Success Stories
Case Studies & Success Stories
New return condensate water treatment system with performance enhancement and increased run length
Background
The client is an oil and gas multinational company ranked on Fortune Global 500. The plant is an LNG liquefaction plant located in Sarawak, Malaysia.
Challenge
The existing condensate polisher units (3 units) were underperforming where design output parameters were not consistently achieved. The plant was designed to treat 850 m3/h of boiler return condensate water and produce product that has a conductivity of less than 0.3 uS/cm with pH ranging between 6.5 to 8.0 with a run length of 610,000 m3. The units generally only produced the desired output up to a run length of 300,000 m3 to 350,000 m3 only. This resulted in the unit being shut down more frequently to undergo a regeneration process to re-activate the anion and cation resins.
Our Solution
Through studies conducted, it was observed that the vessel design and the amount of cation resins utilised was inadequate. The new polisher vessel was designed with a larger HOS (Height on Straight) to accommodate the increased resin volumes as well as the required free board to cater for correct backwash flowrates.
Outcome
The unit has been performing above expectations so far. It has consistently produced an 
average output conductivity of 0.06 uS/cm (design 0.30 uS/cm) and achieved the run length requirement of 610,000 m3. Below is the reading at run length of 610000 m3.
| Item No. | Parameter | Unit | Location | Average Reading | Design Requirement |
| 1 | Flowrate | m3/h | Inlet | 300.00 | 200 to 850 |
| 2 | Temperature | 0C | Inlet | 54.91 | < 60.00 |
| 3 | Conductivity | µS/cm | Inlet | 2.62 | < 5.00 |
| Outlet | 0.060 | < 0.300 | |||
| 4 | pH | Outlet | 7.03 | 6.50 – 8.00 |
Upgradation of an old CPI unit to meet today’s waste water discharge requirements
Background
Upgradation of an old CPI unit to meet today’s waste water discharge requirements
Challenge
The client was facing and issue concerning their oil/water separators. The plates were closely stacked and positioned horizontally, instead of inclined. The waste water to be treated was not supposed to contain suspended solids, only hydrocarbons. In practice however the oily waste water did contain suspended solids with TSS concentrations ranging from 50 to 150 mg/l. Solids settled in the corrugations troughs, but because the plates were not inclined transport of solids out of the plate packs did not happen. Because the separator discharged off-spec treated water directly to a nearby river, the client needed to improve the separator’s performance.
Our Solution
The separators were upgraded with inlet flow distribution, installation of three new Cross Flow plate packs, installation of sludge collection troughs underneath the plate packs, installation of new adjustable oil skim weirs, installation of new adjustable effluent overflow weirs and installation of an online sludge removal system. During the upgrade work the oily waste water stream was treated in our rental separator.
Outcome
Since the commissioning of the upgraded separator, the client performs sludge draw-off at regular intervals of a month. Treatment results remain consistent so that it can be concluded that up to now there is no fouling of the plate packs. The separator’s performance is given in the below table:
| Flow rate | Oil density | Solids density | Water density | Water dynamic viscosity | Oil droplets intercepted | Solids intercepted |
| m3/h | kg/m3 | kg/m3 | kg/m3 | cP | µm | µm |
| 100 | 750 | 2000 | 1000 | 1.002 (20ºC) | ≥ 21 100% | ≥ 11 |
| 100 | 850 | 2000 | 1000 | 1.002 (20ºC) | ≥ 27 100% | ≥ 11 |
| 100 | 900 | 2000 | 1000 | 1.002 (20ºC) | ≥ 33 100% | ≥ 11 |
| 125 | 750 | 2000 | 1000 | 1.002 (20ºC) | ≥ 23 100% | ≥ 21 |
| 125 | 850 | 2000 | 1000 | 1.002 (20ºC) | ≥ 30 100% | ≥ 21 |
| 125 | 900 | 2000 | 1000 | 1.002 (20ºC) | ≥ 37 100% | ≥ 21 |
TPI modification to address inlet parameter fluctuations
Background
The client is a Dutch company that stores and handles various oil and natural gas-related products. The terminal is situated in Rotterdam, Netherlands.
Challenge
The client has an existing TPI separator which is not performing well. Due to high inlet TSS concentration of the contaminated storm water run-off, separated solids particles accumulated on the flat bottom of the TPI bays whereby the sludge layer eventually reached and blocked the outlet side of the plate packs. Furthermore, a large part of the solids particles was oil coated. This not only decreased the particles’ density, but also facilitated a tendency of ‘lumping’. TPI plate packs are installed at an angle of 45° which is suitable for oil separation and low TSS concentrations, but not for high inlet TSS concentrations. This phenomenon results in fouling and clogging of the plate packs.
Our Solution
The TPI part was upgraded and converted into a Cross Flow (CFI) separator. The 24 TPI plate packs were replace by 12 Cross Flow plate packs with a plate interval of 30 mm and a plate inclination of 60°. With these plate packs the total effective plate surface could be increased from 1020 m² to 1530 m². Underneath the Cross Flow plate packs sludge collection hoppers with facilities for online sludge removal were installed.
Outcome
After the upgrade no more fouling of plate packs occurred.
Cross flow technology (CFI) solution to meet waste water discharge requirements
Background
The client is a Dutch company that stores and handles various oil and natural gas-related products. The terminal is situated in Rotterdam, Netherlands.
Challenge
The terminal has an existing TPI separator which has a serious plate pack clogging problems due to high inlet TSS concentrations. As per existing design, the TPI separator had an unusual depth. Because of this, the sludge holding capacity underneath the plate packs for each bay is a prodigious 7 m³. Under these conditions, it may take months for the sludge layer to reach the bottom of the plate packs.
Our Solution
It would be more expedient and cheaper to build one or two above grade Cross Flow separators and to use the TPI basin as storm water buffer. As a first step to upgrade the treatment facilities the drain system was modified in the sense that contaminated waste water and storm water run-off were segregated. It was further determined that two storm water run-off CFI oil/water separators were required with a combined design capacity of 140 m³/h. This was considered to be the maximum first flush. For the treatment of contaminated waste water a CFI oil/water separator with a design capacity of 20 m³/h was to be installed. Upgrade works were completed in early 2014.
Outcome
As of time of writing, all three CFI separators have been operating without shutdown for cleaning.
Locating water source in drought locations
Background
The project is situated in one of drought locations in Spain.
Challenge
The community in the area are looking for accessible water source for daily usage. Geological and hydrological tests were done previously to locate water sources within the area but the results came back negative.
Our Solution
Utilising our proprietary technology, we manage to locate a water vein which we accessed at 160 meters, under layers of bed rock. As a result of the pressure within the vein the water rose by 115 meters within the bore well which makes it accessible at just 45m below surface.
Outcome
We manage to locate the water vein using our technology while the conventional methods could not. The local community thrive on our success.
Desalination Plant solution for Onshore Gas Terminal, Turkmenistan (360,000 litre/day)
Background 
Client is Fortune 500 companies which is the first Oil Exploration Company signing Production Sharing Agreement with Turkmenistan Government. This agreement paves the way for development of Oil & Gas industry in Turkmenistan in global scale.
Challenge
With water scarcity at under-develop part of Central Asia, Client has turn to MEC to provide reliable & sustainable solution to back up their operational requirement in large scale.
Our Solution
A 360,000 l/d Sea Water Reverse Osmosis desalination plant is installed which incorporates the latest in membrane, pumping, and process control technology which produces high quality drinking water with minimal energy consumption and environmental impact. Also included in the package is a 24×7 Remote Integrated System Monitoring to ensure optimised plant performance and extended asset life. This is to ensure maintenance costs are kept at a minimum.
Outcome
The plant is functioning well at the time of writing.