Black Powder Management in KOC West Kuwait Facilities: Analysis of Operations Data and Laboratory Evaluation of Chemical Treatments

Abstract Black powder formation in sweet and sour oil and gas production facilities presents unique challenges for maintenance, corrosion, instrumentation plugging, and equipment damage, which may ultimately affect product quality and result in production losses. The typical composition of black powder includes iron-based corrosion products, oxides, water, mineral scales, and asphaltenes, which can exist as either dry powder or wet sludge. This paper presents the outcomes of a research study focused on understanding and mitigating the adverse effects associated with black powder formation in the West Kuwait (WK) petroleum production and distribution facilities. The analysis includes a thorough review of historical operations data from WK facilities such as process flowcharts, production conditions, fluid analyses, and black powder composition reports. It also encompasses maintenance and inspection reports for production flowlines, gathering centers, and crude and gas export pipelines. Key parameters responsible for corrosion and black powder formation are identified and reported. Additionally, a laboratory investigation was conducted on the chemicals used in the gathering center, including corrosion and scale inhibitors, oxygen scavengers, and biocides. The experiments involved partitioning between water and oil, individually evaluating the efficiency of each chemical, and testing combinations of different additives to verify synergistic or antagonistic effects.