseline and help in further investigations. Environ Toxicol Chem 2022;41:2928-2949. © 2022 The Authors. Environmental Toxicology and Chemistry published by Wiley Periodicals LLC on behalf of SETAC.

Treatment and recycling of acidic fracturing flowback fluid

Acidic fracturing flowback fluid (AFFF) has the characteristics of low pH value, high chemical oxygen demand (COD), high corrosiveness and complex components. Surface discharge without treatment may contaminate the environment. However, wastewater treatment after centralized transportation has potential safety risks and requires high costs. In this study, we confirmed that calcium and magnesium could affect cross-linking property of fracturing fluid prepared by flowback fluid, and conducted a three-step process, two-stage filtration, chemical precipitation, and flocculation precipitation, on AFFF. After treatment, we made new hydraulic fracturing fluid using the treated acidic flowback fluid as base fluid and compared the quality of the new hydraulic fracturing fluid to the ones used freshwater as base fluid. The results showed when concentration of sodium carbonate, polyaluminium chloride (PAC), polyacrylamide (PAM) were 145, 1000, and 20 mg/L respectively, the treatment result was optimal. After treatment, the oil content of AFFF decreased from 7400 to 26.53 mg/L and suspended solids (SS) from 650 to 18.24 mg/L, and the removal rate of high-valence metal ions was more than 99%. The rheological properties and viscoelasticity of new fracturing fluid prepared by the treated AFFF were similar to the ones prepared by freshwater, which met the requirements of high temperature and shear resistance for ultra-deep wells.

A Review on the Nanofiltration Process for Treating Wastewaters from the Petroleum Industry

Activities and/or processes in different segments of the petroleum industry, including upstream and downstream, generate aqueous waste streams containing oil and various contaminants that require treatment/purification before release/reuse. Nanofiltration (NF) technology has been approved as an efficient technology for treating wastewater streams from the petroleum industry. The primary critical issues in an NF treatment process can be listed as mitigation of membrane fouling; selection of appropriate pre-treatment process; and selection of a suitable, cost-effective, non-hazardous cleaning strategy. In this study, NF separation mechanisms, membrane fabrication/modification, effective factors on NF performance, and fouling are briefly reviewed. Then, a summary of recent NF treatment studies on various petroleum wastewaters and performance evaluation is presented. Finally, based on the gaps identified in the field, the conclusions and future perspectives are discussed.

Oil field-produced water treatment: characterization, photochemical systems, and combined processes

Produced water, a mixture of inorganic and organic components, comprises the largest effluent stream from oil and gas activities. The removal of contaminants from this wastewater is receiving special attention of the researchers since most of them are persistent and difficult to remove with simple techniques. Several technologies from conventional to advanced oxidation processes have been employed to treat produced water. However, the achievement of greater efficiency may be conditioned to a combination of different wastewater treatment techniques. Hereupon, the present paper discusses three important aspects regarding produced water treatment: analytical methods used for characterization, relevant aspects regarding photochemical systems used for advanced oxidation processes, and combined techniques for treating oil field wastewaters. Analytical methods employed for the quantification of the main species contained in produced water are presented for a proper characterization. Photochemical aspects of the reaction systems such as operating conditions, types of irradiation sources, and technical details of reactors are also addressed. Finally, research papers concerning combined treatment techniques are discussed focusing on the essential contributions. Thus, this manuscript aims to assist in the development of novel techniques and the improvement of produced water treatment to obtain a high-quality treated effluent and reduce environmental impacts.

Fabrication, Optimization, and Performance of a TiO2 Coated Bentonite Membrane for Produced Water Treatment: Effect of Grafting Time

The main problem usually faced by commercial ceramic membranes in the treatment of produced water (PW) is low water flux even though ceramic membrane was well-known with their excellent mechanical, thermal, and chemical properties. In the process of minimizing the problem faced by commercial ceramic membranes, titanium dioxide (TiO₂) nanocomposites, which synthesized via a sol-gel method, were deposited on the active layer of the hydrolysed bentonite membrane. This paper studied the influence of grafting time of TiO₂ nanocomposite on the properties and performance of the coated bentonite membranes. Several characterizations, which are Fourier transform infrared (FTIR), scanning electron microscopy (SEM), energy-dispersive X-ray Spectroscopy (EDX), contact angle, porosity, and average pore size, were applied to both pristine and coated bentonite membranes to compare the properties of the membranes. The deposition of TiO₂ nanoparticles on the surface of the coated bentonite membranes was successfully confirmed by the characterization results. The pure water flux performance showed an increment from 262.29 L h⁻¹ m⁻² bar⁻¹ (pristine bentonite membrane) to 337.05 L h⁻¹ m⁻² bar⁻¹ (Ti-Ben 30) and 438.33 L h⁻¹ m⁻² bar⁻¹ (Ti-Ben 60) as the grafting time increase but when the grafting time reached 90 min (Ti-Ben 90), the pure water flux was decreased to 214.22 L h⁻¹ m⁻² bar⁻¹ which is lower than the pristine membrane. The oil rejection performance also revealed an increase in the oil rejection performance from 95 to 99%. These findings can be a good example to further studies and exploit the advantages of modified ceramic membranes in PW treatment.

Effective anaerobic treatment of produced water from petroleum production using an anaerobic digestion inoculum from a brewery wastewater treatment facility

Produced water is a major waste problem in oil production yet it also represents a potential water source if treated properly, especially in arid regions. In this study, we investigate the anaerobic treatability of an oil-produced water with extremely high chemical oxygen demand (COD) and total dissolved organic carbon (TOC) from Wyoming's Greater Green River Basin using anaerobic microcosms inoculated with a microbial consortium derived from a brewery wastewater treatment facility. The results demonstrate that for this water and an appropriate microbial inoculation, high-COD/TOC can be effectively removed with concomitant energy recovery as a form of methane. 93% and 89% of the COD and TOC were removed with a final high methane yield of 33.9 mmol/g carbon (848 μmol/g carbon/day). Chemical analyses showed that the ethylacetate-extractable compounds were much more amenable to biodegradation than the CH₂Cl₂ extractable compounds. Furthermore, compounds that were added during drilling and completion remained in the water and contributed significantly to the COD and anaerobic degradability. This study demonstrates that produced waters are amenable to anaerobic biological treatment and also that thorough chemical analyses are necessary to fully understand the potential for treatment.

Solar distillation of highly saline produced water using low-cost and high-performance carbon black and airlaid paper-based evaporator (CAPER)

The current technologies to treat hypersaline produced water (PW), such as thermal evaporation, are usually energy-intensive and cost-prohibitive. This study developed a low-cost, robust, solar-driven carbon black and airlaid paper-based evaporator (CAPER) for desalination of PW in the Permian Basin, United States. The study aims to better understand the removal of aromatic organic compounds and heavy metals during solar distillation, water output, and heat transfer. Outdoor experiments using CAPER assisted with polystyrene foam in a single slope, single basin solar still achieved an enhanced average evaporation rate of 2.23 L per m² per day, 165% higher than that of a conventional solar still. Analysis of heat transfer models demonstrated that CAPER solar evaporation achieved an evaporative heat transfer coefficient of ∼28.9 W m^-2·K^-1, 27.9% higher than without CAPER. The maximum fractional energy of evaporation and convection heat transfer inside the solar still with and without CAPER was ∼81.4% and ∼78.2%, respectively. For the PW with a total dissolved solids concentration of 134 g L^-1, solar distillation removed 99.97% salts and over 98% heavy metals. The high removal efficiency of 99.99% was achieved for Ca, Na, Mg, Mn, Ni, Se, Sr, and V. Organic characterization revealed that solar distillation removed over 83% aromatic compounds. Solar desalination using CAPER provides a low-cost and high-performance process to treat PW with high salinity and complex water chemistry for potential fit-for-purpose beneficial uses.

Sustainable microalgae-based technology for biotransformation of benzalkonium chloride in oil and gas produced water: A laboratory-scale study

Many countries have implemented stringent regulatory standards for discharging produced water (PW) from the oil and gas extraction process. Among the different chemical pollutants occurring in PW, surfactants are widely applied in the oil and gas industry to provide a barrier from metal corrosion. However, the release of these substances from the shale formation can pose serious hazardous impacts on the aquatic environment. In this study, a low-cost and eco-friendly microalgae laboratory-scale technology has been tested for biotransformation of benzalkonium chloride (BAC_C12 and BAC_C14) in seawater and PW during 14-days of treatment (spiked at 5 mg/L). From the eight microalgae strains selected, Tetraselmis suecica showed the highest removal rates of about 100% and 54% in seawater and PW, respectively. Suspect screening analysis using liquid chromatography coupled to high-resolution mass spectrometry (LC-HRMS) allowed the identification of 12 isomeric intermediates generated coming from biotransformation mechanisms. Among them, the intermediate [OH-BAC_C12] was found as the most intense compound generated from BAC_C12, while the intermediate [2OH-BAC_C14] was found as the most intense compound generated from BAC_C14. The suggested chemical structures demonstrated a high reduction on their amphiphilic properties, and thus, their tendency to be adsorbed into sediments after water discharge. In this study, Tetraselmis suecica was classified as the most successful specie to reduce the surfactant activity of benzalkonium chloride in treated effluents.

Techno-economic analysis of multi-stage ion concentration polarization with recirculation for treatment of oil produced water

The concept of recirculation of diluate/concentrate stream is implemented in multi-stage ion concentration polarization (ICP) desalination to deal with the issue of uncontrolled concentrate streams and deteriorated overall recovery rate to treat highly concentrated oil produce water from refineries. An improved empirical optimization model was established to calculate total energy consumption for operating cost and required membrane area for capital cost for a given set of operating parameters, feed salinity, salt removal ratio, and flow velocity. Using the empirical optimization model, a techno-economic analysis is performed to evaluate the feasibility of two-stage ICP system with recirculation loops. Brine of 160 g/kg is set as the system feed stream, whereas other operating conditions such as dilaute and concentrate streams are being controlled/fixed with 20 g/kg and ~250 g/kg respectively. Also, the system can be flexibly controlled to produce a specific concentration of product water and a recovery ratio with a corresponding water cost. With careful choices of recirculation rates, one can significantly increase the recovery ratio of two-stage ICP brine treatment process (from 25% to 39%) with only minor increase in overall cost (from $16.4-25.9/m³ to $20.6-22.54/m³), which is favourable for brine waste treatment application.

Removal of Ca2+, Mg2+, Ba2+ and Sr2+ from shale gas flowback water from the Sichuan Basin in China by chemical softening under the guidance of OLI Stream Analyzer: precipitation behaviors and optimization study

The disposal of flowback water is recognized as a key issue for the sustainable shale gas development and discharge after reasonable treatment is considered as a feasible pathway. One of the challenges during treatment is the severe mineral scaling potential in reverse osmosis desalination, especially with high amounts of Ca²⁺, Mg²⁺, Ba²⁺ and Sr²⁺ in flowback water. In this study, precipitation behaviors of Ca²⁺, Mg²⁺, Ba²⁺ and Sr²⁺ during traditional chemical softening was evaluated so as to achieve optimal chemical dosage. Both jar tests and OLI Stream Analyzer simulation revealed that the main precipitates were CaCO₃, SrCO₃ and BaSO₄ during Na₂CO₃ addition, and Ba²⁺ could not be removed efficiently by Na₂CO₃ unless a high dosage was applied since Ba²⁺ would react after the precipitation of Ca²⁺ and Sr²⁺. Reverse Osmosis System Analysis simulation indicated that Ba²⁺ was a concern because Ba²⁺ would form tenacious BaSO₄ scale on the reverse osmosis membranes. Finally, the Na₂SO₄-NaOH-Na₂CO₃ process was proposed for chemical softening as it has a high removal efficiency and low chemical cost. Overall, this study presents an effective chemical softening method and OLI Stream Analyzer could serve as a reliable tool for the calculation, which would finally improve the design and operation of shale gas flowback water treatment.

Can we beneficially reuse produced water from oil and gas extraction in the U.S.?

There is increasing interest in beneficial uses of large volumes of wastewater co-produced with oil and gas extraction (produced water, PW) because of water scarcity, potential subsurface disposal limitations, and regional linkages to induced seismicity. Here we quantified PW volumes relative to water demand in different sectors and PW quality relative to treatment and reuse options for the major U.S. shale oil and gas plays. PW volumes from these plays totaled ~600 billion liters (BL, 160 billion gallons, Bgal) in 2017. One year of PW is equal to ~60% of one day of freshwater use in the U.S. For these plays, the total irrigation demand exceeded PW volumes by ~5× whereas municipal demand exceeded PW by ~2×. If PW is reused for hydraulic fracturing (HF) within the energy sector, there would be no excess PW in about half of the plays because HF water demand exceeds PW volumes in those plays. PW quality can be highly saline with median total dissolved solids up to 255 g/L in the Bakken play, ~7× seawater. Intensive water treatment required for PW from most unconventional plays would further reduce PW volumes by at least 2×. Desalination would also result in large volumes of salt concentrates, equivalent to ~3000 Olympic swimming pools in the Permian Delaware Basin in 2017. While water demands outside the energy sector could accommodate PW volumes, much lower PW volumes relative to water demand in most regions would not substantially alleviate water scarcity. However, large projected PW volumes relative to HF water demand over the life of the play in the Permian Delaware Basin may provide a substantial new water source for beneficial use in the future. Large knowledge gaps in PW quality, lack of appropriate regulations, and economic factors currently preclude beneficial uses outside the energy sector in most regions.

Mercury in natural gas streams: A review of materials and processes for abatement and remediation

The role of natural gas in mitigating greenhouse gas emissions and advancing renewable energy resource integration is undoubtedly critical. With the progress of hydrocarbons exploration and production, the target zones become deeper and the possibility of mercury contamination increases. This impacts on the industry from health and safety risks, due to corrosion and contamination of equipment, to catalyst poisoning and toxicity through emissions to the environment. Especially mercury embrittlement, being a significant problem in LNG plants using aluminum cryogenic heat exchangers, has led to catastrophic plant incidents worldwide. The aim of this review is to critically discuss the conventional and alternative materials as well as the processes employed for mercury removal during gas processing. Moreover, comments on studies examining the geological occurrence of mercury species are included, the latest developments regarding the detection, sampling and measurement are presented and updated information with respect to mercury speciation and solubility is displayed. Clean up and passivation techniques as well as disposal methods for mercury-containing waste are also explained. Most importantly, the environmental as well as the health and safety implications are addressed, and areas that require further research are pinpointed.

Organic matter removal from mother liquor of gas field wastewater by electro-Fenton process with the addition of H2O2: effect of initial pH

The electro-Fenton (EF) process was applied to treat mother liquor of gas field wastewater (ML-GFW). The Fe-Fe electrodes were used and H₂O₂ was added to the EF system. Effect of initial pH on chemical oxygen demand (COD) removal efficiency, specific electrical energy consumption (SEEC), specific electrode plate consumption (SEPC) and organic matter removal mechanism was investigated. The results showed that COD removal efficiency reached the maximum (71.9%) at initial pH of 3 after reaction for 3 h. Besides, considering with the SEEC and SEPC, pH of 3 was also the best choice, at which SEEC was 4.7 kW h kg_COD ^-1, SEPC was 0.82 kgFe kg_COD ^-1. Organic matter removal was achieved by two ways: oxidation and flocculation, and oxidation played a major role. With the analysis of GC-MS, the possible degradation pathways of the representative contaminants in the ML-GFW were given.

A cost-effective and environmentally sustainable process for phycoremediation of oil field formation water for its safe disposal and reuse

High volumes of formation water comprising of complex mixture of hydrocarbons is generated during crude oil exploration. Owing to ecotoxicological concerns, the discharge of the formation water without remediation of hydrocarbonaceous pollutants is not permitted. Keeping this into mind, we carried out phycoremediation of hydrocarbons in formation water so that it can be safely discharged or re-used. For this, a native algal species was isolated from formation water followed by its morphological and 18S ribosomal RNA based identification confirming the algal isolate to be Chlorella vulgaris BS1 (NCBI GenBank Accession No. MH732950). The algal isolate exhibited high biomass productivity of 1.76 gm L⁻¹ d⁻¹ (specific growth rate: 0.21 d⁻¹, initial inoculum: 1500 mg L⁻¹) along with remediation of 98.63% petroleum hydrocarbons present in formation water within 14 days of incubation indicating an efficient hydrocarbon remediation process. Concomitantly, the hydrocarbon remediation process resulted in reduction of 75% Chemical Oxygen Demand (COD) load and complete removal of sulfate from formation water making it suitable for safe disposal or reuse as oil well injection water respectively. The present process overcomes the bottlenecks of external growth nutrient addition or dilution associated with conventional biological treatment resulting in a practically applicable and cost-effective technology for remediation of oil field formation water.