Integrated Treatment System (ITS) for Frac Water Management
The Ecologix ITS-1500 (1,500gpm or 51,400bbl/day), has the largest capacity and smallest footprint compared to any of our previous generations of Flowback and Produced Water treatment systems. The system is designed to precipitate and remove TSS (Total Suspended Solids), Emulsified Oil and Dissolved Metal (such as Iron). Furthermore, it can be used to adjust pH, introduce Scaling Inhibitors and Disinfect the water. The process deploys Dissolved Air Flotation (DAF) that has long been used to separate solids from waste streams to float the sludge and remove it with a scraper, but will simultaneously remove heavy solids, as well.
Watch our ITS-1500 in action
The Keys to Recycling Frac Water for Reuse
TSS Removal
No matter the formation, regardless of frac fluid chemistry, suspended solids (TSS) must be removed in order to reclaim flowback and produced water for reuse. Otherwise, solids interfere with frac fluid performance and they plug up the fractures down-hole.
Meeting the Frac Fluid Spec
Depending on the frac species (slickwater, gel, or hybrid) you have to treat water to enable the proper formation of the frac fluid. The general axiom is - use the lowest quality of water that will satisfy the needs of the process. For any formation, TSS removal is priority #1.
Making sound Economic Sense
There are plenty of technology options available promising the ability to recycle frac water. Whether or not they're viable is a numbers game. The ITS technology removes TSS, disinfects, and removes performance inhibiting ions from flowback and produced water, at or below the cost of sourcing, trucking and disposing of fresh water.
The ITS-1500 Standard Components
- Whitewater pump
- Inclined tubes with large surface area of 2850Ft2 (265m2)
- Scrapers, Flights, Weirs and Bottom sludge outlets
- Folding walking mezzanine, safety guards
- Allen Bradley PLC controls and remote monitoring
- Four (4) chemical feed pumps: one (1) Coagulant, one (1) Precipitant, one (1) Caustic and one (1) Polymer feed
- NEMA-4 HDPE panel enclosure, PVC Sch80 and stainless-steel pipes
ITS - 1500 Mobile Water Treatment Specifications
| Design Flowrate | 1500 GPM (51,000 bbl/day) |
| Maximum Loading rate | 0.64 GPM/prj sq. ft. |
| Maximum TSS @ Designed Flow | 1500 mg/l |
| Projected Surface Area | 2850 sq. ft. |
| Shipping Weight | 51,500 lbs |
| Operating Weight | 210,000 lbs |
| White Water Pump Flowrate | 450 GPM @ 185' |
| Sludge Pump Flowrate | 150 GPM @ 93' |
| Overall System Length | 52' |
| Overall System Height | 13' 9" |
| Overall System Width | 11' 6" |
| Total Power Consumption | 50 hp |
ITS - 1500 Power Consumption
| Component | HP | KW/h |
|---|---|---|
| Whitewater Pump | 40 | 29.84 |
| Chemical Mixer | 1 | 0.746 |
| Flash Mixer | 0.5 | 0.373 |
| Flocculent Mixer | 2 | 1.492 |
| Scraper Motor | 2 | 1.492 |
| Auger Motor | 0.5 | 0.373 |
| Chemical Feed Pumps | 1 | 0.746 |
| Sludge Pump | 3 | 2.25 |
| Total Power Consumption | 50 | 37.31 |
Polymer Makedown System Features
- LCD display with touchpad control
- 4-20 mA input to pace pump
- Remote start/stop, General alarm contacts
- Adjustable flush settings
- True multi-zone mixing chamber that delivers a tapered energy profile for proper polymer activation
- Unique injection check valve with easy access for cleaning; Diaphragm and progressive cavity pump options
- System protection against loss of water flowPrecise activated polymer solution delivery
- Open design for easy maintenance; Suction lift or flooded suction
- Twist lock fittings: Selectable emulsion or mannich polymer
ITS-1500 Standard System Components
Polymer Makedown System
Our pre-engineered polymer mixing system is designed with intuitive controls. It is an in-line or makedown unit, and is engineered to meet liquid polymer applications utilizing diaphragm or progressive cavity pump technologies. The unique mixing regime delivers a highly activated polymer solution to every application with optimum performance.
Rotary Lobe Sludge Transfer Pump Skids
Sludge Transfer Skid: 4" skid mounted on a skid. Transfers sludge from DAF system to sludge holding tank, and from sludge holding tank to dewatering system.
Flow Sensor + pH Sensor + TSS sensor
Eight inch, flanged magnetic flow meter for automatic and accurate sensing of influent and effluent flow rates to treatment system. Meter is equipped with an internal PTFE liner for industrial applications.
Remote Monitoring
Easy Remote Access to PLC, HMI, IPC, IP Camera. Industrial VPN router and cell card for wireless communication designed to offer easy remote access across the Internet to machines and installations on customer sites or in the field. Allows troubleshooting of systems remotely without going on site, drastically reducing support costs.
PLC Controls
This control panel contains the Allen Bradley MicroLogix PLC with a 10.5" TFT high resolution HMI. It will run the DAF and several other remote I/O skids, such as chemical feed pumps, instrumentation and water pumps. It can connect to other process skids by just adding power and a single CAT5E Ethernet cable. Included is an industrial VPN router designed to offer easy remote access, across the Internet, to machines and installations on customer sites or in the field. Access may be obtained to PLC, HMI, IPC, IP Camera, etc. Troubleshooting the machines remotely without going on site will drastically reducing support costs.
ITS-1500 Optional System Components
Influent Pumps - Self Priming on a Skids
Vacuum Assisted, Solid Handling Centrifugal Pumps Environmentally Safe Priming System designed for no product leakage. No priming water required in either the pump or the suction lines. Available in Silent Pack Configuration.
Effluent Pumps
End suction centrifugal high pressure pump is ideal for use in demanding industrial applications to ensure process reliability, high efficiency and low operating costs.
Multi Plate Screw Press - will process 793 - 1,377 lbs/h of 100% dry sludge
The Ecologix screw press allows for automatic continuous sludge flocculation, thickening, dewatering and filtrate discharging. The thickening zone allows the system to process both highly concentrated sludge as well as sludge with a high water content.
- 304SS Body
- 793 - 1,377 lbs/hr of dry solids capacity
- Dimensions: 17' L x 7' 6" W x 7' 6" H
- Weight: 11,200 lbs dry
Mobile Sludge Treatment System
Consisting of the following components:
- Mobile chassis
- Sludge tank with sloped bottom, stairs and mezzanine
- Mixer
- Sludge Pump
- Piping
- Connection to controls
- Day Tank (Polymer Make-down Unit, is optional)
- Mezzanine and stairs for screw press
Model 5424-6A Pressure Vessels with 54" diameter/each
Filtered Backwash on multi-tank systems.Fusion bonded epoxy linings. Grooved inlet/outlet connections. Automatic valves in cast iron or brass.Solid state automation with elapsed timer and differential pressure control.Liquid filled, SS pressure gauges. The filtration media used is AGFM - Activated Glass Filtration Media. AGFM replaces traditional sand media in all filtration applications. It is manufactured from a specific glass type and processed to obtain the optimum particle size and shape, and then activated to increase the surface area by 300 times over crushed glass or sand. The high surface area is negatively charged (zeta potential) to electro-statically attract organics and small particles. It also has permanent metal oxide catalysts, creating a high redox potential, to make the AGFM self-sterilizing.
ITS-1500 System Inspection Prior To Delivery
A full inspection of each unit is conducted prior to all deliveries.
