Demulsif Salt
Demulsif Salt
Vol. 32, No. 01, pp. 107 - 118, January - March, 2015
dx.doi.org/10.1590/0104-6632.20150321s00002755
OPTIMIZATION OF DEMULSIFIER
FORMULATION FOR SEPARATION OF WATER
FROM CRUDE OIL EMULSIONS
P. Hajivand and A. Vaziri*
Department of Chemical Engineering , Faculty of Engineering,
Science and Research Branch, Islamic Azad University, Tehran, Iran.
Phone: + 98 21 22014520 Fax: + 98 21 22014519,
E-mail: a.vaziri@srbiau.ac.ir
(Submitted: June 9, 2013 ; Revised: October 26, 2013 ; Accepted: December 9, 2013)
Abstract - In this study, various water-soluble and oil-soluble demulsifiers were selected for separation of
water from crude oil emulsions and their productivity measured using the Bottle-test method at 70 °C and 10
ppm concentration. The best ones among 23 demulsifiers examined through the screening process were fatty
alcohol ethoxylate, triethanol amine and urea from the water-soluble group and Basororol E2032, Basorol
PDB 9935 and TOMAC from the oil-soluble category. Furthermore, the present study investigated the factors
effective for demulsification such as temperature, concentration, pH, salinity and modifiers. It was found that
the separation improves with increasing demulsifier concentration, increasing salt content, increasing
temperature up to 80 °C, keeping the pH values between 5-9. Adding solvent modifiers proved unnecessary.
Two formulations were prepared based on suggested optimal concentrations of demulsifier content by
experimental design using Qualitec 4 and these proved to be highly effective in treating real and synthetic
emulsions.
Keywords: Crude oil; Demulsifier; Water-in-oil emulsion; Formulation.
throughout (Daaou et al., 2009). These molecules more stable at lower ionic strength of the aqueous
can have 30 or more carbons, and they are usually phase.
considered to be the heaviest and the most polar In the present study, the focus is on the investiga-
components of the petroleum, but recent work shows tion of the effect of pH values, temperature, salinity
that the average molecular weight of asphaltenes and alcohol modifiers on the stability of an Iranian
extracted with n-heptane is about 750 g/mol crude oil emulsion. In addition, the influence of a
(Groezin and Mullins, 2007) and surprisingly, lower wide range of chemical demulsifiers on destabiliza-
values (around 400 g/mol) have also been found tion of the emulsion is studied in order to better un-
(Honse et al., 2012). They are characterized by a derstand the water-in-oil emulsion behavior. Qualitec
relatively constant hydrogen/carbon ratio of 1.15 4, an experimental design software, was used to
with a specific gravity near one; however, the nature achieve an optimized formulation for water separa-
of asphaltenes in crude oil is still a subject of debate. tion. These experiments were done by bottle test
Asphaltenes are believed to exist in the oil as a col- method, which is the most common method for
loidal suspension and to be stabilized by resins ad- evaluating the amount of water separated from wa-
sorbed on their surface (Leontaritis and Mansoori, ter-in-oil emulsion (Mat, 2006).
1998). In this regard, the resins act as peptizing
agents for asphaltenes and together form clusters
called micelles. These micelles or colloids contain EXPERIMENTAL SECTION
most of the polar material found in the crude oil and
possess surface-active properties (interfacial active Crude Oil Characterization
material). They in turn result from sulfur, nitrogen,
oxygen, and metal-containing entities in asphaltene Crude oils used for these sets of experiments are
molecules that form polar groups such as aldehydes, from two fields, Omidie and Ahwaz heavy crude oil.
carbonyls, carboxylic acids, amines, and amides, and Their physical characteristics are shown in Table 1.
play a key role in stabilizing emulsions. Resins are Chemical properties play important roles in the sta-
complex high-molecular-weight compounds that are bility of crude oil emulsion. Table 1 shows that the
not soluble in ethylacetate but soluble in n-heptane. oil from the Omidie field is more stable than the
It appears that the asphaltene-resin ratio in crude oil latter as a result of combining four interfacial active
is responsible for the type of film formed (solid or agents in the crude oil.
mobile) and, therefore, is directly linked to the sta-
bility of the emulsion (Strassener, 1968; Borba, Table 1: Chemical characteristics of crude oils.
1990).
There are numerous parameters that contribute to Crude oils Omidie Ahwaz
the stability of the interfacial film and as a result to Chemical analysis
emulsion stability, such as water pH and the additive Density (kg/m3 in 15 °C) 831.3 884
content (Poteau et al., 2005; Fortuny et al., 2007; Salt content (g/m3) 16 14
Daaou et al., 2011), but these effects show different Asphaltene (%w/w) 0.39 0.5
behavior for various oil origins (Strassner, 1968; Resin (%w/w) 23.35 20
Pathak and Kumar, 1995; McLean and Kilpatrick, Wax (%w/w) 15 7.2
1997a; Goldszal et al., 2002). For example, Daou et Solid part (%w/w) 0.5 0.8
al. (2011) studied the effect of pH on Algerian crude Saturated Hydrocarbon (%w/w) 40 30.8
oil emulsions and suggested that a neutral medium is Aromatic Hydrocarbon (%w/w) 20.76 40.7
more efficient than an acidic or basic environment
for stabilizing the emulsions. Fortuny et al. (2007) Materials and Equipment
studied the effects of salinity, temperature, water
content and pH on the stability of crude oil emul- The chemicals and methods used in this study are
sions based on microwave treatment and showed chosen based on suitability and economic feasibility.
that, in emulsions containing high water contents, the The demulsifiers used in this study are shown in
rate of demulsification is high, except when high pH Table 2. The majority of the chemicals used in this
and salt content were simultaneously involved. Ad- study were supplied from Merck, BASF and Kavosh
ditionally, Moradi et al. (2011) studied the impact of Kimia Kerman companies. Table 3 presents the list
salinity on crude oil/water emulsions by measuring of solvents used to increase the pour point and solu-
the droplet-size distribution visualized by an optical bility of solid and viscous demulsifiers. The ho-
microscopy method, and found that emulsions are mogenizer used in this study is Silent Crusher M
manufactured by Heidolph and the incubator is sion was prepared by mixing n-heptane (analytical
Gerhardt, Model THO 500. grade) and Toluene (7:3 V/V); 2 grams of asphalte-
nes are added to a liter of the synthetic crude oil; the
Table 2: Types of chemical demulsifiers. resultant solution is then mixed with water in a 4:1
No. Name Supplier
(volumetric) ratio, resulting in a very stable W/O
1 Urea Kavosh Kimia Kerman emulsion, as was expected (Bhattacharyya, 1992).
2 Polyethylene glycol Kavosh Kimia Kerman The phases were next mixed using a homogenizer at
3 Diethylene glycol Kavosh Kimia Kerman a speed of 15000 rpm for 6 minutes to get a stable
4 Propylene glycol Kavosh Kimia Kerman
5 Fatty alcohol ethoxylate Shazand Petrochemical emulsion. The experiments were repeated three times
Company and the reported results are the mean value of each
6 Monoethylene glycol Kavosh Kimia Kerman result obtained. Relative errors in estimating the
7 N.P.10 Kavosh Kimia Kerman
8 Triethanolamine Kavosh Kimia Kerman
volume of the separated water phase are around 3%
9 2-Ethyl hexyl acrylate Merck for all procedures and steps.
10 Methacrylic acid Merck
11 Sodium dodecyl sulfate Sigma-Aldrich Extraction of Asphaltene
(S.D.S)
12 Butyl acrylate Merck
13 Acrylic acid anhydrous Merck Crude oil was dispersed in n-pentane or n-heptane
14 Methyl methacrylate Merck at a concentration of 1:5 (v/v). The mixture was then
15 Basorol PDB 9946 BASF company
16 Basorol PDB 9947 BASF company sonicated in an ultrasonic bath for 45 minutes and
17 Basorol PDB 9935 BASF company left to settle overnight. After settling, the mixture
18 Basorol PDB 9955 BASF company was sonicated again for 20 minutes. The precipitated
19 Basorol E 2032 BASF company
20 Basorol E 9350 BASF company
asphaltenes were filtered on medium porosity
21 Naphthalene Fluka chemika (Hunktell grade 392) filter paper. The collected as-
22 Methyl trioctyl ammonium Merck phaltenes were mixed again with a 1:2 volume ratio
chloride (TOMAC) of original crude to n-pentane or n-heptane, soni-
23 Dioctylamine Merck
24 VZB 1413 Kavosh Kimia Kerman cated for 45 minutes and left overnight. The asphal-
25 VZB 1414 Kavosh Kimia Kerman tenes were then filtered again and dried at 45 ºC
under vacuum until the solvent was completely
Table 3: list of solvents. evaporated. The asphaltene-solid fractions were con-
sidered to be dry when the change in mass is less
No. Name of Purity Supplier Oil or water
solvent company solubility than 0.1% over a 24 hour period (Gafonva, 2000).
1 butanol >0.99 Merck Water soluble
2 ethanol >0.99 Merck Oil soluble Demulsification Tests
3 Heavy At least Esfahan Oil soluble
aromatic 0.85 Petrochemical
4 Mix xylene >0.95 Petrochimi Oil soluble
The demulsifiers were screened using the bottle-
Bandar Imam test method. Varied amounts of potential demulsifi-
ers were added to a series of tubes or bottles each
Experimental Methods containing the same amount of an emulsion to be
broken (Mat, 2006). The screening process is con-
This study was carried out using two types of ducted at constant temperature, pH and demulsifier
water-in-oil emulsions from real and synthetic oil. concentration at optimal amounts, which were cal-
The bottle-test method was used in both single and culated previously; therefore, the most effective sin-
composite demulsifier screening in order to find out gle demulsifier was found based on water separation
the most effective demulsifiers. from the emulsion system. The assays of the effect of
pH were conducted by adding HCl or NaOH solu-
Emulsion Preparation tions to adjust the pH of emulsion water.
emulsion. Then, the bottles were shaken for 1 min to rate water from water-in-oil emulsions under various
thoroughly mix the demulsifier and the emulsion. pH values. Obviously, changing pH values influence
The bottles were then returned to the incubator. emulsion stability. For acidic medium, the separated
Separation of phases was monitored by the position water volume varied from 12% (of the total added
of the water/emulsion interface and recorded as a water) at pH 3.0 to 49% V/V at pH 5.5. The same
function of time to verify the volume of water sepa- pattern was observed when using Basorol E 2032 as
rated every 15 min. A bottle containing an emulsion a demusifier from the oil soluble group, which
without any additive was employed as a reference showed separation of water varying from 20% V/V
(blank). The volume of water separation from the to 57% V/V. Again the optimum (57% separation of
emulsion system was observed. Water separation the total water) was reached at pH 5.5. In the alkaline
versus time was plotted, which is defined as: medium (pH 9.3–13), separated water varied from
5% V/V to 30% V/V and from 15% V/V to 45% V/V
⎛ V ⎞ V1 (1) by injecting triethanolamine and Basorol E 2032,
⎜ % ⎟ = V ∗100
⎝ V⎠ 2 respectively. At pH 13, the emulsion shows the
greatest stability since little water separates.
where V1 is the volume of separated water and V2 is Therefore, we can conclude that, at very high and
the original volume of water contained. very low pH values, the emulsions seem to be stable,
while intermediate pH values cause instability. The
Optimization of the Demulsifier Formulation range and degree of emulsion stability are very de-
pendent on the crude oil from which the emulsion
The results from experimental runs were used as was prepared. Consequently, the optimal pH for
a factor in optimizing formulations in order to pro- treating crude oil emulsions seem vary from 5 to 9.
duce the best results in breaking the water-in-oil According to Johansen et al. (1989), a main reason
emulsion system. The type of material and the con- for this is that a low permittivity medium causes the
centration were used as the variables in the experi- cancellation of electrostatic repulsion and of any im-
mental design. Thus, the concentrations of water- portance of multivalent counter-ions as destabilizers.
soluble demulsifiers (fatty alcohol ethoxylate, In addition, Poteau et al. (2005) showed that pH has
triethanolamine and urea) change in all runs while a strong influence on the interfacial properties of
keeping the pH and temperature constant at 5.5 and asphaltenes at a Venezuelan crude oil/water interface
70 °C, respectively. The L-8 array method of ex- at high or low pH. This is because, at these pH values,
perimental design that was applied in this work con- asphaltene functional groups become charged, lead-
siders two levels of variables (high and low); thus, ing to enhancing surface activity.
eight runs of the experimental design were used to
optimize the concentration for both oil-soluble and
water-soluble demulsifiers. The optimal concentra-
tion for both factors was then combined as a new
formulation for treating crude oil emulsion systems.
Effect of pH Values
Brazilian Journal of Chemical Engineering Vol. 32, No. 01, pp. 107 - 118, January - March, 2015
112 P. Hajivand and A. Vaziri
Figure 4: Water separation using water-soluble de- Figure 6: Water separation using oil-soluble de-
mulsifiers. Experimental conditions: T = 70 °C, De- mulsifiers. Experimental conditions: T = 70 °C, De-
mulsifier concentration = 10 ppm, pH=5.5. mulsifier concentration = 10-5 volume fraction, pH=5.5.
respectively. Information about the optimum and larly, for oil-soluble demulsifiers, the optimum for-
productivity of each factor is provided in Table 9. In mulation is Basorol E 2032, with the optimum amount
this table, the optimal quantity relevant to each pa- around 15 ppm in addition to 30 ppm TOMAC and 20
rameter and its level are shown. ppm Basorol PDB 9935. In this case, Qualitec 4 pre-
dicts a separation of around 86% V/V of water from
Table 7: Analysis of variance for selected water- emulsion for both groups. It is noteworthy that, due to
soluble demulsifiers. the fact that urea is not effective in the final formula-
tion (0% V/V effectiveness), as shown in Table 7, we
Factors DOF ss Variance Pure %p did not employ it in creating formula A and the com-
Sum position of this formulation were achieved practically;
Urea 1 182.757 182.757 0 0 hence, formula A was produced according to the sug-
Triethanolamine 1 1122.195 1122.195 930.187 25.643 gested composition: 0% urea, 16% triethanolamine,
Fatty alcohol
ethoxylate
1 1718.445 1718.445 1526.43 42.08 20% fatty alcohol ethoxylate, 6% Basorol E2032, 8%
Errors/others 4 768.03 192.007 32.277 Basorol PDB 9935, 12% TOMAC and 39% aromatic
total 7 3627.42 100% solvent. However, another formula (B) containing
urea was produced according to the Qualitec 4 sug-
Table 8: Analysis of variance for selected oil-soluble gestion: 1.53% urea, 11.84% triethanolamine, 14.65%
demulsifiers fatty alcohol ethoxylate, 17.82% Basorol E2032,
12.75% Basorol PDB 9935, 10.89% TOMAC and
Factors DOF ss Variance Pure %p
Sum
30.49% aromatic solvent.
TOMAC 1 950.48 950.48 6.176 14.729
Basorol
1 1300.5 1300.5 8.451 21.202
Comparison of the Optimum Formulae with Com-
PDB 9935 mercial Demulsifier Formulations
Basorol E 2032 1 2541.84 2541.84 16.518 44.153
Errors/others 4 615.508 153.877 19.917
total 7 5408.33 100% Two commercial demulsifier formulations were
used in this experiment to compare the yield of emul-
Table 9: The optimum levels for all selected de- sion resolution. They include demulsifiers VZB1413
mulsifiers. and VZB1414 supplied by Kavosh Kimia Kerman Co.
Emulsions were prepared from Omidie field oil.
Figure 11 presents the result of water separation by
Factor Level Optimum Contribution
description level (%) applying a 10-5 volume fraction of formulations A, B,
(ppm) VZB 1413 and VZB 1414. As Figure 11 shows, for-
Urea 60 2 1.531 mulation A effects the best separation, which is almost
Triethanol amine 50 2 11.843
Fatty alcohol 40 2 14.656
90% V/V, followed by formulation B at 84%,
ethoxylate VZB1414 at 72% and VZB1413 at 65%. As expected,
TOMAC 30 2 10.899 the mixture of oil-soluble and water-soluble demul-
Basorol PDB 9935 20 2 12.75 sifiers results in the best separation.
Basorol E 2032 15 2 17.825
Water-soluble Oil-soluble
demulsifiers demulsifiers
Total Contribution 28.03 41.474
from
all Factors (%)
Current Grand 58.218 44.825
Average of
Performance
(% water separation)
Expected Result at 86.248 86.299
Optimum Condition
(% water separation)
Brazilian Journal of Chemical Engineering Vol. 32, No. 01, pp. 107 - 118, January - March, 2015
116 P. Hajivand and A. Vaziri
Among these, formulation A, suggested by the re- under optimal conditions in terms of temperature
sults of Experimental Design in Qualitec 4, is even (70 °C) and pH (5.5). As the process temperature in-
more effective than the commercial formulations. creased, the concentration of demulsifier and the salt
content of the water of the emulsion positively influ-
Effectiveness of Formulation A on Synthetic Oil enced demulsification, while the optimum pH level
Emulsion was 5.5.
The present study suggested two formulations ac-
Formulation A was also tested on a synthetic oil cording to the Qualitec 4 Analysis System; the more
containing only one interfacial active agent, i.e., it effective formulation (B), which separated almost
contained asphaltene and no resins or waxes. Ac- 90% of a real crude-water emulsion using 10 ppm
cording to Gafonova (2000), resins and waxes could volume fraction contained: 16% triethanolamine, 20%
not individually form emulsions, only asphaltenes fatty alcohol ethoxylate, 6% Basorol E2032, 8%
can individually form emulsions. Figure 12 shows Basorol PDB 9935, 12% TOMAC and 39% aromatic
the results of applying 10 ppm of Formula A to the solvent, but no urea. Also, this new formulation was
synthetic oil. A separation of 98% shows that this is more effective than commercial demulsifier formula-
an easier emulsion to break, most likely due to low tions (VZB 1413 and VZB 1414 with 65% and 72%
viscosity (because of the absence of resins and separation, respectively).
waxes), which decrease the mass transfer limitations
for the movement of the demulsifiers through the
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