CFD and Population Balance Modeling of Crude Oil Emulsions in Batch Gravity Separation—Comparison to Ultrasound Experiments

Water-in-oil emulsion destabilization and separation in a batch gravity separator was investigated experimentally and by numerical modeling. A multiphase computational fluid dynamics (CFD) was used with a population balance model (PBM) to model separation behavior of crude oil emulsions. The inhomogeneous discrete method is used to solve the population balance equations. Closure kernels are applied to model droplet–droplet coalescence. To describe the increase in emulsion viscosity with water concentration, an emulsion viscosity model was selected that predicted emulsion stability and the denser emulsion layer forming above the coalescing interface, otherwise known as the dense packed zone or layer (DPZ). The results from a commercial CFD code are compared to experimental data of the water fraction vertical distribution measured by low-power ultrasound in the batch separator. The predicted time-dependent profiles of water fraction in the separator were found to be in good agreement with the experimental measurements for the range of water content from 6 to 50%. The model predicts the effect of water fraction on the separation kinetics and the evolution of the DPZ. Further studies are underway to apply the models to emulsions from different types of crude oils.     

Investigations into the electrical and coalescence behaviour of water-in-crude oil emulsions in high voltage gradients

The stability of water-in-crude oil emulsions when subjected to high voltage electric fields depends on the nature of the crude oil and the presence of chemical additives. Optical microscopy, conductivity and coalescence measurements have revealed two distinct types of behaviour, designated type I and type II. These are shown to be related to the crude oil/water interfacial rheological properties. For incompressible crude oil/water films, droplet—droplet coalescence is hindered and chains of water droplets are established. These increase the electrical conductivity of the emulsion (type I behaviour). On the other hand, efficient droplet—droplet coalescence accompanied by minimal conduction occurs in electric fields if the interfacial film is compressible (type II).     

Behaviour of formula emulsions containing hydrolysed whey protein and various lecithins

Formula emulsion systems are used as enteral, sports and health products. In some formulas addition of hydrolysed protein is necessary to guarantee ease of digestion and hypoallergenicity. In the low fat emulsion model an increase in the content of lecithin (phospholipid mixture) was required, in consideration of the advice of the Food and Nutrition Board (USA) for choline supplementation. The individual and interactive effects of whey protein isolate (WPI) or hydrolysate (WPH) (3.7 and 4.9% w/w), unmodified deoiled or hydrolysed lecithin (0.48 or 0.7% w/w) and carbohydrate in the form of maltodextrin with dextrose equivalent (DE) 18.5 or glucose syrup with DE 34 (11% w/w) on the properties of formula emulsions with 4% v/w sunflower oil, were investigated using a full factorial design. The emulsions were characterised by particle size distribution, coalescence stability, creaming rate, and also surface protein and lecithin concentration. WPI-containing emulsions proved to be stable against coalescence and showed only little creaming after 1 and 7 days standing. There was a significant increase in the mean droplet size and a significant deterioration of coalescence and creaming stability when WPH instead of WPI was used as the protein source, due to the lower number of large peptides and lower surface activity of the WPH. Increasing the WPH concentration led to an increase in oil droplet size and further deterioration of the stability of the emulsions. The starch hydrolysate and lecithin also significantly influenced the emulsion properties. Their influence was less strong when the emulsion contained WPI. Under the conditions used WPH-based emulsions were more stable, in terms of creaming and coalescence, when a low level of protein was used in conjunction with hydrolysed lecithin and glucose syrup. Oil droplets in emulsions containing unmodified lecithin in either the continuous or disperse phase and WPH in the continuous phase were very sensitive to coalescence. The addition of starch hydrolysates (DE 18.5) induced intensive flocculation and phase separation in these emulsions.     

Stability of Water/Crude Oil Systems Correlated to the Physicochemical Properties of the Oil Phase

A characterization of 30 crude oils has been performed to determine the relative level of influence that individual parameters have over the overall stability of w/o emulsions. The crude oils have been analyzed with respect to bulk and interfacial properties and the characteristics of their w/o emulsions. The parameters include compositional properties, acidity, spectroscopic signatures in the infrared and near‐infrared region, density, viscosity, molecular weight, interfacial tension, dilational relaxation, droplet size distribution, and stability to gravitationally and electrically induced separation. As expected, a strong covariance between several physicochemical properties was found. Near‐infrared spectroscopy proved to be an effective tool for crude oil analysis. In particular, we have showed the importance of the hydrodynamic resistance to electrically‐induced separation (static) in heavy crude oil‐water emulsions. A rough estimate of the drag forces and dielectrophoretic forces seemed to capture the difference between the 30 crude oils. Given enough time, water‐in‐heavy oil emulsions could be destabilized even at very low electric field magnitude (d.c.). When droplets approach each other in an inhomogeneous electric field, strong dielectrophoretic forces disintegrate the films and result in coalescence. The relative contribution from film stability to the overall emulsion stability may therefore be very different in a gravitational field compared to that in an electrical field.     

Demulsification of water-in-oil emulsions via filtration through a hydrophilic polymer membrane

It is known that hydrophobic microfiltration membranes can be used for demulsification of oil-in-water (o/w) emulsion due to coalescence of oil droplets in membrane pores. This study demonstrates that a hydrophilic polymer membrane can be used for the demulsification of surfactant-stabilized water-in-oil (w/o) emulsions. The success of demulsification is dependent on the type of emulsions and membrane used. Membrane pore size and transmembrane pressure were found to affect demulsification efficiency (DM), while other factors, such as membrane thickness and initial water content have slight or almost no effect. A coalescence mechanism of the demulsification phenomenon is also discussed. The separation process is not based on sieving effects due to a difference in membrane pore size, but is determined by droplet interactions with membrane surface.     

Effect of Emulsification Method on the Properties of Lecithin‐ and PGPR‐Stabilized Water‐in‐Oil‐Emulsions

Water‐in‐oil (w/o) emulsions were prepared with phosphatidylcholine‐depleted lecithin or polyglycerol polyricinoleate (PGPR) as emulsifying agents. The effect of different laboratory emulsification devices and the effect of sodium chloride on particle size distribution, coalescence stability, and water droplet sedimentation were investigated. The properties of lecithin‐stabilized w/o emulsions were found to depend more strongly on the emulsifying method than those prepared with PGPR. The rotor‐stator system was not suitable for preparing stable w/o emulsions with lecithin. Whereas the addition of salt was essential to achieve coalescence‐stable emulsions prepared with PGPR, the presence of NaCl favored the coalescence of water droplets and phase separation in emulsions containing lecithin.     

An NMR study of the freezing of emulsion-containing drops

Various nuclear magnetic resonance (NMR) techniques were used to monitor the freezing behaviour of suspended 2-mm-diameter drops. The drops were composed of hydrocarbon oils emulsified in either water or water/sucrose mixtures. As such they were good model systems for the study of spray freezing, sharing structural similarities with potential products such as ice cream. In particular, simple 1H NMR spectroscopy was used to monitor and individually quantify the freezing or solidification behaviour of the various constituent species of the drops. In addition, the effect of freezing on the emulsion droplet size distribution (and hence emulsion stability) was also measured based on NMR self-diffusion measurements. The effect of freeze/thaw cycling was also similarly studied. The nucleation temperature of the emulsion droplets was found to depend on the emulsion droplet size distribution: the smaller the droplets, the lower the nucleation temperature. Emulsion droplet sizing indicated that oil-in-sucrose-solution emulsions were more stable, showing minimal coalescence, whereas oil-in-water emulsions showed significant coalescence during freezing and freeze/thaw cycling.     

Contribution of the Sedimentation and Coalescence Mechanisms to the Separation of Concentrated Water-in-Oil Emulsions

Crude oil is, in the vast majority of cases, produced together with formation water in the form of water/oil emulsions. Until recently oil/water separators were simply designed using Stokes' law. In order to improve the design of these separators the two main contributing mechanisms, sedimentation and coalescence, have to be better understood. This article presents a method that distinguishes the respective contributions of the sedimentation and coalescence mechanisms. Two series of experiments have been carried out, the first with a system heavily charged in surfactant that only allows sedimentation of the emulsions droplets. The second with a much lower surfactant concentration allows both sedimentation and coalescence to take place. By comparing the separation velocities of the oil/emulsion interfaces of the two series of experiments, it seems possible to determine the contribution of the two mechanisms towards the separation.     

FRAGMENTATION OF PRIMARY FLOCS IN EMULSIONS AND THE SUBSEQUENT REDUCTION OF COALESCENCE

In existing theories emulsion desiabilization is considered as the combined processes of irreversible flocculation and coalescence of dispersed droplets. This approach can be justified when the potential pit characterizing the energy of droplet interaction is sufficiently deep, i.e. excluding small droplet dimensions, strong electrosiatic repulsion and low electrolyte concentrations. For smaller droplet dimensions and stronger electrostatic repulsions the emulsion instability must be considered as a combined process of reversible flocculation and coalescence. In this paper a mathematical model that couples the kinetics of flocculation, coalescence and floe fragmentation is developed in order to quantify the kinetic instability of emulsions with charged submicron droplets. The characteristic limes for flocculation (Smoluchowski's time τ_c) for coalescence (coalescence time τ_c) and for disaggregation (doublet lifetimeτ_d) are considered model parameters. The mathematical model applies to the case when and τ_d<< τ_c, which corresponds to a situation with a small multiplet concentration compared to the concentration of doublets and a singlet-doublet quasi-equilibrium. It is established that at singlet-doublet quasi-equilibrium the rate of the decline in the total droplet concentration is described by second order kinetics in distinction to the exponential time dependence valid for coalescence at irreversible flocculation. The double disintegration reduces the entire coalescence rate, expressed as τ_sm/ τ_d. This reduction is very large at small values of Td. The mathematical model presented can hased on the spontaneous disintegration of doublets predict changes in emulsion stability for model systems and also for technologically important emulsions.     

Effect of oil phase transition on freeze/thaw-induced demulsification of water-in-oil emulsions

Recently, there has been an increasing interest in the breakage of water-in-oil (W/O) emulsions by the freeze/thaw method. Most of the previous works focused on the phase transition of the water droplet phase. This paper emphasizes the effect of continuous oil phase transition. A series of oils with different freezing points were used as oil phases to produce model emulsions, which were then frozen and thawed. The emulsion whose oil phase froze before the water droplet phase did (OFBW) on cooling was readily demulsified with a dewatering ratio as high as over 80%, but the emulsion whose oil phase did not freeze when the water droplet phase did (NOFBW) was relatively hard to break. The difference in demulsification performance between them resulted from the distinction between their demulsification mechanisms via the analyses of the emulsion stability, emulsion crystallization/melting behaviors, oil phase physical properties, and wettability of the frozen oil phase, etc. For the OFBW emulsion, the first-frozen oil phase was ruptured by the volume expansion of the subsequently frozen droplet phase, and meanwhile, some liquid droplet phase was drawn into the fine gaps/crevices of the frozen oil phase to bridge droplets, which were considered to be essential to the emulsion breakage, whereas for the NOFBW emulsion, the demulsification was attributed to the collision mechanism proposed in our previous work. The findings may provide some criteria for selecting a proper oil phase in the emulsion liquid membrane (ELM) process and then offer an alternative approach to recycle the oil phase for continuous operation. This work may also be useful for emulsion stability against temperature cycling.     

Comparison of Pickering and network stabilization in water-in-oil emulsions

We compared the efficacy of Pickering crystals, a continuous phase crystal network, and a combination thereof against sedimentation and dispersed phase coalescence in water-in-oil (W/O) emulsions. Using 20 wt % water-in-canola oil emulsions as our model, glycerol monostearate (GMS) permitted Pickering-type stabilization, whereas simultaneous usage of hydrogenated canola oil (HCO) and glycerol monooleate (GMO) primarily led to network-stabilized emulsions. A minimum of 4 wt % GMS or 10 wt % HCO was required for long-term sedimentation stability. Although there were no significant differences between the two in mean droplet size with time, the free water content of the network-stabilized emulsions was higher than Pickering-stabilized emulsions, suggesting higher instability. Microscopy revealed the presence of crystal shells around the dispersed phase in the GMS-stabilized emulsions, whereas in the HCO-stabilized emulsion, spherulitic growth in the continuous phase and on the droplet surface occurred. The displacement energy (E(disp)) to detach crystals from the oil-water interface was ～10(4) kT, and was highest for GMS crystals. Thermal cycling to induce dispersed phase coalescence of the emulsions resulted in desorption of both GMS and GMO from the interface, which we ascribed to solute-solvent hydrogen bonding between the emulsifier molecules and the solvent oil, based on IR spectra. Overall, Pickering crystals were more effective than network crystals for emulsion stabilization. However, the thermal stability of all emulsions was hampered by the diffusion of the molten emulsifiers from the interface.     

Particle self-assembly in oil-in-ionic liquid Pickering emulsions

We have studied polydimethylsiloxane (PDMS)-in-1-butyl-3-methylimidazolium hexafluorophosphate ([BMIM][PF(6)]) Pickering emulsions stabilized by polystyrene microparticles with different surface chemistry. Surprisingly, in contrast to the consensus originating from oil/water Pickering emulsions in which the solid particles equilibrate at the oil-water droplet interfaces and provide effective stabilization, here the polystyrene microparticles treated with sulfate, aldehyde sulfate, or carboxylate dissociable groups mostly formed monolayer bridges among the oil droplets rather than residing at the oil-ionic liquid interfaces. The bridge formation inhibited individual droplet-droplet coalescence; however, due to low density and large volume (thus the buoyant effect), the aggregated oil droplets actually promoted oil/ionic liquid phase separation and distressed emulsion stability. Systems with binary heterogeneous polystyrene microparticles exhibited similar, even enhanced (in terms of surface chemistry dependence), bridging phenomenon in the PDMS-in-[BMIM][PF(6)] Pickering emulsions.     

Effects of Surfactant Volume Fraction on the Antioxidant Efficiency and on The Interfacial Concentrations of Octyl and Tetradecyl p-Coumarates in Corn Oil-in-Water Emulsions

Surfactants have been used for decades in the food industry for the preparation of lipid-based emulsified food stuffs. They play two main roles in the emulsification processes: first they decrease the interfacial tension between the oil and water, facilitating droplet deformation and rupture; second, they reduce droplet coalescence by forming steric barriers. However, addition of surfactants to binary oil-water mixtures also brings up the formation of three-dimensional interfacial layers, surrounding each emulsion droplet, that significantly alter chemical reactivity. This is the case, for instance, in the inhibition reaction between antioxidants and the lipid radicals formed in the course of the spontaneous oxidation reaction of unsaturated lipids, which are commonly employed in the preparation of food-grade emulsions. The rate of the inhibition reaction depends on the effective concentrations of antioxidants, which are mostly controlled by the amount of surfactant employed in the preparation of the emulsion. In this work, we analyze the effects of the surfactant Tween 20 on the oxidative stability and on the effective concentrations of two model antioxidants derived from cinnamic acid, determining their interfacial concentrations in the intact emulsions to avoid disrupting the existing equilibria and biasing results. For this purpose, a recently developed methodology was employed, and experimental results were interpreted on the grounds of a pseudophase kinetic model.     

Influence of pH on the stability of oil-in-water emulsions stabilized by a splittable surfactant

A laboratory study was conducted to evaluate the effect of pH on the stability of oil-in-water emulsions stabilized by a commercial splittable surfactant Triton SP-190 by comparison with the results obtained by a common surfactant Triton X-100. The emulsion stability was explored by measuring the volume of oil phase separated and the size of the dispersed droplets. It was found that the addition of inorganic acids did not significantly affect the stability of emulsions stabilized by Triton X-100, but had a profound influence on the stability of emulsions stabilized by Triton SP-190. Moreover, the droplet size of a Triton X-100-stabilized emulsion and its dynamic interfacial activity were insensitive to acids. However, at lower pH the droplet size of the emulsions stabilized by Triton SP-190 was considerably increased. From the dynamic interfacial tension measurements the dynamic interfacial activity of Triton SP-190 at the oil/water interface was found to be strongly inhibited by the addition of acids, resulting in a slower decreasing rate of dynamic interfacial tension. The results demonstrate that the dramatic destabilization of Triton SP-190-stabilized emulsions could be realized by the use of acids, which evidently changed the interfacial properties of the surfactant and resulted in a higher coalescence rate of oil droplets.     

Influence of oil polarity on droplet growth in oil-in-water emulsions stabilized by a weakly adsorbing biopolymer or a nonionic surfactant

The influence of oil type (n-hexadecane, 1-decanol, n-decane), droplet composition (hexadecane:decanol), and emulsifier type (Tween 20, gum arabic) on droplet growth in oil-in-water emulsions was studied. Droplet size distributions of emulsions were measured over time (0-120 h) by laser diffraction and ultrasonic spectroscopy. Emulsions containing oil molecules of low polarity and low water solubility (hexadecane) were stable to droplet growth, irrespective of the emulsifier used to stabilize the droplets. Emulsions containing oil molecules of low polarity and relatively high water solubility (decane) were stable to coalescence, but unstable to Ostwald ripening, irrespective of emulsifier. Droplet growth in emulsions containing oil molecules of relatively high polarity and high water solubility (decanol) depended on emulsifier type. Decanol droplets stabilized by Tween 20 were stable to droplet growth in concentrated emulsions but unstable when the emulsions were diluted. Decanol droplets stabilized by gum arabic exhibited rapid and extensive droplet growth, probably due to a combination of Ostwald ripening and coalescence. We proposed that coalescence was caused by the relatively low interfacial tension at the decanol-water boundary, which meant that the gum arabic did not absorb strongly to the droplet surfaces and therefore did not prevent the droplets from coming into close proximity.     

Temperature-induced protein release from water-in-oil-in-water double emulsions

A model water-in-oil-in-water (W1/O/W2) double emulsion was prepared by a two-step emulsification procedure and subsequently subjected to temperature changes that caused the oil phase to freeze and thaw while the two aqueous phases remained liquid. Our previous work on individual double-emulsion globules1 demonstrated that crystallizing the oil phase (O) preserves stability, while subsequent thawing triggers coalescence of the droplets of the internal aqueous phase (W1) with the external aqueous phase (W2), termed external coalescence. Activation of this instability mechanism led to instant release of fluorescently tagged bovine serum albumin (fluorescein isothiocyanate (FITC)-BSA) from the W 1 droplets and into W2. These results motivated us to apply the proposed temperature-induced globule-breakage mechanism to bulk double emulsions. As expected, no phase separation of the emulsion occurred if stored at temperatures below 18 degrees C (freezing point of the model oil n-hexadecane), whereas oil thawing readily caused instability. Crucial variables were identified during experimentation, and found to greatly influence the behavior of bulk double emulsions following freeze-thaw cycling. Adjustment of these variables accounted for a more efficient release of the encapsulated protein.     

Impact of oil composition on formation and stability of emulsions produced by spontaneous emulsification

In this study, triglycerides of different chain lengths were mixed with paraffin oil, and their effectiveness in forming emulsions produced by spontaneous emulsification upon the addition of water was investigated. The emulsion droplet size exhibited a similar trend as a function of the triglyceride/paraffin oil composition for medium-chain (MCTs) (C8–C10) and long-chain (C18) triglycerides (LCTs). However, emulsions formulated with MCTs and LCTs have a much smaller droplet size (about 50?nm) than emulsions based upon short-chain (C4) triglycerides (SCTs). The addition of SCTs resulted in droplet sizes around 800?nm and the emulsions formed were very unstable. The droplet size, polydispersity index, zeta potential, and emulsion stability of these systems will be described as a function of the oil phase composition.     

Thickening properties and emulsification mechanisms of new derivatives of polysaccharides in aqueous solution

The thickening properties of aqueous solutions of HHM-HEC (hydrophobically-hydrophilically modified hydroxyethylcellulose) and the emulsification mechanisms of HHM-HEC/water/oil systems were investigated. A dramatic increase in viscosity was observed with increased HHM-HEC concentration in water, caused by aggregation of hydrophobic alkyl chains. At higher concentrations of HHM-HEC (above 0.6 wt%) in water, it forms an elastic gel, which has good thixotropic properties and a high yield value. O/W (oil-in-water) type emulsions were obtained using HHM-HEC, which can emulsify various kinds of oil, including hydrocarbon, silicone, and perfluoropolymethylisopropyl ether. The viscosity of these emulsions depends only upon the oil volume fraction, not on the kind of oil. In addition, the oil particle size in the emulsions remained constant after a certain period because HHM-HEC formed a strong gel network structure and a protective layer, which prevented the emulsion from coalescing. Measurements of interfacial tension revealed that the alkyl chains in HHM-HEC did not significantly lower the interfacial tension at the water/oil interface when 0.5 wt% of HHM-HEC was added to water. Steady flow and oscillatory experimental results show that the rheological behavior of HHM-HEC/water/oil emulsions was similar to that of aqueous solutions of HHM-HEC. In the HHM-HEC/water/oil emulsion system, oil droplets were dispersed and kept stable in the strong gel structure of HHM-HEC. The aqueous solution of HHM-HEC showed salt resistance. It is thought to be due to sulfonic acid groups in HHM-HEC. The stability of the emulsion using HHM-HEC is based on both protective colloidal effects and associative thickening caused by alkyl chains in HHM-HEC.     

Studies of Kinetics of Coalescence of Water‐in‐Furrial Crude Oil Emulsions by Confocal Microscopy

The kinetic of coalescence of water in Furrial crude oil emulsions (W/O) during the initial stage of demulsification process is showed through of high‐resolution image micrographics by using a confocal microscope. Furrial crude oil from Monagas state is a crude oil extra heavy with severe flocculation/aggregation problems. The kinetic of the initial stage in the coalescence process is critical and of great importance in the definition of the foreword behavior. This information allowed us to characterize the demulsification rate process in a Furrial crude oil. Total W/O emulsion separation was achieved about of 2 hours at 80ºC. The initial fast coalescence is characterized by a short binary coalescence time, which is followed by a large binary coalescence time. Our results demonstrate that the initial coalescence rate determinate the time necessary to achieve a total separation.     

The effect of brine salinity on water-in-oil emulsion stability through droplet size distribution analysis: A case study

Water-in-oil emulsion usually forms during waterflooding in some heavy oil reservoirs. The composition and salinity of the injected water critically affect the w/o emulsion droplet size distribution, which control the emulsion stability and emulsion flow in porous media. The aim of the present work is to assess the effect of different sea water salinities on w/o emulsion stability through microscopic imaging. Therefore, w/o emulsions were prepared with different sea water samples, which were synthesized to resemble Persian Gulf, Mediterranean, Red Sea, and North Sea water samples. The results showed that log-normal distribution function predicts very well the experimental data to track the emulsion droplet size distribution, and then it was used for the emulsion stability analysis. It was found that among the four emulsion samples, North Sea emulsion with the lowest NaCl and TDS concentration of 24.12?g/L and 34.44?g/L remained stable up to almost 24 hours, while Red sea emulsion with the highest NaCl and TDS concentration of 32.39?g/L and 41?g/L became unstable after 6-hour period. This indicated that as the brine concentration increases, the w/o emulsion droplets would be larger due to the higher rate of aggregation and coalescence, and the emulsion stability decreases.