Cationic Polymer Emulsions for Heavy Oil Viscosity Reduction
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Solution Overview
Problem
The transport of highly viscous heavy oils from petroleum operations is hindered by high viscosity, leading to low pump efficiency, increased energy costs, and equipment wear, as current methods like heating and diluents are costly and inefficient.
Innovation Solution
Contacting hydrocarbon fluids with polymers containing at least 25 mole percent cationic monomers to create low-viscosity oil-in-water emulsions, reducing apparent viscosity and facilitating transport without the need for heated pipelines or diluents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical pumping is used to transport viscous heavy oil, then the oil can be moved from well sites to refineries, but pump volumetric efficiency is low, flow rates are reduced, and flow pressure drop is high
Solution Approach 1:
The invention changes the physical-chemical parameters of the oil by forming an emulsion with water and surfactant, transforming the bulk phase from oil to water. This fundamentally alters the flow characteristics, reducing viscosity and pressure drop while maintaining transport capability
Solution Approach 2:
The invention introduces water as an intermediary fluid and surfactant as a mediator substance. The water forms the continuous phase of the emulsion, while the surfactant mediates between the oil droplets and water phase, enabling stable emulsion formation that reduces viscosity and improves pumpability
2Ease of operation
If heating is used to reduce oil viscosity for transport, then the oil becomes more pumpable, but energy consumption is large and cost is ineffective
Solution Approach 1:
Instead of changing temperature to reduce viscosity, the invention changes the compositional parameters by forming an emulsion. The water-oil emulsion with surfactant fundamentally alters the fluid's rheological properties, reducing viscosity without thermal energy input
Solution Approach 2:
The invention replaces the thermal heating system with a chemical/emulsion-based system. Rather than using heat to reduce viscosity, the patent uses surfactant-mediated emulsion formation to achieve the same pumpability improvement without energy consumption
3Ease of operation
If diluents are used to reduce viscosity for pumping and transport, then the oil becomes more flowable, but the large amount of diluent required is not readily available in the production area and must be recovered and pumped back over great distances
Solution Approach 1:
The invention uses water, which is already present in the production area as formation water or available infrastructure, as the diluent medium. The system is self-sufficient, using locally available water to form emulsions that improve pumpability without requiring external diluent supply or complex recovery systems
Solution Approach 2:
The invention introduces water as an intermediary fluid that is already available in the production environment. This eliminates the need to transport and recover diluents over long distances, as the water is either formation water or can be obtained from existing water infrastructure in the area
4Use of energy by stationary object
If prolonged pumping interruptions occur, then energy consumption is reduced, but cold crude oil causes plugging of pipes and pumps
Solution Approach 1:
The invention changes the temperature parameter by using water (at ambient or formation temperature) as the continuous phase in the emulsion. This eliminates the need for heating, allowing pumping interruptions without temperature-related plugging issues, as the water-based emulsion remains fluid at lower temperatures
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method significantly reduces pressure drops and equipment wear, enhances oil production, and increases transport efficiency by converting high viscosity oils into low viscosity emulsions that can be separated easily, thus improving the overall productivity and cost-effectiveness of oil transport.
Implementation Method 1
contacting the hydrocarbon fluid with an effective amount of a composition comprising at least one polymer having at least 25 mole percent cationic monomers... to create simple or complex emulsions thereby reducing the apparent viscosity of the hydrocarbons
Data Source
AI summary
A method for reducing the viscosity of a hydrocarbon fluid encountered in petroleum operations is disclosed. The method includes contacting the hydrocarbon fluid with an effective amount of a composition comprising at least one polymer having at least 25 mole percent cationic monomers.