Field-Proven Separation & Desalination Packages
Pre-commissioned, modular process packages designed for offshore oilfields, tight gas fracturing flowback, refinery effluents, and semiconductor-grade requirements.
Global Procurement Demand for Produced Water Treatment Packages
Exploration and production (E&P) operators, floating production storage and offloading (FPSO) builders, and Tier-1 EPC contractors require certified, modular produced water treatment packages that resolve tight footprint limits, extreme salinity swings, and aggressive reinjection standards.
Rigid Environmental Reinjection Standard
Global environmental mandates—such as the OSPAR Convention for North Sea offshore discharge (<30 mg/L dispersed oil, often targeted at <10 mg/L) and deep-well subterranean disposal protocols in Central Asia—dictate uncompromising particulate and hydrocarbon removal. Produced water containing emulsified crude and polyacrylamide friction reducers requires primary coalescing, advanced induced gas flotation (IGF), and ultra-tight tubular ceramic microfiltration.
Offshore Space & Weight Constraints
FPSO decks and fixed offshore platforms operate under severe deck-load restrictions and volatile pitching motions. Procurement engineers favor CE certified packaged skids engineered with dual-inlet cyclones and high-pressure disc-tube reverse osmosis (DTRO) modules. These deliver high volumetric mass transfer in 40% less footprint than traditional API gravity separators, while resisting heavy swell and motion vibrations.
CAPEX-to-OPEX Lifecycle Optimization
Treating high-TDS flowback water (>150,000 mg/L TDS) presents severe risks of barium sulfate (BaSO₄) scaling, strontium scaling, and high-temperature fouling. Packaging plants with automated variable-frequency high-pressure pumps, ceramic anti-fouling barriers, and energy recovery devices reduces power draw from 11 kWh/m³ down to <6.8 kWh/m³, yielding millions in OPEX savings over standard evaporation lines.
Macro Industry Solutions: Multistage Treatment Integration
Tongjie packages are structured as an integrated multi-barrier treatment train designed to handle fluctuating oil content, high solids, and extreme salt loads from oil & gas reservoirs worldwide.
| Treatment Stage | Core Process Technology | Target Pollutant Removal | Operational Efficiency | Effluent Parameter Quality |
|---|---|---|---|---|
| Primary Separation | Hydrocyclone De-oiler + Corrugated Plate Interceptor (CPI) | Free oil, heavy hydrocarbons, coarse sands | Oil removal: 85% - 92% | Oil content < 100 mg/L |
| Secondary De-emulsification | Induced Gas Flotation (IGF) & Walnut Shell Filters | Dispersed oil droplets (5–20 μm), suspended solids | Turbidity reduction > 95% | Oil ≤ 10 mg/L, TSS ≤ 5 mg/L |
| Tertiary Conditioning | Tubular Ceramic Membrane / Ultrafiltration (UF) | Colloidal silica, heavy metals, sub-micron solids | SDI₁₅ < 2.5 consistently | Oil ≤ 2 mg/L, TSS ≤ 1 mg/L |
| Salinity Concentration | Disc Tube Reverse Osmosis (DTRO) & STRO Systems | Dissolved salt ions (Na⁺, Cl⁻, SO₄²⁻), TDS | Concentration up to 160,000 mg/L TDS | Permeate TDS < 500 mg/L (Reinjection / Reuse) |
| ZLD Solidification | MVR Mechanical Vapor Recompression + Crystallizer | Concentrated brine, crystallization into salts | 98.5% Total Water Recovery | Dry solid cake for certified disposal |
Water Assay Analysis
Detailed evaluation of raw water TDS, oil droplet size, Ba/Sr scaling indexes, and ambient H₂S levels.
Process Simulation
RO projection simulation, P&ID generation, 3D structural skid finite-element stress modeling.
Factory FAT Testing
100% full-flow wet testing at our Jiading, Shanghai factory with pressure envelope hydrotests.
Skid Modularization
Standard container or heavy offshore structural skid delivery with marine epoxy coating (C5-M).
Plug & Play Startup
Rapid site connection, automated SCADA calibration, and operational handover within ~15 days.
Technical Roadmap & Next-Gen Technology Horizons
How Shanghai Tongjie combines materials science, artificial intelligence, and extreme thermodynamic design to pioneer the next decade of zero liquid discharge (ZLD) in hydrocarbon processing.
AI-Enabled Adaptive SCADA & Digital Twin
Traditional water packages suffer from delayed operator reactions to rapid raw water fluctuations. Tongjie's next-gen packages deploy edge computing neural networks that monitor inline UV-vis spectrometers and ultrasonic salinity sensors in real time. The package automatically modulates anti-scalant dosing rates, optimizes DTRO operating pressures, and initiates CIP cycles dynamically before irreversible fouling occurs.
Silicon Carbide (SiC) Ceramic Membranes
Polymeric membranes degrade rapidly when exposed to hydrocarbons above 100 mg/L or aromatic solvents such as benzene, toluene, and xylene (BTEX). Our advanced packages incorporate inorganic Silicon Carbide (SiC) flat-sheet and tubular membranes capable of operating across pH 0–14 at temperatures reaching 120°C. SiC channels feature extreme hydrophilicity, repelling free oil and yielding steady flux rates >500 LMH.
Osmosis-Assisted Reverse Osmosis (OARO)
Standard reverse osmosis is thermodynamically bounded by hydraulic pressure limits (typically 120 bar). By pairing Disc Tube membranes with Osmosis-Assisted RO (OARO), our systems dilute the draw salinity step-by-step, allowing brine concentration up to 240,000 mg/L TDS before thermal evaporation. This reduces the thermal evaporative load by up to 60%, drastically slashing steam utility consumption.
Global Commercial Landscapes & Regional Field Realities
Different oil provinces operate under vastly distinct geology, climate, and compliance regimes. Shanghai Tongjie delivers custom-tailored metallurgy, controls, and enclosures built for the world’s most demanding energy corridors.
Middle East (GCC)
Conditions: Desert ambient temps up to 55°C, high H₂S presence (sour gas fields), extreme seawater and formation water TDS (>180,000 mg/L).
Package Customization: Severe corrosive environments require Super Duplex 2507 piping, NACE MR0175 compliant valves, explosion-proof HVAC systems, and sand-trap louvers to withstand heavy desert sandstorms.
North American Shale
Conditions: Permian, Bakken, and Marcellus shale basins with rapid multi-well pad shifts and high fracturing flowback rates containing viscous gels and heavy boron.
Package Customization: Skid-mounted, heavy-duty trailer packages designed for DOT road transport, fast flanged hookups, automated boron-chelating resin units, and rapid winterization thermal tracing.
Central Asia (Caspian)
Conditions: Sub-zero winter extremes down to -40°C in Kazakhstan and Turkmenistan, requiring unyielding frost protection and remote unmanned operations.
Package Customization: Polyurethane-insulated sea containers with internal space heaters, fire & gas suppression packages, satellite telemetry SCADA links, and high-efficiency pre-heaters.
Southeast Asia Offshore
Conditions: Tropical maritime humidity, continuous wave motion, and highly dispersed light crude fractions.
Package Customization: Compact three-phase separation skids, DNV 2.7-1 certified lifting frames, 316L stainless skid framing, and multi-angle weir skimming systems resistant to pitch and roll.
CE Certification Directives & International Code Compliance
Shipping equipment into Europe or multinational energy joint ventures demands total conformity to harmonized statutory standards. Tongjie guarantees complete regulatory dossier delivery with third-party verified inspections.
CE Machinery Directive (2006/42/EC)
Full risk assessments under EN ISO 12100 ensure operator safety across high-pressure rotating pumps, automated actuated valving, and high-voltage motor control centers (MCC). Certified dual-channel emergency stop circuits (SIL 2 / PL d compliant) and ergonomic maintenance clearances are engineered into every skid.
Pressure Equipment Directive (PED 2014/68/EU)
Produced water packages operate at hydraulic pressures up to 120 bar. Tongjie designs pressure vessels, DTRO membrane housings, and manifold headers conforming strictly to Module H/H1 certified design verification, EN 13445 or ASME Section VIII Div 1 standards, backed by 100% X-ray weld inspection and hydrostatic testing.
ATEX / IECEx Explosion Proofing (2014/34/EU)
Because produced water releases dissolved flammable hydrocarbons and volatile organic compounds (VOCs), our packages are fully certified for Zone 1 or Zone 2 hazardous areas. All instruments, transmitters, level switches, motors, and local junction boxes carry Ex d, Ex e, or Ex ia intrinsically safe certification.
Engineered & Fabricated by Shanghai Tongjie
Headquartered at No. 1980 Waiqian Highway, Jiading District, Shanghai, Tongjie has specialized in precision membrane manufacturing and complex separation contracting since 2010.
Integrated Contracting Power
Tongjie holds Class II contracting qualifications in environmental protection engineering and mechanical/electrical installation. Our clients work directly with the manufacturing facility—from computational fluid dynamics (CFD) modeling to structural skid assembly—eliminating contractor markups and engineering disconnects.
Certified Quality Ecosystem
We operate full ISO 9001 (Quality), ISO 14001 (Environmental Management), and ISO 45001 (Occupational Health & Safety) workflows. Over 38 invention and utility patents protect our proprietary high-recovery membrane arrangements, chemical CIP auto-dosing systems, and heavy-duty gas flotation nozzles.
Rapid 15-Day Commissioning
By pre-piping, pre-wiring, and performing complete Factory Acceptance Testing (FAT) with simulated feed water in our Shanghai testing bay, on-site commissioning typically takes just ~15 days. Systems ship in standard ISO container dimensions ready for quick plug-in operation worldwide.
Engineers & Procurement FAQ
Detailed technical answers addressing feed characterization, membrane longevity, hazardous area zoning, and turnkey logistics.
1. What parameters are required to calculate package dimensions and membrane flux?
To deliver an accurate mass balance and proposal, we require: raw water TDS, oil & grease (O&G) concentration, free vs. emulsified oil ratio, total suspended solids (TSS), turbidity/SDI, particle size distribution, temperature range, presence of H₂S/CO₂, calcium/magnesium/barium/strontium concentrations, daily capacity (m³/day or BPD), and target effluent limits (e.g. reinjection ≤5 mg/L oil, ≤1 mg/L TSS).
2. How does the package prevent organic and biological membrane fouling from high oil loads?
Our packages deploy a progressive 3-tier barrier. First, hydrocyclones and induced gas flotation remove 95%+ of free and dispersed oil. Next, hydrophilic ceramic ultrafiltration removes all residual droplets down to <2 mg/L. Finally, open-channel Disc Tube Reverse Osmosis (DTRO) modules—equipped with patented octagonal flow deflectors—generate high hydraulic turbulence that prevents cake-layer deposition on membrane surfaces.
3. Can the package be certified for ATEX Zone 1 and Zone 2 hazardous operating environments?
Yes. Every produced water skid can be supplied with complete CE ATEX / IECEx conformity for Zone 1 (flammable gases present under normal operations) or Zone 2. This includes flameproof Ex d high-pressure pump motors, pressurized Ex p local control consoles with air purge, intrinsically safe Ex ia transmitters, anti-static grounding continuity, and non-sparking fan assemblies.
4. What makes DTRO membranes superior to standard spiral-wound membranes for produced water?
Standard spiral-wound elements utilize narrow feed mesh spacers (28–34 mil) that trap suspended solids and oil emulsions, leading to rapid irrecoverable fouling and high differential pressures within days. DTRO utilizes open, unrestricted flow channels where water passes across flat membrane cushions without mesh obstruction. DTRO can handle feed SDI > 15 and oil up to 10 mg/L with simple chemical CIP restoring 100% flux.
5. What is the typical lead time, delivery format, and site installation scope?
Standard packages deliver within 10 to 14 weeks from drawing freeze. All equipment is factory pre-assembled inside 20-foot or 40-foot heavy-duty container enclosures or structural skids. Upon arrival at site, operators need only complete main raw water inlet, permeate outlet, concentrated brine outlet, drain, and electrical power cable connections. Our factory engineers provide on-site or remote tele-commissioning within ~15 days.
Industrial Demineralized, ZLD & High-Salinity Packages
OEM & ODM membrane packages engineered for high-recovery industrial recycling, Zero Liquid Discharge (ZLD), and ultrapure process water.
Request a Custom Produced Water Package Simulation
Submit your reservoir water chemistry assay and platform footprint limitations. Our engineering team at Shanghai Tongjie will perform membrane projection modeling, energy balance calculations, and generate preliminary P&ID proposals within 48 business hours.