Reduction of Breakdown Pressure by Filter Cake Removal Using Thermochemical Fluids and Solvents: Experimental and Numerical Studies

The process of well cleanup involves the removal of an impermeable layer of filter cake from the face of the formation. The inefficient removal of the filter cake imposes difficulty on fracturing operations. Filter cake’s impermeable features increase the required pressure to fracture the formation. In this study, a novel method is introduced to reduce the required breakdown pressure to fracture the formation containing the water-based drilling fluid filter cake. The breakdown pressure was tested for five samples of similar properties using different solutions. A simulated borehole was drilled in the core samples. An impermeable filter cake using barite-weighted drilling fluid was built on the face of the drilled hole of each sample. The breakdown pressure for the virgin sample without damage (filter cake) was 6.9 MPa. The breakdown pressure increased to 26.7 MPa after the formation of an impermeable filter cake. Partial removal of filter cake by chelating agent reduced the breakdown pressure to 17.9 MPa. Complete dissolution of the filter cake with chelating agents resulted in the breakdown pressure approximately equivalent to the virgin rock breakdown pressure, i.e., 6.8 MPa. The combined thermochemical and chelating agent solution removed the filter cake and reduced the breakdown pressure to 3.8 MPa. Post-treatment analysis was carried out using nuclear magnetic resonance (NMR) and scratch test. NMR showed the pore size redistributions with good communication between different pores after the thermochemical removal of filter cake. At the same time, there was no communication between the different pores due to permeability impairment after filter cake formation. The diffusion coupling through NMR scans confirmed the higher interconnectivity between different pores systems after the combined thermochemical and chelating agent treatment. Compressive strength was measured from the scratch test, confirming that filter cake formation caused added strength to the rock that impacts the rock breakdown pressure. The average compressive strength of the original specimen was 44.5 MPa that increased to 73.5 MPa after the formation of filter cake. When the filter cake was partially removed, the strength was reduced to 61.7 MPa. Complete removal with chelating agents removed the extra strength that was added due to the filter cake presence. Thermochemical and chelating agents resulted in a significantly lower compressive strength of 25.3 MPa. A numerical model was created to observe the reduction in breakdown pressure due to the thermochemical treatment of the filter cake. The result presented in this study showed the engineering applications of thermochemical treatment for filter cake removal.     

Use of Mesophilic Fungal Amylases Produced by Solid-state Fermentation in the Cold Hydrolysis of Raw Babassu Cake Starch

Amylases constitute one of the most important groups of industrial enzymes, presenting several applications, such as in the food, textile, and ethanol manufacturing. In this work, a starchy residue from the Brazilian agroindustry, namely babassu cake, was used for the production of amylases by solid-state fermentation and for obtaining sugar hydrolysates, which can be used as building blocks for future bioconversions. Eight filamentous fungi from the genera Aspergillus and Penicillium were screened. Regarding amylase production, A. awamori strains showed well-balanced endoamylase and exoamylase activities, while A. wentii produced an amylolytic complex much richer in the endo-acting enzymes. Simultaneous liquefaction and saccharification using the crude enzyme extracts from the four most promising fungal strains was then investigated applying DOE techniques. The highest total reducing sugar content (24.70 g L^?1) was obtained by the crude extract from A. awamori IOC-3914, corresponding to a hydrolysis yield of 52% of total starch in the cake, while A. awamori IOC-3915 produced the most appropriate extract in terms of glucose release (maximum of 5.52 g L^?1). Multivariate analysis of the DOE studies indicated that these extracts showed their best performance at 50–57 °C under acid conditions (pH 3.6–4.5), but were also able to act satisfactorily under milder conditions (36 °C and pH 5.0), when TRS and glucose released were about 65% of the maximum values obtained. These data confirm the high potential of the enzyme extracts under study for cold hydrolysis of starch.     

Solid-State Treatment of Castor Cake Employing the Enzymatic Cocktail Produced from <Emphasis Type="Italic">Pleurotus djamor</Emphasis> Fungi

In this work, the enzymatic cocktail produced by Pleurotus djamor fungi extracted at pH of 4.8 and 5.3 was employed for castor cake solid-state treatment. Proximal, X-ray powder diffraction and scanning electron microscopy analysis of the pristine castor cake were carried out. First, Pleurotus djamor stain was inoculated in castor cake for the enzymatic production and the enzymatic activity was determined. The maximum enzymatic activity was identified at days 14 (65.9 UI/gss) and 11 (140.3 UI/gss) for the enzymatic cocktail obtained at pH 5.3 and 4.8, respectively. Then, the enzymatic cocktail obtained at the highest enzymatic activity days was employed directly over castor cake. Lignin was degraded throughout incubation time achieving a 47 and 45% decrease for the cocktail produced at pH 4.8 and 5.3, correspondingly. These results were corroborated by the SEM and XRD analysis where a higher porosity and xylan degradation were perceived throughout the enzymatic treatment.     

Distillation of LiCl from the LiCl–Li2O molten salt of the electrolytic reduction process

Electrolytic reduction of the uranium oxide in LiCl–Li₂O molten salt for the treatment of spent nuclear fuel requires the separation of the residual salt from the reduced metal product, which contains about 20 wt% salt. In order to separate the residual salt and reuse it in the electrolytic reduction, a vacuum distillation process was developed. Lab-scale distillation equipment was designed and installed in an argon atmosphere glove box. The equipment consisted of an evaporator in which the reduced metal product was contained and exposed to a high temperature and reduced pressure; a receiver; and a vertically oriented condenser that operated at a temperature below the melting point of lithium chloride. We performed experiments with LiCl–Li₂O salt to evaluate the evaporation rate of LiCl salt and varied the operating temperature to discern its effect on the behavior of salt evaporation. Complete removal of the LiCl salt from the evaporator was accomplished by reducing the internal pressure to <100 mTorr and heating to 900 °C. We achieved evaporation efficiency as high as 100 %.     

Biodegradation study of plasticised corn flour/poly(butylene succinate-co-butylene adipate) blends

Plasticised corn flour/poly(butylene succinate-co-butylene adipate) (PBSA) materials were prepared by extrusion and injection in order to study the impact of PBSA ratio on their physicochemical properties and biodegradability. Scanning electron microscopy observations showed that corn flour and PBSA are incompatible. Three types of morphology have been observed: (i) starch dispersed in a PBSA matrix, (ii) a “co-continuous-like” morphology of starch and PBSA, and (iii) PBSA dispersed in a starch matrix. As expected, the extent of plasticised corn flour starch hydrolysis by amylolytic enzymes decreased when the amount of PBSA increased. Addition of a lipase to hydrolyse PBSA ester bonds enhanced enzymatic hydrolysis of starch by amylolytic enzymes in materials where PBSA formed a continuous phase. This suggests that PBSA formed a barrier restricting the access of amylolytic enzymes to starch. This was consistent with aerobic and anaerobic biodegradation assays, which also showed lower biodegradability of materials containing a majority of PBSA.     

Synthesis of a copolymer with filter aid,dihydration, and scale inhibition abilities and its application to wet phosphoric acid

A new type of multifunction copolymer PAMA having filter aid, dihydration, and dynamic scale inhibition properties was synthesized using acrylamide (AM) and a homemade polyoxyethylene octylphenol ether acrylic ester (AOP) as the feedstock and persulfate as the initiator in an aqueous solution. The structure of the copolymer was characterized using FTIR and ¹H NMR spectroscopy. Scanning electron microscopy and the software Matlab 7.0 were used to investigate the influence of the copolymer on filter aid and scale inhibition. The results indicated that the copolymer consists of AM and AOP. The filtration rates of the phosphogypsum slurry increased 3.8 times compared to the blank group, and the water content of the phosphogypsum cake was reduced by 10.42% with the addition of 10 ppm of PAMA. The dynamic scale inhibition rate of sodium fluorosilicate and potassium fluorosilicate can reach up to 53.5% when the experiment runs continuously for 12 h. The experiments related to mechanism indicate that PAMA has a strong adsorbability and high bridge effect on the phosphogypsum crystals. Concurrently, PAMA can efficiently improve the microstructure of a filter cake and remove the scale layer of sodium fluorosilicate and potassium fluorosilicate adhering to the wall of a stainless steel pipe, which is beneficial for increasing the filter rate, decreasing the moisture content of the filter cake, and preventing scale layer formation on the filter.     

Retrogradation characteristics of high hydrostatic pressure processed corn and wheat starch

High hydrostatic pressure (HHP) has been investigated as an alternative to thermal processing for food preservation. HHP has been known to affect high molecular weight polymers causing phase change. Starch is gelatinized at a pressure on the order of 600–700 MPa, at 25 °C. Gelatinized starch recrystallizes during storage affecting the texture and shelf life of food products. The effect of HHP processing on the crystallization of starches from different botanical origins during storage at 4 and 23 °C was investigated. Crystallization kinetics of HHP treated wheat and corn starch gels were compared using DSC. The effect of crystallization on structure was evaluated in terms of storage modulus. The rate of retrogradation depended on the storage temperature (23 °C and 4 °C) and the botanical origin of the starch. The least crystallization was observed in HHP treated wheat starch stored at 23 °C. The storage modulus increased with crystallization of starch.     

Saccharification and alcohol fermentation in starch solution of steam-exploded potato

Steam explosion pretreatment of potato for the efficient production of alcohol was experimentally studied. The amount of water-soluble starch increased with the increase of steam pressure, but the amounts of methanol-soluble material and Klason lignin remained insignificant, regardless of steam pressure. The potatoes exploded at high pressure were hydrolyzed into a low molecular liquid starch, and then easily converted into ethanol by simultaneous saccharification and fermentation using mixed microorganisms: an amylolytic microorganism,Aspergillus awamori, and a fermentation microorganism,Saccharomyces cerevisiae. The maximal ethanol concentration was 4.2 g/L in a batch culture at 15 g/L starch concentration, and 3.6 g/L in a continuous culture fed the same starch concentration. In the fed-batch culture, the maximal ethanol concentration increased more than twofold, compared to the batch culture.     

The solid–liquid separation characteristics of pure LiCl–KCl eutectic salt using different types of crucibles

Uranium deposits were recovered at the solid cathode of an electrorefining system, and deposited uranium dendrite normally contains about 30–40 wt% LiCl–KCl eutectic salts. Therefore, a separation of the eutectic salts from deposited uranium is essential for reusing these salts and uranium. A process such as distillation was employed for cathode processing due to the advantages of a minimal generation of secondary waste, a compact unit process, and simple and low-cost equipment. However, the realization of a wide evaporation area or high distillation temperature is limited by various factors such as the material or structure of a distiller. Also, the electrical energy flow from outside has a lot of consumption to maintain the high temperature. Hence, in this study, solid–liquid separation experiments are proposed to increase the throughput of the salt removal process by the separation of the liquid salt prior to the distillation of the LiCl–KCl eutectic salt. The solid–liquid separation of salt was carried out in a vertical type distiller. The behavior of the solid–liquid separation of pure eutectic salt was investigated as a function of temperature, pressure, sieve size, and crucible shape. From the experimental results using pure eutectic salts, the amount of salt separation was achieved at more than 94 wt%. The rate of solid–liquid separation of salt using 600 °C is higher than that of 500 °C under the same condition. The influence of a vacuum for solid–liquid separation can be disregarded, and the separation rate of a 100 mesh was higher than that of a 150 mesh. In addition, the rate of separation for salts using a porous crucible is higher than that in a non-porous crucible.     

Study on the microfiltration of Escherichia coli-containing fermentation broth by a ceramic membrane filter

Microfiltration (MF) of a fermentation broth containing Escherichia coli is reported in this article. We used a ceramic membrane filter (zirconia on sintered carbon) having a nominal pore size of 0.2 μm. Our results indicate that the filtration resistance was mainly caused by the cake formed on the membrane surface. Both transmembrane pressure (TMP) and fluid sweeping velocity influenced this cake resistance. Resistances due to membrane itself and due to internal pore blockage by E. coli were less important and insensitive to both TMP and fluid sweeping velocity. Preliminary results also showed that the cell density could be significantly increased when we connected such a ceramic filter on-line with our fermentation system. In particular it was found that the gas bubbles entrained in the broth side of the filter could increase the filtration flux by as much as 80%.     

Acid Pullulanase from Bacillus polymyxa MIR-23

Within the frame of a screening program aimed at the isolation of amylolytic sporeformers, one strain with high amylolytic activity designated MIR-23 was selected. The microbial characterization was carried out by morphological and biochemical tests and, by means of statistical treatment, was identified asBacillus polymyxa. The organism could grow in acidic conditions (pH 5.0) on a starch medium and produce α-amylase, pullulanase, and α-glucosidase. Batch cultures showed the highest enzyme activities in the stationary phase. Pullulanase activity exhibited an optimal temperature of 52–57°C at pH 4.5–5.5. These properties would allow its use in the saccharification processes in the starch industries.     

Pressure and concentration profiles in filter cake consisting of core/shell latex particle

Poly(styrene-co-acrylic acid) latex particles with different acrylic acid contents have been synthesized and used for filtration studies. Effective pressure and dry matter concentrations were measured at different positions in the filter cakes during the filtration processes, and dry matter concentration was not found to change significantly with effective pressure. Nevertheless, the local dry matter concentration did increase with time for latex particles containing 1 and 3%, w/w acrylic acid, which indicate that filter cake comprising latex particles with a high acrylic acid content will creep during the filtration stage. The filter cakes were examined using stepped-pressure filtration experiments as well, and an almost instantaneous deformation of the filter cake was observed after the pressure step. Furthermore, a minor deformation was observed over the following 2 h for latex particles both containing and not containing acrylic acid. This is thought to be due to the rearrangement of particles in the filter cake.     

Wall Effects on Spheres Settling Through Non-Newtonian Fluid Media in Cylindrical Tubes

Experimental study is performed to understand and quantify the wall and eccentric retardation effects on spheres settling in shear thinning and shear-thinning viscoelastic fluids over a wide range of diameter ratios (0.02 < λ < 0.9). The four-parameter Carreau viscosity equation has been chosen to represent the apparent viscosity-shear rate of polyacrylamide solutions. Two new wall factor corrections are presented with excellent agreement compared to experimental data.

The terminal settling velocity of a sphere in bounded fluid is significantly reduced by the presence of confining boundaries, named wall retardation effect that decreases due to the shear-thinning behavior of power law fluids, which is weaken further by the elastic effect of viscoelastic fluids. The wall factors of spheres settling in viscoelastic fluids increase at low ξ up to 50, followed by a horizontal confidence region (0.7 ≤ f ≤ 1) at high ξ. In this region, the wall factor is mainly dominated by fluids’ elasticity, which is more distinguished for small spheres. As the settling spheres approach to the wall (b/R → 1), the neighboring wall exert more intensive retardation that reduce the terminal settling velocity greatly when b/R > 0.6 in pure shear-thinning fluids, and the extra retardation effect of nearby wall increases at high concentration due to the enhanced non-Newtonian property. In contrast, the eccentric effect on settling velocity in viscoelastic fluids is cut down greatly by the fluid's elasticity, which is negligible.     

Pulsed Discharge Regeneration of Diesel Particulate Filters

A novel method for the removal of soot from a diesel particulate filter using pulsed electric discharges is presented. High voltage pulses of between 18 and 25 kV of nano to microsecond duration and with pulse energies of typically 100–200 mJ were applied to the filter via a series spark gap. Initial slow erosion of the soot layer proceeds via the formation of microdischarges. Subsequent spark discharges removed the accumulated soot more effectively from a larger filter volume. Average soot removal rates of ～0.1–0.2 g/min were achieved at 50 Hz breakdown frequency by optimizing both electrode geometry and breakdown voltage. On-engine long term testing of the technology showed soot removal by pulsed discharge to be reliable, efficient and uniform; a total of 100 g of soot was deposited and removed over 18 filter regeneration cycles.     

Local properties of cake in cross-flow microfiltration of submicron particles

The local properties of filter cakes, such as porosity and specific filtration resistance, in cross-flow microfiltration of submicron particles are studied based on an analysis of force. The packing of particles in a filter cake can be divided into two modes. When the solid compressive pressure is smaller than the critical value, there exists an equilibrium distance between neighbouring particles due to the electrostatic repulsive force, and the local cake porosity can be estimated by using the cell model proposed in this study. When the solid compressive pressure is greater than the critical value, the compressive force can overcome the repulsive barrier, the particles then come into contact with neighbours, and the power-type empirical relationship between cake porosity and solid compressive pressure can be employed to estimate the local cake porosity. It can be found that the half of the cake near the filter membrane has a compact structure, and a high filtration resistance within the operating conditions of this study. On the other hand, the portion of cake near the cake surface has a high porosity due to the separation of particles. By using this model, the effect of electrolyte concentration on cake properties can be analyzed, and the estimated values of average porosity and average specific filtration resistance under various electrolyte concentrations, cross-flow velocities, and filtration pressures agree fairly well with the experimental data.     

Enzymatic Hydrolysis of Sodium Dodecyl Sulphate (SDS)—Pretreated Newspaper for Cellulosic Ethanol Production by Saccharomyces cerevisiae and Pichia stipitis

Fermentation of enzymatic hydrolysate of waste newspaper was investigated for cellulosic ethanol production in this study. Various nonionic and ionic surfactants were applied for waste newspaper pretreatment to increase the enzymatic digestibility. The surfactant-pretreated newspaper was enzymatically digested in 0.05 M sodium citrate buffer (pH 4.8) with varying solid content, filter paper unit loading (FPU/g newspaper), and ratio of filter paper unit/β-glucosidase unit (FPU/CBU). Newspaper pretreated with the anionic surfactant sodium dodecyl sulphate (SDS) demonstrated the highest sugar yield. The addition of Tween-80 in the enzymatic hydrolysis process enhanced the enzymatic digestibility of newspaper pretreated with all of the surfactants. Enzymatic hydrolysis of SDS-pretreated newspaper with 15% solid content, 15 FPU/g newspaper, and FPU/CBU of 1:4 resulted in a newspaper hydrolysate conditioning 29.07 g/L glucose and 4.08 g/L xylose after 72 h of incubation at 50 °C. The fermentation of the enzymatic hydrolysate with Saccharomyces cerevisiae, Pichia stipitis, and their co-culture produced 14.29, 13.45, and 14.03 g/L of ethanol, respectively. Their corresponding ethanol yields were 0.43, 0.41, and 0.42 g/g.     

Biorefining of Waste Paper Biomass: Increasing the Concentration of Glucose by Optimising Enzymatic Hydrolysis

Waste copier paper is a potential substrate for the production of glucose relevant for manufacture of platform chemicals and intermediates, being composed of 51 % glucan. The yield and concentration of glucose arising from the enzymatic saccharification of solid ink-free copier paper as cellulosic substrate was studied using a range of commercial cellulase preparations. The results show that in all cellulase preparations examined, maximum hydrolysis was only achieved with the addition of beta-glucosidase, despite its presence in the enzyme mixtures. With the use of Accellerase® (cellulase), high substrate loading decreased conversion yield. However, this was overcome if the enzyme was added between 12.5 and 20 FPU g substrate^?1. Furthermore, this reaction condition facilitated continual stirring and enabled sequential additions (up to 50 % w/v) of paper to be made to the hydrolysis reaction, degrading nearly all (99 %) of the cellulose fibres and increasing the final concentration of glucose whilst simultaneously making high substrate concentrations achievable. Under optimal conditions (50 °C, pH 5.0, 72 h), digestions facilitate the production of glucose to much improved concentrations of up to 1.33 mol l^?1.     

Enhanced Bioethanol Production from Potato Peel Waste Via Consolidated Bioprocessing with Statistically Optimized Medium

In this study, an extensive screening was undertaken to isolate some amylolytic microorganisms capable of producing bioethanol from starchy biomass through Consolidated Bioprocessing (CBP). A total of 28 amylolytic microorganisms were isolated, from which 5 isolates were selected based on high α-amylase and glucoamylase activities and identified as Candida wangnamkhiaoensis, Hyphopichia pseudoburtonii (2 isolates), Wickerhamia sp., and Streptomyces drozdowiczii based on 26S rDNA and 16S rDNA sequencing. Wickerhamia sp. showed the highest ethanol production (30.4 g/L) with fermentation yield of 0.3 g ethanol/g starch. Then, a low cost starchy waste, potato peel waste (PPW) was used as a carbon source to produce ethanol by Wickerhamia sp. Finally, in order to obtain maximum ethanol production from PPW, a fermentation medium was statistically designed. The effect of various medium ingredients was evaluated initially by Plackett-Burman design (PBD), where malt extracts, tryptone, and KH₂PO₄ showed significantly positive effect (p value < 0.05). Using Response Surface Modeling (RSM), 40 g/L (dry basis) PPW and 25 g/L malt extract were found optimum and yielded 21.7 g/L ethanol. This study strongly suggests Wickerhamia sp. as a promising candidate for bioethanol production from starchy biomass, in particular, PPW through CBP.     

Synthesis of Fructooligosaccharides from Aspergillus niger Commercial Inulinase Immobilized in Montmorillonite Pretreated in Pressurized Propane and LPG

Commercial inulinase from Aspergillus niger was immobilized in montmorillonite and then treated in pressurized propane and liquefied petroleum gas (LPG). Firstly, the effects of system pressure, exposure time, and depressurization rate, using propane and LPG, on enzymatic activity were evaluated through central composite design 2³. Residual activities of 145.1 and 148.5 % were observed for LPG (30 bar, 6 h, and depressurization rate of 20 bar?min^?1) and propane (270 bar, 1 h, and depressurization rate of 100 bar?min^?1), respectively. The catalysts treated at these conditions in both fluids were then used for the production of fructooligosaccharides (FOS) using sucrose and inulin as substrates in aqueous and organic systems. The main objective of this step was to evaluate the yield and productivity in FOS, using alternatives for enhancing enzyme activity by means of pressurized fluids and also using low-cost supports for enzyme immobilization, aiming at obtaining a stable biocatalyst to be used for synthesis reactions. Yields of 18 % were achieved using sucrose as substrate in aqueous medium, showing the potential of this procedure, hence suggesting a further optimization step to increase the process yield.