Successful Batch Processing of Heavy Oil Sludge at Oman (2011 to 2014)

Abstract

Abstract Sludge is an intrinsic by-product of the Oil & Gas Industry, it is considered a hazardous waste and there are few technologies within the industry to process it under an environmentally sound protocol. Sludge to Oil Technology (STO) is a proprietary process utilized to break emulsions of hydrocarbons/water/solids. The process is based on a series of chemical reactions involving surfactants that interact with other reagents in releasing heat and neutralize the non-covalent forces that form the bonds between the substrate and the wetting agent. Final separation is achieved by using specific gravity differential between the different components of the de-emulsified mixture. The byproducts of the reactions are inorganic salts, water and carbon dioxide. Two different centrifuges are used to achieve a fast and accurate separation. The byproducts of the reactions are inorganic salts, water and carbon dioxide. This technology has been successfully implemented at the operator site by the contractor under a pilot project. Over the term of the contract, more than 100,000 bbl of raw sludge had been treated meeting the following KPI's: Oil < 1.0% BS&W, Water < 20 ppm OIW and Solids < 1.0% TPH. The process has been applied in-situ where the emulsions are stored and has recovered more than 50,000 barrels of saleable crude oil. The recovered water has been sent for re-injection and the solids meet all the requirements of the Ministry of Environment and Climate Affairs (MECA) - Oman as a treated waste under international standards. At a time when crude oil prices have reached over $100.00 USD/bbl this technique can prove to be not only environmentally sound but also an addition value to the operator's production bottom line. The STO process was applied directly in the field where the emulsions are stored and can bring great technical and economical advantages to the user. At a time when crude oil prices have hiked this technique can prove to be very economical not only for oil recovery, but for also as preventative maintenance and to mitigate from potential environmental liabilities.