Nanotechnology in the Oil Industry: Development of a Graphene Oxide-Based Demulsifier and its Implementation

Abstract A nanotechnology-based demulsifier has been developed, emphasizing its significance for the oil and gas industry and the benefits of nanomaterials, particularly graphene oxide. The paper details the fabrication, scaling up, functionalization, and blending of graphene oxide to resolve water-in-oil (W/O) emulsions from conventional and non-conventional reservoirs. Results from pilot tests and field validation are presented, highlighting the product's tailor-made feature. The fabrication process of graphene oxide involves electrochemical exfoliation of graphite. The design and scale-up of the process led to the establishment of a semi-industrial production plant. The functionalization and blending of graphene oxide with molecules that interact effectively with emulsifiers stabilizing W/O emulsions are explained. Lab-scale bottle tests and pilot tests validated the product. The validation process at different treatment plants is described, showcasing the nanodemulsifier's outstanding performance, which achieved better efficiency than traditional demulsifiers and demonstrated a dual role as a demulsifier and paraffin dispersant. Two paths were developed: a graphene oxide plant and demulsifier formulation. The production used an electrochemical exfoliation strategy, scaled up to a semi-industrial plant with a 2,4 kg/day capacity (patented in the US 18/626,041). Concurrently, graphene oxide was functionalized with molecules interacting with emulsifiers stabilizing W/O emulsions. Formulations were validated at oil treatment plants (also patented in the US 63/436,989). The validation process was conducted at a treatment plant with a capacity of 800-1000 m³/day over 30 days, achieving an optimal dosage of 65 ppm, outperforming the traditional chemical that operated at 130 ppm. Additionally, the dual role of the product as a demulsifier and paraffin dispersant was validated at another treatment plant with a capacity of 3200 m³/day over 30 days, showing high efficiency at lower dosage. Consumption was 25% lower than the combination of dispersant and demulsifier used in the field. The optimal dosage was 90 ppm of the graphene oxide-based product against 60 ppm of dispersa nt and 60 ppm of demulsifier. The novelty of the technology lies in the development of a tailor-made product based on nanotechnology, with the advantage of its dual role as a demulsifier and paraffin dispersant and its outstanding efficiency at lower dosage. This innovative demulsifier is currently being implemented. The semi-industrial graphene oxide production plant developed is the first in Latin America, and the Graphene oxide-Based Demulsifier was patented.