Optimization of physico-chemical and membrane filtration processes to remove high molecular weight polymers from produced water in enhanced oil recovery operations.

Abstract Polymer flooding is an enhanced oil recovery technique to extract the large portion of leftover subsurface oil following conventional extraction methods. In the flooding process, a long-chain polymer, such as partially hydrolyzed polyacrylamide (HPAM), is added to the displacing fluid to increase the mobility and extraction of the oil phase. Nevertheless, the challenge of managing produced water from polymer flooding operations is high because residual HPAM results in significantly high viscosity and organic content in the stream. Commonly used methods for produced water treatment, such as gravity settling and flotation, cannot be applied to obtain a purified stream efficiently, while innovative techniques are not yet feasible in practical operations. In this work, a simple method of polymer precipitation prompted by divalent ions is evaluated, optimized, and compared to membrane ultrafiltration. The physico-chemical properties of the HPAM are investigated and polymer precipitation tests are conducted by varying the main operational parameters, including pH, salinity, temperature, calcium and/or magnesium concentration, and polymer concentration. Response surface developed by central composite design method is used to optimize the process and identify the correct dosage of divalent cations coagulants and pH, the two main factors promoting HPAM separation. The removal of HPAM is well-described and maximized (>85%) by the model, which is also validated on three synthetic samples representing real wastewaters from polymer flooding applications. Optimized ultrafiltration, using ceramic membranes with surface pore size of 15 kDa, also shows the ability to remove HPAM effectively from water, but the precipitation method seems to be more versatile and easier to apply. The two processes, precipitation and ultrafiltration, may potentially be used in sequence as they complement each other in several ways.