Patent Application
20240287402
The present disclosure generally relates to compositions and methods for controlling fouling of the equipment used to process raw natural gas.
To enhance the recovery of hydrocarbon from wells, operators inject compositions comprising water, brine, carbon dioxide and surfactants. The compositions are used to increase and maintain the efficiency of the recovery of oil and gas. Although the compositions vastly improve the efficiency of the hydrocarbon recovery, the additives in the compositions cause significant problems.
Water and carbon dioxide can lead to the formation of hydrates, which block pipes. The mixture of water and carbon dioxide is acidic, which leads to the corrosion of the process equipment. As such, corrosion inhibitors are added to the compositions to minimize the damage to the equipment. Typically, corrosion inhibitors are surfactants. Operators also use surfactants or compounds that produce foam as lifting agents. Foam modifies the composition of the subterranean hydrocarbons, thereby increasing the recovery rates of the same. All the aforementioned additives adversely affect operations in downstream processes.
For example, foaming is a major and underestimated problem with respect to the process of cleaning and compressing raw natural gas. Foam, as a gas dispersed in a liquid, has low buoyancy such that it entrains liquids, dissolved solids, as well as insoluble solids attached to the surface of the bubbles. The entrained liquids and solids lead to the fouling of equipment used to clean and compress the natural gas. Foaming, therefore, leads to inefficient cleaning of the recovered gas streams. Contaminants entrained in the raw gas comprise water, hydrocarbon liquids, dissolved hydrocarbons solids, suspended hydrocarbon particles, sand, and metal salts. After deposition onto the internal surfaces of the equipment, the removal of the foulants is very difficult. Rapid equipment fouling and frequent shutdowns result in costly and unscheduled operational stoppages, and frequently damaged compressor parts must be replaced.
The present disclosure provides compositions and methods for controlling fouling. In some embodiments, a method for controlling fouling in a process for cleaning a hydrocarbon gas is disclosed, which comprises adding an effective amount of a composition to a conduit comprising the hydrocarbon gas. The composition comprises an anti-foam compound.
In some embodiments, the conduit further comprises a member selected from the group consisting of an entrained hydrocarbon liquid condensate, an entrained aqueous phase, an entrained dissolved organic solid, a dissolved inorganic solid, an insoluble organic solid, an insoluble inorganic solid, and any combination thereof.
In some embodiments, the hydrocarbon gas is a C1 hydrocarbon, a C2 hydrocarbon, a C3 hydrocarbon, a C4 hydrocarbon, or any combination thereof.
In certain embodiments, the method is carried out online.
In some embodiments, the anti-foam composition comprises the following Formula I:
In some embodiments, R1, R2, R3, R4, R5, R6, R7 and R8 are independently selected from a methyl group, an ethyl group, a propyl group, a butyl group, and any combination thereof. In certain embodiments, each of R1, R2, R3, R4, R5, R6, R7 and R8 is a methyl group.
In some embodiments, the anti-foam compound comprises a polydimethylsiloxane.
In some embodiments, the composition further comprises a solvent selected from the group consisting of water, methanol, ethanol, propanol, isopropanol, n-butanol, isobutanol, sec-butanol, tert-butanol, a C5 to C18 hydrocarbon, and any combination thereof. In certain embodiments, the composition comprises from about 5 wt. % to about 95 wt. % of the solvent.
In some embodiments, the composition further comprises a surfactant selected from the group consisting of an anionic surfactant, a cationic surfactant, a nonionic surfactant, a zwitterionic surfactant, and any combination thereof. In certain embodiments, the composition comprises from about 1 wt. % to about 25 wt. % of the surfactant.
In some embodiments, the composition comprises from about 1 wt. % to about 100 wt. % of the anti-foam compound.
In some embodiments, the effective amount is from about 0.1 ppm to about 10,000 ppm.
In certain embodiments, the composition is added upstream or downstream of a primary slug catcher. In some embodiments, the composition may be added to an amine unit slug catcher and/or upstream of an amine unit slug catcher. In some embodiments, the composition is added upstream of a primary slug catcher but downstream of a subterranean formation. In certain embodiments, the composition is added downstream of a primary slug catcher but upstream of a secondary slug catcher. In some embodiments, the composition is added downstream of a secondary slug catcher but upstream of a tertiary slug catcher. In some embodiments, the composition is added downstream of a slug catcher but upstream of a scrubber.
In certain embodiments, the composition further comprises an additive selected from the group consisting of an emulsion-stabilizing compound, an imidazoline, an imidazolium compound, agar, carrageenan, gellan, gelatin, guar gum, sodium alginate, xanthan gum, and any combination thereof.
In some embodiments, the emulsion-stabilizing compound comprises the following Formula II:
In some embodiments, the composition comprises from about 0.01 wt. % to about 1.00 wt. % of the additive.
In certain embodiments, the composition is added at ambient temperature.
In some embodiments, the anti-foam compound is selected from the group consisting of a polydimethylsiloxane, ethylene glycol butyl ether, diethylene glycol methyl ether, diethylene glycol ethyl ether, diethylene glycol butyl ether, triethylene glycol butyl ether, triethylene glycol methyl ether, triethylene glycol ethyl ether, ethylene glycol propyl ether, diethylene glycol propyl ether, triethylene glycol propyl ether, propylene glycol butyl ether, propylene glycol ethyl ether, propylene glycol methyl ether, dipropylene glycol methyl ether, dipropylene glycol ethyl ether, dipropylene glycol butyl ether, tripropylene glycol butyl ether, tripropylene glycol propyl ether, tripropylene glycol methyl ether, butylene glycol methyl ether, butylene glycol ethyl ether, butylene glycol propyl ether, butylene glycol butyl ether, dibutylene glycol butyl ether, tributylene glycol butyl ether, tetraethylene glycol butyl ether, tetrapropylene glycol methyl ether pentaethylene glycol butyl ether, pentapropylene glycol methyl ether ethanol, 2-(2-butoxyethoxy)ethanol (BuCa), ethylene glycol butyl ether (EBGE), propylene glycol (PG), ethylene glycol (EG), hydrophobic silica, silicone oil, and any combination thereof.
In some embodiments, the composition comprises hydrophobized silica, a fatty acid ester of a polyethylene glycol sorbitan surfactant, benzoic acid, erythorbic acid and deionized water. In certain embodiments, the composition comprises polydimethylsiloxane and kerosene. In some embodiments, the composition comprises hydrophobic silica, a silicone surfactant, and polydimethylsiloxane.
In some embodiments, the composition consists of or consists essentially of the anti-foam compound and optionally the additive, the surfactant and/or the solvent. In certain embodiments, the method consists of or consists essentially of adding the composition to the conduit.
The present disclosure also provides a method for controlling fouling of equipment used during a process for cleaning and compressing a hydrocarbon gas. The method comprises adding an effective amount of a composition to the equipment comprising the hydrocarbon gas, wherein the composition comprises an anti-foam compound.
In some embodiments, the equipment is selected from the group consisting of a slug catcher, a scrubber, a suction drum, a compressor, and any combination thereof.
In some embodiments, the composition is added to a conduit upstream of the equipment, optionally wherein the conduit further comprises a member selected from the group consisting of an entrained hydrocarbon liquid condensate, an entrained aqueous phase, an entrained dissolved organic solid, a dissolved inorganic solid, an insoluble organic solid, an insoluble inorganic solid, and any combination thereof.
In certain embodiments, the hydrocarbon gas is a C1 hydrocarbon, a C2 hydrocarbon, a C3 hydrocarbon, a C4 hydrocarbon, or any combination thereof.
In some embodiments, the method is carried out online.
In some embodiments, the anti-foam composition comprises the following Formula I:
In certain embodiments, R1, R2, R3, R4, R5, R6, R7, and R8 are independently selected from a methyl group, an ethyl group, a propyl group, a butyl group, and any combination thereof. In some embodiments, each of R1, R2, R3, R4, R5, R6, R7, and R8 is a methyl group.
In some embodiments, the anti-foam compound comprises a polydimethylsiloxane.
In certain embodiments, the composition further comprises a solvent selected from the group consisting of water, methanol, ethanol, propanol, isopropanol, n-butanol, isobutanol, sec-butanol, tert-butanol, a C5 to C18 hydrocarbon, any combination thereof. In some embodiments, the composition comprises from about 5 wt. % to about 95 wt. % of the solvent.
In some embodiments, the composition further comprises a surfactant selected from the group consisting of an anionic surfactant, a cationic surfactant, a nonionic surfactant, a zwitterionic surfactant, and any combination thereof. In certain embodiments, the composition comprises from about 1 wt. % to about 25 wt. % of the surfactant.
In some embodiments, the composition comprises from about 1 wt. % to about 100 wt. % of the anti-foam compound.
In some embodiments, the effective amount is from about 0.1 ppm to about 10,000 ppm.
In certain embodiments, the composition is added upstream or downstream of a primary slug catcher. In some embodiments, the composition is added upstream of a primary slug catcher but downstream of a subterranean formation. In some embodiments, the composition is added downstream of a primary slug catcher but upstream of a secondary slug catcher. In certain embodiments, the composition is added downstream of a secondary slug catcher but upstream of a tertiary slug catcher. In some embodiments, the composition is added downstream of a slug catcher but upstream of a scrubber.
In some embodiments, the composition further comprises an additive selected from the group consisting of an emulsion-stabilizing compound, an imidazoline, an imidazolium compound, agar, carrageenan, gellan, gelatin, guar gum, sodium alginate, xanthan gum, and any combination thereof.
In some embodiments, the emulsion-stabilizing compound comprises the following Formula II:
In certain embodiments, the composition comprises from about 0.01 wt. % to about 1.00 wt. % of the additive.
In some embodiments, the composition is added at ambient temperature.
In some embodiments, the anti-foam compound is selected from the group consisting of a polydimethylsiloxane, ethylene glycol butyl ether, diethylene glycol methyl ether, diethylene glycol ethyl ether, diethylene glycol butyl ether, triethylene glycol butyl ether, triethylene glycol methyl ether, triethylene glycol ethyl ether, ethylene glycol propyl ether, diethylene glycol propyl ether, triethylene glycol propyl ether, propylene glycol butyl ether, propylene glycol ethyl ether, propylene glycol methyl ether, dipropylene glycol methyl ether, dipropylene glycol ethyl ether, dipropylene glycol butyl ether, tripropylene glycol butyl ether, tripropylene glycol propyl ether, tripropylene glycol methyl ether, butylene glycol methyl ether, butylene glycol ethyl ether, butylene glycol propyl ether, butylene glycol butyl ether, dibutylene glycol butyl ether, tributylene glycol butyl ether, tetraethylene glycol butyl ether, tetrapropylene glycol methyl ether pentaethylene glycol butyl ether, pentapropylene glycol methyl ether ethanol, BuCa, EBGE, PG, EG, hydrophobic silica, silicone oil, and any combination thereof.
In certain embodiments, the composition comprises hydrophobized silica, a fatty acid ester of a polyethylene glycol sorbitan surfactant, benzoic acid, erythorbic acid and deionized water. In some embodiments, the composition comprises polydimethylsiloxane and kerosene. In some embodiments, the composition comprises hydrophobic silica, a silicone surfactant, and polydimethylsiloxane.
In certain embodiments, the composition consists of or consists essentially of the anti-foam compound and optionally the additive, the surfactant and/or the solvent.
In some embodiments, the method consists of or consists essentially of adding the composition to the equipment.
The foregoing has outlined rather broadly the features and technical advantages of the present disclosure in order that the detailed description that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter that form the subject of the claims of this application.
A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. In case of conflict, the present document, including definitions, will control. Examples of methods and materials are described below, although methods and materials similar or equivalent to those described herein can be used in practice or testing of the present disclosure. All publications, patent applications, patents and other reference materials mentioned herein are incorporated by reference in their entirety. The materials, methods, and examples disclosed herein are illustrative only and not intended to be limiting.
Unless otherwise indicated, an alkyl group as described herein alone or as part of another group is an optionally substituted linear or branched saturated monovalent hydrocarbon substituent containing from, for example, one to about sixty carbon atoms, such as one to about thirty carbon atoms, in the main chain. Examples of unsubstituted alkyl groups include methyl, ethyl, n-propyl, i-propyl, n-butyl, i-butyl, s-butyl, t-butyl, n-pentyl, i-pentyl, s-pentyl, t-pentyl, and the like.
The terms “aryl” or “ar” as used herein alone or as part of another group (e.g., arylene) denote optionally substituted homocyclic aromatic groups, such as monocyclic or bicyclic groups containing from about 6 to about 12 carbons in the ring portion, such as phenyl, biphenyl, naphthyl, substituted phenyl, substituted biphenyl or substituted naphthyl. The term “aryl” also includes heteroaryl functional groups. It is understood that the term “aryl” applies to cyclic substituents that are planar and comprise 4n+2 electrons, according to Huckel's Rule.
“Cycloalkyl” refers to a cyclic alkyl substituent containing from, for example, about 3 to about 8 carbon atoms, preferably from about 4 to about 7 carbon atoms, and more preferably from about 4 to about 6 carbon atoms. Examples of such substituents include cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, and the like. The cyclic alkyl groups may be unsubstituted or further substituted with alkyl groups, such as methyl groups, ethyl groups, and the like.
“Heteroaryl” refers to a monocyclic or bicyclic 5- or 6-membered ring system, wherein the heteroaryl group is unsaturated and satisfies Huckel's rule. Non-limiting examples of heteroaryl groups include furanyl, thiophenyl, pyrrolyl, pyrazolyl, imidazolyl, 1,2,3-triazolyl, 1,2,4-triazolyl, isoxazolyl, oxazolyl, isothiazolyl, thiazolyl, 1,3,4-oxadiazol-2-yl, 1,2,4-oxadiazol-2-yl, 5-methyl-1,3,4-oxadiazole, 3-methyl-1,2,4-oxadiazole, pyridinyl, pyrimidinyl, pyrazinyl, triazinyl, benzofuranyl, benzothiophenyl, indolyl, quinolinyl, isoquinolinyl, benzimidazolyl, benzoxazolinyl, benzothiazolinyl, quinazolinyl, and the like.
Compounds of the present disclosure may be substituted with suitable substituents. The term “suitable substituent,” as used herein, is intended to mean a chemically acceptable functional group, preferably a moiety that does not negate the activity of the compounds. Such suitable substituents include, but are not limited to, halo groups, perfluoroalkyl groups, perfluoro-alkoxy groups, alkyl groups, alkenyl groups, alkynyl groups, hydroxy groups, oxo groups, mercapto groups, alkylthio groups, alkoxy groups, aryl or heteroaryl groups, aryloxy or heteroaryloxy groups, aralkyl or heteroaralkyl groups, aralkoxy or heteroaralkoxy groups, HO—(C═O)— groups, heterocylic groups, cycloalkyl groups, amino groups, alkyl- and dialkylamino groups, carbamoyl groups, alkylcarbonyl groups, alkoxycarbonyl groups, alkylaminocarbonyl groups, dialkylamino carbonyl groups, arylcarbonyl groups, aryloxy-carbonyl groups, alkylsulfonyl groups, and arylsulfonyl groups. In some embodiments, suitable substituents may include halogen, an unsubstituted C1-C12 alkyl group, an unsubstituted C4-C6 aryl group, or an unsubstituted C1-C10 alkoxy group. Those skilled in the art will appreciate that many substituents can be substituted by additional substituents.
The term “substituted” as in “substituted alkyl,” means that in the group in question (i.e., the alkyl group), at least one hydrogen atom bound to a carbon atom is replaced with one or more substituent groups, such as hydroxy (—OH), alkylthio, phosphino, amido (—CON(RA)(RB), wherein RA and RB are independently hydrogen, alkyl, or aryl), amino(-N(RA)(RB), wherein RA and RB are independently hydrogen, alkyl, or aryl), halo (fluoro, chloro, bromo, or iodo), silyl, nitro (—NO2), an ether (—ORA wherein RA is alkyl or aryl), an ester (—OC(O)RA wherein RA is alkyl or aryl), keto (—C(O)RA wherein RA is alkyl or aryl), heterocyclo, and the like.
When the term “substituted” introduces a list of possible substituted groups, it is intended that the term apply to every member of that group. That is, the phrase “optionally substituted alkyl or aryl” is to be interpreted as “optionally substituted alkyl or optionally substituted aryl.”
The terms “polymer,” “copolymer,” “polymerize,” “copolymerize,” and the like include not only polymers comprising two monomer residues and polymerization of two different monomers together, but also include (co)polymers comprising more than two monomer residues and polymerizing together more than two or more other monomers. For example, a polymer as disclosed herein includes a terpolymer, a tetrapolymer, polymers comprising more than four different monomers, as well as polymers comprising, consisting of, or consisting essentially of two different monomer residues. Additionally, a “polymer” as disclosed herein may also include a homopolymer, which is a polymer comprising a single type of monomer unit.
Unless specified differently, the polymers of the present disclosure may be linear, branched, crosslinked, structured, synthetic, semi-synthetic, natural, and/or functionally modified. A polymer of the present disclosure can be in the form of a solution, a dry powder, a liquid, or a dispersion, for example.
The present disclosure provides compositions and methods for controlling fouling of the equipment used to process raw natural gas. The term “controlling” used herein is intended to encompass actions like reducing, abating, preventing, inhibiting, slowing, etc. Compositions comprising anti-foam compounds are disclosed herein and may be used in methods for abating foaming and equipment fouling while cleaning and compressing natural gas. When the present disclosure refers to an “anti-foam compound,” it is to be understood that this term covers a single anti-foam compound and in certain instances, the term covers multiple anti-foam compounds. For example, in some embodiments, a composition of the present disclosure may include a solvent and an anti-foam compound. The anti-foam compound may comprise polydimethylsiloxane alone, in some embodiments, but in other embodiments, the anti-foam compound may comprise polydimethylsiloxane, ethylene glycol butyl ether, and optionally diethylene glycol methyl ether.
While “anti-foam” compounds may be said to prevent foaming and “de-foaming” compounds may be said to reduce foaming, the presently disclosed term “anti-foam” compound may be used to cover both “anti-foam” compounds as well as “de-foaming” compounds. In some embodiments, however, the term may be used to cover only “anti-foam” compounds or “de-foaming” compounds. In certain embodiments, the term “anti-foam” compound covers any compound that prevents or reduces foaming.
In accordance with some embodiments of the present disclosure, the anti-foam compound may comprise one or more compounds selected from the following Formula I:
For example, “n” may be selected from 1 to 900, 1 to 800, 1 to 700, 1 to 600, 1 to 500, 1 to 400, 1 to 300, 1 to 200, 1 to 100, 1 to 75, 1 to 50, 1 to 40, 1 to 30, 1 to 20, 1 to 10, 10 to 25, 10 to 35, 10 to 45, 10 to 55, 10 to 75, 10 to 100, to 200, 10 to 300, 10 to 400, 10 to 500, 10 to 600, 10 to 700, 10 to 800, 10 to 900, 50 to 900, 100 to 900, 200 to 900, 300 to 900, 400 to 900, 500 to 900, 600 to 900, 700 to 900 or 800 to 900.
In certain embodiments, R1, R2, R3, R4, R5, R6, R7 and R8 may be independently selected from a C1-C18 alkyl group, such as a C1-C15 alkyl group, a C1-C12 alkyl group, a C1-C1 alkyl group, a C1-C8 alkyl group, a C1-C6 alkyl group, a C1-C4 alkyl group, a C1 or C2 alkyl group, a C2-C18 alkyl group, a C4-C18 alkyl group, a C6-C18 alkyl group, a C8-C18 alkyl group, a C10-C18 alkyl group, a C12-C18 alkyl group, a C14-C18 alkyl group, a C16-C18 alkyl group, or a C1, C2, C3, C4, C5, C6, C7, C8, C9, C10, C11, C12, C13, C14, C15, C16, C17, or a C18 alkyl group.
In some embodiments, R1, R2, R3, R4, R5, R6, R7 and R8 may be independently selected from a C6-C18 aryl group, such as a C6-C17 aryl group, a C6-C16 aryl group, a C6-C15 aryl group, a C6-C14 aryl group, a C6-C13 aryl group, a C6-C12 aryl group, a C6-C11 aryl group, a C6-C10 aryl group, a C6-C9 aryl group, a C6-C8 aryl group, a C6-C7 aryl group, or a C6, C7, C8, C9, C10, C11, C12, C13, C14, C15, C16, C17, or a C18 aryl group.
In certain embodiments, R1, R2, R3, R4, R5, R6, R7 and R8 may be independently selected from a C7-C18 alkylaryl group, such as a C7-C17 alkylaryl group, a C7-C16 alkylaryl group, a C7-C15 alkylaryl group, a C7-C14 alkylaryl group, a C7-C13 alkylaryl group, a C7-C12 alkylaryl group, a C7-C11 alkylaryl group, a C7-C10 alkylaryl group, a C7-C9 alkylaryl group, a C7-C8 alkylaryl group, a C8-C18 alkylaryl group, a C9-C18 alkylaryl group, a C10-C18 alkylaryl group, a C11-C18 alkylaryl group, a C12-C18 alkylaryl group, a C13-C18 alkylaryl group, a C14-C18 alkylaryl group, a C15-C18 alkylaryl group, a C16-C18 alkylaryl group, a C17-C18 alkylaryl group, or a C7, C8, C9, C10, C11, C12, C13, C14, C15, C16, C17, or a C18 alkylaryl group.
In some embodiments, R1, R2, R3, R4, R5, R6, R7 and R8 may be independently selected from a C7-C18 arylalkyl group, such as a C7-C17 arylalkyl group, a C7-C16 arylalkyl group, a C7-C15 arylalkyl group, a C7-C14 arylalkyl group, a C7-C13 arylalkyl group, a C7-C12 arylalkyl group, a C7-C11 arylalkyl group, a C7-C1 arylalkyl group, a C7-C9 arylalkyl group, a C7-C8 arylalkyl group, or a C7, C8, C9, C10, C11, C12, C13, C14, C15, C16, C17, or a C18 arylalkyl group.
As illustrative, non-limiting examples, R1, R2, R3, R4, R5, R6, R7 and R8 may be independently selected from a methyl group, an ethyl group, a propyl group, a butyl group, and any combination thereof. As an additional, non-limiting example, each of R1, R2, R3, R4, R5, R6, R7 and R8 may independently comprise a methyl group or an ethyl group. In some embodiments, all of R1, R2, R3, R4, R5, R6, R7 and R8 are methyl groups.
In some embodiments, the anti-foam compound is selected from the group consisting of a polydimethylsiloxane, ethylene glycol butyl ether, diethylene glycol methyl ether, diethylene glycol ethyl ether, diethylene glycol butyl ether, triethylene glycol butyl ether, triethylene glycol methyl ether, triethylene glycol ethyl ether, ethylene glycol propyl ether, diethylene glycol propyl ether, triethylene glycol propyl ether, propylene glycol butyl ether, propylene glycol ethyl ether, propylene glycol methyl ether, dipropylene glycol methyl ether, dipropylene glycol ethyl ether, dipropylene glycol butyl ether, tripropylene glycol butyl ether, tripropylene glycol propyl ether, tripropylene glycol methyl ether, butylene glycol methyl ether, butylene glycol ethyl ether, butylene glycol propyl ether, butylene glycol butyl ether, dibutylene glycol butyl ether, tributylene glycol butyl ether, tetraethylene glycol butyl ether, tetrapropylene glycol methyl ether pentaethylene glycol butyl ether, pentapropylene glycol methyl ether ethanol, 2-(2-butoxyethoxy)ethanol (BuCa), ethylene glycol butyl ether (EBGE), propylene glycol (PG), ethylene glycol (EG), hydrophobic silica, silicone oil, and any combination thereof.
In certain embodiments, the anti-foam compound comprises a polydimethylsiloxane.
In an illustrative embodiment, a composition of the present disclosure comprises hydrophobized silica, a fatty acid ester of polyethylene glycol sorbitan surfactant, benzoic acid, erythorbic acid and deionized water.
In an illustrative embodiment, a composition of the present disclosure comprises Anti-foam Agent 1, which comprises about 10 wt. % hydrophobized silica, about 87.44 wt. % deionized water, about 0.65 wt. % fatty acid esters of polyethylene glycol sorbitan surfactants, about 1.35 wt. % mono[fatty acid]sorbitan ester (sorbitan monostearate), about 0.03 wt. % benzoic acid, about 0.03 wt. % erythorbic acid, and about 0.50 wt. % xanthan gum.
In an illustrative embodiment, a composition of the present disclosure comprises Anti-foam Agent 2, which comprises about 1 wt. % to about 99 wt. %, such as from about 9 wt. % to about 50 wt. %, about 9 wt. % to about 25 wt. %, or about 9 wt. % poly(dimethylsiloxane) and about 1 wt. % to about 99 wt. %, such as from about 50 wt. % to about 91 wt. %, about 75 wt. % to about 91 wt. %, or about 91 wt. % kerosene.
In an illustrative embodiment, a composition of the present disclosure comprises Anti-foam Agent 3, which is Xiameter™ ACP-0544 (available from Dow), which is a water dispersible 100% active silicone anti-foam compound containing hydrophobic silica, silicone surfactants and polydimethylsiloxane.
The amount of anti-foam compound present in the composition may be selected based on certain factors, such as the amount or estimated amount of foam present in the system. In some embodiments, the composition comprises from about 100 wt. % to about 1 wt. % of the anti-foam compound, such as from about 100 wt. % to about 10 wt. %, about 100 wt. % to about 20 wt. %, about 100 wt. % to about 30 wt. %, about 100 wt. % to about 40 wt. %, about 100 wt. % to about 50 wt. %, about 100 wt. % to about 60 wt. %, about 100 wt. % to about 70 wt. %, about 100 wt. % to about 80 wt. %, about 100 wt. % to about 90 wt. %, about 90 wt. % to about 1 wt. %, about 80 wt. % to about 1 wt. %, about 70 wt. % to about 1 wt. %, about 60 wt. % to about 1 wt. %, about 50 wt. % to about 1 wt. %, about 40 wt. % to about 1 wt. %, about 30 wt. % to about 1 wt. %, about 20 wt. % to about 1 wt. %, or about 10 wt. % to about 1 wt. % of the anti-foam compound.
In accordance with certain embodiments of the present disclosure, a composition may comprise a solvent. The solvent may comprise, for example, water, methanol, ethanol, propanol, isopropanol, n-butanol, isobutanol, sec-butanol, tert-butanol, a C5 to C18 hydrocarbon, or any combination thereof.
The amount of solvent present in the composition is not particularly limited. For example, the composition may comprise from about 5 wt. % to about 95 wt. % of the solvent, such as from about 10 wt. % to about 95 wt. %, from about 15 wt. % to about 95 wt. %, from about 20 wt. % to about 95 wt. %, from about 25 wt. % to about 95 wt. %, from about 30 wt. % to about 95 wt. %, from about 35 wt. % to about 95 wt. %, from about 40 wt. % to about 95 wt. %, from about 45 wt. % to about 95 wt. %, from about 50 wt. % to about 95 wt. %, from about 55 wt. % to about 95 wt. %, from about 60 wt. % to about 95 wt. %, from about 65 wt. % to about 95 wt. %, from about 70 wt. % to about 95 wt. %, from about 75 wt. % to about 95 wt. %, from about 80 wt. % to about 95 wt. %, from about 85 wt. % to about 95 wt. %, or from about 90 wt. % to about 95 wt. % of the solvent.
In accordance with some embodiments of the present disclosure, the composition further comprises a surfactant. The surfactant may comprise, for example, an anionic, nonionic, cationic, and/or a zwitterionic surfactant.
Examples of anionic surfactants include, but are not limited to, carboxylates, such as alkylcarboxylates and polyalkoxycarboxylates, alcohol ethoxylate carboxylates, and nonylphenol ethoxylate carboxylates; sulfonates, such as alkylsulfonates, alkylbenzenesulfonates, alkylarylsulfonates, and sulfonated fatty acid esters; and sulfates, such as sulfated alcohols, sulfated alcohol ethoxylates, sulfated alkylphenols, alkylsulfates, sulfosuccinates, and alkylether sulfates. Specific examples include sodium alkylarylsulfonate, alpha-olefinsulfonate, and fatty alcohol sulfates.
Examples of nonionic surfactants include, but are not limited to, those having a polyalkylene oxide polymer as a portion of the surfactant molecule. Such nonionic surfactants include, but are not limited to, chlorine-, benzyl-, methyl-, ethyl-, propyl-, butyl- and other like alkyl-capped polyethylene glycol ethers of fatty alcohols; polyalkylene oxide free nonionics, such as alkyl polyglycosides; sorbitan and sucrose esters and their ethoxylates; alkoxylated amines, such as alkoxylated ethylene diamine; alcohol alkoxylates, such as alcohol ethoxylate propoxylates, alcohol propoxylates, alcohol propoxylate ethoxylate propoxylates, and alcohol ethoxylate butoxylates; nonylphenol ethoxylate, polyoxyethylene glycol ether; carboxylic acid esters, such as glycerol esters, polyoxyethylene esters, ethoxylated and glycol esters of fatty acids; carboxylic amides, such as diethanolamine condensates, monoalkanolamine condensates, and polyoxyethylene fatty acid amides; and polyalkylene oxide block polymers.
An example of a commercially available ethylene oxide/propylene oxide block polymer includes, but is not limited to, PLURONIC®, available from BASF Corporation, Florham Park, N.J. and BEROL@ available from AkzoNobel Surface Chemistry, Chicago, Ill. An example of a commercially available silicone surfactant includes, but is not limited to, ABIL@ B8852, available from Goldschmidt Chemical Corporation, Hopewell, Va. A suitable surfactant is D500, an ethylene oxide/propylene oxide polymer available from BASF Corporation, Florham Park, N.J.
Examples of cationic surfactants that can be used in the composition include, but are not limited to, amines, such as primary, secondary and tertiary monoamines, optionally with C18 alkyl or alkenyl chains, ethoxylated alkylamines, alkoxylates of ethylenediamine, imidazoles, such as a 1-(2-hydroxyethyl)-2-imidazoline, a 2-alkyl-1-(2-hydroxyethyl)-2-imidazoline, and the like; and quaternary ammonium salts, such as alkylquaternary ammonium chloride surfactants, such as n-alkyl(C12-C18)dimethylbenzyl ammonium chloride, n-tetradecyldimethylbenzylammonium chloride monohydrate, and a naphthylene-substituted quaternary ammonium chloride, such as dimethyl-1-naphthylmethylammonium chloride.
Examples of zwitterionic surfactants that can be used in the composition include, but are not limited to, betaines, imidazolines, and propionates.
The amount of surfactant present in the composition is not particularly limited. For example, the composition may comprise from about 0 wt. % to about 25 wt. % of the surfactant, such as from about 1 wt. % to about 20 wt. %, about 1 wt. % to about 15 wt. %, about 1 wt. % to about 10 wt. %, or about 1 wt. % to about 5 wt. %.
The compositions disclosed herein may include an additive, such as an emulsion-stabilizing compound, an imidazoline, an imidazolium compound, agar, carrageenan, gellan, gelatin, guar gum, sodium alginate, xanthan gum, and any combination thereof.
In some embodiments, the emulsion-stabilizing compound comprises a compound selected from the following Formula II:
In some embodiments, “a” is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, or any sub-range thereof, such as 1-50, 1-40, 1-30, 1-20, 1-10, or 1-5.
In some embodiments, “b” is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, or any sub-range thereof, such as 1-50, 1-40, 1-30, 1-20, 1-10, or 1-5.
In some embodiments, “c” is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, or any sub-range thereof, such as 1-50, 1-40, 1-30, 1-20, 1-10, or 1-5.
In some embodiments, “d” is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, or any sub-range thereof, such as 1-50, 1-40, 1-30, 1-20, 1-10, or 1-5.
The amount of the additive present in the composition is not particularly limited. For example, the composition may comprise from about 0.01 wt. % to about 1.00 wt. %, from about 0.01 wt. % to about 0.75 wt. %, from about 0.01 wt. % to about 0.5 wt. %, from about 0.01 wt. % to about 0.25 wt. %, from about 0.01 wt. % to about 0.1 wt. %, or from about 0.01 wt. % to about 0.05 wt. % of the additive.
In some embodiments, the composition consists of or consists essentially of the anti-foam compound. In some embodiments, the composition consists of or consists essentially of the anti-foam compound and the additive. In certain embodiments, the composition consists of or consists essentially of the anti-foam compound and the surfactant. In some embodiments, the composition consists of or consists essentially of the anti-foam compound and the solvent. In some embodiments, the composition consists of or consists essentially of any combination of the anti-foam compound, the additive, the surfactant, and the solvent.
The compositions and methods disclosed herein are capable of controlling complex foulants, such as those including inorganic salts (e.g., sodium chloride), sand, limestone, water from the gas wells, and/or hydrocarbon from the gas wells.
The process for the efficient recovery of both gas-phase and liquid-phase hydrocarbons entails the deliberate use of brine and foaming agents. These hydrocarbons, such as natural gas, are typically transferred directly from the field to the processing plant. As a result, sodium chloride in the brine solution is transferred from the gas well to the gas-processing plant. Other additives in drilling and gas-recovery fluids may be similarly entrained with the raw gas and hydrocarbon condensate, such as different types of surfactants.
For example, surfactants are used to prevent the corrosion of assets used in the process of recovering the gas. Filming agents may also be used. As surface-active agents, the filming agents adversely cause stable emulsions and foaming. Surfactants are also deliberately added as foaming agents. Inevitably, foaming anterior to the compressor stage results in the carryover of liquids, dissolved solids and insoluble solids. However, contaminants from the raw gas are not supposed to make it all the way to the compressor stations in a properly functional gas-cleaning process.
To solve these and other problems, the present disclosure provides methods of using the compositions disclosed herein for controlling fouling in processes for cleaning a hydrocarbon gas. The methods may comprise adding an effective amount of a composition as disclosed herein to a conduit comprising the hydrocarbon gas, wherein the composition comprises the anti-foam compound disclosed herein.
The compositions and methods disclosed herein are advantageously effective even if the conduit comprises materials in addition to the hydrocarbon gas, such as an entrained hydrocarbon liquid condensate, an entrained aqueous phase, an entrained dissolved organic solid, a dissolved inorganic solid, an insoluble organic solid, an insoluble inorganic solid, and any combination thereof.
The entrained hydrocarbon liquid condensate may comprise, for example, a C5 to C18 hydrocarbon, such as a a C5 to C15 hydrocarbon, a C5 to C12 hydrocarbon, a C5 to C9 hydrocarbon, a C8 to C18 hydrocarbon, a C11 to C18 hydrocarbon, a C15 to C18 hydrocarbon, a C7 to C15 hydrocarbon, and/or a C9 to C12 hydrocarbon.
The hydrocarbon gas in the conduit may comprise, for example, a C1 hydrocarbon, a C2 hydrocarbon, a C3 hydrocarbon, a C4 hydrocarbon, or any combination thereof. In some embodiments, the hydrocarbon gas may comprise methane, ethane, propane, butane, or any combination thereof.
The effective amount of the composition to be added to the conduit is not particularly limited. In some embodiments, the effective amount may be from about 0.1 ppm to about 10,000 ppm. For example, the effective amount may be from about 0.1 ppm to about 5,000 ppm, from about 0.1 ppm to about 2,000 ppm, from about 0.1 ppm to about 1,000 ppm, from about 0.1 ppm to about 750 ppm, from about 0.1 ppm to about 500 ppm, from about 0.1 ppm to about 250 ppm, from about 0.1 ppm to about 100 ppm, from about 0.1 ppm to about 50 ppm, from about 0.1 ppm to about 10 ppm, from about 1 ppm to about 10,000 ppm, from about 10 ppm to about 10,000 ppm, from about 25 ppm to about 10,000 ppm, from about 50 ppm to about 10,000 ppm, from about 100 ppm to about 10,000 ppm, from about 1,000 ppm to about 10,000 ppm, or from about 5,000 ppm to about 10,000 ppm.
The composition disclosed herein may be added at one or more locations during a process of cleaning and compressing a hydrocarbon gas. For example,
For example, in accordance with some embodiments of the present disclosure, a composition may be added upstream or downstream of a primary slug catcher (10). In certain embodiments, the composition may be added upstream of a primary slug catcher (10) but downstream of a subterranean formation (not shown). In various embodiments, the composition may be added downstream of a primary slug catcher (10) but upstream of a secondary slug catcher (30). In some embodiments, the composition is added downstream of a secondary slug catcher (30) but upstream of a tertiary slug catcher (40). In accordance with certain embodiments, the composition may be added downstream of one or more of the slug catchers but upstream of a scrubber (60,70). In some embodiments, the composition may be added to an amine unit slug catcher and/or upstream of an amine unit slug catcher.
Any of the methods disclosed herein may consist of or consist essentially of the step of adding the composition to the conduit (at one or more locations depicted in
The present disclosure also provides methods for controlling fouling of equipment used during a process for cleaning and compressing any hydrocarbon gas disclosed herein. The methods may comprise, for example, adding an effective amount of any composition disclosed herein to the equipment comprising the hydrocarbon gas, wherein the composition comprises any anti-foam compound disclosed herein.
The methods disclosed herein are useful for controlling fouling of any piece of equipment that may be used during the cleaning and compressing processes, such as a slug catcher (10, 30, 40), a scrubber (60, 70), a suction drum (80, 90), a reciprocating compressor (100, 110), and any combination thereof. In some embodiments, the composition is added to a conduit upstream of the particular piece or pieces of equipment to be treated.
The effective amount of the composition to be added to the equipment is not particularly limited. In some embodiments, the effective amount may be from about 0.1 ppm to about 10,000 ppm. For example, the effective amount may be from about 0.1 ppm to about 5,000 ppm, from about 0.1 ppm to about 2,000 ppm, from about 0.1 ppm to about 1,000 ppm, from about 0.1 ppm to about 750 ppm, from about 0.1 ppm to about 500 ppm, from about 0.1 ppm to about 250 ppm, from about 0.1 ppm to about 100 ppm, from about 0.1 ppm to about 50 ppm, from about 0.1 ppm to about 10 ppm, from about 1 ppm to about 10,000 ppm, from about 10 ppm to about 10,000 ppm, from about 25 ppm to about 10,000 ppm, from about 50 ppm to about 10,000 ppm, from about 100 ppm to about 10,000 ppm, from about 1,000 ppm to about 10,000 ppm, or from about 5,000 ppm to about 10,000 ppm.
The equipment and/or conduit (if applicable) may comprise other materials in addition to the hydrocarbon gas, such as an entrained hydrocarbon liquid condensate, an entrained aqueous phase, an entrained dissolved organic solid, a dissolved inorganic solid, an insoluble organic solid, an insoluble inorganic solid, and any combination thereof.
The composition may be added at any location, or any combination of locations disclosed in the present application and/or in
In some embodiments, the method consists of or consists essentially of adding the composition to the equipment to be treated and/or to a conduit upstream of the equipment to be treated.
The compositions disclosed herein may be added to the conduit and/or to the equipment at operating temperatures, such as temperatures from about −10° C. to about 50° C., such as from about 0° C. to about 45° C., about 5° C. to about 40° C., or about 10° C. to about 35° C. In some embodiments, the composition is added at ambient temperature, which covers a temperature range from about 15° C. to about 30° C.
The methods disclosed herein may advantageously be carried out online, meaning that the methods may be carried out while conducting the gas cleaning and/or compressing processes. The cleaning and/or compressing processes do not need to be halted/shut down while carrying out the methods of the present disclosure.
The foregoing may be better understood by reference to the following examples, which are intended for illustrative purposes and are not intended to limit the scope of the disclosure or its application in any way.
The following tests were carried out using various embodiments of compositions disclosed herein comprising anti-foam compounds to demonstrate the feasibility of the proposed compositions and use thereof.
A composition comprising hydrophobized silica, a fatty acid ester of a polyethylene glycol sorbitant surfactant, benzoic acid, erythorbic acid and deionized water was used as an embodiment of a composition of the present disclosure. This composition was designated Anti-foam Agent 1.
Into a 100 mL measuring cylinder was charged 20 mL of a field sample. To the cylinder, about 50 ppm of Anti-foam Agent 1 were added and then the mixture was sparged with a stream of nitrogen gas. It took about 30 seconds for the resultant foam to rise up and spill over the top of the cylinder. At a dose of about 100 ppm, the foam reached the 100-mL mark after about 120 seconds. However, the foam did not spill over the top or reach the 50-mL mark after about 120 seconds for the 150 ppm dose. For the 200 ppm and 250 ppm doses, no foam was observed. When the sparging was stopped, the foam collapsed in a surprisingly rapid manner similar to what was observed when the experiment was conducted with only deionized water (without the addition of an anti-foam compound). The comparative results, as foam height, in an untreated sample and a sample treated with about 200 ppm of Anti-foam Agent 1 are shown in
2.0 g of a deposit collected from a natural gas compressor were dissolved in 98 g of demineralized water. The mixture was shaken until all the deposit was dissolved. This was further diluted to yield a solution including about 0.2% (w/w) of the foulant gum in deionized water. To a 100 mL measuring cylinder, about 20 mL of the mixture were added. As in Example 1, a nitrogen stream was used to sparge the mixture and generate foaming. Within about 20 seconds, foam began spilling out of the top of the cylinder.
In another cylinder, the same test was carried out. However, the 20 mL of test solution were treated with about 200 ppm of Anti-foam Agent 2. Sparging did not result in foaming beyond that observed with demineralized water. Although the sparging was continued for about 240 seconds, the foam height of the treated sample remained constant. The resultant foam collapsed immediately when sparging was stopped.
A 20 mL portion of the mixture prepared in Example 2 was used to determine the anti-foam effectiveness of Anti-foam Agent 3. The mixture was added into a 100 mL measuring cylinder followed by the treatment with about 200 ppm of Anti-foam Agent 3. The anti-foam agent was in a hydrocarbon medium. In another measuring cylinder, 10 mL of the foaming solution, which is an aqueous solution laden with a foaming agent, used in Example 1 were added to the measuring cylinder followed by 10 mL of toluene, thus mimicking the two immiscible liquid phases characteristic of the field compositions. No sustained foaming was observed as both mixtures were sparged.
All of the compositions and methods disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure. While this invention may be embodied in many different forms, there are described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. In addition, unless expressly stated to the contrary, use of the term “a” is intended to include “at least one” or “one or more.” For example, “a compound” is intended to include “at least one comound” or “one or more compounds.”
Any ranges given either in absolute terms or in approximate terms are intended to encompass both, and any definitions used herein are intended to be clarifying and not limiting. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges (including all fractional and whole values) subsumed therein.
Any composition disclosed herein may comprise, consist of, or consist essentially of any element, component and/or ingredient disclosed herein or any combination of two or more of the elements, components or ingredients disclosed herein.
Any method disclosed herein may comprise, consist of, or consist essentially of any method step disclosed herein or any combination of two or more of the method steps disclosed herein.
The transitional phrase “comprising,” which is synonymous with “including,” “containing,” or “characterized by,” is inclusive or open-ended and does not exclude additional, un-recited elements, components, ingredients and/or method steps.
The transitional phrase “consisting of” excludes any element, component, ingredient, and/or method step not specified in the claim.
The transitional phrase “consisting essentially of” limits the scope of a claim to the specified elements, components, ingredients and/or steps, as well as those that do not materially affect the basic and novel characteristic(s) of the claimed invention.
Unless specified otherwise, all molecular weights referred to herein are weight average molecular weights and all viscosities were measured at 25° C. with neat (not diluted) polymers.
As used herein, the term “about” refers to the cited value being within the errors arising from the standard deviation found in their respective testing measurements, and if those errors cannot be determined, then “about” may refer to, for example, within 5%, 4%, 3%, 2%, or 1% of the cited value.
Furthermore, the invention encompasses any and all possible combinations of some or all of the various embodiments described herein. It should also be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the invention and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.
| Number | Date | Country | |
|---|---|---|---|
| 63485952 | Feb 2023 | US |
