Production Chemicals
In the oil and gas industry, extracting, processing, and transporting hydrocarbons is a complex process. From the reservoir deep underground to the surface processing facilities, the mixture of oil, gas, and water is subjected to changing pressures and temperatures. These changes can cause a host of problems that can slow down production, damage equipment, and create safety hazards.
Production chemicals are specialized chemical solutions designed to address these challenges. They are crucial for maintaining the safe and efficient operation of the oil and gas industry. As oilfields mature, the need for these chemicals increases to ensure a steady and optimized production flow. These additives are used in various applications, from downhole in the well to topside facilities and pipelines, to protect assets and maximize recovery.
Major Categories of Production Chemicals
Production chemicals can be broadly grouped into three main categories based on their primary function. Understanding these categories helps in selecting the right solution for a specific operational challenge.
Flow Assurance Chemicals:
These are designed to ensure the continuous and uninterrupted flow of hydrocarbons from the reservoir to the point of sale. They prevent or mitigate blockages caused by the natural components of crude oil and gas.
Asset Integrity Chemicals:
This group of chemicals focuses on protecting the physical equipment and infrastructure from damage. Pipelines, vessels, and downhole equipment are constantly exposed to harsh and corrosive environments, and these chemicals preserve their operational lifespan.
Phase Separation Chemicals:
In production, crude oil is mixed with water and gas. Phase separation is a critical step to separate these components. These chemicals help to efficiently break emulsions (mixtures of oil and water) and remove unwanted foam, ensuring the quality of the crude oil and the effectiveness of the separation process.
Detailed Breakdown by Category
Flow Assurance Chemicals
1- Scale Inhibitors
Family: Proscal®
These chemicals prevent the formation of mineral scale deposits (like calcium carbonate and barium sulfate) that can clog pipelines and equipment. Changes in water pressure, temperature, or pH can cause these scales to form. Scale inhibitors work by distorting the crystal growth of the scale or by adhering to scale surfaces. Common types include phosphonates, polyacrylates, and other polymers.
2- Paraffin & Asphaltene Inhibitors/Dispersants
Family: Proflow®
Paraffins (waxes) and asphaltenes are heavy organic molecules in crude oil that can precipitate and deposit in pipelines as the temperature and pressure drop, leading to restricted flow. Inhibitors act as dispersants or crystal modifiers to keep these components from agglomerating and causing blockages.
Asset Integrity Chemicals
1- Corrosion Inhibitors
Family: Pronox®
Description: Corrosion is a major issue that can degrade pipelines and equipment, caused by exposure to water, H₂S, and CO₂. Corrosion inhibitors protect metal surfaces by forming a protective film, which acts as a barrier. They can be classified as anodic, cathodic, or mixed inhibitors and come in various chemical forms like amine-based compounds, Imidazolines, pyridines and phosphate esters.
2- Biocides
Family: Procide®
Description: These chemicals are used to control the growth of microorganisms like bacteria, fungi, and algae in water systems. Unchecked microbial growth can lead to several problems, including microbiologically influenced corrosion (MIC), reservoir souring (production of H₂S), and the formation of biofilms that can clog systems. Biocides can be oxidizing (like chlorine compounds) or non-oxidizing (like glutaraldehyde, THPS and quaternary ammonium compounds).
3- H₂S & Oxygen Scavengers
Family: Proscav®
Description: Hydrogen sulfide (H₂S) is a toxic and corrosive gas that can “sour” crude oil and gas. H₂S scavengers are chemicals that react with and neutralize H₂S like Triazines, Glyoxals and Zinc compounds.
Similarly, oxygen scavengers remove dissolved oxygen from water systems to prevent oxygen-driven corrosion like Ammonium Bisulfides and Sodium Bisulfides either normal of catalyzed versions.
Phase Separation Chemicals
1- Demulsifiers (Emulsion Breakers) and Reverse Demulsifiers
Family: Profas®
Description: Crude oil is often produced with water in a stable mixture called an emulsion. Demulsifiers are specialty chemicals that break these emulsions, allowing the oil and water to separate easily. This is a critical step to ensure crude oil meets quality specifications for refining. Common demulsifiers include various types of polymers, alcohols, and resins.
While Reverse Demulsifiers role comes after the primary separation of oil and water, the produced water still contains small droplets of oil and suspended solids. Water clarifiers and flocculants help to aggregate these fine particles, allowing them to be more easily removed, ensuring the water can be treated and disposed of in an environmentally responsible manner.
2- Defoamers (Antifoam Agents)
Family: Prosurf®
Description: During the separation process, foam can form, which reduces the efficiency of separator vessels and can cause operational issues. Defoamers are chemicals that quickly break down existing foam, while antifoam agents prevent it from forming in the first place. Common Types include silicon based, glycol based and alcohol based antifoam agents.