Surfactant Package Emulsion Prevention in Completion Brines

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The formation of emulsions in wellbore fluids during oil extraction leads to increased energy consumption, pump stress, and formation damage, as well as difficulties in separating and transporting petroleum mixtures, due to the interaction of aqueous and oleaginous fluids, which existing technologies fail to effectively address.

Innovation Solution

A composition and method utilizing a surfactant package with a specific ratio of sorbitan esters and nonionic surfactants, which acts as a non-emulsifying additive to prevent or modify emulsion formation, maintaining phase separation and reducing pumping pressure, and is environmentally friendly, meeting stringent North Sea regulations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wellbore fluids are circulated to remove drill cuttings and control subsurface pressures, then wellbore operations are maintained, but emulsions form between aqueous and oleaginous fluids leading to increased energy consumption and pump stress

Engineering Contradiction:

Improvewellbore operationsVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The surfactant package is added to the wellbore fluid before circulation begins, pre-establishing the emulsion prevention mechanism. This preliminary action ensures that when aqueous and oleaginous fluids contact during circulation, emulsions are prevented from forming in the first place, avoiding the energy consumption issues that would arise from treating formed emulsions

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The surfactant package acts as an intermediary substance between aqueous and oleaginous fluids. It modifies the interfacial properties between these immiscible phases, preventing the formation of stable emulsions while allowing both fluid types to coexist in the wellbore environment, thus maintaining reliable operations without the harmful effects of emulsion formation

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If wellbore fluids are used to isolate formation fluids, then wellbore integrity is maintained, but emulsion formation occurs causing formation damage and adverse rheology changes

Engineering Contradiction:

Improvewellbore integrityVSAvoidformation damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The surfactant package is introduced into the wellbore fluid in advance to counteract the emulsion formation tendency before it can cause formation damage. By pre-establishing emulsion prevention, the harmful effects on formation are avoided while the wellbore integrity function is maintained

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The surfactant package serves as a protective intermediary between the wellbore fluid and the formation. It prevents direct harmful interactions that would lead to formation damage, while allowing the wellbore fluid to maintain its isolation function

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If fracturing fluid is pumped into formation, then treatment is delivered, but viscous emulsions form inhibiting further pumping and increasing operating costs

Engineering Contradiction:

Improvetreatment deliveryVSAvoidpumping operation

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The surfactant package is added to the fracturing fluid before pumping begins, pre-establishing emulsion prevention capability. This ensures that when the fluid contacts oleaginous materials in the formation, emulsions are prevented from forming, maintaining ease of pumping operation throughout the treatment process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The surfactant package acts as an intermediary that modifies the interaction between fracturing fluid and formation materials. It prevents viscous emulsion formation that would inhibit pumping, while allowing the fracturing treatment to be delivered effectively

Inventive Principle:

Principle #24Intermediary (Mediator)

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 solution effectively reduces energy consumption and pump stress, decreases the need for emulsion breakers, and facilitates the separation of hydrocarbon fluids from wellbore wastes, while being environmentally safe, thus lowering operational costs and maintaining the integrity of the wellbore.

Implementation Method 1

Methodology Applied

Scientific EffectSurfactant: Surfactant

Data Source

PatentUS10537829B2Emulsion preventer for completion brines

Publication Date: 2020.01.21 M I LLC(US)

AI summary

Emulsion-preventing compositions may contain one or more sorbitan esters; and one or more non-ionic surfactants; where the ratio of the one or more sorbitan esters to the one or more non-ionic surfactants is in the range of 1:1 to 1:5. Methods may include contacting an emulsion with a treatment fluid, the treatment fluid containing one or more sorbitan esters and one or more non-ionic surfactants, where the ratio of the one or more sorbitan esters to the one or more non-ionic surfactants is in the range of 1:1 to 1:5; and separating the emulsion into an aqueous phase and an oleaginous phase.