BREAXIT Emulsion Breakers
Essential Expertise
for Water, Energy and Air
SM
Oilfield Separation Technologies
WHY
Oil/water separation and success are mutually inclusive
Among the most critical aspects of petroleum production, no matter what
the production system, is separating produced crude from water and basic
sediments. Your profits depend on doing so efficiently. But at the same
time, dealing with produced water in an efficient and environmentally
sustainable way is equally important. Effective separation is the key to
success on both fronts. At Nalco, that’s our business. As the global leader
in water management technologies, emulsion breaking has been a core
competence and major R&D focus for over 75 years. Combined with our
extensive global involvement with petroleum production chemistries of
all types, Nalco brings you a combination of experience, local expertise
and advanced technologies that delivers measurable, sustainable flow
assurance, asset protection and production maximization.
Maximizing Production
The Nalco BREAXIT portfolio includes over 190 emulsion breakers (EBs)
and over 40 reverse emulsion breakers (REBs). These are worldwide
field-proven products specifically designed to provide cost-effective
performance for virtually every type of crude oil production system from
light condensates to heavy oil and bituminous oil sands.
Product formulation is conducted via highly developed selection processes
and the deployment of extensively trained, experienced demulsifier
experts. Our team of professionals includes onsite consultants, field
service technicians, demulsifier specialists, and process and operations
personnel.
Nalco invests heavily in the development of new chemicals and techniques
to enhance the selection process for the formulation and application of new
products. The combination of our products and techniques allow for more
rapid selection protocols while at the same time increasing the success
rate during field trials.
Solutions begin with understanding causal factors
Nalco is a pioneer in the application of advanced statistical analysis
techniques to identify the root causes for separation issues. Using
customer process data together with chemical and analytical data,
we analyze the separation process to determine the major factors that
cause separation problems in the field. The separation process is mapped
to determine operational parameters and process settings for optimum
separation performance. Our clients benefit from decreased production
losses and increased production.
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HOW
Our mission and innovation deliver value
Nalco’s mission is to enable sustainable profitability concurrent with
sustainable environmental performance. The two concepts are
inseparable, and our innovation strategies address both.
Extensive R&D resources, focused on petroleum production
Nalco employs over 500 researchers, 40% of whom have PhD’s. This
commitment to R&D has resulted in over 2,000 patents, with new products
representing over 40% of our oil field chemicals sales over the past two
years. It’s the very definition of “continuous improvement” as Nalco R&D
teams work closely with customers to stay ahead of changing environmental regulations and develop innovative products that are cutting edge
for both their performance and their low environmental impact. We have
developed a portfolio of Flow Assurance, Asset Integrity and Production
Maximization chemistries based on meeting or exceeding the most
stringent environmental regulations. BREAXIT technologies are superb
examples of this commitment.
Responsible Care® global initiative
Nalco Safety, Health and Environment programs are structured on
Responsible Care, a chemical industry-specific, and voluntary, global
initiative. Responsible Care has become part of our culture since we
helped establish the program in 1985.
Responsible Care is implemented through a management system
approach that offers an integrated, structured method focused on seven
key areas of our operations: community awareness and emergency
response; security; distribution; employee health and safety; pollution
prevention; process safety and product stewardship. Implementing
Responsible Care in the United States includes mandatory independent
third-party verification of those management systems.
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WHAT
BREAXIT Emulsion Breaker technology delivers
The most important objective of any oil production facility is the separation of
water and other foreign materials from the produced crude. The breaking of
these crude oil and water emulsions constitutes one of the more challenging
problems in today’s petroleum industry.
During the productive life of an oil or gas well, a stage is reached when water
will be coproduced in unacceptable quantities. This water coexists with the
hydrocarbons in the reservoir and gradually infiltrates into the hydrocarbon
bearing region of the formation. Eventually water becomes part of the
production from the wells regardless of the method of recovery.
In oil production today, water is an inevitable byproduct. In fact, nearly 90% of
crude contains oil and water emulsions. The gradual encroachment of water
into oil-bearing formations and the advent of secondary and tertiary recovery
methods have led to the development of new technologies to break crude oil
and water emulsions.
BREAXIT Emulsion Breakers are designed to resolve emulsions caused
by the process of extraction and production of crude oil. The result is
dehydrated crude petroleum at minimum cost to the operator. We’ve
specialized in this type of demulsification for more than 50 years. Operators
attain exceptionally rapid oil-water separations with Nalco demulsifiers,
which treat virtually all types of emulsions.
Nalco continues to develop new emulsion breakers for the oil and gas
industry today. New areas of research include production enhancement
through downhole viscosity reduction and improved separation of heavy
crude emulsions including those found in the SAGD recovery processes.
Our emulsion breakers offer the benefits below, including:
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Rapid, sharp separation
No heavy metals or organic halides added
Versatility in treating all types of emulsions
Convenient to handle, easily dispersed
WHAT
BREAXIT Reverse Emulsion Breaker technology delivers
Oilfield produced water often contains residual quantities of oil and in many
cases, solid particles. The oil can be either a source of revenue if removed,
or a source of problems if left in the water. In the case of lost revenue, any oil
left in the water wastes the time and money spent bringing it to the surface.
The recovery of small amounts of oil removed from the water over a period
of time can lead to significant increases in revenue.
With regard to the problems that can occur if oil is left in the water, produced
water that contains oil or other contaminants must be clean in order to be
used to supply a water flood project or steam injection program. Oil and solids
can quickly foul expensive water softening resin beads. Dirty water can also
lead to costly maintenance programs for injection wells.
For both of the reasons, many types of equipment and chemical treatments
are used to remove as much oil as possible from the water stream. Water
clarification chemicals can be used to improve the efficiency of the separation
equipment and reduce the total cost of operation.
The solids found in produced water are commonly particles of silt, sand and
clay from the formation or can be the byproducts of corrosion and scale
formation. These solids are usually removed along with the oil. They are
eventually removed from the system as a waste material or passed to the
refinery with the salable oil.
In addition to the loss of revenue and the reuse of produced water, concerns
for nature have resulted in many new laws, regulations and agencies that
closely monitor the oil left in produced water. Producers are severely penalized for discharging water to the environment that exceeds regulatory limits.
Offshore platforms have been shut down for discharging water into the ocean
that leaves a visible sheen.
Water clarification chemicals combined with Nalco’s field expertise can
ensure that your produced water meets environmental requirements while
increasing the amount of saleable oil and avoiding costly equipment repairs.
An oil and gas producer’s overall ROI improves significantly with the proper
selection of these products and service packages.
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WHERE
Nalco technology contributes to maximize sustainable
Faster solutions through Statistical Bottle Testing (SBT)
Subsea and Downhole Applications
Our research and development group has created a statistically driven
selection program that augments traditional bottle testing techniques.
Through specialized crude oil characterization and application of chemical
markers for separation, our customers benefit from:
The Nalco Manufacturing Certification
Program represents a paradigm shift in
quality assurance, in terms of SAE
specifications and other built-in checks and
balances. BREAXIT products intended for
use in umbilicals must adhere to strict
standards for quality and purity to ensure
trouble-free chemical delivery for downhole
and subsea systems. The SurFlo Plus
certification provides assurance that these
standards have been met or exceeded.
Nalco has developed advanced testing
systems by working with customers
worldwide to meet their umbilical chemical
requirements. Nalco processes include:
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Faster demulsifier selection and formulation
Customized products according to produced fluid compositions
Accurate identification of the specific chemistry requirements for
optimal separation and cost efficiency
SBT provides a scientific process for the development of next generation
intermediates and products. It also significantly reduces the time for product
development to allow for a timely and continuous improvement of performance
and cost-effectiveness for our customers.
Enhanced Oil Recovery (EOR) Separations
BREAXIT EOR chemicals are specifically designed for treating highly stable
emulsions formed during EOR applications that utilize Alkaline Surfactant
Polymer/Surfactant Polymer (ASP/SP) Flooding Technologies. In ASP/SP
flooding applications, low concentrations of surfactants are used to reduce the
interfacial tension between the trapped oil and the injection fluids while the
polymer is responsible for increasing the viscosity of the injected fluids to
minimize channeling and provide mobility control. It is inevitable that at some
point during the life of the EOR project, polymer and surfactants will break into
the producing wells causing severe emulsion problems. Nalco’s new, patented
technology, BREAXIT EOR, effectively separates persistent oil and water
emulsions produced during ASP/SP flooding. Our experienced field engineers
can help you determine the best solutions for emulsion separation problems in
your EOR project.
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Cold stress testing
Automated particle size analysis
Umbilical flow loop testing
Specific gravity testing
Pour point measurement
Viscosity testing – ambient and high
temperature/pressure
Flash point, vapor pressure analysis
Materials suitability data
Hydrate resistance testing
Thermal stability testing
Umbilical storage fluid compatibility
production
Our BREAXIT product line includes
emulsion breakers that completed the
SurFlo Plus process and are certified
for subsea umbilical applications.
These products reduce or eliminate
the potential for plugging capillary strings
or umbilical lines. Our experienced Nalco
field engineers can help you identify the
appropriate BREAXIT product to solve your
downhole emulsion treatment problems.
Maximize flow with Emulsion Viscosity Reducers (EVRs)
BREAXIT EVR technology is utilized for reducing the apparent viscosity of crude
oil containing naturally occurring emulsions. The controlled emulsion breaking
activity of the EVR chemicals is responsible for causing the reduction in apparent
viscosity of the produced fluids. The effective application of Nalco EVR products
usually leads to a decrease in the total cost of operation by reducing energy
consumption, pump stress and failures, and need for topside emulsion breaker
chemicals.EVR chemicals are designed for application through umbilical and
capillary string lines to reduce bottom hole back pressure and enhance the
production of crude oil. Measurable increase in oil production is attained when
EVR is injected downhole.
To further lower costs, BREAXIT EVRs enable partial demulsification at the
higher downhole temperatures, there is less heat required at the surface.
Additionally, they reduce the tendency of gas-lift wells, or wells with high gas
volumes, to slug fluids and “kick.”
Oil Sands and Heavy Oil
As the global demand for energy grows, oil sands production grows with it.
While Canada’s vast reserves promise significant oil production, they also require
a substantial input of energy and water to extract and upgrade the bitumen.
Additionally, environmental concerns are forcing oil sands producers to find
sustainable solutions that minimize the impact on their surroundings.
Each phase of the oil sands production and upgrading process has specific
challenges. Nalco offers a comprehensive approach built on knowledge and
experience in all phases. We understand the challenges faced by the producer
from extraction to refining. Our innovative BREAXIT technologies for emulsion
breaking, slop oil reduction, maximizing heat exchanger performance and using
automation to ensure reliability are driven by the issues faced in SAGD and Mining
operations. We’re focused on cost-effective and environmentally sustainable
solutions that can be applied to optimize the entire system.
We utilize Nalco Total System Analysis (TSA) to do a complete evaluation of your
entire operation to identify areas for improvement. The TSA involves a thorough
review of equipment, operating history, software modeling, laboratory analysis, and
chemical treatment program. The outcome is an optimized operation and chemical
treatment plan for your heavy oil and oil sands operation.
Sustainable Chemistries
BREAXIT chemistries have been developed to meet or exceed the environmental
regulations to which our customers adhere, and to promote the sustainable
development ethos. The majority of our components are tested against strict
toxicity, biodegradation and bioaccumulation requirements to minimize substitution
warnings and achieve the best hazard ratings. Our procedures satisfy testing
requirements for chemical applications in the North Sea. But wherever you do
business, we can meet your most demanding testing requirements.
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The Nalco Commitment to Sustainability
Nalco demonstrates and delivers world-class leadership on environmental sustainability
for our customers with strong efforts toward Nalco operations related to environmental,
social and economic objectives of sustainable development.
Helping Customers Operate Sustainably
Nalco Company is the world’s leading environmental solutions provider. We create value
for customers and Nalco through services and technologies that save water and energy,
enhance production and improve air quality, all while reducing total cost of operation.
Nalco programs create significant economic value for customers. The environmental return
on investment (eROISM) we provide includes savings from reducing water and energy use,
conserving assets, reducing solid waste disposal, and improving utilization of natural
resources and raw materials.
Our performance as disclosed in our annual Sustainability Report includes:
Waste Reduction: Since 2005, the total amount of waste generated by Nalco
manufacturing operations worldwide has been cut by 23%. While a portion of that
decline is a result of decreased production due to the global recession, we have a
number of focused waste reduction projects at our global manufacturing sites.
Energy Reductions and Greenhouse Gas (GHG) Emissions: Nalco is committed to
a 10% reduction in energy use from 2007 levels by 2012. Because of the direct relationship
between energy use and GHG, this will mean a percentage reduction in GHG emissions in
the high single-digits over the same period.
As part of our commitment to continuously improving our environmental performance,
our manufacturing plants around the world are undergoing a comprehensive program
of accreditation to either ISO14001 or Responsible Care®14001, the global standards
for environmental performance.
We can always improve, which is why we continuously strive to do better – for our
employees, our communities and our customers.
NALCO COMPANY OPERATIONS
North America:Headquarters –1601 West Diehl Road • Naperville, Illinois 60563-1198 • USA
Energy Services Division – 7705 Highway 90-A • Sugar Land, Texas 77478 • USA
Europe: Ir.G.Tjalmaweg 1 • 2342 BV Oegstgeest • The Netherlands
Asia Pacific: 2 International Business Park • #02-20 The Strategy Tower 2 • Singapore 609930
Latin America: Av. das Nações Unidas 17.891 • 6° Andar 04795-100 • São Paulo • SP • Brazil
www.nalco.com
NALCO, the logos and the tagline, BREAXIT, SurFlo and SurFlo Plus are trademarks of Nalco Comapny.
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