Transcript HEAT TRANSFER ENHANCEMENT: WHAT SORT OF BLOCKS

Intensification of Highly Stable Water-in-Crude Oil
Emulsion Separation Under Electric Field in the
Presence of Micro-Cellular Demulsifiers
G. Akay*, Z. Z. Noor*, M Dogru*, B. Calkan and SR Larter**
*Process Intensification and Miniaturization Centre,
School of Chemical Engineering and Advanced Materials,
and
**School of Civil Engineering and Geosciences
University of Newcastle, Newcastle upon Tyne, NE1 7RU (UK)
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
OBJECTIVES
1. Breakdown (separation) of the emulsion (CRUD) produced
during nuclear reprocessing.
2. To develop an INTENSIFIED (very fast and small
volume) oil – water separation process for applications in
CRUDE OIL PRODUCTION under DOWNHOLE and
SUBSEA conditions.
3. Equipment development for the above.
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
EMULSION SEPARATION TECHNIQUES
 ESTABLISHED METHODS
 Chemical Demulsifiers
 Hydrocyclones
 Electric Field

Membranes
 NOVEL METHODS
 High Pressure
 Novel Micro-porous Polymeric Demulsifiers
COMBINED METHODS FOR SYNERGY
(Demulsifier + Electric Field + Pressure)
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
MICRO-POROUS DEMULSIFIER / ADSORBER
(SULPHONATED MICRO-POROUS POLYHIPE POLYMER)
(PHP)
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
PHP
PHP-SO3Na
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APPLICATIONS OF POLYHIPE POLYMERS (PHP)
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Tissue engineering
Intensified oil-water emulsion separation
Intensified gas / liquid separation
Gas clean-up
Water clean-up
Nano-structured micro-porous metals
Micro-bioreactors
Bioprocess intensification
etc
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Preparation of High Internal Phase Emulsions &
POLYHIPE POLYMERS
High Internal Phase Emulsion
Emulsion
with ε>74%
Add
more
aqueous
phase
Monomer
Aqueous phase
Polymerisation
Concentrated emulsion with
dispersed phase volume (ε)=74%
Pore wall with interconnecting holes
(interconnects)
PolyHIPE Polymer (PHP)
New Trends in Chemical Engineering
TYPES OF PORE IN POLYHIPE POLYMERS
Primary Pores
0.5 < D < 300 μm
Coalescence Pores
Size up to ~ 10 mm
Capillary
Network
Nano Pores
by mixed monomer
Nano-structured Microporous Catalyst Support for
Bio- and Chemical – Catalysis
Nickel catalyst / support
Nano-structured Microporous Catalyst Support for
Bio- and Chemical – Catalysis
Nickel Catalyst / Support
PROCESS INTENSIFICATION IN EMULSION SEPARATION
DEMULSIFICATION OF CRUDE OIL – WATER EMULSIONS
( EFFECT OF PRESSURE / DEMULSIFIER ADSORBER )
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
NEED FOR NOVEL OIL - WATER
SEPARATION TECHNIQUES
 Crude oil contains 10 – 90 % dispersed water
 Current technology is designed for onshore
applications
 Offshore
separation
requires
small
processing equipment
 Current technology is ineffective for highly
viscous crude
or when high
levels of
indigenous surfactants are present.
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
REASONS FOR INTENSIFICATION IN CRUDE OIL PRODUCTION
 Reduction of Environmental Impact
 Reduction of Crude Oil/ Water Pumping Cost
 Utilisation of the Potential Energy at Downhole /
Subsea Conditions
(High Pressure and Temperature)
 Lower Capital and Running Costs
 Small Offshore Processing Equipment
 Oil-in-Water Emulsions are More Common & Environment
Restriction More Strict
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
EXPERIMENTS WITH BP AMOCO VISCOUS (HARDING) CRUDE
Emulsion Preparation
•
Water –in –oil emulsion (50/50)
•
Aqueous phase is model sea water (0.6g CaCl2/L, 5.0g
MgCl2 /L and 28.1g NaCl /L)
•
Mixing at 2000 rpm for 15 minutes
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Stable emulsion for more than 4 weeks (no separation)
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
Equipment for Electric Field Separation
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
ELECTRIC FIELD SEPARATION
PROCESS INTENSIFICATION IN EMULSION SEPARATION
BP AMOCO CRUDE OIL
EXPERIMENTAL PROCEDURE
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0.5 g/kg Demulsifier/adsorber is mixed with emulsion
• Above mixture pumped into the electric separator
while mixing
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Top electrode is positive (also isolated) while bottom
electrode is earthed
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Emulsion is collected from the top and bottom and
oil-water separation was measured within 10 mins,
after 1 hour or 24 hours (no agitation during storage)
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
Constant Electric Field Strength (E=2.5 kV); Variable Flow Rate
Immediate Separation
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
Constant Electric Field Strength (E=2.5 kV); Variable Flow Rate
After 1 hour
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
Constant Electric Field Strength (E=2.5 kV); Variable Flow Rate
After 24 hours
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
Constant Flow Rate (Q= 2.5 ml/min); Variable Electric Field strength
Immediately after passage through the separator
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
Constant Flow Rate (Q= 2.5 ml/min); Variable Electric Field Strength
1 hour after passage through the separator
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
Scanning Electron Microscopy and EDAX Analysis
• PHP demulsifier absorbed several of the ionic species that
were present in both phases, i.e., Na, Ca, Al, Pb and Mg as
well as other compounds including Cl.
• Thus the demulsifier is also useful for the cleaning of the
‘produced water’ and crude oil. Therefore it is called PHP
Demulsifier/Adsorber.
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
CONCLUSIONS
• The presence of PHP demulsifier/adsorber intensifies the
electric field separation at high emulsion flow rates or
at low electric field strengths
• PHP demulsifier/adsorber also adsorbes metals as well as
phenols
• Demulsification appears to be the result of selective adsorption
of surface active species from the emulsion
• Synergy between the demulsifier/absorber and electric field
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
INTENSIFIED PROCESSING EQUIPMENT
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Intensified rotating disk granulator (particle technology)
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Intensified separator
* Electric field
* Pressure
* Flow field
* Mixing of PHP Demulsifier/absorber
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Intensified rotating disk reactor for viscous reactions
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
Equipment -2: Rotating Porous Disk Separator and Reactor
EMULSION
DEMULSIFIER
Retantate
for
analysis
Emulsion-Demulsifier
Separator
Demulsifier
for
analysis
OIL
Retantate
Recycle
Porous Disk
(Stationary)
Porous Disk
(Rotating)
WATER
Rotating Porous Disk-CDDM-Separator in Shear Flow Configuration
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
TYPICAL ROTOR ELEMENT TO ACHIVE PUMPING, MIXING, SOLID CONVEYING
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
INTESIFIED ROTATING POROUS DISK SEPARATOR / REACTOR
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PROCESS INTENSIFICATION IN EMULSION SEPARATION
ACKNOWLEDGEMENTS
This research was initially supported by
BNFL & Norsk Hydro
CURRENT SUPPORT FROM
SUSTAINABLE TECHNOLOGIES INITIATIVE (LINK):
*Engineering and Physical Sciences Research Council (UK)
* Department of Trade and Industry (UK)
*Avecia
*BLC Research
*BP-Amoco
* Intensified Technologies Incorporated (ITI)
*Safety - Kleen Europe
*Triton Chemical Systems
*Willacy Oil Services Ltd
*University Technology of Malaysia (for ZZ Noor)
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