Random Hydroxyacrylate Bipolymers for Acid-Stable Crude Oil Demulsification
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Solution Overview
Problem
Current demulsifying agents for breaking down water-in-crude oil emulsions are inefficient under high stability conditions, require multiple synthesis steps, and are unstable under acidic conditions, leading to decreased performance and increased production costs.
Innovation Solution
Development of random bipolymers based on alkyl acrylate-hydroxyalkyl acrylate monomers with controlled molecular mass, synthesized through semi-continuous emulsion polymerization, which are stable under acidic conditions and effective in destabilizing water-in-crude oil emulsions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyether-based demulsifying agents are used, then emulsion breakdown is achieved, but they become unstable under acidic conditions leading to decreased performance
Solution Approach 1:
The patent changes the chemical composition parameters by replacing polyether-based compounds with acrylic-based random copolymers containing carboxylic acid groups. This parameter change enables the demulsifier to maintain stability and functionality under acidic conditions where polyether-based agents fail, directly resolving the contradiction between reliability and chemical stability.
Solution Approach 2:
The invention uses composite material design by creating random copolymers with specific monomer compositions (alkyl acrylate, hydroxyalkyl acrylate, and carboxylic acid-containing monomers). This composite structure provides both demulsifying effectiveness and acid stability, overcoming the limitations of single-component polyether-based agents.
2Productivity
If conventional demulsifying formulations are used, then water removal is achieved, but multiple synthesis steps are required increasing production complexity
Solution Approach 1:
The patent merges multiple functions into a single copolymer structure that simultaneously provides emulsion breakdown, water droplet coalescence, and clarified water separation capabilities. This eliminates the need for multi-component formulations and multiple synthesis steps, directly addressing the contradiction between productivity and manufacturing complexity.
Solution Approach 2:
The random copolymer is designed with universal functionality to perform all demulsifying operations (breakdown, coalescence, clarification) through its integrated monomer structure. This multi-functional agent replaces the need for separate specialized agents, simplifying both application and synthesis processes.
3Reliability
If higher doses of demulsifying agents are used, then emulsion breakdown is improved, but production costs increase
Solution Approach 1:
The patent optimizes the molecular weight parameters of the copolymer (number average molecular weight between 10,000-1,000,000 g/mol) to achieve maximum demulsifying efficiency at lower concentrations. This parameter optimization allows the agent to be more effective at lower dosages, reducing the quantity of substance needed while maintaining or improving breakdown effectiveness.
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
The bipolymers efficiently break down water-in-crude oil emulsions across a wide range of API gravities, maintaining effectiveness under acidic conditions without the need for overdosing, thus improving efficiency and reducing production costs.
Implementation Method 1
These chemical products are firstly applied from the producing well, subsequently, during the transportation of crude oil and, finally, upon arrival at the refineries, seeking to fulfill the requirements of maximum water and salts content before its processing.
Implementation Method 2
synthesized through semi-continuous emulsion polymerization
Data Source
AI summary
The present disclosure provide bipolymers, based on alkyl acrylate and hydroxyalkyl acrylate, with high randomness and controlled molecular mass, that are useful as demulsifying and dehydrating agents for crude oil. The synthesis of these bipolymers is carried out in a single stage by emulsion polymerization, a process that, in addition to having moderate reaction conditions, allows the control of the homogeneity of the chain size, the molecular mass, and the demulsifying efficiency. These random bipolymers are soluble in organic phase; therefore, these cannot be carried away by the removed water, and are eliminated in the atmospheric distillation stage. An additional advantage is the superior demulsifying and clarifying efficiency of these random bipolymers compared with the polyether formulations widely used at industrial level. In addition, these random bipolymers provide single molecule that performs three functions: breaker, coalescer and clarifier, in contrast to formulations based on at least three different polyethers.