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Specific Challenge

Refinery experiencing performance issues with crude blends from a pipeline

REGION

Latin America

REGION

Challenge

  • Desalting performance impacted by polymer presence
  • Slop oil generation off KPI spec
  • Sporadic water carryover slows production

Solution

  • Implemented specialty chemical program in crude oil pipeline to break polymeric chains
  • Augmented emulsion breaker program with adjunct chemistry to reduce rag layer and oil carry, preventing water carryover
  • Established continuous monitoring program

Result

  • Reduced slop oil generation from 132 m³/day to 55 m³/day (meeting KPI of less than 60 m³/day max)
  • Eliminated water carryover events

Challenge 

A refinery in Latin America experienced performance issues with challenging crude blends coming from a pipeline. Higher rates of shale oil and tertiary oil recovery crudes which contained polymers, such as polyacrylamides, were causing process challenges.

The presence of polymers significantly affected desalting performance. These polymers prevented water droplets from coalescing and stabilized water-in-oil emulsions. Consequently, oil carry-under occurred in the brine, which led to increased slop oil generation. The refinery consistently generated an average of 132 m³/day, well above the maximum limit of 60 m³/day, and sporadic water carryover episodes further complicated operations, causing slowdowns and limiting production.

Solution 

To address these challenges, Halliburton implemented a comprehensive solution: 

  • Specialty Chemistry (RPA-722): This chemistry contained an organic acid and was injected into the crude oil pipeline via an injection quill. Its purpose was to break the polymeric chains.
  • Adjunct Chemistry (RPA-709AR): Applied in batch alongside the emulsion breaker RPA-581AR, this chemistry reduced the rag layer inside the desalters, prevented oil carry-under, and avoided water carryover.
  • Asphaltene Dispersant (RPA-357): When the presence of asphaltene caused desalting issues, this dispersant was used.

We provided around-the-clock service to support early detection and resolution of potential issues in the desalters and the slop oil generation system. To assess challenges related to polymers, surfactants, and asphaltenes, daily brine extractions using toluene, heptane, and IPA were performed. Monitoring would allow them to adjust dosages and optimize performance.

Result

While no other competitor could advise on polymer presence in the crude oil, including organic acid injection to break polymers in crude oil pipeline, Halliburton provided the entire set of adjunct chemistries and continuous service coverage for the desalters and slop oil system.

The implementation of these measures led to a significant improvement. Slop oil generation decreased from 132 m³/day to 55 m³/day, meeting the key performance indicator of less than 60 m³/day. Furthermore, no additional water carryover events were registered.

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