Challenges During Operation and Shutdown of Waxy Crude Pipelines
Challenges During Operation and Shutdown of Waxy Crude Pipelines
Challenges During Operation and Shutdown of Waxy Crude Pipelines
Abstract
Transportation of waxy crude oil faces great challenges due to shear and
temperature dependency. At high temperatures, waxy crude exhibits low viscous
Newtonian behavior where the resistance to flow due to friction is low, and hence
low pumping pressure is required to transport it. At low temperatures, however,
the crude exhibits shear thinning non-Newtonian behavior where its apparent
viscosity becomes shear-dependent. In such cases, the operated pipeline needs to
maintain a high pressure to guarantee a continuous flow. Moreover, due to heat
transfer between the internal pipeline and surroundings, oil temperature declines
along the pipeline. It follows that the crude viscosity and, hence, frictional resis-
tance increase. If the flow is interrupted for any reason, i.e., emergency or planned
shutdown, then the restartability of the pipeline becomes a challenge because of
the nonexistence of heating generated from friction. In this chapter, the challenges
normally facing transportation of waxy crude oil will be discussed. The chapter
will introduce the rheological properties of waxy crude oil and explain and describe
how these properties can affect the pressure losses inside the pipeline during its
operation and shutdown. The measures that need to be considered when designing
a waxy crude pipeline will be discussed.
1. Introduction
Flow assurance is one of the major technical challenges in oil and gas production
operations. The formation of gas hydrate, wax, halite, asphaltenes, mineral scales,
and naphthenic acids can all result in serious operational and economic concerns.
The industry needs novel and innovative techniques to reduce the costs associated
with flow assurance and to improve the overall operation performance. Nowadays,
with the decrease in conventional oil reserves, oil companies are improving uncon-
ventional oil fields where the reserved hydrocarbons are heavy and possess complex
properties. The most important consequence of these ultraheavy hydrocarbons is
that they hinder the flow through different production and transportation sys-
tems. In particular, for oil transportation through pipelines, we have to consider
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Processing of Heavy Crude Oils - Challenges and Opportunities
the complexity of the fluid rheology as an important factor that needs to be fully
controlled in order to generate a smooth transportation.
The crude oil that possesses a high amount of wax, known as waxy crude oil,
can cause many operational obstacles during production, storage, and transporta-
tion. It is considered that the most important obstacle is the crystallization and
sedimentation of wax in the crude oil in the pipes during transportation. While
waxy crude oil is flowing through the pipeline, and due to continuous cooling of
the oil caused by heat transfer toward surroundings, crystals of wax form and grow
in size to form partial to total blockage of the pipe cross-sectional area. This process
continues with shutdown time, and farther the distance from the pipeline inlet, the
faster is the wax deposition on the pipe internal wall and the higher tendency of
the wax crystals to enlarge in size. This results in a continuous decrease in the pipe
internal diameter, and, as the frictional loss is inversely proportional to the pipe
diameter, higher frictional pressure loss will occur. Because of that, the pumping
pressure needs to be increased in order to preserve the desired flow rate. However,
knowing the mobility of the flow is an important issue for effective and frugal
process of a pipeline framework. The main concern of waxy crude oil is the stream
restart after delay in planned or emergency shutting down of the flow process for
any reason.
Wax precipitation and deposition also contribute significantly in changing the
original rheology of the oil. While wax crystals are precipitated and deposited,
viscosity of the crude oil rises to convert it to a high viscous fluid that adhered to the
internal pipe wall to decrease the effective cross-sectional area of the pipe. A solu-
tion to this issue can be achieved by applying various methods to lower the viscosity
and pour point. The most common methods extensively implemented are heating
of the transported crude, dilution with lighter fluid, and adding chemical addi-
tives, known as flow improvers/modifiers, to the flow stream. Each one of the three
methods has its own advantages and disadvantages; however, generally speaking,
chemical additives stay the most commonly recognized solution as compared to the
other choices.
Usually the waxy crude oil is pumped at temperatures above its wax appearing
temperature (WAT) in order to prevent forming of wax on the wall of the pipes.
The pressure pumped should be high enough to hold the stability of the fluid. When
temperature gets lower due to heat transfer, the crude becomes more viscous. And
if the temperature lowers enough to initiate wax deposition, then there will be a
double effect that results in higher frictional pressure, viz., higher viscosity and
smaller pipe diameter.
Waxy crude oil can be defined as the crude oil that contains high amount of
long-chain paraffin wax (alkanes) components, making the crude to possess a high
pour point and, may be, a low API gravity. A waxy crude oil is distinguished by the
fact that it exhibits non-Newtonian rheological behavior at low range of tempera-
ture (i.e., about 20 F above the pour point). For such non-Newtonian behaved crude
oils, the effective viscosity is not only temperature dependent but also a function of
the effective rate of shear in the pipeline. At reservoir conditions, due to high pres-
sure and temperature, wax molecules are normally dissolved in the crude oil to form
a single continuous hydrocarbon liquid phase. While flowing through pipelines,
especially in sub-sea environments, due to cooling down, wax crystals may start to
precipitate from this continuous phase, and eventually the fluid may lose its liquid-
ity behavior. This change of flow behavior normally starts to occur when the crude
temperature becomes lower than its cloud point or WAT [1].
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Challenges during Operation and Shutdown of Waxy Crude Pipelines
DOI: http://dx.doi.org/10.5772/intechopen.89489
The wax existing in crude oil mostly contains paraffin hydrocarbon (C18-C36)
recognized as paraffin wax and naphthenic hydrocarbon (C30-C60). The hydro-
carbon element of wax is able to present in several phases, i.e., gas, liquid, and
particles (solids), relying on the flow conditions, i.e., pressure and temperature.
When the temperature of wax decreases, the agglomerates and the wax crystals
from paraffin wax are recognized as microcrystalline or naphthenic hydrocarbon
[2]. Chemical flow modifiers can be used to enhance the crude flowability at flow
conditions where crystallization or gelling is expected. These flow modifiers can
delay the crude crystallization by reducing its pour point and viscosity. According
to [3], the temperature of the waxy crude oil at the time of injecting the chemical
additives is an important factor to determine their efficiency. If the temperature
is very low, surely some amount of wax will be formed, and this accumulated wax
will affect the rendering of chemicals. It has been observed that a high molecular
weight wax chemical flow modifier has better performance for lowering waxy
crude pour point. The crystal growth development rate of the lower-molecular-
weight wax inhibitor is much slower than that of the higher molecular weight wax
inhibitor.
Wax deposition along the pipeline is affected by several factors that include
temperature, pressure, wax molecular weight, and the other crude oil components.
For a proper design, operation, and optimization of a waxy crude production and
transportation system, the effect of each of these factors is to be investigated care-
fully following documented experimental procedures and standards.
Wax deposition onto the production system generally requires a nucleating
agent, such as asphaltenes and inorganic solids. The wax deposits vary in consis-
tency from a soft mush to a hard brittle material. Paraffin deposits will be harder
if longer-chain n-paraffin is present. Paraffin deposits can also contain other
materials such as asphaltenes, resins, gums, fine sand, silt, clays, salt, and water.
High-molecular-weight waxes can deposit even in the higher-temperature sec-
tions of a well, while lower-molecular-weight fractions tend to deposit in lower-
temperature regions. Prior to solidification, the solid wax crystals in the liquid oil
change the flow properties from a Newtonian low viscosity fluid to a high viscous
non-Newtonian shear-dependent fluid. With further temperature reduction, the
oil may eventually turn into a very-complex-flow behavior gel with yield stress (i.e.,
becomes yield-pseudoplastic or yield-plastic non-Newtonian fluid). Regardless
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Processing of Heavy Crude Oils - Challenges and Opportunities
of the rheological behavior the oil is exhibiting, oil viscosity is always inversely
proportional to the oil temperature. As the temperature of oil increases, the oil
viscosity decreases and vice versa.
The wax solubility is also directly proportional to process temperature.
According to Sadeghazad and Christiansen [4], when water is present in the crude,
wax deposition tends to reduce. This is because the water decreases the oil’s temper-
ature drop keeping the solution above the pour point temperature. They stated that
water is able to maintain the oil temperature because oil has only half the specific
heat as compared to that of water.
The second factor that affects the wax deposition is the pressure. The wax
present in oil has a positive divergence, i.e., the solubility of the wax present in
the solution decreases with the increase in applied pressure. This is because of the
intermolecular forces between molecules [4].
The third factor controlling wax deposition is the wax molecular weight. The
higher the molecular weight of the wax, the lesser its solubility because of its melt-
ing point increasing with the increase in the molecular weight [4, 5]. Al-Shafey and
his co-workers stated that the solution composition greatly affects the wax deposi-
tion as well [6]. A set of experiments conducted by Sadeghazad and Christiansen
reveals that the cloud point decreases for a wax solution with a lighter composition,
i.e., it would take longer time for the wax to deposit [4].
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Challenges during Operation and Shutdown of Waxy Crude Pipelines
DOI: http://dx.doi.org/10.5772/intechopen.89489
where Ds is the shear dispersion coefficient (m2/s); a is the particle diameter, m;
Cw is the wax volume fraction concentration excluding the wall, fraction; and ɤ is the
oil shear rate on the wall, s−1.
When tiny solid crystals are suspended within the oil, they collide frequently
with thermally vibrant molecules. Due to such collision, a Brownian movement is
initiated. At a concentration differential of these particles, the motion will cause
diffusion. Coefficient of the Brownian diffusion is expressed as:
RT
D b = _ (2)
6𝜋𝜇aN
As the waxy crystals are denser than the oil particles, they tend to settle down
and deposit. However, according to some results, it is believed that the gravitational
deposition is insignificant toward the wax deposition. The turbulent flow or the shear
dispersion would disperse the settling particles thus eliminating the gravity settling.
The most commonly used parameter to describe fluids’ rheology is the vis-
cosity, defined as the amount of resistance exhibited by the fluid to start the
deformation process once shear stress is applied. As the waxes are precipitating,
the fluid changes into a non-Newtonian fluid. This generally occurs when the
process temperature decreases below the WAT [13]. Moreover, the waxy crude oils
possess high yield stresses when the temperature further declines to values below
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Processing of Heavy Crude Oils - Challenges and Opportunities
the pour-point temperature. When the temperature is lower than the pour-point
temperature, the oil loses its total mobility and turns into a gel-like structure
that would require critical value of stress to flow, known as yield stress value of
the gel. At low temperatures (below WAT), waxy crude oils generally exhibit
non-Newtonian flow behavior (namely, pseudoplastic fluids). The main feature
of the pseudoplastic non-Newtonian fluid is the dependency of viscosity on
shear rate (while it is constant for Newtonian fluids). Figure 1 shows typical flow
curves of fluids exhibiting different types of rheological behavior as proposed by
Wardhaugh and others [3]. The upper curve (a) shows the variation of applied
shear stress and shear rate as measured by a viscometer. The lower curve (b)
shows the variation of fluid viscosity with shear rate. It is clear that the viscosity
of Newtonian fluid is independent of shear rate, while the viscosity of non-
Newtonian fluids decreases with increasing shear rate. Viscosity is the amount of
resistance exhibited by the fluid to start the deformation process once shear stress
is applied. Different correlations are used to derive viscosity as per the case. The
value of viscosity of crude oil depends on many factors including the composition
of oil, temperature, amount of gas dissolved, and pressure or stress. The viscosity
can be calculated as the ratio of shear stress (Pa) to shear rate (s−1); hence, the SI
unit of viscosity is Pa·s.
Figure 1.
Typical flow curves of fluids exhibiting different types of rheological behaviors [3].
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Challenges during Operation and Shutdown of Waxy Crude Pipelines
DOI: http://dx.doi.org/10.5772/intechopen.89489
As the fluid flows through a pipeline, it starts a deformation due to the slip-
page action occurring. Shear stress is a force that is acting parallel to the flow
propagation of the fluid. The main cause of the shear stress is the friction exerted
between the particles, which is proportionally related to the viscosity of the fluid.
Mathematically, the shear stress is the force applied on a surface divided by the
F , where τ is the shear stress in N/m2 (or Pascal), F is the applied
_
surface area, i.e., τ =
A
force in N, and A is the cross-sectional area of the fluid parallel to the applied force
2
in m .
The shear rate is the rate at which the deformation caused by the shear stress is
taking place. In Newtonian fluids, the shear rate increases as the flow rate increases.
As in the case of flow through pipelines, the shear rate is the gradient of change in
velocity across the radius of the pipe assuming that the top and bottom flows are
not in similar velocities. Assuming two parallel plates with one moving while the
other is stationary, the shear rate can be defined as _ v1 − v2
where v1 is the velocity
h
at the top plane, v 2 is the velocity at the bottom plane, and h is the gap between
the plates. This radial velocity and shear distribution are similar to what happens
during oil flow through pipelines. While flow velocity is constant along the pipeline
(since the pipe diameter is constant), there is a radial velocity variation along the
cross-sectional area due to the effect of shear. At the pipe wall, where the shear
stress is maximum, velocity is zero, whereas the maximum velocity occurs at the
center of the pipe. Figure 2 shows an example of the radial velocity distribution at
three values of flow rates [3], where A is the highest flow rate and C is the lowest
flow rate as indicated by radial velocity distribution showing a turbulent flow and
laminar flow, respectively.
Figure 2.
Radial velocity distribution in the pipeline at three values of flow rate (VA > VB > VC) [3].
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Processing of Heavy Crude Oils - Challenges and Opportunities
Since pipelines are the main transportation methods of waxy crude oils, proper
precautions and measures should be adopted to ensure a safe and smooth flow at
various operating conditions. For long-distance pipelines, in particular, the tem-
perature variation along the pipeline causes axial change of the rheological behavior
which results in complexity of prediction of pressure losses at different segments
along the pipeline.
Two cases need to be considered of a waxy crude pipeline, operating conditions
and shutdown conditions.
During operation, the flow of the transported waxy crude tends to facilitate the
pipeline operation due to continuous shear of the fluid, from one hand, and the
heat generation due to friction, from the other hand. The former causes reduction
of the crude viscosity, which results in the decreasing of the generated frictional
pressure losses, and hence, less pumping pressure is required. The latter adds a
significant heating to the transported fluid, which can compensate part of the
heat losses resulting from the heat transfer due to temperature difference between
Figure 3.
Temperature distributions along Higleig-Portsudan pipeline (inlet temperature 60°C and flow rate 0.33 m3/s) [18].
Figure 4.
Variation of temperature and viscosity along pipelines [19].
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Challenges during Operation and Shutdown of Waxy Crude Pipelines
DOI: http://dx.doi.org/10.5772/intechopen.89489
the fluid and surroundings. As a result, the temperature along the pipeline can be
maintained to be always above the WAT. Figure 3 is an example of temperature
distribution along the Sudanese Higleig-Portsudan pipeline assuming two values
of soil temperature [18]. The figure indicates that the shear action due to flow can
maintain the temperature and delay the distance at which the temperature falls
down to surrounding (soil) temperature. This distance is directly proportional to
the fluid flow rate.
Figure 4 shows a typical variation of temperature and viscosity along a waxy
crude pipeline [19]. As we go far from the inlet, temperature declines due to
heat transfer between the fluid and the pipeline surroundings. The temperature
Figure 5.
Fula pipeline profile and pressure transverse between initial and terminal pump stations [20].
Figure 6.
Fula pipeline profile and pressure transverse between pump stations (3 pump stations) [20].
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Processing of Heavy Crude Oils - Challenges and Opportunities
Figure 7.
Transient temperature distribution along the pipeline every 12 h after shutdown (inlet temperature 60°C, soil
temperature 42°C, flow rate 0.33 m3/s) [18].
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Challenges during Operation and Shutdown of Waxy Crude Pipelines
DOI: http://dx.doi.org/10.5772/intechopen.89489
the pipeline distance reaches the surrounding temperature after 2 days from the
shutdown moment.
The most worse shutdown scenario is where the crude temperature drops below
pour point and results in the gelling of the crude inside the pipeline. In such com-
plex scenario, the restartability of the pipeline becomes a challenge, and the opera-
tor may become unable to restart it. It is, therefore, essential to avoid these complex
scenarios by different measures such as heating, chemical additives, dilution of the
crude with lighter fluids, and shortening the shutdown periods to ensure that the
temperature is always at a value permitting a smooth restarting of the pipeline.
4. Conclusions
Author details
© 2019 The Author(s). Licensee IntechOpen. Distributed under the terms of the Creative
Commons Attribution - NonCommercial 4.0 License (https://creativecommons.org/
licenses/by-nc/4.0/), which permits use, distribution and reproduction for
non-commercial purposes, provided the original is properly cited.
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Processing of Heavy Crude Oils - Challenges and Opportunities
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Challenges during Operation and Shutdown of Waxy Crude Pipelines
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