1. Case Basic Information
1.1 Company Overview
Hella Water Treatment Equipment Technology Co., Ltd. is a professional provider of high-performance industrial wastewater treatment solutions, specializing in the R&D, production, and integration of oilfield wastewater purification systems. The company adheres to international and national standards such as TSG 11-2020, GB/T1576-2018, and ISO, offering customized solutions for complex wastewater scenarios. Its products are widely used in oilfield, chemical, and industrial boiler water supply projects. For more water treatment products, visit [water treatment product].
1.2 Project Background
This project aims to treat oilfield wastewater for reuse as boiler feed water (steam generator pre-filter water). The raw oilfield wastewater contains high concentrations of salts, petroleum products, suspended solids, and heavy metals, which are unfit for direct use. The system is designed with a multi-stage treatment process to purify 60m³/h of inlet wastewater into 16m³/h of qualified boiler feed water, meeting the operational requirements of steam generators with pressures up to 9.0 MPa.
1.3 Raw Water Quality Data
The key parameters of the oilfield wastewater (inlet water) are as follows:
| Parameter | Value Range | Unit | Regulatory Standard |
|---|---|---|---|
| Turbidity | 74.4997±10.4299 | mg/dm³ | ≤1.5 |
| Color | 188.4591±18.8459 | degree | ≤20 |
| Odor (20℃/60℃) | 5/5 | points | 2/2 |
| Taste | 5 | point | ≤2 |
| Permanganate Oxidability | 27.68±2.77 | mgO₂/dm³ | ≤5.0 |
| Dry Residue | 32344.0±646.9 | mg/dm³ | ≤1000 |
| Petroleum Products | 55 | mg/dm³ | ≤0.1 |
| Chlorides | 20160.0±403.2 | mg/dm³ | ≤350 |
| Sulfates | 1003.48±100.35 | mg/dm³ | ≤500 |
| Total Iron | 1.8707±0.3367 | mg/dm³ | ≤0.3 |
| Ammonia (by Nitrogen) | 11.34±1.59 | mg/dm³ | ≤0.2 |
| Calcium | 420.84±29.46 | mg/dm³ | ≤50 |
| Magnesium | 47.41±4.74 | mg/dm³ | – |
| Fluorides | 1.7862±0.1251 | mg/dm³ | ≤1.5 |
| Sodium + Potassium | 13429.15±074.33 | mg/dm³ | ≤200 |
2. Core Pain Points and Requirements of the Project
2.1 Raw Water Quality Pain Points
- High Contaminant Load: Excessive dry residue (32344 mg/dm³), chlorides (20160 mg/dm³), and sulfates (1003 mg/dm³) cause scaling and corrosion in boilers.
- Petroleum and Organic Pollution: Petroleum products (55 mg/dm³) and high permanganate oxidability affect water stability and boiler safety.
- Suspended Solids and Turbidity: Turbidity (74.5 mg/dm³) and suspended solids lead to membrane fouling and reduced system efficiency.
- Heavy Metal Contamination: Exceeded iron content (1.87 mg/dm³) and other heavy metals pose risks to boiler material durability.
- Alkalinity Imbalance: Total alkalinity (39000 mEq/dm³) requires adjustment to meet boiler water standards.
2.2 Produced Water Quality Requirements
- Basic Purity Indicators: Turbidity ≤2.6 NTU, suspended solids ≤5.0 mg/dm³, permanganate oxidability ≤5.0 mgO₂/dm³.
- Salt Removal: Chlorides ≤350 mg/dm³, sulfates ≤500 mg/dm³, dry residue ≤1000 mg/dm³, total hardness ≤20 mcg-eq/dm³.
- Pollutant Control: Petroleum products ≤0.5 mg/L (for 9.0 MPa boilers), iron ≤0.3 mg/dm³, ammonia ≤0.2 mg/dm³.
- Boiler Compatibility: pH 8.5-10.5 (25℃), dissolved oxygen ≤30 μg/L, silica (SiO₂) ≤10.0 mg/dm³.
- Compliance: Meets GB/T1576-2018 “Industrial Boiler Water Quality” and steam generator operating standards (pressures up to 9.0 MPa).
2.3 Project Scale and Operation Requirements
- Treatment Capacity: Inlet flow 60 m³/h, produced water flow 16 m³/h (recovery rate ~27%).
- Automation Level: Fully automatic control (PLC+touchscreen) with manual backup; 24/7 continuous operation.
- Durability: Corrosion-resistant materials (304 stainless steel, FRP, UPVC) to withstand harsh oilfield wastewater conditions.
- Safety Features: Overload protection, pressure monitoring, and interlock systems for boiler safety.
- Installation and Cycle: Equipment construction period 50 days; design service life ≥10 years.
3. Hella Water Customized Solutions
3.1 System Model and Core Configuration
Hella Water provides the HLOWW-60T Oilfield Wastewater Treatment System, integrating multi-stage pretreatment, ultrafiltration (UF), and two-stage reverse osmosis (RO) for deep purification. The detailed configuration is as follows:
| No. | Part Name | Description |
|---|---|---|
| 1 | Pretreatment System | Stacked screw filter press + dissolved air flotation machine + flocculation sedimentation tank + quartz sand&activated carbon filter tanks (2 sets) |
| 2 | Dosing System | PAM&PAC dosing device (2000L PE barrels, 150L/h metering pumps); scale inhibitor and reducing agent dosing for RO protection |
| 3 | Ultrafiltration (UF) System | 50 m³/h capacity, 18 PVDF UF membranes (Ф225), precision filter (40″ 36 core), PLC control |
| 4 | First-Stage RO System | 20 m³/h high-desalination RO, 36 SW8040HR-400 membrane elements, 2205 material high-pressure pump (30+55 kW) |
| 5 | Second-Stage RO System | 16 m³/h secondary RO, 15 composite polyamide membrane elements, 304 stainless steel high-pressure pump (11 kW) |
| 6 | Cleaning System | CIP cleaning system (2000L PE tank for UF/RO; 500L PE tank for secondary RO), cleaning pumps |
| 7 | Control System | Siemens PLC + touchscreen, automatic/manual integration, explosion-proof control cabinets |
| 8 | Auxiliary Equipment | Heater, water sampling/testing platform, pressure gauges, flow meters, conductivity/ORP meters |
For more details on ultrafiltration systems, visit [ultrafiltration].
3.2 Key Technical Parameters of HLOWW-60T
| Parameter | Specification |
|---|---|
| Inlet Flow Rate | 60 m³/h |
| Produced Water Flow Rate | 16 m³/h |
| Operating Temperature | 5℃～45℃ |
| UF Membrane Type | PVDF, Ф225, 18 pieces |
| RO Desalination Rate | ≥98% (first stage), ≥99% (two-stage) |
| Total Installed Power | ~120 kW (including pumps, stirrers, controls) |
| Power Supply | 380V/50Hz, 3-phase |
| Equipment Construction Period | 50 days |
| Design Service Life | ≥10 years |
3.3 Process Design
3.3.1 Pretreatment Process
- Stacked Screw Filter Press: Removes sludge and large suspended solids; sludge moisture content 78-83%, processing capacity 3.5-5.0 m³/h.
- Dissolved Air Flotation Machine: Removes petroleum products and colloids; 60 m³/h capacity, equipped with PAC/PAM dosing for flocculation.
- Flocculation Sedimentation Tank: Further removes suspended solids and heavy metals via inclined tube packing and coagulation stirring.
- Quartz Sand&Activated Carbon Filters: 4 filter tanks (Φ2.4×4.5m) for removing fine particles, residual organics, and odors; quartz sand (10 tons) and activated carbon (3.2 tons) as filter media. For pre-treatment systems, see [pre treatment filtration system].
3.3.2 Core Purification Process
- Ultrafiltration (UF): 50 m³/h UF system with PVDF membranes (0.01μm accuracy) removes bacteria, colloids, and residual suspended solids, ensuring RO inlet SDI ≤1.
- First-Stage RO: High-desalination RO removes 98% of salts (chlorides, sulfates) and organic matter; 36 SW8040HR-400 membranes in 6 FRP pressure vessels.
- Second-Stage RO: Deep purification to meet boiler water standards; 15 membrane elements, producing 16 m³/h qualified water. For reverse osmosis systems, visit [reverse osmosis].
3.3.3 Dosing and Control
- Pretreatment Dosing: PAC (coagulant) and PAM (flocculant) for efficient solid-liquid separation.
- RO Dosing: Scale inhibitor (NSF-certified) and reducing agent to prevent membrane scaling and oxidation. For chemical dosing systems, see [chemical dosing system].
- Automatic Control: PLC system monitors pressure, flow, and water quality; automatic backwashing for UF/RO membranes and CIP cleaning for fouling control.
4. Project Effect Verification
4.1 Produced Water Quality Test Results
After treatment by the HLOWW-60T system, the produced water meets boiler feed water requirements, with key indicators as follows:
| Parameter | Raw Water Value | Produced Water Value | Unit |
|---|---|---|---|
| Turbidity | 74.5 | ≤2.6 | NTU |
| Petroleum Products | 55 | ≤0.5 | mg/L |
| Chlorides | 20160 | ≤350 | mg/dm³ |
| Sulfates | 1003 | ≤500 | mg/dm³ |
| Dry Residue | 32344 | ≤1000 | mg/dm³ |
| Total Iron | 1.87 | ≤0.3 | mg/dm³ |
| Total Hardness | – | ≤20 | mcg-eq/dm³ |
| pH (25℃) | – | 8.5-10.5 | pH |
| Dissolved Oxygen | – | ≤30 | μg/L |
| Silica (SiO₂) | – | ≤10.0 | mg/dm³ |
4.2 System Operation Performance
- Stability: Continuous 72-hour operation test shows produced water quality fluctuation ≤±3%, no membrane fouling or system downtime.
- Pollutant Removal Efficiency: Petroleum products removal rate ≥99%, suspended solids removal rate ≥99%, salt removal rate ≥98%.
- Energy Efficiency: Variable frequency pumps reduce energy consumption; total operating power ~100 kW during stable operation.
- Corrosion Resistance: All wastewater-contacting components show no corrosion after 6-month operation, meeting design durability requirements.
- Compliance: Passes GB/T1576-2018 and TSG 11-2020 inspections, qualified for use in 9.0 MPa steam generators.
4.3 Industry Application and Certifications
- Case Validation: Successfully deployed in oilfield boiler water supply projects, with boiler operational efficiency improved by 15% and maintenance costs reduced by 20%.
- Standards Compliance: Complies with GB 50273-2022 “Boiler Installation Construction and Acceptance Standards” and NB/T47034-2021 “Industrial Boiler Technical Requirements”. For industrial water filtration solutions, visit [industrial water filtration].
5. Case Corresponding Product Quotation Description
5.1 Main Equipment Quotation (Estimated)
| Item | Model | Qty | Unit Price (USD) | Total Price (USD) | Description |
|---|---|---|---|---|---|
| Stacked Screw Filter Press | HLFP-301 | 1 | 18,500 | 18,500 | 304 stainless steel, sludge moisture 78-83%, 1.65 kW power |
| 60m³/h Dissolved Air Flotation Machine | – | 1 | 22,800 | 22,800 | FRP body, PAC/PAM dosing device included |
| Flocculation Sedimentation Tank | – | 1 | 15,200 | 15,200 | Carbon steel anti-corrosion, inclined tube packing |
| 60m³/h Quartz Sand&Activated Carbon Filters | – | 2 | 16,300 | 32,600 | 4 filter tanks total, quartz sand + activated carbon media |
| 50m³/h UF System | – | 1 | 38,900 | 38,900 | 18 PVDF membranes, PLC control, precision filter |
| 20m³/h First-Stage RO System | – | 1 | 45,700 | 45,700 | 36 SW8040HR-400 membranes, 2205 high-pressure pump |
| 16m³/h Second-Stage RO System | – | 1 | 32,400 | 32,400 | 15 composite membranes, 304 high-pressure pump |
| Auxiliary Equipment & Controls | – | 1 | 18,900 | 18,900 | Heater, sampling platform, PLC touchscreen, explosion-proof cabinets |
| Total Estimated Price | – | – | – | 225,000 | EXW price, excluding installation and transportation |
5.2 Payment Terms & Logistics
| Term Type | Details |
|---|---|
| Payment Term | T/T (Telegraphic Transfer): 40% deposit for production, 60% balance paid before shipment |
| Lead Time | 50 days from receipt of deposit |
| Packaging | International transportation standard packaging (anti-corrosion, anti-collision) |
| Warranty | 12 months from delivery; free repair/replacement for non-human-induced failures |
| Installation & Training | On-site installation and training available at additional cost; free online technical support |
5.3 Consumables Price List (Annual Estimate)
| Consumable Name | Specification | Unit Price (USD/kg) | Annual Consumption | Annual Cost (USD) |
|---|---|---|---|---|
| PAC (Coagulant) | Food-grade | 0.85 | 5,000 kg | 4,250 |
| PAM (Flocculant) | Anionic | 3.20 | 800 kg | 2,560 |
| Scale Inhibitor | RO-specific (NSF-certified) | 4.10 | 1,200 kg | 4,920 |
| UF Membranes | Φ225 PVDF | 850/piece | 6 pieces | 5,100 |
| RO Membranes | SW8040HR-400 | 1,200/piece | 12 pieces | 14,400 |
| Annual Consumables Cost | – | – | – | 31,230 |
6. Common Questions (FAQ)
6.1 Maintenance and Consumables
Q1: What is the replacement cycle for key membranes and media?A1: UF membranes (3-4 years), RO membranes (2-3 years), quartz sand (2-3 years), and activated carbon (1-2 years). Consumables like PAC/PAM are replenished monthly based on usage. For replacement parts, visit [accessory supporting equipment].
Q2: How often is chemical cleaning required for UF/RO systems?A2: UF systems: monthly low-pressure flushing, quarterly chemical cleaning; RO systems: bi-annual chemical cleaning (acid for inorganic fouling, alkaline for organic fouling).
6.2 Warranty and After-Sales Service
Q1: What is covered under the 12-month warranty?A1: The warranty includes manufacturing defects in equipment (pumps, filters, membranes, control system). Consumables (chemicals, filter media) and human-induced damages are excluded. Free online technical support is provided for life.
Q2: How to handle system abnormalities (e.g., low water output, high conductivity)?A2: The PLC system triggers alarms for abnormalities. Contact technical support for remote troubleshooting; on-site service is available for complex issues (customer bears travel costs).
6.3 Installation and Operation
Q1: What preparations are required before installation?A1: The customer needs to prepare a flat installation site (≥200㎡), stable power supply (380V/50Hz 3-phase), and wastewater inlet/discharge pipelines. Civil engineering (e.g., sludge pond) is required for sludge disposal.
Q2: Can the system adapt to fluctuations in raw water quality?A2: Yes. The adaptive dosing system and variable frequency pumps adjust operating parameters in real-time to handle raw water quality fluctuations (e.g., turbidity, petroleum content spikes).
6.4 System Performance
Q1: What is the system’s recovery rate, and can it be improved?A1: The current recovery rate is ~27% (16m³/h produced from 60m³/h inlet). It can be increased to 35-40% with additional RO stages, but this may increase scaling risks and require more frequent cleaning.
Q2: Is the system explosion-proof for oilfield environments?A2: Yes. Key components (pumps, control cabinets) are explosion-proof certified, complying with oilfield safety regulations for hazardous areas.
Would you like me to help you create a detailed maintenance schedule for this system, including weekly/monthly/annual maintenance tasks, troubleshooting flowcharts, and consumable replacement guides?
English 
Chinese 
German 
Russian 
Japanese 
French 
Dutch 
Italian 