Patent Application
20220282148
The present disclosure relates to paraffin inhibitor formulations used to inhibit formation of paraffin aggregates and paraffin deposition on the metal surfaces during hydrocarbon production, transportation, and refining processes.
Crude oils are complex multicomponent mixtures of different chemical compounds including alkanes, aromatics, cycloalkanes, resins and asphaltenes. The mixtures can contain dissolved paraffin/waxes which are typically miscible with the crude oil under reservoir conditions of high pressure and temperature. The dissolved paraffins are primarily C18 to C80+ carbon chain alkanes. Such paraffins can precipitate and deposit out of the crude oil under certain conditions. For example, the paraffins can precipitate in wellbore tubing during production when the temperature and pressure becomes lower as the oil reaches the surface or within the reservoir matrix if the reservoir pressure is depleted. Typically, deposition occurs when the temperature drops below the Wax Appearance Temperature (“WAT”) which can cause crystallization of the paraffin. Nucleation, growth, and aggregation can also increase the size of the paraffin deposit. The crystal morphologies can be orthorhombic, hexagonal, monoclinic, and triclinic. These crystal aggregates can bind to the metal surfaces owing to the temperature gradient between the crude oil and metal surface.
Paraffin deposition during hydrocarbon production, transportation, and refining processes are one of the major flow assurance issues faced by oil and gas industry. In upstream applications, paraffin deposition can lead to plugging of wellbore tubing, surface production equipment, and pumps and can result in complete well shutdown and pose a major operational and safety challenge. Paraffin blockage remediation is a costly process for operators. There are several paraffin prevention and remediation techniques adopted by the oil and gas industry. These include mechanical intervention, thermochemical reactions, cold flow technology, special pipe coatings, solvent treatment, hot oiling and the use of paraffin inhibitors and dispersants.
According to one embodiment, a paraffin inhibitor formulation includes one or more anionic sulfonated surfactants, one or more polymers, and one or more solvents.
As used herein, the term “pour-point” refers to the lowest temperature below which a liquid stops pouring or flowing.
As used herein, the term “surfactant” or “surface-active agents” refers to chemical species that comprise a hydrophobic tail and hydrophilic head which have an affinity to diffuse to the fluid-fluid interface and to lower the interfacial tension.
As used herein, the term “subterranean formation” or “subsurface formation” means a hydrocarbon-containing reservoir that is present below the ground which has a porosity and permeability to store and flow hydrocarbon fluids. The lithology of the reservoir can comprise sedimentary rocks, carbonates such as limestones and dolomites, sandstones, shales, coals, evaporites, igneous, and metamorphic rocks, and combinations thereof. These reservoirs can be fully or partially consolidated or unconsolidated in nature. These formations can be an offshore or onshore reservoir.
As used herein, the term “salt” refers to a chemical compound comprising an ionic assembly of cations and anions. The term includes inorganic salts such as potassium chloride, ammonium chloride, sodium chloride, calcium chloride, magnesium chloride and organic salts such as sodium acetate, sodium citrate and combination thereof.
As used herein, the term “stable” means a formulation that is both thermally stable as well as colloidally stable at the specified temperature. The formulation is free from any coagulation, phase-separation, or precipitation of any component/phase of the mixture.
The present disclosure generally relates to paraffin inhibitor formulations that can inhibit formation of paraffin aggregates and paraffin deposition on metal surfaces during oil and gas production. In certain embodiments, the formulations can be a mixture of one or more surfactants, solvents, and polymers. The polymers can be known paraffin inhibiting additives such as wax crystallization modifiers. The methods and formulations disclosed herein can be useful to prevent issues related to paraffin aggregates and deposition in applications including upstream hydrocarbon production, transportation, storage, and refining.
As can be appreciated, paraffin inhibitors are known to hinder the growth and deposition of paraffin. For example, paraffin inhibitors can alter the wax crystallization behavior. The paraffin inhibitors can also, or alternatively, affect the nucleation process or can co-crystallize with the paraffin crystals affecting and retarding their crystallization behavior. The commonly used wax crystallization modifiers used in the oil and gas industry can include polymer-based chemical additives such as ethylene-vinyl acetate copolymer (EVA), modified ethylene vinyl acetates, alkyl phenol resins, alkyl acrylates, and mixtures thereof.
It has presently been recognized that the performance of paraffin inhibitors can be improved by including the inhibitors in a formulation with one or more surfactants. These formulations can synergistically improve the performance of the paraffin inhibitors in different aspects such as an increment in the percentage paraffin inhibition, a reduction in pour point, improvement in paraffin dispersancy, and reduction in affinity of paraffin to attach to metal surfaces. The surfactants can work synergistically with the polymer additives to improve the technical performance and economic advantage of the polymer additives alone.
Surfactants and wax crystallization modifiers, such as polymer additives, can synergistically assist in the flow assurance process during subsurface applications by performing one or more of the following functions:
Suitable surfactants for the presently disclosed paraffin inhibitor formulations can be, or can comprise mixtures of, an anionic sulfonated surfactant represented by Formula I:
wherein:
In certain embodiments, the surfactant can be represented by Formula I where:
In other embodiments, the surfactant can be a surfactant from the following family: CALFAX-type sulfonated surfactants, DOWFAX-type sulfonated surfactants, ARISTONATE-type sulfonated surfactants, and CALIMULSE-type sulfonated surfactants. DOWFAX-type sulfonated surfactants are available from the Dow Chemical Co. (Midland, Mich.). CALFAX-type, ARISTONATE-type, and CALIMULSE-type sulfonated surfactants are available from the Pilot Chemical Co. (Cincinnati, Ohio).
The composition of CALFAX-type specialized surfactant can include C10 (Linear) Sodium Diphenyl Oxide Disulfonate; C16 (Linear) Sodium Diphenyl Oxide Disulfonate; C6 (Linear) Diphenyl Oxide Disulfonic Acid; C12 (Branched) Sodium Diphenyl Oxide Disulfonate; C12 (Branched) Diphenyl Oxide Disulfonic Acid; Sodium Alkyl Diphenyl Oxide Sulfonate; Sodium Decyl Diphenyl Oxide Disulfonate; Benzenesulfonic Acid, Decyl(sulfophenoxy)-, Disodium Salt; Sodium Hexadecyl Diphenyl Oxide Disulfonate; Benzenesulfonic Acid, Hexadecyl(sulfophenoxy)-, Disodium Salt; Hexyl Diphenyl Oxide Disulfonic Acid; Benzene, 1,1′-oxybis-, Sec-hexyl Derivs., Sulfonated; Sodium Dodecyl Diphenyl Oxide Disulfonate; 1,1′-oxybisbenzene Tetrapropylene Derivs., Sulfonated, Sodium Salt; Benzenesulfonic acid, branched dodecyl(sulfophenoxy), disodium salt; Benzenesulfonic acid, decyl(sulfophenoxy), disodium salt; Dodecyl Diphenyl Oxide Disulfonic Acid; Benzene, 1,1′-oxybis-, Tetrapropylene Derivs., Sulfonated; Disodium oxybis(dodecylbenzenesulfonate); Disodium dodecyl(sulfophenoxy)-benzenesulfonate; Sodium dodecyl(phenoxy)-benzenesulfonate; Sodium oxybis(dodecylbenzene)sulfonate; Benzenesulfonic acid, branched dodecyl-, (branched dodecyl phenoxy), sodium salt; Benzenesulfonic acid, phenoxy, branched dodecyl-, sodium salt; Benzenesulfonic acid, oxybis(branched dodecyl-), disodium salt; Disodium oxybis(dodecylbenzenesulfonate); Disodium dodecyl(sulfophenoxy)-benzenesulfonate; and Sodium dodecyl(phenoxy)-benzenesulfonate Disodium dodecyl(sulfophenoxy)-benzenesulfonate.
Specific surfactants suitable for the present disclosure available in the CALFAX family can include CALFAX 10L-45, CALFAX 16L-35, CALFAX 6LA-70, CALFAX DB-45, CALFAX DBA-40, CALFAX DBA-70, and CALFAX 16LA.
Suitable CALFAX-type surfactants can include non-neutralized, acid versions of the surfactants.
In certain embodiments, the surfactant in the paraffin inhibitors formulations can include DOWFAX-type surfactants. Such surfactants can include a pair of sulfonate groups on a diphenyl oxide backbone. The attached hydrophobe can be a linear or branched alkyl group comprised of six to sixteen carbons.
The composition of DOWFAX-type specialized surfactant can include 1,1′-oxybisbenzene Tetrapropylene Derivs., Sulfonated, Sodium Salt; Benzene, 1,1′-oxybis-, Sec-hexyl Derivs., Sulfonated; Benzene, 1,1′-oxybis-, Tetrapropylene Derivs., Sulfonated; Benzenesulfonic acid, branched dodecyl(sulfophenoxy), disodium salt; Benzenesulfonic acid, branched dodecyl-, (branched dodecyl phenoxy), sodium salt; Benzenesulfonic acid, decyl(sulfophenoxy), disodium salt; Benzenesulfonic Acid, Decyl(sulfophenoxy)-, Disodium Salt; Benzenesulfonic Acid, Hexadecyl(sulfophenoxy)-, Disodium Salt; Benzenesulfonic acid, oxybis(branched dodecyl-), disodium salt; Benzenesulfonic acid, phenoxy, branched dodecyl-, sodium salt; C10 (Linear) Sodium Diphenyl Oxide Disulfonate; C12 (Branched) Diphenyl Oxide Disulfonic Acid; C12 (Branched) Sodium Diphenyl Oxide Disulfonate; C16 (Linear) Sodium Diphenyl Oxide Disulfonate; C6 (Linear) Diphenyl Oxide Disulfonic Acid; Disodium dodecyl(sulfophenoxy)-benzenesulfonate; Disodium dodecyl(sulfophenoxy)-benzenesulfonate; Disodium oxybis(dodecylbenzenesulfonate); Disodium oxybis(dodecylbenzenesulfonate); Dodecyl Diphenyl Oxide Disulfonic Acid; Hexyl Diphenyl Oxide Disulfonic Acid; Sodium Alkyl Diphenyl Oxide Sulfonate; Sodium Decyl Diphenyl Oxide Disulfonate; Sodium Dodecyl Diphenyl Oxide Disulfonate; Sodium dodecyl(phenoxy)-benzenesulfonate; Sodium dodecyl(phenoxy)-benzenesulfonate Disodium dodecyl(sulfophenoxy)-benzenesulfonate; Sodium Hexadecyl Diphenyl Oxide Disulfonate; and Sodium oxybis(dodecylbenzene)sulfonate.
Suitable surfactants available in the DOWFAX family can include DOWFAX 2A1, DOWFAX 3B2, DOWFAX C10L, DOWFAX 8390, DOWFAX C6L, DOWFAX 30599, and DOWFAX 2AO.
Suitable DOWFAX-type surfactants can include non-neutralized, acid versions of the surfactants.
In certain embodiments, the anionic surfactants used in the paraffin inhibitors formulations can be represented by the general Formula II:
In certain embodiments, suitable surfactants can be an alkyl benzene or alkyl aryl sulfonate-type anionic surfactant represented by Formula II, wherein:
In certain embodiments, suitable surfactants for the paraffin inhibitors formulations can be ARISTONATE-type surfactants. Such surfactants can be anionic sulfonated surfactants in either salt or acid forms.
Suitable ARISTONATE-type specialized surfactants can include Sodium Alkyl Aryl Sulfonate, Alkyl Xylene Sulfonates, Calcium Alkyl Aryl Sulfonate, Aristonate C-5000, Aristonate H, Aristonate L, Aristonate M, Aristonate MME-60, Aristonate S-4000, Aristonate S-4600, Aristonate S-5000, and Aristonate VH-2.
In certain embodiments, suitable surfactants for the paraffin inhibitor formulations can include CALIMULSE-type surfactants. Suitable CALIMULSE-type surfactants can be anionic sulfonated surfactants in either salt or acid forms.
ARISTONATE-type specialized surfactants can include Isopropylamine Branched Alkyl Benzene Sulfonate, Isopropylamine Linear Alkyl Benzene Sulfonate, Sodium Alpha Olefin Sulfonate, Sodium Cl4-16 alpha olefin sulfonate, Sodium Branched Alkyl Benzene Sulfonate, Branched Dodecyl Benzene Sulfonic Acid, Sodium Linear Alkyl Benzene Sulfonate, Sodium Linear Alkyl Benzene Sulfonate, Sodium Lauryl Sulfate, and Sodium Branched Dodecyl Benzene Sulfonate.
In certain embodiments, suitable surfactants can comprise mixtures of two or more surfactants represented by aforementioned Formula I, Formula II, ARISTONATE-type specialized surfactant, and ARISTONATE-type specialized surfactant.
In certain embodiments, the paraffin inhibitor formulation includes mixture of one or more surfactants and one or more polymer additives.
As can be appreciated, polymer-based paraffin inhibitors can act as pour point depressants and/or can act to reduce the viscosity of the paraffinic crude oil to improve their flow characteristics. In the present disclosure, suitable polymer additives can alter the paraffin wax crystallization behavior and can inhibit paraffin aggregation.
In certain embodiments, suitable polymer additives include olefin/maleic esters, olefin/maleic imides, ethylene copolymers such as ethylene-vinyl acetate copolymer (EVA), modified ethylene vinyl acetates, alkyl phenol resins, alkyl acrylates, and mixtures thereof.
In certain embodiments, the polymeric additives can include mixtures of alkylene oxide modified alcohol surfactants and amino dicarboxylic acid diesters.
In certain embodiments, the polymeric additives can be comb-shaped copolymers such as maleic anhydride copolymer. Such copolymers can include non-polar alkyl chain groups and polar groups such as ethyl vinyl, styrene, esters, and carboxylic groups.
In certain embodiments, the polymeric additives can be styrene-maleic acid dialkyl ester polymers formed of building blocks having the following formulas:
In certain embodiments, a suitable styrene-maleic acid dialkyl ester polymers can be formed of the building blocks of Formulas III and IV in a ratio from about 10:90 to about 90:10.
In certain embodiments, about 90% or more of the polymeric additives can be styrene-maleic acid dialkyl ester polymer.
In certain embodiments, the polymeric additives can be formed of alkylphenol-formaldehyde building blocks of Formula V:
In certain embodiments, about 90% or more of the polymeric additive can comprise the alkylphenol-formaldehyde building blocks of Formula V.
In certain embodiments, the polymeric additives can comprise acrylates polymers formed of building blocks of Formula VI:
In certain embodiments, the polymeric additive can be of combinations of two or more types of acrylates with building blocks of Formula VI, each of the two or more acrylates having different R11.
In certain embodiments, the polymeric additives can comprise copolymers formed of one or more alpha-olefin monomers of general formula VII and maleic anhydride monomers of general formula VIII.
In certain embodiments, the polymeric additives can be copolymers formed of alpha-olefin monomers and unsaturated dicarboxylic acid anhydride monomers.
In the present disclosure, different polymeric additives can have synergistic interactions with the aforementioned surfactant compositions. The synergistic interactions can improve the technical performance of the paraffin inhibitor.
The novel paraffin inhibitor formulations described in the present disclosure can include solvent to reduce the viscosity of the final concentrated product and to make it easier to pump. Suitable solvents can include oil-soluble organic liquids which can disperse the surfactant and the polymer. In certain embodiments, the solvent can be selected from benzene, toluene, xylene, ethyl benzene, propyl benzene, trimethyl benzene, cyclopentane, cyclohexane, carbon disulfide, decalin and mixtures thereof.
Paraffin inhibitor formulations described herein can be useful for paraffin inhibiting and/or remediation during different upstream applications such hydraulic fracturing, production in conventional and unconventional reservoirs, midstream applications such as pipelines flows and downstream application such as refinery.
In certain embodiments, the paraffin inhibitor formulations described herein can include about 5% to about 95%, by weight solvent, about 1% to about 95%, by weight, surfactants, and about 1% to about 95%, by weight, of wax crystallization modifiers such as polymers additives. As can be appreciated, small amounts of additional components such as viscosity modifiers, stabilizers, and biocides can be included in certain embodiments.
In certain embodiments, paraffin inhibitor formulations can be formed by combining the polymer (wax crystallization modifier) and surfactants together and then diluting with a solvent until the formulation reaches a desired viscosity. Generally, each of the components can be admixed together as known in the art using, for example, mixing equipment.
As can be appreciated, certain paraffin inhibitor formulations can be formed to allow for easier transport and additional flexibility by incorporation of less or even no solvent. Prior to use, such paraffin inhibitor formulations can incorporate additional solvent to become a diluted paraffin inhibitor formulation. The additional solvent can be the same solvent used to the form the paraffin inhibitor formulation or a different solvent such as one or more of benzene, toluene, xylene, ethyl benzene, propyl benzene, trimethyl benzene, cyclopentane, cyclohexane, carbon disulfide, decalin and mixtures thereof. The concentration of additional solvent used to dilute the diluted paraffin inhibitor formulation can vary from about 0% to about 95% by weight.
The paraffin inhibitor formulations in both diluted and non-diluted forms can remain stable before injection in the wellbore, within the wellbore, as well as when it interacts and mixes with the formation fluids at reservoir temperatures. The paraffin inhibitor formulation can remain stable irrespective of the salinity or salt content of the formation water. Hydrocarbon producing subterranean formation can be treated to mitigate paraffin related issues by admixing the paraffin inhibitor formulation described herein with the formation fluid. In such methods, the paraffin inhibitor formulation could be admixed with a formation fluid within a wellbore or flowline. Alternatively, the paraffin inhibitor formulation can also be admixed with a formation fluid by injecting the paraffin inhibitor formulation into production equipment handling hydrocarbons from the subsurface reservoir.
The paraffin inhibitor formulation can be injected into the formation through an injection well. The reservoir temperature of the subterranean formation where such treatment can be applied can be greater than 68° F. (20° C.). The concentration of paraffin inhibitor used in such application can be between 5 ppm to 20,000 ppm (weight:weight)
The Wax Appearance Temperature (“WAT”) of the paraffin waxes was determined using cross-polarization microscopy. Carbon chain analysis of the wax was performed using High-Temperature Gas Chromatography (“HTGC”). The physical properties of the crude oil samples evaluated are depicted in Table 1. The crude oil samples were sourced from the Permian Basin.
The procedure utilized in the cold finger test is as follows:
The procedure utilized in the modified cold finger testing is as follows:
The procedure utilized in the cold flask paraffin dispersant testing is as follows:
The following examples are reported to illustrate the efficacy of the paraffin inhibitor formulations described herein.
The properties of the crude oil and wax samples are depicted in Table 1. A commercial multi-place cold finger setup was used according to the test procedures described herein.
A comprehensive polymer screening was performed to determine the best polymer additive for the paraffin inhibitor formulation. The chemistries of the experimental polymers in the current evaluations are depicted in Table 2.
Oil samples containing fixed amount of paraffins were preheated at 82° C. (above the wax appearance temperature, WAT) and mixed thoroughly to ensure a homogenous solution with no thermal history for the wax crystallization behavior. 80 mL of this oil was transferred to a sample container maintained at a temperature of 41.9° C. using a thermostat bath and a magnetic stir rate of 100 rpm. Cold finger sleeves which mimic wellbore tubing were maintained at a lower fixed temperature of 19.7° C. The cold finger sleeves were lowered into the 80 mL oil solution and paraffin was allowed to deposit on the cold finger sleeve for 16 hours. The amounts of paraffin deposited were recorded as the base case (e.g., without the paraffin inhibitor formulations). In the subsequent test, paraffin inhibitor formulations with different polymer chemistries were evaluated by adding the formulations to the 80 mL oil samples at concentrations of 50 ppm, 100 ppm, and 250 ppm. The amount of paraffin deposition was measured gravimetrically and the percent wax removal was calculated by comparing to the base case deposition.
The efficacy of the different polymers was further evaluated using the cold flask method. In the cold flask evaluation, about 2 gm of wax was placed on the glass wall of the square-shaped jar. A 50-ml solution (90% water and 10% crude oil) with no polymer additive was poured in the jar and mixed for 2 hours on a shaker table.
In the next evaluation, polymers A to G were evaluated in similar jars with wax deposited on the wall. The jars were mixed for 2 hours with polymer dosing of 250 ppm and were monitored for changes in the wax deposition.
In the subsequent working evaluations, the effect of varying the ratio of surfactant to polymer was evaluated on total paraffin inhibition using a cold finger test. The total reduction in chemical cost as compared to the use of only polymer was also determined. As can be appreciated, polymers are typically more expensive than surfactants. The use of synergistic surfactants as described in the present disclosure can allow for identical or improved paraffin inhibition performance with reduced cost compared to the use of a polymer alone. This reduction in overall cost of the paraffin inhibitor formulation can make it attractive for oilfield applications.
The effect of different ratios of Surfactant H to Polymer E (copolymer ester) on paraffin inhibition was evaluated using cold finger tests. The results of this evaluation are depicted in
As depicted in
In the next evaluation, the effect of differing ratios of Surfactant I to Polymer E (copolymer ester) on percentage paraffin inhibition was evaluated using cold finger tests. Surfactant I is an ARISTONATE-type surfactant. This surfactant is an anionic, oil-soluble sulfonated surfactant in acid form. The results of this evaluation are depicted in
In the next evaluation, the effect of differing ratios of Surfactant J to Polymer E (copolymer ester) on percentage paraffin inhibition was evaluated using cold finger tests. Xylene was used as a solvent to mix the polymer and surfactant and was present at a concentration of 20% by weight. Surfactant J is a mixture of two surfactants. The ratio of these two surfactants in the Surfactant J blend was 1:1 by weight. One of the surfactants was in its acid-form (non-neutralized) represented by Formula I:
The second surfactant was represented by Formula II:
The ratio of polymer to surfactant in the final paraffin inhibitor formulation was 2:1 by weight.
As depicted in
Based on the above examples, it is clear that for any crude oil-paraffin system, an optimal surfactant to polymer ratio can be determined which will yield high percent inhibition and reduce the overall chemical cost.
The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value.
It should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
Every document cited herein, including any cross-referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests, or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in the document shall govern.
The foregoing description of embodiments and examples has been presented for purposes of description. It is not intended to be exhaustive or limiting to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed and others will be understood by those skilled in the art. The embodiments were chosen and described for illustration of various embodiments. Certain embodiments disclosed herein can be combined with other embodiments as would be understood by one skilled in the art. The scope is, of course, not limited to the examples or embodiments set forth herein but can be employed in any number of applications and equivalent articles by those of ordinary skill in the art. Rather it is hereby intended the scope be defined by the claims appended hereto.
The present application claims the priority benefit of U.S. Provisional Patent App. Ser. No. 63/200,450, entitled PARAFFIN INHIBITOR FORMULATIONS FOR OIL AND GAS APPLICATIONS, filed Mar. 8, 2021, which is hereby incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63200450 | Mar 2021 | US |
