Efficient Removalof Dissolved Organics and NaphthenicAcids from Offshore Produced Water: Performance and Challenges ofan Electrochemical Pilot Plant

Abstract Oilfield produced water (OPW) is a complex wastewater, including recalcitrant compounds and stable emulsions. Although electrochemical treatment has shown promising laboratory-scale results for treating this effluent, pilot-scale validation and scale-up remain poorly explored. Therefore, this study investigates the treatment of real offshore OPW using two electrochemical pilot plants (6 and 15 L). Under the optimum operating conditions (25 A·m–2 and a residence time of 4 min), the process reduced total oil and grease from 152 to 3 mg·L–1, turbidity from 69.4 to 1.0 NTU, and total organic carbon from 561 to 42 mg·L–1. In addition, the larger pilot unit achieved similar or improved performance, confirming the feasibility of process scale-up. The results indicate that electrocoagulation/flocculation and electro-oxidation occurred simultaneously, promoting the rapid removal of dissolved organic compounds and anodic transformation of the naphthenic acids. Practical aspects relevant to offshore implementation, including energy demand (7.8 kWh kg of TOG removed–1), heat generation (166 W), gas evolution (13.5 L·h–1), and process footprint (10 m·h–1 and 15 h–1), are also discussed, highlighting the feasibility of industrial implementation.