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INTEGROIL Report Summary

Project ID: 688989
Funded under: H2020-EU.3.5.4.

Periodic Reporting for period 1 - INTEGROIL (Demonstration of a Decision Support System for a Novel Integrated Solution aimed at Water Reuse in the Oil & Gas Industry)

Reporting period: 2016-06-01 to 2017-11-30

Summary of the context and overall objectives of the project

The Oil&Gas industry is one of the eight most water-intensive industries due to the high volumes of water that are involved in oil extraction (the so-called Produced Water –PW-), and the subsequent amount of wastewater that is generated during refining activities (the so-called refinery wastewater –RW-).
Both PW and RW are extremely complex to be treated, either for the number of contaminants present as for the high variability on the features of the extraction site and the technique used, whichprevents them from being reused. On the other hand, water scarcity and stricter environmentally regulations are pushing this industry to adopt innovative technologies that allow them to make a more efficient use of water and even reuse it (i.e. for irrigation purposes) and recycling it (i.e. in refinery downstream scenarios as fire water, cooling makeup water and demineralized water). The lack of specific water knowledge in the O&G sector required the proposed technologies, besides being flexible and robust to deal with the high variability and complexity of the O&G waters, to be easily operated.
Integroil project will bring a new solution for treating water flows with variable composition to increase the level of reuse by 50 % by developing and demonstrating an integrated solution for treating this kind of water. The O&G sector is the ideal environment for this application although it is expected that the solution can be also implemented in other industrial sectors that also deal with complex waters.
The proposed solution involves a combination of different technologies such as dissolved air flotation, polymer and ceramic membrane filtering, advanced oxidation and the addition of low-impact chemical products and formulations. The technologies will be controlled by a Decision Support System (DSS), the key component of the integrated solution that ensures the integrated optimization of the system according to different objectives (low energy consumption, low chemical consumption, high water conversions or a combination of these).
In short, INTEGROIL platform is conceived as an adaptive (able to treat wastewaters from different industries), flexible (able to hand variable wastewaters and complying with regulation) and easy to use (environmental expertise is integrated within DSS, so users do not need to be experts) tool.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

In the first stage of the project a detailed input water characterization was carried out to identify the main features and average values needed to produce water suitable for technology adaptation. Three potential scenarios for reusing the water treated were defined and four key alternative markets where the INTEGROIL technology could be commercialized with minor modifications were identified (iron and steel, petrochemical, mining and pharmaceutical). A preliminary assessment of the suitability of the solution was made by experts of these markets.
With the results of this stage, the common technical specifications for the INTEGROIL prototypes were agreed among all the technology developers and validated by end-users. Then, each individual technology that is part of the global solution was adapted for the treatment of wastewaters generated in the O&G sector. The task ended with the INTEGROIL solution scheme for both scenarios. The pilot plant was designed, built and it is operative since November 2017.
The solution includes an integrated automatic control system that operates the plants according to the best configuration algorithm. It is based on mathematical and simulation models of the different processes and on expertise collected from all the partners about each technology. Apart from the Supervisory control and data acquisition (SCADA) running at the plant's premises, an advanced visualization platform is designed and deployed as a SaaS on a server.
The INTEGROIL integrated solution is going to be demonstrated in a scenario representative of crude extraction conditions, and afterwards, in a refinery. To this end, a demonstration and validation plan is developed.
All communication and dissemination activities are being carried out according the project dissemination guidelines and the communication plan. Dissemination activities carried out up to now include press releases, a dedicated website, attendance to conferences (15), a distribution list with more than 15,000 recipients, etc.
To support exploitation activities, described in a preliminary exploitation plan, partners identified the key preliminary technical documents to be produced in order to commercialized the technology in the O&G sector and other vertical markets.
In order to conduct a Sustainability Assessment on the technology, the framework for the analysis has been set out. To this end, the technologies to be assessed by LCA, water quality parameters and impact assessment methods were identified. The scope for both upstream and downstream scenarios was selected, too.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The detailed analysis on the state of the art revealed that there is no integrated solution that is easy to operate and maintain that addresses at the same time the challenges associated with O&G and the need of producing high quality water amenable for reuse. Furthermore, the application of a DSS has not been addressed.
The relevance of the DSS, together with advanced visualisation tools, are a key point that were also highlighted by the different experts consulted. Both tools make the operation and understanding of the system easy and make possible to overcome the key barrier to implement the proposed technology.
The project contributes to achieve the potential impacts listed in the Work Programme and some other environmental and social impacts. So far, the potential impacts already addressed are:
The integrated solution is being developed according to the necessities of end-users, involved in the project both as partners and members of the Advisory Board.
The project contributes to implementing the EIP Water strategy being aligned with several vertical and cross-cutting priorities.
INTEGROIL is fully aligned with SPIRE vision and objectives on industrial water reuse.
Two long-term demonstration phases will take place for the remaining of the project.
Some market opportunities within the O&G market are in Europe but large markets are in the Americas and Asia. The project is an excellent opportunity to penetrate these markets, taking advantage of an expected first full-scale implementation at TUPRAS facilities in Turkey.
Producing water by means of the INTEGROIL technology that met the quality criteria of the reuse scenario contributes to benefits alleviate the pressure on water resources and reducing the dependence to fresh water sources and wider utilization of reused water.
The project is developing environmentally acceptable chemicals and an integrated process considering eco-design criteria, which clearly contribute to benefit increase environmental care.

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