Factory Direct Supply
High-Efficiency Membrane & Produced Water Equipment
Explore our factory-tested modular skids, high-pressure membrane concentration systems, and off-grid containerized configurations manufactured in Shanghai for global EPC projects.
Global Macro & Industrial Status
Global Dynamics of Produced Water Management & Regulatory Pressure
A technical overview of produced water handling across onshore exploration, offshore platforms, shale hydraulic fracturing, and refinery processing worldwide.
Hydraulic Fracturing & Unconventional Basins
In regions such as the Permian Basin, Eagle Ford, and Sichuan Basin, hydraulic fracturing generates immense volumes of flowback and produced water laden with extreme total dissolved solids (TDS reaching 80,000 to 250,000 mg/L), scale-forming divalent cations (Ba, Sr, Ca), and recalcitrant polyaromatic hydrocarbons. Deep-well disposal (Class II injection) faces severe seismic constraints and regulatory caps, elevating the urgency of localized recycling architectures.
Offshore Platforms & Space-Constrained Fields
Floating Production Storage and Offloading (FPSO) units and offshore fixed rigs in the North Sea, Gulf of Guinea, and South China Sea require extremely stringent de-oiling prior to ocean discharge (OSPAR ≤ 30 mg/L aliphatic hydrocarbons; local mandates tightening to ≤ 10 mg/L). Weight, footprint, and vibration resistance necessitate skid-mounted DTRO and microfiltration assemblies engineered in corrosion-proof super duplex stainless steels.
Mature Waterflood Reservoirs & EOR Schemes
Mature onshore fields across Central Asia and the Middle East operate at high water cuts exceeding 90-95%. Sustaining reservoir pressure requires low-fouling water injection. Suspended solids (≤ 1.0 mg/L) and oil-in-water (≤ 5.0 mg/L) must be strictly managed to prevent near-wellbore formation damage, pore plugging, and reservoir souring driven by sulfate-reducing bacteria (SRB).
Application Playbooks
Localized Engineering Blueprints for Extreme Environments
From the arid deserts of the Middle East to sub-zero permafrost basins, our OEM produced water treatment plants are parameterized to site-specific feedwater analytics.
Middle East Desert Oilfields (GCC)
Feed Condition: High ambient heat (>50°C), salinity up to 160,000 mg/L TDS, severe calcium/magnesium scaling tendency.
System Configuration: DAF → walnut shell coalescing filter → microfiltration → DTRO high-pressure train housed inside fully air-conditioned ISO 40HC containers equipped with sand-storm acoustic louvers.
Central Asia Steppe (Kazakhstan / Uzbekistan)
Feed Condition: Extreme seasonal swings (-35°C to +40°C), paraffin-rich crude emulsions, high silica loads.
System Configuration: Skid-mounted electrocoagulation + ceramic ultrafiltration + STRO (Spacer Tube Reverse Osmosis) with automatic glycol tracing and insulated rock-wool cladding.
North American Shale Hydraulic Re-use
Feed Condition: High-rate flowback, friction reducers, polymer chemical residuals, volatile organic aromatics (BTEX).
System Configuration: Chemical precipitation (lime/soda ash softening) → multi-stage organoclay absorption → OARO (Osmosis Assisted Reverse Osmosis) enabling brine concentration up to 180,000 mg/L without phase-change thermal costs.
Refinery Effluent & Petrochemical ZLD
Feed Condition: Stripped sour water, high COD, phenolic compounds, variable ammonia-nitrogen and chlorides.
System Configuration: Biological MBR → Fenton oxidation → dual-pass RO → MVR (Mechanical Vapor Recompression) evaporator → crystallizer for commercial-grade salt recovery.
Process Train Engineering
Technology Roadmap: Comparing Produced Water Separation Trains
Selecting the optimal technological combination balances initial capital expenditure (CAPEX), membrane lifetime, electrical parasitic load, and brine volume minimization.
| Treatment Technology Stage | Contaminant Target | Operating Pressure / Energy | Effluent Purity Standard | OEM Design Advantage |
|---|---|---|---|---|
| Primary Separation: DAF + Walnut Shell | Free oil, dispersed oil, gross suspended solids | 0.3 - 0.5 MPa 0.2 - 0.4 kWh/m³ |
Oil: ≤ 10 - 20 ppm TSS: ≤ 10 ppm |
Dual-media auto backwash, compact skid, non-clogging nozzle system. |
| Secondary Clarification: Tubular Ceramic MF/UF | Emulsified droplets, colloidal silica, biomass | 0.2 - 0.6 MPa 0.8 - 1.5 kWh/m³ |
Oil: ≤ 2.0 ppm SDI15: ≤ 2.5 |
Inorganic membrane withstands solvent washes, steam cleaning, pH 0-14. |
| High-Pressure Concentration: Disc Tube RO (DTRO) | Dissolved solids (TDS up to 120,000 ppm), salts | 7.5 - 12.0 MPa 4.5 - 9.0 kWh/m³ |
Permeate TDS: ≤ 500 ppm Water Recovery: 70 - 85% |
Open-channel construction eliminates dead zones; single-disc replacement without complete vessel discard. |
| Hypersaline Osmotic RO (OARO / STRO) | Brine concentration up to 180,000 ppm TDS | 10.0 - 16.0 MPa 6.0 - 12.0 kWh/m³ |
Permeate: ≤ 1,000 ppm Brine Volume: -60% |
Substantially cuts thermal evaporator size; eliminates thermal corrosion cracking in early stages. |
| Thermal Finalization: MVR Evaporation & Crystallization | Terminal brine, crystalline Na2SO4, NaCl salts | Vacuum thermal 25 - 45 kWh/m³ |
Distillate TDS: ≤ 20 ppm Zero Liquid Discharge (ZLD) |
Titanium Gr.2 and Hastelloy C-276 construction; automated anti-scaling forced circulation. |
Download Complete Produced Water Treatment Engineering PDF
Access our comprehensive 48-page technical manual detailing mass-balance calculations, P&ID blueprints, membrane flux models, and metallurgy selection matrices for oil & gas produced water systems.
Supply Chain Authority
Chinese Manufacturing Ecosystem: High Resilience, Precision & Scalability
Combining world-class component sourcing, automated robotic welding, and Shanghai's maritime export logistics to deliver cost-predictable water engineering packages globally.
End-to-End In-House Fabrication
Unlike engineering brokers who outsource skids, Shanghai Tongjie maintains dedicated pressure vessel manufacturing, automated frame fabrication, laser cutting, and certified ASME pipe welding in our Shanghai industrial center. From structural pickling and passivation to dual-layer epoxy marine coatings, all fabrication steps are tightly supervised under ISO 9001 quality protocols.
Tier-1 Component Integration
We combine China's cost-efficient domestic supply chain with international high-spec components per buyer request: Grundfos / Danfoss / FEDCO axial piston high-pressure pumps, Siemens / Schneider / Allen-Bradley programmable automation controllers, and Toray / DuPont / Hydranautics membrane elements, achieving superior reliability with up to 30-40% overall CAPEX optimization.
Rigorous Factory Acceptance Testing (FAT)
Before any container or skid leaves our Shanghai facility, it undergoes hydraulic hydrostatic pressure verification, electrical loop checks, instrument calibration, and simulated water test runs. Factory testing eliminates 95% of job-site startup bugs, allowing operators to transition from shipping off-load to clean permeate production in under 15 operational days.
Global Compliance & Support
Engineering Compliance, International Standards & Field Assurance
Ensuring complete peace of mind for EPCs, offshore concession operators, and international environmental consultancies through rigorous certified benchmarks.
International Certifications
Every system is compliant with EU CE Machinery Directive, Low Voltage Directive, and EMC Directive standards. Pressure retaining components comply with ASME Section VIII and PED 2014/68/EU directives, backed by ISO 9001, ISO 14001, and ISO 45001 corporate management certifications.
IoT Cloud Telemetry & Remote SCADA
Industrial cellular / satellite IoT gateways deliver encrypted telemetry to operators and Tongjie technical specialists. Real-time differential pressure tracking, automated CIP (Clean-in-Place) alerts, and predictive membrane fouling algorithms minimize downtime in uncrewed field operations.
Full Turnkey Documentation
Export packages include exhaustive engineering dossiers: P&IDs, electrical schematics (AutoCAD/EPLAN), 3D isometric piping models, motor/instrument lists, factory FAT reports, weld NDT inspections, and multilingual operation & maintenance manuals suitable for site audits.
Global Field Dispatch & Spares Consignment
Our multilingual commissioning engineers are readily dispatchable for international on-site startup, commissioning, and client staff training. Furthermore, standard spare parts packages (cartridges, seal kits, sensors) are maintained in regional distribution hubs for rapid transit.
Specialized Plant Configurations
Explore Additional Custom Engineered Water Treatment Lines
Continuous innovation across zero-liquid discharge, high-recovery membrane descaling, and high-purity water systems configured to your feed specifications.
Technical Q&A
Frequently Asked Questions on Produced Water Treatment Specifications
In-depth responses authored by our senior process engineers addressing membrane fouling, recovery thresholds, reinjection quality, and customization options.
What data points are critical in raw water analysis to accurately size a produced water membrane system?
To generate a comprehensive mass balance, hydraulic projection, and equipment quotation, our engineering team requires:
- Physical & Salinity Metrics: Total Dissolved Solids (TDS), electrical conductivity, operating temperature fluctuations, and specific gravity.
- Oil & Organic Fractions: Free oil, emulsified oil-in-water (OIW), chemical oxygen demand (COD), total organic carbon (TOC), and presence of volatile BTEX compounds.
- Fouling & Scaling Cations/Anions: Ca2+, Mg2+, Ba2+, Sr2+, SO42-, reactive silica (SiO2), and iron/manganese levels.
- Suspended Matter: Turbidity, total suspended solids (TSS), and Silt Density Index (SDI15).
- Target Constraints: Daily volumetric flow rate (m³/day), desired permeate recovery (%), target treated discharge/reinjection limits, and electrical power specifications (voltage/frequency/explosion-proof zone classification).
How does DTRO (Disc Tube Reverse Osmosis) prevent organic fouling compared to standard spiral-wound membranes?
Spiral-wound membrane elements employ feed spacers that create narrow stagnant zones, easily fouled by residual crude oil droplets and bio-polymers. In contrast, DTRO uses an open-channel hydrodynamic geometry where water flows across radial hydraulic discs with turbulator studs. This creates an intense cross-flow vortex that continuously shears off boundary layer concentration polarization and foulant cakes. As a result, DTRO operates steadily at SDI > 5, turbidity > 15 NTU, and COD up to thousands of mg/L without the catastrophic irreversibility common to traditional membrane configurations.
Can Tongjie produced water treatment equipment reliably meet oilfield reinjection and environmental discharge limits?
Yes. Our multi-barrier treatment train routinely reduces free and dissolved oil to ≤ 5.0 mg/L (with optional carbon/polishing achieving ≤ 1.0 mg/L) and suspended solids to ≤ 1.0 mg/L, while eliminating bacterial spores and scale nuclei. This completely complies with SY/T 5329 Class A1 oilfield reinjection standards as well as stringent offshore ocean discharge caps (OSPAR convention ≤ 30 mg/L, regional EPA caps ≤ 15 mg/L), effectively preventing reservoir formation plugging and environmental penalties.
What is the typical delivery schedule, containerization footprint, and commissioning timeline for export orders?
Standard containerized skids (200 m³/d to 1,500 m³/d capacity) are designed within standard CSC-certified ISO 20ft or 40ft High Cube containers. Production and factory testing in our Shanghai plant require approximately 8 to 12 weeks depending on metallurgy specifications (Super Duplex 2507 vs 316L). Because systems are pre-assembled, pre-piped, and wet-tested before shipping, on-site commissioning typically takes just 10 to 15 operational days following site utility tie-in.
Do you provide white-label (OEM/ODM) manufacturing for international water engineering brands and EPC contractors?
Yes. Over 40% of our export output is manufactured under OEM/ODM partnerships for EPC contractors, water treatment corporations, and system distributors across Europe, the Middle East, Southeast Asia, and the Americas. We provide custom container color-matching, private-label branding, customized HMI interface languages, PLC program customization (Allen-Bradley, Siemens, Omron), and tailored engineering documentation suited to your end-client handover requirements.