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Oil emulsion prevention
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Emulsions are always a drain on the operating budget. It is almost impossible to eliminate emulsions during crude production; however, emulsion problems can be reduced and optimized by following good operating practices. The following points should be included in operating practices.
- Solids management. Fine solids stabilize emulsions, and efforts should be made to reduce solid contaminants during production. These solids include asphaltenes, which can be controlled by effective asphaltene management, dispersants, etc.; scales, which should be reduced by scale inhibitors; and waxes, which should be controlled with pour-point depressants or heating.
- Reduction of corrosion products. These products can be reduced with effective corrosion inhibitors.
- Acidization. Stimulation with acids can cause very tight emulsions; consequently, acid jobs should be designed with care, and their field performance should be reviewed. To avoid emulsion upsets, the acid job design should incorporate effective demulsifiers at relatively high concentrations, use mutual solvents, and minimize fines and precipitates during acidization.
- Mixing or turbulence. Chokes and other devices such as pumps should be controlled to optimize shear and mixing. While a moderate amount of mixing is necessary and beneficial, severe mixing leads to tight emulsions or even re-emulsification after water separation. Another place to control mixing is in gas lift operations by injecting the optimum amount of gas.
- Compatibility of chemicals. Increasingly, more chemicals are being used for improved oil recovery and crude processing. The chemical may be the source of the emulsion problem. Compatibility studies should be performed with the chemicals that are used during crude oil production (from the reservoir to the separation facilities), and their emulsion-forming tendencies should be evaluated.
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