Production Chemicals: Essential ingredients for efficient oil and gas operations

 

Production chemicals

What is it?
Production chemicals refer to the various chemicals that are used at different stages of oil and gas production, processing, transportation and refining. They play a vital role in enhancing production, protecting equipment and pipelines from corrosion, reducing scale formation and paraffin deposition, emulsion breaking, and ensuring efficient downstream operations. Some of the major categories of production chemicals include:

Corrosion and Scale Inhibitors
Corrosion of pipes, vessels and other Production Chemical equipment can lead to leaks, equipment failure and environmental hazards. Corrosion inhibitors form a protective film or barrier on metal surfaces to prevent corrosion from occurring. They are commonly used to treat production streams, pipelines and refinery equipment. Scale inhibitors prevent the precipitation of insoluble salt scales on internals during production and processing. Common scales include calcium carbonate, barium sulfate and strontium sulfate. Without effective scale control, production can drop considerably.

Paraffin Inhibitors
Waxy paraffin deposits from heavier oil grades often lead to plugging of lines and flow assurance issues. Paraffin inhibitors prevent the solidification of paraffin crystals and subsequent deposition on walls at low temperatures. Common paraffin inhibitors are solvents, dispersants and pour point depressants. They maintain paraffin in a liquid state or dispersed form during transportation and storage.

Demulsifiers
Emulsions refer to stable mixtures of oil and water that don’t separate naturally. Demulsifiers promote separation of emulsions into distinct oil and water phases. They displace water from the oil-water interface and reduce surface tension. Common applications are in production treating, desalting, crude stabilization and tank cleaning. Good demulsification is essential for trouble-free downstream processing.

Biocides
Biocides are crucial for protecting production systems and petroleum streams from souring by sulfate-reducing bacteria (SRB) and other microbes. Untreated biodegradation can lead to corrosion, reservoir souring, and equipment damage over time. Common biocides used are glutaraldehyde, isothiazolones and quaternary ammonium compounds. Continuous treatment maintains microbiological control throughout facilities.

Hydrate Inhibitors
Hydrates or gas hydrates resemble ice but are crystalline solid complexes of water and gases like methane. They can plug pipelines during oil & gas production in deepwater. Hydrate inhibitors prevent agglomeration of gas hydrates by altering crystal structure. Common types are thermodynamic inhibitors, kinetic inhibitors and anti-agglomerates. They allow safe transportation of gases over long distances.

Defoamers
Entrained gas foams arise in tank batteries, crude units, pipelines due to mechanical agitation and low pressure drop. Excessive foaming causes production upsets, loss of tank capacity and compromises safety. Defoamers control foam by reducing surface tension at the air-liquid interface. Common defoamers contain silicones, hydrocarbon oils and polymers. Careful dosing minimizes foam formation across facilities.

Corrosion Inhibitors - How do they work?
Corrosion inhibitors function by forming an inhibitive protective film or barrier on metal surfaces. This film prevents direct contact between the metal and corrosive environment. There are mainly three types of inhibitors based on inhibition mechanism:

- Anodic Inhibitors - They absorb and block anodic active sites on the metal where oxidation occurs during corrosion. Examples are tannins, formaldehyde.

- Cathodic Inhibitors - They absorb on the metal and block cathodic active sites where reduction occurs. Common cathodic inhibitors are aryl phosphates.

- Mixed Inhibitors - They act on both anodic and cathodic sites simultaneously to give high inhibition efficiency. Typical mixed inhibitors are benzotriazoles, mercaptobenzimidazoles.

Modern corrosion inhibitors have polar functional groups which enable strong adsorption onto the metal surface via either physical or chemical adsorption. Common functional groups are amine, carboxyl, mercapto, phosphonate etc. Synergistic blends of inhibitors often show additive or multiplied inhibition compared to individual components. Continuous injection maintains long-term inhibition under corrosive production conditions.

Application methods of Production Chemicals
Production chemicals have to be introduced precisely into target process streams, locations and facilities spread over large production sites. Some common application methods are:

- Direct Injection - Liquids are pumped via permanent installed dosing skids directly into well streams, manifolds or pipelines. Ensures accurate dosing at required treatment points.

- Batch Treatment - Chemicals are added in predetermined doses to production or storage vessels, then recirculated until homogenous mixing is achieved. Useful for larger vessels and tanks.

- Metering Pumps - Diaphragm, peristaltic or progressive cavity pumps meter precise chemical volumes on a continuous or intermittent basis. Often used for corrosion inhibition of pipelines.

- On-line Diluters - Packaged skid-mounted units dilute and transfer chemicals on demand directly from supplier drums into process lines. Automated control improves consistency.

- Gas Lift injection - Used for downhole injection of chemicals like hydrate inhibitors, scale inhibitors or biocides into producing wells using compressed gas.

Proper equipment selection, installation, calibration and maintenance are indispensable for effective and reliable chemical injection across oil and gas facilities. Automation further aids remote monitoring and optimization of treatments.

With increasing global energy demand and emphasis on heavy oil/deepwater production, the production chemicals industry is projected to grow steadily. Emerging technologies are supporting higher recovery rates from mature fields through enhanced oil recovery efforts. However, environmental regulations remain a key challenge for developers to bio-degradeable, non-toxic chemicals. Ongoing R&D explores ways to minimize chemical consumption and discharge through real-time process analyzers, precision inhibition and chemical-free concept selection. Overall, production chemicals will continue playing an essential role in unlocking hydrocarbon reserves through efficient and responsible operations.

 

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About Author:

Money Singh is a seasoned content writer with over four years of experience in the market research sector. Her expertise spans various industries, including food and beverages, biotechnology, chemical and materials, defense and aerospace, consumer goods, etc. (https://www.linkedin.com/in/money-singh-590844163)