Microemulsion Demulsifier for Solvent-Free Crude Oil Emulsion Breaking
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Solution Overview
Problem
Current demulsifiers for crude oil production are inefficient in breaking emulsions without organic solvents, leading to operational issues like corrosion, reduced handling capacity, and incomplete separation, especially in complex emulsions.
Innovation Solution
A microemulsion-based demulsifier composition comprising nonionic surfactants with a hydrophilic-lipophilic balance (HLB) of less than 9, a coupling agent, water-soluble nonionic surfactants, additional surfactants, and water, which forms microemulsions to break emulsions without water-insoluble organic solvents, enhancing fluid recovery and reducing viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional demulsifiers (AFRA, PAG, organic sulfonates) are used, then emulsion breaking capability is achieved, but organic solvents are required to reduce viscosity which creates environmental concerns and operational complexity
Solution Approach 1:
The patent changes the physical-chemical parameters of the demulsifier by incorporating it into a microemulsion system with specific HLB value surfactants (HLB < 9), coupling agents, and co-surfactants. This transforms the demulsifier from a high-viscosity pure substance into a low-viscosity microemulsion dispersion, eliminating the need for additional organic solvents while maintaining demulsification effectiveness.
Solution Approach 2:
The patent creates a composite microemulsion system combining multiple components: surfactant (oil-like phase), coupling agent, co-surfactant (water-soluble nonionic), additional surfactants (anionic/cationic/amphoteric), and nonionic demulsifier. This composite structure provides both the demulsification function and the fluidity needed for application without requiring separate organic solvent additives.
2Productivity
If demulsifiers are used to break emulsions, then water separation is improved, but incomplete separation occurs leading to operational issues like corrosion and reduced handling capacity
Solution Approach 1:
The patent applies local quality by using surfactants with specific HLB values (< 9) that are optimized for interfacing with crude oil emulsions. The coupling agent and co-surfactants are specifically selected to stabilize the microemulsion structure while maintaining compatibility with the emulsion being treated, creating localized optimal conditions for demulsification at the oil-water interface.
Solution Approach 2:
The microemulsion-based demulsifier composition performs multiple functions simultaneously: it acts as a demulsifier to break emulsions, serves as a viscosity reducer for easy application, provides corrosion inhibition through the coupling agent and surfactant system, and ensures complete separation through the synergistic action of multiple surfactant types (nonionic, anionic, cationic, amphoteric).
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 microemulsion-based demulsifier effectively breaks emulsions, reduces viscosity, and enhances oil production by forming small droplets that quickly act on the oil/water interface, improving separation efficiency and reducing well damage.
Implementation Method 1
microemulsion-based demulsifier composition effective in resolving emulsions of at least one hydrocarbon and water
Implementation Method 2
an oil-like phase comprising at least one nonionic surfactant having a hydrophilic-lipophilic balance (HLB) of less than about 9
Data Source
AI summary
Disclosed and claimed is a microemulsion-based demulsifier composition and a method of demulsifying an emulsion comprising hydrocarbon and water. The demulsifier composition includes (i) an oil-like phase comprising at least one nonionic surfactant having a hydrophilic-lipophilic balance (HLB) of less than about 9; (ii) a coupling agent capable of stabilizing the demulsifier composition; (iii) at least one water-soluble or dispersible nonionic surfactant that is different from the at least one nonionic surfactant in the oil-like phase; (iv) at least one additional surfactant selected from anionic, cationic, amphoteric, and combinations thereof; (v) at least one nonionic demulsifier; and (vi) water.