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Introduction
Frequently, severe emulsion upsets occur in surface treating facilities following acid stimulation. Such upsets usually occur after production from the stimulated well is
commingled with other production from nonstimulated
wells. These emulsions have been extremely difficult to
treat and have resulted in loss of considerable oil produced
as an untreatable emulsion and a reluctance, in some
areas, to use acid stimulation.
Results presented in this paper show that acids partially
spent on formation solids contain, in solution, potentially
precipitable materials. As the pH of the produced acid
increases upon commingling with other production, fine
solids are precipitated; these solids are capable of stabilizing extremely tight emulsions. The stability of such emulsions is far greater than that of emulsions stabilized by fine
particles loosened from the formation or by oil-wet formation particles. Preventing upsets in the field requires using
optimum demulsifiers and eliminating, or at least
minimizing, the formation of precipitates from partially
spent acids. Examples are given for handling such problems in the field. A novel technique for the reproducible
formation and the study of emulsions in the laboratory is
presented. The use of the technique in selecting optimum
demulsifiers for the field is described.
Background
Historically, emulsion treatment has played a significant
role in petroleum production. Much of the world's oil is
produced with water and, in many cases, stable water in
oil emulsions occurs. An entire technology has been de-
Severe emulsion upsets in surface treating facilities following acid stimulation frequently
occur after production from the stimulated well is commingled with o"ther production.
Preventing such upsets requires using optimum demulsifiers at high concentrations and
eliminating, or at least minimizing, the formation of precipitates.
1060
treatments at high concentrations of effective demulsifiers; (2) one of the most successful applications of
hydroxy-aluminum was as a post-acid stimulation treatment, 4,5 and there was concern that hydroxy-aluminum
might aggravate the emulsion problem or that continued
emulsion upsets might hamper full development of the
hydroxy-aluminum application; and (3) it had not yet been
demonstrated why the emulsion upsets were aggravated
by commingling.
The results of our investigation show that produced
formation fines and pr~cipitates formed after commingling, with the latter being the dominant factor, are the
major sources of emulsion upsets. The critical effect of the
precipitated material explains why the post-acid emulsion
problem may not occur at the wellhead.
The study shows that to avoid emulsion upsets one
should (1) select and use an effective demulsifier at high
concentrations, (2) avoid commingling, and (3) minimize
the amount of fines andjprecipitates in thelsystem at any
one time where it is not possible to avoid commingling.
Experimental Methods
Emulsification was accomplished using the emulsator illustrated in Fig. 1. Such an instrument was first described
by Becher. 6 The emulsator is essentially a homogenizer
consisting of two 10-ml hypodermic syringes connected
by a double-hubbed, 18-gauge needle. The two syringes.
are held in a cradle while an air-actuated ram forces the
liquids back and forth through the needle orifice. The
energy input can be modified by adjusting the air pressu~e
on the arm; the orifice size can be varied by using needles
of varying gauge; and the processing time can be controlled by varying the number of passes of the liquids through
Emulsator.
1061
the orifice as recorded on an electrical counter. All emulsions reported in this study were prepared using 40-psi
gauge pressure for 100 cycles.
This method has the advantages of (1) allowing the use
of small volumes, (2) highly reproducible energy input,
and (3) avoiding introduction of air into the emulsion.
In practice, 7.5 ml of oil were placed in one syringe,
and 2.5 ml of the aqueous phase were placed in the other
syringe. Additives such as demulsifiers and fines then
were added to the aqueous phase before emulsification
was started. After emulsification, the fluids were transfered to plastic tubes and demulsification was observed as
a function of time and temperature. All results in this
study report percent of water breakout.
Spent acid was prepared by reacting one volume of
solids with two volumes of 12-percent HCl/3-percent HF
in plastic containers for 24 hours. Clear spent acid was
removed by centrifuging in polypropylene tubes. Solids
used for acid spending were either actual field core material or a substitute solid composed of 50-percent silica flour
and 50-percent bentonite. Fines were added to the clear
spent acid at a ratio of 0.25 gm/2.5-ml aqueous phase.
Simulated commingled spent acid was obtained by diluting spent acid and adding sodium hydroxide solution to
bring the pH to either 3.0 or 7.0, as determined by a pH
meter. The concentration of precipitated solids obtained
this way may be somewhat higher than similar materials
occurring in the field, but it adequately demonstrates the
nature of the problem.
SAMPLING POINTS
FREEWATEA
KNOCKOUT (IN)
WELL
HEATER
]1:
100
50
TIME
Fig. 2 -
24 HR.E;;l24 HR.@1400F)
DEMULSIFIER
(03 HR. D
NONE
1%
B
1%
A
5%
B
5%
100
50
HCI-HF
120/0-3%
SPENT/CORE
ADD FINES
1-----1
I.-!.-1..-J
HCI-HF
120/0-3%
SPENT/SUB
ADD FINES
TIME (03 HR., 024 HR., [Zh4 HR.@1400 F)
Fig. 3 -
Emulsion stability -
Figs. 4 and 5 show similar, but more extensive, evaluation of demulsifiers on Main Pass Block 41 and West
Delta Block 30 crude oil emulsions. Fig. 4 shows that
hydroxy-aluminum systems are no more difficult to treat
than fresh-water systems. Also shown is the high degree
of demulsifier selectivity of the systems employing acid
spent on the substitute core material. Of the nine demulsifiers tested, four (Demulsifiers A, B, C, and D) were
effective on systems containing acid spent on actual core
material, but only one (Demulsifier B) was effective on
systems containing acids spent on the substitute core material. Fig. 5, for a crude oil from a different area, again
generally shows only moderate emulsion problems with
systems containing hydroxy-aluminum that were easily
treated by many demulsifiers. Emulsions consisting of
this crude oil and acid spent on the substitute core material
were effectively treated by two of the tested demulsifiers
(Demulsifiers C and F). Demulsifier B, which had been
most effective on crude oil systems from Main Pass Block
41, did not appear to treat successfully West Delta Block
30 emulsions. Demulsifier C has been used successfully
on West Delta Block 30 emulsions.
Laboratory results such as these, along with service
company recommendations, have lead to the successful
field use of certain new and economically competitive
demulsifiers. Fig. 6 shows the results of a comparison of
two new demulsifiers (Demulsifiers J and K) on six Gulf
Coast crude oils. All emulsions in this comparison were
made with 12-percent HCl/3-percent HF acid spent on
substitute core material and contained added fines. Demulsifier J was tested up to 10 percent because its significantly lower cost made it feasible to consider using such a
concentration. It can be seen in several cases, that Demulsifier J was not as effective as the material being used in
the field (Demulsifier B); however, for Main Pass Blocks
69 and 144, Demulsifier J appeared to be the more effective demulsifier and is currently being considered for field
application. These results also show that Demulsifier J
TABLE 1 -
100
ROMERE
PASS
~-rE1-rfij
_w...fl -~ _J1:d _JYj _~ _JL1
-n
50
_L-1-L.J
_L-L....L..l
_~
_L...L...L.J
_L.-L-.1.....J
_L-L...L..J
_~
_L.l..J...J
~-
50
100
Fig. 4 -
Demulsifier study -
W.OELTA
BLOCK 30
L..J-...L..J
0
100
100
MAIN
PASS 69
~
MAIN
PASS 41
HYDROXY
ALUMINUM
O.3M
_L.l..J...J
_L...L1.J
SEPTEMBER. 1975
TIME (D 3 HR.,
TIMEID3HR.,D24HR,,[ZJ24HR,@1400F)
Demulsifier study -
VJ _L.l.....C2I
_L..LLI_L.L.LJ _L..L..LJ
- Fi1
-UJij
MAIN
PASS 144
Fig. 5 -
Fig. 6 -
50
0
100
:0
100
50
Demulsifier study -
BEFORE
EMULSifiCATION
100 -
WJ
u...
en
....J
::::J
:liE
WJ
~ 50-
a:::
w
0...
0OEMULS1FIEH
B (1'Y;,J
B (5f,~/ol
B (5%)
B\5%.. )
NO
YES
YES
YES
YES
pH
00
0,0
3.0
3,0
],0
PAFCIPfTATFS
NO
NO
NO
YES
YFS
{FILTEREO
AT pH 3,0)
Fig. 7 1064
BHi%)
FORMATION FINES
tions where such things as corrosion inhibitors and sandconsolidation-system components are capable of leaving
surfaces strongly oil wet. Certainly, such oil-wetting tendencies can influence relative saturations in the formation
and return relative permeabilities following stimulation
jobs. Also, systems with oil-wetting tendencies (crude
oils) can show greater tendencies for emulsion stabilization in produced fluids. However, our results have shown
that emulsion stabilization can occur without the oil wetting and may result from just the presence of either produced or precipitated fines.
Additional tests have been made on systems containing
5- and 1O-percent EGMBE. Where precipitated fines were
present, the addition of EGMBE did not appreciably affect the demulsification tendencies.
Effect of Wettability
It has been reported both that wettability of fines was a
major factor in emulsion stabilityl,2 and that wettability of
fines was of minor importance in emulsion stability in the
presence of nonemulsifying surfactants. 3 We found the
effect of wettability to be less critical than the presence of
formation fines or the presence of precipitates fro~8pent
acid.
Fig. 8 is a comparison of demulsification studies on two
systems: (1) a water-wet system where the oil phase was a
pure, refined, white oil, and (2) a system using a Gulf
Coast crude that has moderate oil-wetting tendencies.
Strongly oil-wetting systems were not studied, nor were
systems where oil-wet surfaces were created during
acidization.
For the systems containing only oil and spent acid with
no demulsifier, a very definite effect of wettability was
seen. The water-wet system showed moderately good
separation, whereas the oil-wet system showed no separation. However, with the addition of 1 percent of demulsifier, the crude oil and white oil systems are quite similar
in their demulsification characteristics. Also, with formation fines with and without demulsifiers present, the two
systems show similar behavior. These results agree with
the findings of Sutton and Lasater. 3 As the pH of the spent
acid is increased and in the presence of the resulting precipitates, the effect of wettability disappears altogether. Even in very clean water-wet systems,
the precipitates from spent acid can form extremely
stable emulsions.
Wettability may be a significant factor in field opera-
B-%
0%
5%
ACID-pH
ACID ppt
FINES
0.0
7.0
YES
YES
WHITE OIL
CRUDE
OIL
mJ-
EFFECT
WITH
DEMULSIFIER
mJ-~ ~
EFiECT
WITH
FINES
PRESENT
EFFECT
AT pH 3.0
50
EFFECT
WITH
PRECIPITATES
PRESENT
D WATER WET
~
Fig. 8 -
DILWET
SEPTEMBER, 1975
::0
100
Field Applications
has been produced. This practice also has avoided emulsion upset problems. Both procedures can act to emulsify
oil in water and may require additional water treatment
to assure maintaining water of acceptably low oil content.
Summary
Laboratory results have shown the following.
1. Severe emulsion problems following acid treatment
are caused by the presence of solid materials. Precipitates
formed in the spent acid after commingling are the most
serious problem. Produced formation fines also contribute
significantly to the problem.
2. The presence of hydroxy-aluminum does not contribute to the emulsion problem. In fact, produced fluids
following post-acid hydroxy-aluminum jobs should have
less fines and should produce less precipitates upon commingling. The latter is because job design is such that acid
must be more fully spent in the formation than in straight
acid jobs.
3. A laboratory screening method has been developed
that helps select optimum demulsifiers for given fields.
The method shows that demulsifier concentrations have to
be high (about 5 percent) to be effective in emulsions
containing solids.
4. Field observations that report greater emulsion
stabilization after commingling production than at the
wellhead of the treated well have been simulated in the
laboratory using field samples.
5. In the presence of fine solids, oil wettability is not a
necessary condition for emulsion stabilization.
Using these laboratory results has successfully resolved
the field problem. Where possible, commingling is completely avoided and noncommingled, acid-job returns are
treated separately and handled easily. Where it is not
possible to avoid commingling, laboratory-selected demulsifiers at appropriate concentrations are being used
1066
Acknowledgments
I wish to acknowledge the contributions and active support of all those who have furnished materials and information. I especially wish to thank F. R. Daigle and W. J.
Kuebler of Chevron Oil Co. for their summaries of field
operations.
References
1. Gidley, J. L. and Hanson, H. R.: "Prevention of Central Terminal
Upsets Related to Stimulation and Sand Consolidation Treatments, "
paper SPE 4551 presented at the SPE-AIME 48th Annual Fall Meeting, Las Vegas, Nev., Sept. 3D-Oct. 3, 1973.
2. Green, E. B., Lybarger, J. H., and Richardson, E. A.: "In-Situ Acid
Neutralization System Solves Facility Upset Problems," J. Pet.
Tech. (Oct. 1974) 1153-1155.
3. Sutton, G. D. and Lasater, R. M.: "Aspects of Acid Additive
Selection in Sandstone Acidizing, paper SPE 4114 presented at the
SPE-AIME 47th Annual Fall Meeting, San Antonio, Tex., Oct.
8-11, 1972.
4. Coppel, C. P., Jennings, H. Y., Jr., and Reed, M. G.: "Field Results
From Wells Treated With Hydroxy-Aluminum," J. Pet. Tech.
(Sept. 1973) 1108-1112.
5. Blevins, T. R., Cotten, W. R., and Dugas, E. J.: "OH-Al Treatments Sustain Acid Stimulated Production," World Oil (Aug. I,
1973) 26-29.
6. Becher, P.: "Effect of Preparation Parameters on the Initial Size
Distribution Function in Oil-in-Water Emulsions," J. Coli. and Int.
Science (1967) 24, 9196.
JPT
Original manuscript received in Society of Petroleum Engineers office Aug. 12,
1974. Revised manuscript received July 10, 1975. Paper (SPE 5154) was first
presented at theSPE-AIME 49th Annual Fall Meeting, held in Houston, Oct. 6-9,
1974. Copyright 1975 American Institute of Mining, Metallurgical, and Petroleum Engineers, Inc.