Portable water treatment system and apparatus
A portable water treatment system and apparatus is disclosed that can effectively and efficiently treat aqueous fluids by quickly and reliably adjusting and controlling the free residual level of disinfectants, contaminants or additives through the addition of one or more treating agents such as oxidizing chemicals and/or other special-purpose additives, and that can continuously store, log, retrieve and report the related fluid composition data and other operating parameters on a real-time basis at either the use site or a remote location. A preferred use for the subject system and apparatus is managing the chemistry of disinfectant, contaminant and/or additive levels in aqueous fluids used in hydraulic fracturing operations, and controlling the free residual levels of the disinfectant or contaminants within the fluids, including fluids maintained in frac tanks during temporary cessation of a hydraulic fracturing operation.
1. A portable frac water treatment and management system for in-line use downstream of a frac water supply and upstream of a plurality of frac tanks disposed at a well site, the system comprising:
at least one programmable controller;
at least one primary fluid flow line having at least one inlet end and at least one outlet end, the at least one inlet end having a first coupling device attachable in fluid communication with the frac water supply to receive a pressurized flow of aqueous fluid into the system, and the at least one outlet end having a second coupling device attachable in fluid communication with the plurality of frac tanks;
a first sensor disposed downstream of the at least one inlet end that monitors and communicates on a continuous, real-time basis to the at least one programmable controller a first parameter corresponding to a flow rate of the pressurized flow of aqueous fluid through the at least one fluid flow line;
a second sensor disposed downstream of the at least one inlet end that monitors and communicates on a continuous, real-time basis to the at least one programmable controller a second parameter corresponding to an initial concentration of chlorine dioxide in the pressurized flow of aqueous fluid;
at least one sidestream disposed downstream of the first and second sensors, which at least one sidestream diverts a portion of the pressurized flow of aqueous fluid for treatment with chlorine dioxide;
a chlorine dioxide generator disposed in fluid communication with an at least one sidestream, which chlorine dioxide generator generates a chlorine dioxide solution having a second concentration of chlorine dioxide that is regulated by the at least one programmable controller;
an eductor disposed in fluid communication with the chlorine dioxide generator and with the at least one sidestream, through which eductor chlorine dioxide solution is drawn into the at least one sidestream, thereby utilizing the pressurized flow of aqueous fluid as a motive force for introducing and mixing the chlorine dioxide solution into the at least one sidestream to produce a treated aqueous fluid having a chlorine dioxide concentration higher than the initial concentration of chlorine dioxide in the pressurized flow of aqueous fluid upstream of the at least one sidestream;
a third sensor disposed in the at least one sidestream at a location downstream of the eductor, which third sensor monitors and communicates on a continuous, real-time basis to the at least one programmable controller the concentration of chlorine dioxide in the treated aqueous fluid in the at least one sidestream at a location downstream of the eductor;
a plurality of treated aqueous fluid flow lines disposed downstream of the third sensor through which flow is selectively controllable by the at least one programmable controller to direct treated aqueous fluid directly to the frac tanks or back into the pressurized flow of aqueous fluid from which the at least one sidestream was diverted;
at least one recirculation flow line configured to recirculate the treated aqueous fluid from any of the plurality of frac tanks and introduce the treated aqueous fluid through a fourth sensor and into the pressurized flow of aqueous fluid at a point upstream of the at least one sidestream; and
at least one motor vehicle or towable carrier unit within which the at least one programmable controller, first sensor, second sensor, at least one sidestream, chlorine dioxide generator, eductor and third and fourth sensors are self-contained for transport to the well site.
2. The portable frac water treatment and management system of claim 1 , further comprising a manifold providing selective fluid communication between the chlorine dioxide generator and the plurality of frac tanks.
3. The portable frac water treatment and management system of claim 1 wherein the chlorine dioxide generator comprises an in-line chemical reactor that produces at least part of the chlorine dioxide solution.
4. The portable frac water treatment and management system of claim 3 , comprising a purge system for the chemical reactor.
5. The portable frac water treatment and management system of claim 4 wherein the purge system comprises a neutralizing agent injectable into the chemical reactor.
6. The portable frac water treatment and management system of claim 1 wherein the at least one programmable controller comprises at least one on-site controller and at least one remotely located programmable controller.
7. The portable frac water treatment and management system of claim 1 wherein the pressurized flow of aqueous fluid comprises frac pond water associated with an oil or gas well.
8. The portable frac water treatment and management system of claim 1 wherein the pressurized flow of aqueous fluid comprises produced water from an oil or gas well.
9. The portable frac water treatment and management system of claim 1 wherein the pressurized flow of aqueous fluid is divided into a plurality of flow paths upstream of the at least one sidestream comprising an eductor.
10. The portable frac water treatment and management system of claim 1 wherein the at least one primary fluid flow line is looped or coiled within the at least one motor vehicle or towable carrier unit.
11. The portable frac water treatment and management system of claim 1 wherein the at least one recirculation flow line and the at least one programmable controller have the capability to selectively recirculate the treated aqueous fluid either continuously or intermittently from at least one of the plurality of frac tanks to the at least one primary fluid flow line at a point upstream of the at least one sidestream comprising an eductor for introducing chlorine dioxide solution.
12. The portable frac water treatment and management system of claim 1 wherein the at least one recirculation flow line and the at least one programmable controller have the capability to selectively recirculate the treated aqueous fluid either independently from at least one of the plurality of frac tanks or by consolidation from the plurality of frac tanks into a single return header to at least one primary fluid flow line at a point upstream of the at least one sidestream comprising an eductor for introducing chlorine dioxide solution.
13. The portable frac water treatment and management system of claim 1 wherein the treated aqueous fluid has a free residual level of chlorine dioxide that is between about 0.25 ppm and about 5.0 ppm.
14. The portable frac water treatment and management system of claim 1 wherein the at least one programmable controller has the capability to log and store physical and compositional parameters of the treated aqueous fluid on a continuous, real-time basis.
15. The portable frac water treatment and management system of claim 14 wherein the at least one programmable controller selectively reports the stored physical and compositional parameters.