Optimization of acoustic parameters for ultrasonic separation of emulsions with different physical properties

Understanding Separation of Oil-Water Emulsions by High Surface Area Polymer Gels Using Experimental and Simulation Techniques

This work examines the functional dependence of the efficiency of separation of oil-water emulsions on surfactant adsorption abilities of high surface area polymer gels. The work also develops an understanding of the factors and steps that are involved in emulsion separation processes using polymer gels. The work considers four polymer gels offering different surface energy values, namely, syndiotactic polystyrene (sPS), polyimide (PI), polyurea (PUA), and silica. The data reveal that surfactant adsorption abilities directly control the emulsion separation performance. The gels of sPS and PI destabilize the emulsions due to significant surfactant adsorption. The surfactant-lean oil droplets are then absorbed in the pores of sPS and PI gels due to the preferential wettability of the oil phase. The PUA and silica gels are more hydrophilic and show a lower surfactant adsorption ability. These gels cannot effectively remove the surfactant molecules from the emulsions, leading to a poor emulsion separation performance. The study uses simulation data to understand the adsorption characteristics of two poly(ethylene oxide)-poly(propylene oxide)-poly(ethylene oxide) block copolymer surfactants. The simulation results are used for the interpretation of emulsion separation performance by the gels.

Magnetic field effects on the surfactant concentration over ferrofluid droplet surfaces in shear flows

We investigate the impact of a magnetic field on surfactant concentration and interfacial forces across droplet surfaces within shear flows. Our analysis centers on a single two-dimensional ferrofluid droplet covered with surfactants, suspended in an immiscible, non-magnetizable liquid. The model combines incompressible Navier-Stokes equations and Maxwell's equations in the superparamagnetic limit in the single-fluid formulation, augmented by terms accounting for Marangoni, capillary, and magnetic forces at the droplet interface. We solve the surfactant convection-diffusion equation at the surface, while a non-linear Langmuir equation of state relates surfactant concentration to surface tension. The model is numerically solved using finite differences, a level-set method for multiphase flow computation, and the closest-point method for concentration equation. Our findings reveal that even though the surfactant is magnetically neutral, the presence of a magnetic field significantly modifies its distribution at the interface. A magnetic field perpendicular to the primary flow direction shifts the maximum concentration zone from the droplet tips toward the flow vorticity direction, while a parallel field produces the opposite effect. Alterations in surfactant distribution directly impact the surface tension field, offering a potential wireless means of controlling droplet dynamics.

Mechanism study of aging oil demulsification and dehydration under ultrasonic irradiation

With the tertiary oil recovery in the oilfield, the content of aging oil emulsion with high water content and complex components has become more prevalent, so it is crucial for aging oil to break the emulsification. In this paper, the experimental laws of water content are explored under the conditions of different transducer input powers through the ultrasonic reforming of aging oil, and the microscopic topography, particle size, components, etc. of oil samples before and after the irradiation of ultrasound are characterized through the microscopic analysis, particle size analysis and component analysis and other ways. The results show that the oil samples achieve the effect of demulsification and dehydration in the presence of ultrasonic cavitation effect, with a maximum dehydration rate of 98.24 %, and that the dehydration rate follows an "M-type" trend with the increase of power. The results of microscopic and particle size analyses demonstrate that ultrasonic irradiation destabilizes the oil-water interfacial membrane, and causes droplets of different sizes to collide, agglomerate, and settle. It was also observed that the droplets of the emulsion system are more evenly distributed and the intervals are increased. Furthermore, we hypothesize that ultrasound may be less irreversible in demulsification and dehydration of aging oil.

Recent advances of ultrasound applications in the oil and gas industry

In the last two decades, ultrasound (US) technologies research has increasingly earned attention for applications in the oil and gas industry. Numerous laboratory and field research have proven ultrasonics as an efficient, sustainable and cost-effective technology for improving well productivity. This paper pursues the elaboration of a comprehensive review of the most recent research related to ultrasonic technologies for applications in the oil and gas industry. Statistical analysis of different functional categories and classification of the research publications were performed. Considering the research reviewed, there is a huge gap between numerical and field studies in comparison with the numerous laboratory studies, deeming it necessary to increase efforts on developing mathematical and numerical models and field-testing cases of the ultrasonic effect. A comprehensive review of the ultrasonic waves' mechanisms of action for enhanced oil recovery (EOR) and emulsification/demulsification was conducted. Despite the lack of consensus regarding the mechanisms, cavitation and thermal effects on wellbore fluid and formation rock have been widely accepted as two of the most influencing mechanisms. A compilation of the state-of-the-art research of numerical, laboratory and field studies in the last two decades was assembled. Most authors agreed that ultrasonics is a highly efficient method for EOR and emulsion treatment if the optimal conditions are identified and achieved. The development of screening criteria for the application of ultrasonic waves was recommended, as this technique and the same parameters should not be utilized for all reservoir types. Treatment with ultrasound waves has shown improvement of oil recovery efficiency rates of over 90% and viscosity reduction values over 80%. The most efficient results were observed when in combination with another conventional EOR method, where ultrasound boosts recovery efficiency. Potential new applications related to rock mechanics and additional research topics were also recommended.

Evaporation issues of acoustically levitated fuel droplets

Fuel droplet evaporation is essential to the generation of flammable mixtures in thermal engines. Generally, liquid fuel is injected directly into the hot, high-pressure atmosphere to form scattered droplets. Many investigations on droplet evaporation have been conducted with techniques involving the influence of boundaries, such as suspended wires. Ultrasonic levitation is a non-contact and non-destructive technology that can avoid the impact of hanging wire on droplet shape and heat transfer. Besides, it can simultaneously levitate multiple droplets and allow them to associate with each other or be used to study droplet instability behaviors. This paper reviews the influences of the acoustic field on levitated droplets, the evaporation characteristics of acoustically levitated droplets, and the prospects and limitations of ultrasonic suspension methods for droplet evaporation, which can serve as references for relevant studies.

Biomimetic cellulose-nanocrystalline-based composite membrane with high flux for efficient purification of oil-in-water emulsions

The massive discharge of oily wastewater and oil spills are causing serious pollution to water resources. It is urgent to require clean and efficient method of purifying oily emulsions. Although the separation membranes with selective wettability have been widely used in the efficient purification of oil/water emulsions. It is still very challenging to develop functional films that are environmentally friendly, fouling resistant, inexpensive, easy to prepare, easy to scale, and highly efficient. Cellulose nanocrystalline-based composite membranes (CCM) were prepared by surface-initiated atom transfer radical polymerization (SATRP) and vacuum self-assembly. The prepared CCM is superhydrophilic and superoleophobic underwater due to the hydrophilic nature of the modified cellulose-nanocrystalline and the micro-nano surface structure. The CCM shows high separation efficiency (> 99.9 %), high flux (16,692 L^-1·m^-2·h^-1·bar^-1) for surfactant-stabilized oil-in-water emulsions, good cycle stability and anti-fouling performance. This biomass-derived membrane is green, cheap, easy to manufacture, scalable, super-wettability, and durability, it promises to be an alternative to separation membranes in today's market.

A 3D smart wood membrane with high flux and efficiency for separation of stabilized oil/water emulsions

Oily sewage discharged from indiscriminate industrial and frequent oil spills have become a serious global problem. There is an urgent need to separate stable oil/water emulsions by efficient and environmentally friendly methods. Membrane separation technology has the advantages of low energy consumption and low cost, thus is an effective solution to the problems of oily wastewater. However, the manufacture of multifunctional membranes with high efficiency, high flux and self-cleaning using renewable materials remains a challenge. Herein, three-dimensional (3D) smart membranes with switchable superhydrophobic-hydrophilic surfaces were prepared by grafting photo-responsive poly-spiropyran (PSP) on wood-based substrates via surface atom transfer radical polymerization. This novel membrane can efficiently separate stabilized water-in-oil and oil-in-water emulsions due to reversible hydrophilic-hydrophobic transition by switching UV and visible light irradiation. Remarkably, after immobilization, the PSP grafted on the wood substrate exhibited a faster photo response effect than the free spiropyran (SP). More importantly, the prepared 3D smart membranes showed exceptional high flux (4392 L•m^-2•h^-1) and efficiency (above 99.99 %), good cycle stability (99.99 % after 12 times) and durability (available for at least 60 days) for the separation of surfactant-stabilized water-in-oil emulsions. This work opens a new avenue for the design of functional biomass-derived membranes for efficient and sustainable oily wastewater treatment with high flux, easy scale-up, and green regeneration.

Numerical assessment of ultrasound supported coalescence of water droplets in crude oil

In this study, a numerical assessment of the coalescence of binary water droplets in water-in-oil emulsion was conducted. The investigation addressed the effect of various parameters on the acoustic pressure and coalescence time of water droplets in oil phase. These include transducer material, initial droplet diameter (0.05-0.2 in), interfacial tension (0.012-0.082 N/m), dynamic viscosity (10.6-530 mPas), temperature (20-100 °C), US (ultra sound) frequency (26.04-43.53 kHz) and transducer power (2.5-40 W). The materials assessed are lead zirconate titanate (PZT), lithium niobate (LiNbO₃), zinc oxide (ZnO), aluminum nitride (AlN), polyvinylidene fluoride (PVDF), and barium titanate (BaTiO₃). The numerical simulation of the binary droplet coalescence showed good agreement with experimental data in the literature. The US implementation at a fixed frequency produced enhanced coalescence (t = 5.9-8.5 ms) as compared to gravitational settling (t = 9.8 ms). At different ultrasound (US) frequencies and transducer materials, variation in the acoustic pressure distribution was observed. Possible attenuation of the US waves, and the subsequent inhibitive coalescence effect under various US frequencies and viscosities, were discussed. Moreover, the results showed that the coalescence time reduced across the range of interfacial tensions which was considered. This reduction can be attributed to the fact that lower interfacial tension produces emulsions which are relatively more stable. Hence, at lower interface tension between the water and crude oil, there was more resistance to the coalescence of the water droplets due to their improved emulsion stability. The increment of the Weber number at higher droplet sizes leads to a delay in the recovery of the droplet to spherical forms after their starting deformation. These findings provide significant insights that could aid further developments in demulsification of crude oil emulsions under varying US and emulsion properties.

The Utilization of Ultrasound for Improving Oil Recovery and Formation Damage Remediation in Petroleum Reservoirs: Review of Most Recent Researches

The ultrasound method is a low-cost, environmentally safe technology that may be utilized in the petroleum industry to boost oil recovery from the underground reservoir via enhanced oil recovery or well stimulation campaigns. The method uses a downhole instrument to propagate waves into the formation, enhancing oil recovery and/or removing formation damage around the wellbore that has caused oil flow constraints. Ultrasonic technology has piqued the interest of the petroleum industry, and as a result, research efforts are ongoing to fill up the gaps in its application. This paper discusses the most recent research on the investigation of ultrasound’s applicability in underground petroleum reservoirs for improved oil recovery and formation damage remediation. New study areas and scopes were identified, and future investigations were proposed.

Recent developments, challenges, and prospects of ultrasound-assisted oil technologies

There has been consistent drive towards research and innovation in oil production technologies in order to achieve improved effectiveness and efficiency in their operation. This drive has resulted in breakthrough in technologies such as the application of ultrasound (US) in demulsification and enhanced oil recovery (EOR), and usage of high-volume hydraulic fracturing and special horizontal well for shale oil and gas extraction. These can be observed in the increment in the number of commercial oil technologies such as EOR projects that rose from 237 in 1996 to 375 in 2017. This sustained expansion in EOR resulted in their total oil production rising from 1.5 million barrels per day in 2005 to 2.3 million barrels per day in 2020. And this is predicted to increase to about 4.7 million barrels per day in 2040, which represent about 4% of total production. Consequently, in this review, the developments in the utilization of US either as standalone or integrated with other technologies in EOR and dehydration of water in oil emulsions were analyzed. The studies include the optimization of fluid and US properties in EOR and demulsification. Reports on the treatment of formation damage resulting from inorganic salts, organic scales, drilling fluid plugs, condensate, paraffin wax and colloidal particle with US-assisted EOR were also highlighted. Moreover, the mechanisms were examined in order to gain insightful understanding and to aid research investigations in these areas. Technologies such as US assisted green demulsification, high intensity focused ultrasound, and potential pathways in field studies were assessed for their feasibilities. It is essential to evaluate these technologies due to the significant accrued benefits in them. The usage of green demulsifiers such as deep eutectic solvents, ionic liquids and bio-demulsifiers has promising future outlook and US could enhance their technical advancement. HiFU has been applied successfully in clinical research and developments in this area can potentiality improve demulsification and interfacial studies (fluid-fluid and solid-fluid interactions). As regards field studies, there is need to increase actual well investigations because present reports have few on-site measurements with most studies being in laboratory scale. Furthermore, there is need for more detailed modeling of these technologies as it would assist in conserving resources, saving research time and fast-tracking oil production. Additional evaluative studies of conditions such as the usage of Raschig rings, crude oil salinity and high temperature which have improved demulsification of crude oil emulsions should be pursued.

Application of Cavitation in Oil Processing: An Overview of Mechanisms and Results of Treatment

The integrated effect on homogeneous and heterophase liquids that can be used for technological purposes has drawn the attention of researchers in various sciences. Cavitation impact on oil is among the efficient methods of intensifying chemical-technological, hydromechanical, and mass-exchange processes and the destruction of substances. This work reviews in detail and analyzes the mechanisms of impact and application of cavitation in various processes in the petroleum industry, including the refining processes, that are associated with crude oil and petroleum waste, such as reduction of viscosity, demulsification, desulfurization, and improvement of quality of heavy oil and petroleum refinery products, including oil sludge and waste oil-containing water.

Mechanism of Ultrasonic Physical-Chemical Viscosity Reduction for Different Heavy Oils

In this study, the mechanism of physical-chemical viscosity reduction of different heavy oils under ultrasonic wave is explored. Experiments of viscosity reduction and viscosity recovery of different heavy oils under ultrasonic excitation were carried out, and the optimal ultrasonic parameters, ultrasonic physical disturbance, and cavitation viscosity reduction extent of different oil samples were determined. Based on the element analysis methods, four-component analysis, gas chromatography analysis, and formation water pH value test, the micro-mechanism of the oil chemical structure change and water samples under ultrasonic wave was analyzed. The results show that the water content, temperature, and initial viscosity of heavy oil are the key to reduce the viscosity of heavy oil. The higher viscosity of the initial oil sample, the higher water content, and the temperature were needed. Compared with the lower viscosity oil sample, the higher viscosity oil sample has higher extent of cavitation viscosity reduction and lower extent of physical disturbance viscosity reduction under ultrasonic wave. After ultrasonic treatment, the contents of heteroatoms, resins, and asphaltenes in heavy oil samples with high viscosity decreased significantly, and the conversion extent of high carbon chain to low carbon chain was greater. In addition, the pH of water in heavy oils decreased after ultrasonic treatment, and the pH of water in high viscosity heavy oil decreased more significantly after ultrasonic treatment.

Recent advances in applications of power ultrasound for petroleum industry

Power ultrasound, as an emerging green technology has received increasing attention of the petroleum industry. The physical and chemical effects of the periodic oscillation and implosion of acoustic cavitation bubbles can be employed to perform a variety of functions. Herein, the mechanisms and effects of acoustic cavitation are presented. In addition, the applications of power ultrasound in the petroleum industry are discussed in detail, including enhanced oil recovery, oil sand extraction, demulsification, viscosity reduction, oily wastewater treatment and oily sludge treatment. From the perspective of industrial background, key issue and resolution mechanism, current applications and future development of power ultrasound are discussed. In addition, the effects of acoustic parameters on treatment efficiency, such as frequency, acoustic intensity and treatment time are analyzed. Finally, the challenges and outlook for industrial application of power ultrasound are discussed.