Project Overview
A major Marcellus operator wanted 100% water reuse across 6 active pads — eliminating produced-water hauling ($3.50–4.50/bbl) and freshwater trucking ($1.80/bbl) by treating flowback and produced water on-pad for reuse in the next frac job. Water TDS ranged 70,000–220,000 mg/L with high barium, strontium, and sulfates.
The Challenge
On-pad reuse requires consistent water quality regardless of TDS swings between pads and stages. Traditional fixed facilities could not move with the rig schedule, and trucking water between a central plant and the pads negated the cost savings.
WFS Solution
WFS deployed a fleet of RapidDeploy™ mobile treatment trains — primary separation, DAF, multimedia/UF filtration, ion-exchange softening, and chemical conditioning — sized to follow the operator's pad schedule. SCADA telemetry from every unit fed a central operations dashboard for real-time quality assurance.
Technologies Applied
- ▸Mobile 3-Phase Separation
- ▸Compact DAF
- ▸Multimedia + UF Filtration
- ▸Ion-Exchange Softening
- ▸Fleet SCADA Telemetry
Results Achieved
Performance Outcomes
- ✓Water reuse jumped from 12% baseline to 96%
- ✓$28M/year of disposal and freshwater costs eliminated
- ✓15 million barrels treated in Year 1
- ✓7.8 million bbl/yr of freshwater sourcing displaced
Your Project Could Be Next
Talk to a WFS engineer about your specific water challenge.