John A. Boxall

Droplet Size Scaling of Water-in-Oil Emulsions under Turbulent Flow

The size of droplets in emulsions is important in many industrial, biological, and environmental systems, as it determines the stability, rheology, and area available in the emulsion for physical or chemical processes that occur at the interface. While the balance of fluid inertia and surface tension in determining droplet size under turbulent mixing in the inertial subrange has been well established, the classical scaling prediction by Shinnar half a century ago of the dependence of droplet size on the viscosity of the continuous phase in the viscous subrange has not been clearly validated in experiment. By employing extremely stable suspensions of highly viscous oils as the continuous phase and using a particle video microscope (PVM) probe and a focused beam reflectance method (FBRM) probe, we report measurements spanning 2 orders of magnitude in the continuous phase viscosity for the size of droplets in water-in-oil emulsions. The wide range in measurements allowed identification of a scaling regime of droplet size proportional to the inverse square root of the viscosity, consistent with the viscous subrange theory of Shinnar. A single curve for droplet size based on the Reynolds and Weber numbers is shown to accurately predict droplet size for a range of shear rates, mixing geometries, interfacial tensions, and viscosities. Viscous subrange control of droplet size is shown to be important for high viscous shear stresses, i.e., very high shear rates, as is desirable or found in many industrial or natural processes, or very high viscosities, as is the case in the present study.

Investigation of the Hydrate Plugging and Non-Plugging Properties of Oils

Three laboratories (Norwegian Institute of Science and Technology [NTNU], Institut Français du Pétrole [IFP], and the Colorado School of Mines [CSM]) determined hydrate plug formation characteristics in three oils, each in three conditions: (1) in their natural state, (2) with asphaltenes removed, and (3) with naturally occurring acids removed from the oil. The objective was to determine the major variables that affect hydrate plugging tendencies in oil-dominated systems, to enable the flow assurance engineer to qualitatively assess the tendency of an oil to plug with hydrates. In the past, it was indicated that chemical effects, for example, water-in-oil/hydrate-in-oil (emulsion/dispersion) stability, prevented hydrate plugs. For example, deasphalted oils provided low emulsion/dispersion stability and thus hydrate particles aggregated. In contrast pH 14-extracted oils were reported to remove stabilizing naphthenic acids, causing asphaltene precipitation on water/hydrate droplets, stabilizing the emulsion/dispersion to prevent aggregation and pluggage. This work suggests that in addition to chemistry, shear can enable plug-free operation in the hydrate region. High shear can prevent hydrate particle aggregation, while low shear encourages particle aggregation and plugging. As a result, flow assurance engineers may be able to forecast hydrate plug liability of an oil by a combination of chemistry and flow variables, such as: a) measurements of live oil emulsion stability, b) predictions of flow line shear, and c) knowledge of water cut. Plug formation qualitative trends are provided for the above three variables. Implications for flow assurance are given.

GAS HYDRATE FORMATION AND DISSOCIATION FROM WATER-IN-OIL EMULSIONS STUDIED USING PVM AND FBRM PARTICLE SIZE ANALYSIS

An understanding of the mechanism for hydrate formation from water-in-oil emulsions is integral for progressing from preventing hydrate formation through expensive thermodynamic means to hydrate blockage prevention. This work presents hydrate formation and agglomeration in a stirred system studied using two complementary particle size analysis techniques, a Particle Video Microscope (PVM) and a Focused Beam Reflectance Measurement (FBRM). The PVM provides qualitative visual information through digital images in the black oil illuminated by a series of lasers. The FBRM provides a quantitative chord length distribution of the particles/droplets in the system. Three sets of experiments were performed using two different Crude oils, Conroe with a very small asphaltene content and poor emulsion stability, and Caratinga with a much higher asphaltene content and emulsion stability. The first experiments looked at ice as an analogy to hydrates, studying the morphology with both the PVM and FBRM. The second experiments looked at the effect of droplet size on hydrate formation and agglomeration, and the third set of experiments studied the dissociation process using a combination of the PVM and in situ conductivity measurements to determine the continuous phase. For hydrate formation, droplet size was found to have a major effect on whether or not agglomeration will occur. During dissociation agglomeration is extremely dramatic due to the creation of surface water on the particles. The dissociation of these agglomerates results in a significant destabilization of the suspension into a water/hydrate phase at the bottom of the cell until dissociation is complete. The dissociation conceptual picture presented illustrates an important implication when operating a flow line with hydrates present; dissociation within the pipeline should be prevented until the hydrates are out of the flow line.

HYDRATE PLUG FORMATION PREDICTION TOOL – AN INCREASING NEED FOR FLOW ASSURANCE IN THE OIL INDUSTRY

Hydrate plugging of hydrocarbon production conduits can cause large operational problems resulting in considerable economical losses. Modeling capabilities to predict hydrate plugging occurrences would help to improve facility design and operation in order to reduce the extent of such events. It would also contribute to a more effective and safer remediation process. This paper systematically describes different operational scenarios where hydrate plugging might occur and how a hydrate plug formation prediction tool would be beneficial. The current understanding of the mechanisms for hydrate formation, agglomeration and plugging of a pipeline are also presented. The results from this survey combined with the identified industrial needs are then used as a basis for the assessment of the capabilities of an existing hydrate plug formation model, called CSMHyK (The Colorado School of Mines Hydrate Kinetic Model). This has recently been implemented in the transient multiphase flow simulator OLGA as a separate module. Finally, examples using the current model in several operational scenarios are shown to illustrate some of its important capabilities. The results from these examples and the operational scenarios analysis are then used to discuss the future development needs of the CSMHyK model.

HYDRATE BLOCKAGE POTENTIAL IN AN OIL-DOMINATED SYSTEM STUDIED USING A FOUR INCH FLOW LOOP

An understanding of the blockage potential for an oil dominated system is an important step in moving from hydrate prevention to hydrate management. To better understand this problem a series of experiments were performed by varying the water cut, fluid velocity, and gas-liquid volume fraction using the ExxonMobil (XoM) flow loop in Houston, Texas, USA. The XoM large loop is a three pass, four inch internal diameter flow loop with a sliding vane pump capable of generating liquid velocities of up to 4 m/s. The systems that were studied include a range of water cuts from 5%-50% in a light crude oil (Conroe crude) and a gas phase of either pure methane for sI or 75% methane and 25% ethane which has sII as the thermodynamically stable phase. The results are compared with the hydrate plug prediction tool, CSMHyK, integrated into the multiphase flow simulator OLGA5 ® . The comparison between the model and the flow loop results serve as a basis for improving hydrate formation and plug prediction. In addition, the experimental variables that promote plug formation in the flow loop and how these may translate into the field are discussed.

A STUDY OF HYDRATE FORMATION AND DISSOCIATION FROM HIGH WATER CUT EMULSIONS AND THE IMPACT ON EMULSION INVERSION.

Methane hydrate formation and dissociation studies from high water content (>60 vol% water) – crude oil emulsions were performed. The hydrate and emulsion system was characterized using two particle size analyzers and conductivity measurements. It was observed that hydrate formation and dissociation from water-in-oil (W/O) emulsions destabilized the emulsion, with the final emulsion formulation favoring a water continuous state following re-emulsification. Hence, following dissociation, the W/O emulsion formed a multiple o/W/O emulsion (60 vol% water) or inverted at even higher water cuts, forming an oil-in-water (O/W) emulsion (68 vol% water). In contrast, hydrate formation and dissociation from O/W emulsions (≥71 vol% water) stabilized the O/W emulsion.