Integrated Treatment System for Frac Water Management (ITS)

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 precipitated 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.

ITS Frac Water Treatment System Model 1500 Right Side ISO View
ITS-1500 Left Side View
ITS Frac Water Treatment System Model 1500 Left Side ISO View
ITS-1500 Right Side View

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 1440 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 50' 6 7/8"
Overall System Height 13' 5"
Overall System Width 15' 1 1/8"
Total Power Consumption 55 hp

ITS - 1500 Power Consumption

Component HP KW
Influent Pump 35 26.11
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 7.5 5.595
Effluent Pump 75 55.95
Total Power Consumption 164 123

The Keys to Recycling Frac Water for Reuse

Remove TSS

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.

Meet 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.

Make 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.

Frac Water Jar Test Chemical Coagulant and Flocculant Jar Test

The ITS-1500 Standard 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.

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 cleaningDiaphragm and progressive cavity pump options
  • System protection against loss of water flowPrecise activated polymer solution delivery
  • Open design for easy maintenanceSuction lift or flooded suction
  • Twist lock fittings
  • Selectable emulsion or mannich polymer
Polymer makedown system

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.

Rotary Lobe Sludge Transfer Pump Skid

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.

Flow Sensor + pH Sensor + TSS sensor

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.

PLC Controls

The ITS-1500 Optional 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

Influent Pump - Self Priming on a Skid

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.

Effluent Pump

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
  • 3Weight: 11,200 lbs dry
multi plate dewatering screw press

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
Mobile Sludge Treatment System

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 the AGMF - 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.

Model 5424-6A Pressure Vessels

ITS Inspection Prior To Delivery

Full inspection of each unit is conducted prior to all deliveries

ITS 1500 Frac Wastewater Treatment System inspection prior to delivery to Texas oil fields
ITS 1500 Frac Wastewater Treatment System inspection prior to delivery to Texas oil fields
ITS 1500 Frac Wastewater Treatment System inspection prior to delivery to Texas oil fields
ITS 1500 Frac Wastewater Treatment System inspection prior to delivery to Texas oil fields

ITS In Operation

The video below shows the ITS running in an oil field in Texas