Applying ultrasonic fields to separate water contained in medium-gravity crude oil emulsions and determining crude oil adhesion coefficients

Separating produced water is a key part of production processing for most crude oils. It is required for quality reasons, and to avoid unnecessary transportation costs and prevent pipework corrosion rates caused by soluble salts present in the water. A complicating factor is that water is often present in crude oil in the form of emulsions. Experiments were performed to evaluate the performance of ultrasonic fields in demulsifying crude oil emulsions using novel pipe-form equipment. A horn-type piezoelectric ultrasonic transducer with a frequency of 20 kHz and power ranging from 80 W to 1000 W was used for experimental purposes. The influences of the intensity of ultrasonic fields, ultrasonic irradiation time, and the initial water content of crude oils were evaluated to establish the rate of water segregation from oil. The experiments applied ultrasonic-field intensities of $0.25$ W/cm³, $0.5$ W/cm³, $0.75$ W/cm³ and $1$ W/cm³ to synthetic emulsions with 10%, 15%, 20%, and 25% of the water in crude oil. Crude oil demulsification occurred for each ultrasonic field intensity tested for all the samples tested. Function β involving adhesion coefficients was expressed in terms of wave-field intensity and initial concentration of water in each of the three crude oil samples tested. The experiments demonstrated that despite the absence of any chemical demulsifier involved, water separation caused by applying ultrasonic fields was effective and occurred rapidly. As the intensity of the ultrasonic field applied increased, the amount of water segregated from crude oil also increased. Subjected to constant field intensity, higher initial water cuts (up to 15% or so) in the crude oil samples and higher ultrasonic irradiation times, resulted in greater segregation of water from crude oil in percentage terms. However, in samples with initial water cuts of 20+% long irradiation times (~5 min), resulted in a decline in water separation compared to 2-min tests. Ultrasonic field treatments offer commercially-viable and environmentally-friendly alternatives to treatments using chemical demulsifiers as they reduce desalination requirements of wastewater.     

Theoretical and experimental investigation of desalting and dehydration of crude oil by assistance of ultrasonic irradiation

In this paper desalting/dehydration process of crude oil by ultrasonic irradiation in a novel batch standing-wave resonator reactor is studied both theoretically and experimentally. The effect of main parameters including ultrasonic irradiation parameters, namely irradiation input power and irradiation time, and also operating parameters, such as temperature and injected water, on the removal efficiencies of salt and water is examined. The obtained results demonstrate that finding the optimum values of the above mentioned parameters is important to prevent a significant decrease in the removal efficiencies of water and especially salt. Thus, crude oil was subjected to optimal ultrasonic irradiation with an input power of 57.7 W, and irradiation time of 6.2 min at temperature of 100 °C. The injected water to dissolve the salt of crude oil was 7 vol.%. Also, the applied settling time and dosage of chemical demulsifier were 60 min and 2 ppm, respectively. Under these optimum conditions the removal efficiencies of the desalting/dehydration process were 84% and 99.8%, respectively, which are suitable for refineries.Also, based on the optimal experimental data, two inferential estimators are developed to obtain the relationships between the salt and water removal efficiencies, and input energy density. These empirical relationships can offer a proper estimation for the salt and water removal efficiencies with irradiation input energy.     

Experimental and theoretical study of crude oil pretreatment using low-frequency ultrasonic waves

In this work, an ultrasound experimental setup was designed to investigate the feasibility of using low-frequency ultrasonic waves as a substitute to reduce the consumption of chemical demulsifiers in the pretreatment of crude oil. The experiments were planned to study the effects of irradiation time, ultrasonic field intensity and initial water content on the efficiency of separation. The results of experiments showed that by selecting a proper irradiation time and field intensity, it is possible to decrease the usage of demulsifiers by 50%. Moreover, a population balance model was proposed to explicate the experimental data. A hybrid coalescence model was developed to determine the frequency of aggregation. The parameters of the model were estimated by linear regression. The parameter estimation was performed using a parallel execution of the particle swarm optimization algorithm. The results of the model showed a decent agreement with the experimental data.     

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.     

Study on ultrasound-assisted oxidative desulfurization for crude oil

The existence of sulfur compounds in crude oil will bring many problems such as corrosion, catalyst poisoning and pollution to the petroleum processing process. Therefore, how to reduce the sulfur content as much as possible in the process of crude oil processing has become an important research topic in the petroleum processing industry. In this paper, ultrasonic-oxidative desulfurization is studied. The effects of reaction temperature, reaction time, amount of oxidant and demulsifier on desulfurization rate are investigated. And the effect of oxidative desulfurization and single oxidative desulfurization under ultrasonic treatment are compared. It is found that the addition of ultrasonic treatment can enhance the desulfurization effect of desulfurizer, the desulfurization efficiency can be increased by about 10% under ultrasonic treatment (100 W, 70 kHz); ultrasonic wave plays an auxiliary role in the system, it can promote heterogeneous reactions, improve the activity of oxidants, and promote the degradation of macromolecular compounds. Finally, physical desulfurization, chemical desulfurization and biological desulfurization technologies are compared.     

Intensification of ultrasonic-assisted crude oil demulsification based on acoustic field distribution data

Water removal is an essential step during crude oil production due to several problems such as increased transportation costs and high corrosion rate due to dissolved salts. Indirect low frequency ultrasonic energy (US), using baths, has been recently proposed as an effective alternative for crude oil demulsification. However, the reactor position during sonication and its influence on the demulsification efficiency for crude oil has not been evaluated. In this sense, the aim of this study was to develop an automated system based on an open source hardware for mapping the acoustic field distribution in an US bath operating at 35 kHz using a hydrophone. Data acquired with this system provided information to evaluate the demulsification efficiency in the different positions of the US bath and correlate it with the acoustic intensity distribution. The automated 3D-mapping system revealed a higher acoustic intensity in the regions immediately above the transducers (ca. 0.6 W cm⁻²), while the other regions presented a relatively lower intensity (ca. 0.1 W cm⁻²). Experimental data demonstrated that reactors positioned in the most intense acoustic regions provided a much higher efficiency of demulsification in comparison with the ones positioned in the less intense acoustic field regions. Demulsification efficiency up to 93% was obtained with 15 min of sonication (100% amplitude) using few amount of chemical demulsifier. Hence, this work demonstrated that the information acquired with the developed mapping system could be used for inducing a higher efficiency of demulsification only by finding the more suitable position of reactor in the US bath, which certainly will help development of appropriate reactors design when looking for such approach.     

Physicochemical characterization of black seed oil-milk emulsions through ultrasonication

The ultrasonic formation of stable emulsions of a bioactive material, black seed oil, in skim milk was investigated. The incorporation of 7% of black seed oil in pasteurised homogenized skim milk (PHSM) using 20 kHz high intensity ultrasound was successfully achieved. The effect of sonication time and acoustic power on the emulsion stability was studied. A minimum process time of 8 min at an applied acoustic power of 100 W was sufficient to produce emulsion droplets stable for at least 8 days upon storage at 4 ± 2 °C, which was confirmed through creaming stability, particle size, rheology and color analysis. Partially denatured whey proteins may provide stability to the emulsion droplets and in addition to the cavitation effects of ultrasound are responsible for the production of smaller sized emulsion droplets.     

Ultrasound assisted enzymatic degumming of crude soybean oil

The present work deals with ultrasound assisted enzymatic degumming (UAED) of crude soybean oil quantifying the extent of degumming (EOD), cavitational yield and synergistic index (f) for the combination approaches. The effect of different operating parameters such as enzyme loading, pH, presence of water, temperature and ultrasonic power on the EOD has been investigated. Ultrasound combined with enzyme at loading of 2.0 ml/L resulted in EOD as 92.2% under ambient conditions. Addition of water (5%) in combination with ultrasound and enzyme at 2.0 ml/L loading and pH of 5 resulted in maximum EOD (98.4%) in 120 min of treatment. The extent of phospholipid separation was also observed to be dependent on the power dissipation and maximum phospholipids separation was obtained at 100 W. Scale-up studies were performed at 500 ml and 1 L operating volume under optimized conditions of 2.0 ml/L as the enzyme loading, pH of 5, 5% water addition and ultrasonic power of 100 W where 93.63% and 91.15% phospholipid separation respectively was obtained. The effects of ultrasonic treatment were also quantified in terms of the acid value reduction and oxidative stability for the processed oil. It was demonstrated that suitable reduction in acid value (final value less than 1) and oxidative stability (TOTOX less than 4) is effectively obtained using UAED. Overall the approach of UAED was established to show much higher efficacy for soybean oil processing as compared to only ultrasound or only enzymatic treatment.     

Effects of ultrasound treatment on the starch properties and oil absorption of potato chips

As a non-thermal processing method, the ultrasound treatment prior to the frying process has been demonstrated with great potential in reducing the oil absorption of fried food. This research aimed to evaluate the effect of ultrasound pretreatment on starch properties, water status, pore characteristics, and the oil absorption of potato slices. Ultrasound probe set with two power (360 W and 600 W) at the frequency of 20 kHz for 60 min was applied to perform the pretreatments. The results showed that ultrasound pretreatment led to the surface erosion of starch granules and higher power made the structure of starch disorganized. Moreover, the fraction of bound water and immobilized water were changed after ultrasonic pretreatment. Pores with the minor diameters (0.4–3 μm and 7–12 μm) were formed after ultrasound pretreatment. The penetrated surface oil (PSO) content, and structure oil (STO) content were reduced by 27.31% and 22.25% respectively with lower power ultrasound pretreatment. As the ultrasound power increased, the surface oil (SO) content and PSO content increased by 25.34% and 12.89% respectively, while STO content decreased by 38.05%. By using ultrasonic prior to frying, the quality of potato chips has been greatly improved.     

An experimental study on the motion of water droplets in oil under ultrasonic irradiation

The motion of a single water droplet in oil under ultrasonic irradiation is investigated with high-speed photography in this paper. First, we described the trajectory of water droplet in oil under ultrasonic irradiation. Results indicate that in acoustic field the motion of water droplet subjected to intermittent positive and negative ultrasonic pressure shows obvious quasi-sinusoidal oscillation. Afterwards, the influence of major parameters on the motion characteristics of water droplet was studied, such as acoustic intensity, ultrasonic frequency, continuous phase viscosity, interfacial tension, and droplet diameter, etc. It is found that when the acoustic intensity and frequency are 4.89 W cm⁻² and 20 kHz respectively, which are the critical conditions, the droplet varying from 250 to 300 μm in lower viscous oil has the largest oscillation amplitude and highest oscillation frequency.     

Techno-economic comparative assessment of the ultrasound,electrostatic and microwave supported coalescence of binary water droplets in crude oil

In this study, comparative assessment of the technical performance, energy usage and economic impact of ultrasound, electrostatics and microwave on the coalescence of binary water droplets in crude oil was conducted. The effect of different oil properties such as crude oil viscosity (10.6–106 mPa s) and interfacial tension (IFT) (20–250 mN/m) on the coalescence time and energy consumption was examined. In addition, operation conditions such as inlet emulsion flow velocity (10–100 mm/s), electric field type, ultrasound frequency and applied voltage amplitude (0–30 kV) were evaluated. The numerical models showed good agreement with experimental findings in the literature. Moreover, the process time of the dewatering process increased with rising inlet flow velocities. The elevation of the coalescence time with velocity can be attributed to the increasing effect of flow disturbance, and the reduction of the emulsion residence time. As regards the IFT, the coalescence time reduced as the IFT was increased. This can be associated with the improved stability of emulsions formed at lowered IFT. As the maximum droplet size is directly proportional to the IFT, lowering the IFT reduces the peak diameter of the droplets that are present in the emulsion. Moreover, the coalescence time followed the order: ultrasound < microwave < electrostatics approaches under varying IFT. The coalescence energy increased from ∼15 J, ∼90 J and ∼25 mJ to ∼61 J, ∼235 J and ∼26 mJ for microwave, electrostatics and ultrasound techniques, respectively, as the viscosity was raised from 10.6 to 106 mPa s. Ultrasound coalescence showed significant energy and economic savings in comparison to microwave and electro-coalescence. Hence, ultrasound coalescence would be a potential method for standalone or integrated demulsification over the two other techniques. However, there are indications that beyond a viscosity of 300 mPa s, the effect of ultrasound becomes weak with significant hindrance to droplet movement and accumulation. This analysis provides fundamental insights on the comparative behavior of the three emulsion separation techniques.     

Transesterification of soybean oil by using the synergistic microwave-ultrasonic irradiation

Microwave and ultrasound have been demonstrated to be outstanding process intensification techniques for transesterification of oil. According to their mechanisms, simultaneous effects can surely bring about better enhancement than sole microwave or ultrasound. Therefore, this study aimed to investigate the important factors and their suitable levels in the KOH-catalyzed transesterification of soybean oil with methanol by using synergistic assistance of microwave-ultrasound (CAMU). The feasibility of application of CAMU in transesterification of oil was demonstrated. When the dosage of methanol, soybean oil and KOH were 15.4 g, 34.7 g (with methanol-to-oil molar ratio of 12:1) and 1 g, respectively, and the microwave power, ultrasonic power, ultrasonic mode, reaction temperature and reaction time were 700 W, 800 W, 1:0, 65 °C and 6 min, respectively, the transesterification reached 98.0% of yield, being the highest yield among all the results obtained; while by using 600 W of microwave plus stirring instead of CAMU, only 57.4% of yield could be obtained. Compared with other reaction techniques, the transesterification by applying novel CAMU was found to have remarkable advantages. Furthermore, by monitoring the variation of real-time temperature and microwave power during transesterification reactions with different microwave operation time and by taking comparison of the corresponding yield, it was demonstrated that the main reason for the acceleration of microwave-assisted transesterification was the polarization and further activation of reactants caused by microwave irradiation, but not the factor of fast heating.     

Green extraction of lutein from marigold flower petals,process optimization and its potential to improve the oxidative stability of sunflower oil

Marigold flower petals are considered the richest source of lutein which possesses immense applications in the food and health sector. The study was undertaken to improve the stability of sunflower oil by enriching it with lutein extracted from marigold flower petals using safe and green technology. The extraction of lutein was optimized using Box-Behnken design by ultrasound-assisted extraction (UAE) employing sunflower oil as a solvent. The impact of three independent variables i.e., ultrasonic intensity, solid to solvent ratio, and extraction time were evaluated on the amount of lutein extracted and its antioxidant activity. Highest amount of lutein (21.23 mg/g) was extracted by employing ultrasonic intensity of 70 W/m2, extraction time of 12.5 min, and solid to solvent ratio of 15.75%. FT-IR spectra of lutein extracted by ultrasound and conventional extraction show similar peaks depicting that ultrasound does not have any impact on the functionality of lutein. Sunflower oil incorporated with lutein at 1000 PPM and the synthetic antioxidant (TBHQ) showed good oxidative stability than oil with 500 PPM lutein and no lutein during accelerated storage for a month. The oxidative stability was shown by different oil samples in the following order: TBHQ = 1000PPM lutein˃500PPM lutein ˃control oil. It was concluded that the ultrasound technique extracts lutein efficiently from marigold flowers and this lutein was effective in improving the oxidative stability of sunflower oil under accelerated storage conditions.     

Research on the removal of near-well blockage caused by asphaltene deposition using sonochemical method

Near-well blockage caused by asphaltene deposition often occurs during the process of crude oil exploitation. It can reduce the porosity and permeability of reservoirs and seriously affects the migration and exploitation of oil and gas. In this paper, removing near-well blockage caused by asphaltene deposition using sonochemical method is investigated. Six PTZ transducers with different parameters are used to study the deplugging effect. Results show that the optimal ultrasonic frequency and power for plugging removal are 20 kHz and 1000 W respectively. it is found that lower ultrasonic frequency is good for asphaltene deposition plug removal when ultrasonic power is constant; as the power of the sensor increases, the effect of removing the asphaltene deposition plug gets better, ultrasonic power can well make up for the attenuation of ultrasonic energy caused as frequency increases; the effects of removing asphaltene deposition plug for the three cores with different initial gas logging permeability all get worse no matter what type of transducer is used; the effect of asphaltene deposition plug removal for the three cores samples all become better and then tend to be stable as ultrasonic treatment time increases further; considering of reducing construction cost and oil reservoir protection, ultrasonic processing has a lot of unexampled advantages compared with chemical injection, such as good adaptability, low cost, simple operation, non-pollution and benefit for the sustainable development of oil field; affected by the synergistic effect of ultrasonic and chemical agents, the combined treatment effect of ultrasound and chemical agents is significantly better than using ultrasound or chemical agents alone.     

Ultrasound-assisted transesterification of soybean oil using low power and high frequency and no external heating source

In this work, high frequency and low power ultrasound without external heating source and mechanical stirring in biodiesel production were studied. Transesterification of soybean oil with methanol and catalyzed by KOH was investigated using ultrasound equipment and ultrasonic transducer. The effect of ultrasonic output power (3 W–9 W), ultrasonic frequency (1 MHz and 3 MHz), and alcohol to oil molar ratio (6:1 and 8:1) have been investigated. The increase in ultrasonic power provided higher conversion rates. In addition, higher conversion rates were obtained by increasing the ultrasonic frequency from 1 MHz to 3 MHz (48.7% to 79.5%) for the same reaction time. Results also indicate that the speed of sound can be used to evaluate the produced biodiesel qualitatively. Further, the ultrasound system presented electric consumption (46.2 W∙h) four times lower than achieved using the conventional method (211.7 W∙h and 212.3 W∙h). Thus, biodiesel production using low power ultrasound in the MHz frequency range is a promising technology that could contribute to biodiesel production processes.     

Purification of serratiopeptidase from Serratia marcescens NRRL B 23112 using ultrasound assisted three phase partitioning

The ultrasound assisted three phase partitioning (UATPP) is a novel bioseparation method for separation and purification of biomolecules. In the present work, UATPP was investigated for the first time for purification of serratiopeptidase from Serratia marcescens NRRL B 23112. Effect of various process parameters such as ammonium sulphate saturation, t-butanol to crude extract ratio, pH, ultrasonic frequency, ultrasonic intensity, duty cycle and irradiation time were evaluated and optimized. The optimized conditions were found to be as follows: ammonium sulphate saturation 30% (w/v), pH 7.0, t-butanol to crude ratio 1:1 (v/v), ultrasound frequency 25 kHz, ultrasound intensity 0.05 W/cm², duty cycle 20% and irradiation time 5 min. The maximum purity and recovery obtained from UATPP was 9.4-fold and 96% respectively as compared to the three phase partitioning (TPP) (4.2-fold and 83%). Also the process time for UATPP was significantly reduced to 5 min from 1 h as compared to TPP. The results indicate that, UATPP is an efficient technique for the purification of serratiopeptidase with maximum purity, recovery and reduced processing time.     

Synthesis of biodiesel from waste cooking oil using sonochemical reactors

Investigation into newer routes of biodiesel synthesis is a key research area especially due to the fluctuations in the conventional fuel prices and the environmental advantages of biodiesel. The present work illustrates the use of sonochemical reactors for the synthesis of biodiesel from waste cooking oil. Transesterification of used frying oil with methanol, in the presence of potassium hydroxide as a catalyst has been investigated using low frequency ultrasonic reactor (20 kHz). Effect of different operating parameters such as alcohol–oil molar ratio, catalyst concentration, temperature, power, pulse and horn position on the extent of conversion of oil have been investigated. The optimum conditions for the transesterification process have been obtained as molar ratio of alcohol to oil as 6:1, catalyst concentration of 1 wt.%, temperature as 45 °C and ultrasound power as 200 W with an irradiation time of 40 min. The efficacy of using ultrasound has been compared with the conventional stirring approach based on the use of a six blade turbine with diameter of 1.5 cm operating at 1000 rpm. Also the purification aspects of the final product have been investigated.     

Influence of intensity and frequency of ultrasonic waves on capillary interaction and oil recovery from different rock types

Oil saturated cylindrical sandstone cores were placed into imbibition cells where they contacted with an aqueous phase and oil recovery performances were tested with and without ultrasonic radiation keeping all other conditions and parameters constant. Experiments were conducted for different initial water saturation, oil viscosity and wettability. The specifications of acoustic sources such as ultrasonic intensity (45–84 W/sq cm) and frequency (22 and 40 kHz) were also changed. An increase in recovery was observed with ultrasonic energy in all cases. This change was more remarkable for the oil-wet medium. The additional recovery with ultrasonic energy became lower as the oil viscosity increased. We also designed a setup to measure the ultrasonic energy penetration capacity in different media, namely air, water, and slurry (sand + water mixture). A one-meter long water or slurry filled medium was prepared and the ultrasonic intensity and frequency were monitored as a function of distance from the source. The imbibition cells were placed at certain distances from the sources and the oil recovery was recorded. Then, the imbibition recovery was related to the ultrasonic intensity, frequency, and distance from the ultrasonic source.     

Effects of ultrasonic irradiation on crystallization kinetics,morphological and structural properties of zeolite FAU

In this work, NaX zeolite was synthesized and the effect of ultrasound irradiation on reaction kinetics, morphological and structural properties was investigated. Ultrasound was applied, by using a plate transducer (91.8 kHz), for the first time during the crystallization of zeolite NaX, at high temperature, varying the irradiation moment and its duration. Furthermore, ultrasound was applied after the crystallization by a horn-type transducer (20–24 kHz) at low temperature. The effects of irradiated volume (100–300 mL), sonication time (2–10 min) and ultrasound power (10–200 W) were studied with a power intensity up to 100 W/cm². It was found that the application of ultrasound during the first hour of crystallization resulted in 20% reduction of reaction time compared to a standard crystallization. Ultrasound can also reduce the agglomeration degree of the final powder by combining high power and long sonication time. After 5 min sonication time at 0.3 W/mL, the tapped density of the powder was increased by 10%, from 0.37 to 0.41 g/mL. Finally, by scanning electron microscopy (SEM) it was demonstrated that ultrasound can disrupt the agglomerates without affecting the morphology of individual crystals.     

An experimental study on the coalescence process of binary droplets in oil under ultrasonic standing waves

The coalescence process of binary droplets in oil under ultrasonic standing waves was investigated with high-speed photography. Three motion models of binary droplets in coalescence process were illustrated: (1) slight translational oscillation; (2) sinusoidal translational oscillation; (3) migration along with acoustic streaming. To reveal the droplets coalescence mechanisms, the influence of main factors (such as acoustic intensity, droplet size, viscosity and interfacial tension, etc) on the motion and coalescence of binary droplets was studied under ultrasonic standing waves. Results indicate that the shortest coalescence time is achieved when binary droplets show sinusoidal translational oscillation. The corresponding acoustic intensity in this case is the optimum acoustic intensity. Under the optimum acoustic intensity, drop size decrease will bring about coalescence time decrease by enhancing the binary droplets oscillation. Moreover, there is an optimum interfacial tension to achieve the shortest coalescence time.