Olefin Sulfonate Surfactant Production Cost Reduction
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Solution Overview
Problem
The high cost of producing surfactants based on olefin sulfonates for large industrial applications, particularly in Enhanced Oil Recovery (EOR) processes, necessitates the development of cost-effective and improved methods for their production.
Innovation Solution
The development of surfactant compositions comprising propylene oligomers with specific branching characteristics, which are produced through a process involving sulfonation of propylene oligomers followed by neutralization, allowing for the creation of concentrated surfactant compositions suitable for use in oil and gas operations, including Enhanced Oil Recovery (EOR) techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional sulfonation processes are used to produce olefin sulfonate surfactants, then surfactant functionality is achieved, but production cost increases significantly for large industrial applications
Solution Approach 1:
The patent changes the chemical parameters of the sulfonation process by using specific propylene oligomer ratios, controlling reaction temperature ranges, and adjusting sulfonation time to optimize both cost-effectiveness and surfactant production quantity for EOR applications
Solution Approach 2:
The patent creates surfactants with specific local molecular structures by controlling propylene oligomerization to produce particular branching patterns, which enhances surfactant performance while maintaining cost-effective production through targeted molecular design
2Reliability
If standard olefin sulfonate surfactants are used in EOR processes, then oil recovery is achieved, but production cost becomes prohibitive for large-scale industrial applications
Solution Approach 1:
The patent employs cost-effective propylene oligomers as feedstocks that can be produced through established industrial processes, replacing more expensive conventional surfactant feedstocks while maintaining reliable oil recovery performance in EOR applications
Solution Approach 2:
The patent modifies the molecular parameters of the surfactant by controlling propylene oligomerization degree and sulfonation conditions, creating a product that achieves reliable oil recovery at lower production cost through optimized molecular structure
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 proposed solution provides a cost-effective method for producing surfactants with enhanced properties, improving the efficiency of oil recovery by utilizing surfactant compositions with tailored branching, thereby reducing production costs and enhancing recovery rates in EOR processes.
Implementation Method 1
reacting a propylene oligomer with SO3 in the presence of air to form an olefin sulfonic acid
Implementation Method 2
neutralizing or hydrolyzing the sulfonic acid with a base to form a propylene oligomer sulfonate
Implementation Method 3
neutralizing or hydrolyzing the sulfonic acid with a base to form a propylene oligomer sulfonate
Implementation Method 4
In some embodiments, the propylene oligomer and SO3 are reacted in a falling film reactor
Implementation Method 5
reacting a propylene oligomer with SO3 in the presence of air to form an olefin sulfonic acid
Data Source
AI summary
The present disclosure is directed to surfactants (in particular olefin sulfonates), surfactant packages, compositions derived thereof, and uses thereof in hydrocarbon recovery. Methods of making olefin sulfonate surfactants are also described.