Reverse osmosis system for use with a wellbore and methods of assembling the same

Abstract

A reverse osmosis unit for processing a feed solution is provided. The unit includes a pressure vessel includes an inlet end, an outlet end, and a vessel body extending between the inlet end and the outlet end. The reverse osmosis unit further includes a plurality of first membrane modules positioned within the pressure vessel. Each first membrane module of the plurality of first membrane modules has a first salt permeance value. At least one second membrane module is positioned within the pressure vessel and coupled in flow communication to the plurality of first membrane modules. The at least one second membrane module has a second salt permeance value that is different from the first salt permeance value.

We claim: 
     
         1 . A reverse osmosis unit for processing a feed solution, said unit comprising:
 a pressure vessel comprising an inlet end, an outlet end, and a vessel body extending between said inlet end and said outlet end;   a plurality of first membrane modules positioned within said pressure vessel, each first membrane module of said plurality of first membrane modules comprising a first salt permeance value; and   at least one second membrane module positioned within said pressure vessel and coupled in flow communication to said plurality of first membrane modules, said at least one second membrane module comprising a second salt permeance value that is different from said first salt permeance value by a difference of at least about 0.4×10 −5  cm/sec.   
     
     
         2 . The reverse osmosis unit of  claim 1  wherein said second salt permeance value is greater than said first salt permeance value. 
     
     
         3 . The reverse osmosis unit of  claim 1  wherein said at least one second membrane module is configured to facilitate processing the permeate having a salinity of at least about 500 parts per million. 
     
     
         4 . The reverse osmosis unit of  claim 1  wherein said at least one said second membrane module is positioned within said pressure vessel and between said inlet end and said plurality of first membrane modules. 
     
     
         5 . The reverse osmosis unit of  claim 1  further comprising at least one third membrane module coupled in flow communication to at least one of said first membrane module and said second membrane module and comprising a third salt permeance value which is greater than said first salt permeance value and said second salt permeance value. 
     
     
         6 . The reverse osmosis unit of  claim 1  wherein said plurality of first membrane modules and said at least one second module comprise at least one of spiral-wound configuration and a hollow fiber configuration. 
     
     
         7 . A reverse osmosis system for processing a feed solution, said system comprising:
 a pump configured to discharge the feed solution; and   a first reverse osmosis unit coupled to said pump and comprising:
 a pressure vessel coupled in flow communication to said pump and configured to receive the feed solution, said pressure vessel comprising an inlet end, an outlet end, and a vessel body extending between said inlet end and said outlet end; 
 a plurality of first membrane modules positioned within said pressure vessel, each first membrane module of said plurality of first membrane modules comprising a first salt permeance value; and 
 at least one second membrane module positioned within said pressure vessel and coupled in flow communication to said plurality of first membrane modules, said at least one second membrane module comprising a second salt permeance value that is different from said first salt permeance value, the plurality of first membrane modules and the at least one second membrane module are configured to process the feed solution into a permeate having a salinity of at least about 500 parts per million. 
   
     
     
         8 . The reverse osmosis system of  claim 7  further comprising a computing device coupled to said pump and configured to control said pump to selectively discharge said feed solution into said pressure vessel at least one of an adjustable flow rate and a pressure rate. 
     
     
         9 . The reverse osmosis system of  claim 7  wherein said plurality of first membrane modules and said at least one second membrane module are coupled in flow communication together in series within the pressure vessel. 
     
     
         10 . The reverse osmosis system of  claim 7  further comprising a second reverse osmosis unit coupled in flow communication to said first reverse osmosis unit and comprising a permeate-staged unit. 
     
     
         11 . The reverse osmosis system of  claim 7  further comprising a second reverse osmosis unit coupled in flow communication to said first reverse osmosis unit and comprising a brine-staged unit. 
     
     
         12 . A method of manufacturing a reserve osmosis unit for processing a feed solution, said method comprising:
 positioning a pressure vessel comprising an inlet end, an outlet end, and a vessel body extending between the inlet end and the outlet end;   coupling a plurality of first membrane modules to the pressure vessel, each first membrane module of the plurality of first membrane modules comprising a first salt permeance value; and   coupling at least one second membrane module in flow communication to the plurality of first membrane modules, the at least one second membrane module comprising a second salt permeance value that is different from the first salt permeance value by a difference of at least about 0.4×10 −5  cm/sec.   
     
     
         13 . The method of  claim 12  further comprising coupling at least one third membrane module in flow communication to at least one of the plurality of first membrane modules and the at least one second membrane module, the at least one third membrane module comprising a third permeance value which is greater than the first salt permeance value and the second salt permeance value. 
     
     
         14 . The method of  claim 12  wherein coupling the at least one second membrane module comprises coupling the at least one second membrane module between the inlet end and the plurality of first membrane modules. 
     
     
         15 . The method of  claim 12  wherein coupling the at least one second membrane module comprises coupling the at least one second membrane module between the outlet end and the plurality of first membrane modules. 
     
     
         16 . A method of processing a feed solution, said method comprising:
 discharging the feed solution into a pressure vessel comprising an inlet end, an outlet end, and comprising a first membrane module and a second membrane module coupled in series between the inlet end and the outlet end;   discharging the feed solution into the first membrane module comprising a first salt permeance value and configured to desalinate the feed solution into a first permeate and a first concentrate; and   discharging the first concentrate into the second membrane module comprising a second salt permeance value that is different from the first salt permeance value and configured to desalinate the first concentrate into a second permeate and a second concentrate wherein a collective permeate of the first permeate and the second permeate has a salinity of at least about 500 parts per million.   
     
     
         17 . The method of  claim 16  further comprising discharging the concentrate into at least one third membrane module comprising a third permeance value which is greater than the first salt permeance value and the second salt permeance value. 
     
     
         18 . A method of processing a feed solution into, said method comprising:
 discharging the feed solution into a pressure vessel comprising an inlet end, an outlet end, and comprising a first membrane module and a second membrane module coupled in series between the inlet end and the outlet end;   discharging the feed solution into the second membrane module comprising a second salt permeance value and configured to desalinate the feed solution into a permeate and a concentrate; and   discharging the concentrate into the first membrane module comprising a first salt permeance value that is different from the second salt permeance value and configured to desalinate the concentrate into another permeate and another concentrate wherein a collective permeate of the permeate and other permeate has a salinity of at least about 500 parts per million.