Synthesis, characterization and study of new surfactant nanocomposite as demulsifier to separate emulsions (W/O) in the petroleum industries

Abstract A significant challenge in oil production is the occurrence of fixed emulsions, such as water in oil. These emulsions have a significant impact on the extraction, storage, refinement, and transportation of crude oil. The formation of emulsions during the oil production process is a significant economic problem. The reduced water content of crude oil improves productivity and protects pipelines and equipment from corrosion. Chemical demulsification is the most common method of treating emulsions. Besides, nanotechnology has shown promise in the oil and gas industry, especially nanoparticles modified with surfactants. This study presents a novel nanodemulsifier by synthesizing hybrid oxide nanoparticles (NPs) modified with an organic cationic surfactant. It is made by reacting a cetyltrimethylammonium bromide (CTAB) compound with Al₂O₃B₂O₃ nanoparticles. The nanocomposite is effective in the demulsification of water-in-oil emulsions. Analysis techniques AFM, XRD, EDS, TEM, FESEM, and FT-IR were used to diagnose and confirm the synthesis of the nanocomposite Al₂O₃ B₂O₃-[CTAB]. In addition, the effectiveness of the prepared nanocomposite as a demulsifier was tested using the tube test method. The bottle test results showed the best demulsification efficiency within 90 min at 60 °C and a concentration of 90 ppm. Moreover, time, temperature, and concentration are influential factors in the process of breaking down W/O emulsions. The critical micelle concentration (CMC) is defined as the concentration of surfactant at the minimum interfacial tension (IFT) value.The selection of surfactants for the demulsification of emulsions is frequently conducted on an empirical basis. One such semi-empirical scale for selecting surfactants is the Hydrophilic-Lipophilic Balance (HLB) number. The Hydrophilic-Lipophilic Balance (HLB) value of Al₂O₃·B₂O₃-[CTAB] is 9.4. Molar conductivity is measured for Al 2 O 3 .B 2 O 3 -[CTAB] to determine the CMC value, which is found to be equal to 4 × 10 –4 .The interfacial tension (IFT) of the oil/water mixture gradually decreased from 24.22 mN/m to 5.43 mN/m with increasing concentrations of Al₂O₃-B₂O₃-[CTAB] in this study. A comparison was made between the effectiveness of the prepared nanocomposite and the commercial demulsifier (DRCI1286) used in Halfaya oilfield. The findings indicate that the nanocomposite exhibited a high degree of efficacy in demulsifying water-in-oil emulsions (W/O), with an optimal separation efficiency of 62.7%. Notably, the nanocomposite uses lower concentrations than previous ones, making field applications more cost-effective. This study offers insight into the synergistic mechanisms of hybrid oxide nanoparticles and surfactants through analysis. This study’s findings significantly advance the scientific knowledge base concerning novel chemical demulsifiers, offering a more refined methodological framework.