Integrated Produced Water & High-Salinity Process Portfolio
Heavy-duty, containerized water recovery plants and precision-fabricated OEM/ODM treatment systems engineered for flowback purification, severe salinity reduction, and environmental compliance.
The Paradigm Shift in Oil & Gas Produced Water Remediation
Transitioning from Conventional Disposal to Closed-Loop Resource Valorization, Zero Liquid Discharge (ZLD), and Intelligent Skid Automation.
Produced water represents the single largest volume byproduct stream generated during upstream hydrocarbon exploitation. In mature conventional reservoirs, water-to-oil ratios (WOR) frequently exceed 10:1, while unconventional shale operations yield intensive hydraulic fracturing flowback fluids characterized by extreme dynamic swings in Total Dissolved Solids (TDS from 15,000 to beyond 220,000 mg/L), recalcitrant hydrocarbons, polycyclic aromatic compounds, scale-forming cations (Ca²⁺, Mg²⁺, Ba²⁺, Sr²⁺), and naturally occurring radioactive materials (NORM).
Historically, exploration and production (E&P) operators relied heavily on deep disposal wells (Class II SWD). However, severe regulatory constraints, aquifer protection laws, seismic activity tied to sub-surface injection, and water scarcity in prime basins (such as the Permian, Tarim, Ordos, and Middle Eastern arid tracts) have elevated produced water treatment from a peripheral operational headache into a mission-critical enterprise requirement. Modern engineering demands re-injection quality assurance (Oil ≤ 5 mg/L, Suspended Solids ≤ 1 mg/L), continuous fracturing fluid reuse, or complete desalinated fresh water reclamation for regional agriculture and process utilities.
"As an engineering-driven enterprise founded in 2010, Shanghai Tongjie Environmental Protection Technology Co., Ltd. has bridged the gap between academic membrane thermodynamics and rugged oilfield fabrication. With Class II Contracting Qualifications in Environmental Protection and M&E Installation, over 38 patents, and CE/ISO certified manufacturing, our containerized DTRO and ZLD trains transform volatile produced effluent into certified technical assets."
Why Tier-1 Operators Source ODM Water Skids from Chinese Factories
Strategic supply chain consolidation, metallurgical precision, and certified modular fabrication deliver unmatched lifecycle value.
Corrosion-Resistant Metallurgy
Oilfield brines contain aggressive chlorides and dissolved H₂S/CO₂. Our Shanghai manufacturing complex integrates in-house precision welding for Super Duplex Stainless Steel (2507 / 2205), Hastelloy C-276, Titanium Grade 2, and specialized PVDF/PTFE lined fluid circuits, ensuring compliance with ASME Section VIII and NACE MR0175 standards.
Full-Train Factory Acceptance Testing
Every skid-mounted produced water unit undergoes stringent wet Factory Acceptance Testing (FAT) in Shanghai before shipping. P&ID verification, automated pressure proofing up to 160 bar for high-pressure DTRO circuits, hydrostatic testing, and full loop SCADA/PLC simulation eliminate field commissioning delays in remote desert or offshore locations.
End-to-End Vertical ODM Integration
By controlling process modeling (mass balance calculations, membrane flux simulations), mechanical structural CAD, electrical panel assembly (Siemens, Allen-Bradley, Schneider), and membrane housing fabrication under one roof, we reduce CAPEX by 30-45% compared to Western integrators while maintaining superior lead-time agility.
Comprehensive 4-Stage Oilfield Water Treatment Architecture
A rigorous, multi-barrier process train designed to manage high suspended solids, free & emulsified hydrocarbons, scaling minerals, and high osmotic pressures.
Primary De-Oiling & Separation
- API / Corrugated Plate Interceptors (CPI)
- Induced Gas Flotation (IGF) & DGF units
- Walnut shell & coalescing media filtration
- Removes free oil down to <20 ppm
- Protects downstream membrane elements
Chemical Softening & Clarification
- High-density reaction clarifier systems
- Stoichiometric dosing of NaOH, Na₂CO₃, PAC
- Targeted precipitation of Ca²⁺, Mg²⁺, Ba²⁺, Sr²⁺
- Tubular microfiltration (TMF) or ceramic UF
- Total Hardness reduced to <50 mg/L as CaCO₃
High-Pressure Membrane Concentration
- Disc Tube Reverse Osmosis (DTRO) modules
- Open-channel geometry resistant to scaling
- Operating pressure range: 75 bar to 160 bar
- TDS concentration from 30,000 up to 160,000 mg/L
- Permeate recovery rates between 65% and 85%
Thermal Evaporation & ZLD
- Mechanical Vapor Recompression (MVR)
- Forced circulation flash crystallizers
- Titanium Gr. 2 / Hastelloy heat exchangers
- Pure distillate recovery for boiler feed / reuse
- Solid salt cake output (NaCl/Na₂SO₄ disposal)
| Process Parameter | Raw Produced Water / Flowback | Post De-Oiling & Softening | DTRO Permeate Output | Final ZLD Thermal Stage |
|---|---|---|---|---|
| Total Hydrocarbons (TPH) | 200 – 5,000 mg/L | < 5 mg/L (Reinjection Spec) | Non-Detectable (<0.1 mg/L) | Zero (Destroyed / Separated) |
| Suspended Solids (TSS) | 150 – 1,200 mg/L | < 1 mg/L (Millipore 0.45μm) | 0 mg/L | Solid Salt Cake (Dry Basis) |
| Total Dissolved Solids (TDS) | 25,000 – 180,000 mg/L | 24,000 – 175,000 mg/L | < 500 mg/L (Freshwater Quality) | Condensed Pure Distillate <50 mg/L |
| Barium (Ba²⁺) & Strontium (Sr²⁺) | 50 – 850 mg/L | < 0.5 mg/L | < 0.01 mg/L | Mineralized Crystal Matrix |
| Chemical Oxygen Demand (COD) | 1,500 – 12,000 mg/L | 400 – 1,800 mg/L | < 30 mg/L | Condensate Polished <10 mg/L |
Engineered Solutions for Severe Field Conditions
Field-proven performance across extreme ambient temperatures, variable inlet water chemistries, and stringent environmental discharge jurisdictions.
Shale Gas Fracturing Flowback
Unconventional hydraulic fracturing requires massive water volumes within tight completion windows. Our containerized, mobile reuse units feature dual-train coagulation and high-rate media filtration to recover flowback for immediate slickwater re-fracking.
Desert & Ultra-Arid Operations
Operating in ambient temperatures ranging from -30°C to +55°C. Features automated HVAC container thermal control, sand-storm filtration louvers, remote satellite SCADA telemetry, and unmanned self-cleaning cycles for remote deployment.
Heavy Oil SAGD & Steam Flood
Thermal produced water contains high concentrations of reactive silica (SiO₂ > 400 mg/L) and dissolved organic acids. Tongjie's warm softening coupled with high-flux ceramic membranes delivers boiler feed water without silica scaling.
Emerging Trends Reshaping Oil & Gas Water Stewardship
Technological convergence is transforming wastewater treatment from a cost-sink into an automated, carbon-conscious resource generator.
Inorganic Ceramic Membranes
Silicon carbide (SiC) and alumina ceramic membranes are replacing polymeric membranes in high-temperature, oily environments due to solvent resilience, ozone tolerance, and long operating life.
Electrochemical Catalytic Oxidation
Non-thermal destruction of recalcitrant water-soluble organics, phenols, and naphthenic acids via Boron-Doped Diamond (BDD) anodes, dramatically lowering downstream thermal fouling.
AI-Powered Autonomous Dosing
Edge IoT sensors monitor streaming TDS, zeta potential, and turbidity, while predictive algorithms adjust coagulant and scale-inhibitor dosing in real time to cut chemical OPEX by up to 28%.
Valuable Mineral Extraction
Mining high-salinity brines for critical raw materials—particularly high-purity lithium carbonate (Li₂CO₃), bromine, and industrial-grade sodium chloride—is turning ZLD units into revenue engines.
Engineering Specifications for Global EPC Contractors & Operators
Essential validation criteria, quality documentation, and lifecycle considerations when specifying water treatment skids.
Statutory & Safety Codes
All oilfield equipment must meet regional safety standards. Tongjie designs systems to meet CE-PED (Pressure Equipment Directive), ASME Boiler and Pressure Vessel Code Section VIII, and ATEX / IECEx Zone 1/Zone 2 explosion-proof standards for skid instrumentation and control panels.
Lifecycle OPEX Optimization
Procurement evaluations should weigh electrical and chemical costs equally with initial CAPEX. Through Energy Recovery Devices (ERD isobaric pressure exchangers) on high-pressure membrane stages, our DTRO systems cut specific power consumption to 2.8 – 4.2 kWh/m³, saving millions over a 10-year lifecycle.
Full Turnkey Documentation
Overseas deliveries include full technical packages: isometric drawings, structural finite element analysis (FEA), Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), NDT inspection reports, and full FAT protocols for third-party inspection (SGS, BV, TÜV).
Frequently Asked Questions on Produced Water Systems
Straightforward technical answers to the most common process, manufacturing, and operational questions from project engineers.
Specialized Desalination, Water Reuse & Modular Process Portfolio
Explore our complete range of certified membrane systems, high-recovery water reuse configurations, and thermal ZLD solutions built for challenging industrial duties.
