V6, Generate Oil From Waste
On average, 1% to 5% of daily oil production is sludge (unresolved emulsion). Basically, sludge is a blend of hydrocarbon, water and inorganic sediment. Sludge is highly viscous and non-pumpable. Currently, to recover crude oil from sludge is a long, complex and costly process. In most operations, sludge is classified as waste which is disposed off. Over time, if the sludge is not disposed, it will accumulate and create tank capacity issues, environmental pollution and increase operational cost.
For more than 50 years, crude oil production technology advancement has been incrementally slow, with almost insignificant change occurring. With V6 technology, the oil recovery process is revolutionized. V6 allows for the quick harvesting of crude oil from sludge at low production cost. On average, V6 recovery factor is 95% or higher. V6 is a strategic technology that will bring oil production industry to another level.
Advantages of V6
V6 developed based on nano chemistry technology. This gives significant advantages to extend the potential of the chemistry solution. Typically, oil recovery from ‘unconventional reserve’ requires huge amount of acid, heating equipment and complex operation.
As the photos above, the result show the sludge mixed with V6 is liquified. The sludge viscosity reduces by 90%. In addition, 95% hydrocarbon has been recovered from this sludge. This test proved V6 works even without heat and mechanical mixture. In addition, V6 dosage required is low(less than 400ppm) and V6 is non-acidic solution. Hence, it is safe and non-corrosive.
A lab simulation test was designed to see the performance of V6. The purpose of this test is to see the oil percentage recovery using V6. This to ensure V6 can work in any environment which was simulated in the lab. As the picture shown below, two sets of sludge were prepared. Both mixed with crude oil and one set mixed with V6. The test was conducted in 20 degree Celsius or below room temperature. Both samples were soaked for 4 hours to see the result. The test was repeated with different dosage of V6. Hence, we can find the most optimum dosage for V6 to perform.
Minimal Mechanical Intervention
Resources & Downloads
|1||When you used the V6 additive, how long had these tanks been in service without cleaning?||Tank T-7107 (location : Petronas Melaka Refinery, Malaysia) is in-service since 1994. No cleaning or desludging was done for almost 20 years. T-7107 is a floating roof tank with 500,000 bbls capacity storing crude from ExxonMobil and Petronas Carigali.|
|2||Can you give some specifics on the crude quality stored in the tank(s)?||Tank T-7107 is used to store Tapis crude, which is a light, sweet, paraffinic crude with API 39 to 43; maximum BS&W 15%, comprising of solids and sands ~ 5%.|
|3||Were the chemical tanks and chemical pumps part of Vision’s scope of supply or was the V6 injected using Client’s existing facilities?||Since this is a Turnkey Project, the Client rented the chemical tote tanks and chemical injection skid (with backup pump) from Vision (Note: Vision can also supply on purchase option, if preferred by Client). Vision also provided all required test equipments (viscometer, API tubes, centrifuge, waterbath, etc.) and consumables (sample containers, solvents, glasswares etc). The chemical pump unit was tied-in to inlet (incoming) line to T-7107. The Client provided the pneumatic air supply, SCBA and other items for confined space work (for tank profiling). The Client also provided 24/7 laboratory access and bench space in the refinery.|
|4||Did Vision Petroleum provide personnel for the WORK or did Client only purchase the product from Vision and did the injection and testing themselves?||Vision provided chemical, technical personnel (project supervisor, chemist, lab technician) and pumpman. Client considered it very important for Vision to be able to provide qualified personnel who will be working with specialized chemical and procedures. Vision activities include chemical injection skid commissioning & startup, injection line tie-in to Client piping system, V6 program startup, lab testing, surveillance (to track chemical performance including tank profiling) and final project reporting.|
|5||How many injection – soaking cycles did you go through typically/on average to achieve the fluidization of the sludge and crude recovery? Or did you have sludge left in the tank on the floor that had to be removed mechanically/manually (hydro dozers or the like)? How many days (on average) did it take you to from start of the set-up to opening the tank?||Vision’s pre-startup lab simulation indicated 2 cycles to achieve 95% crude recovery from the sludge. As such, two cycles were planned and executed successfully. After opening the manhole, we observed that the sediment leftover was a flatbed indicating mostly sandy, powdery materials – about 5% based on profiling data and calculations. SGS (3rd party) data and analysis confirmed that the sediment is clean, with no oil trapped in the sediment. The tank cleaning sub-contractor removed the sediment manually using only shovel and conveyor belt to drum and dispose. Since V6 reduced solids leftover, manual cleaning is a lot faster than using conventional procedure. Overall activity takes ~ 4 weeks but a significant time was spent on pumping recovered oil out from the storage tank using Wilden pumps.|
|6||Does the chemical in the recovered product have any impact on the quality of the product itself?||V6 does NOT create any impairments that can either jeopardize the integrity of the storage tank or piping, or quality of the recovered crude (or any other crude mixed with V6) and produced water. This is consistent with the various lab testings conducted prior to the job. Multiple exposure of the process piping and equipments to V6 will not affect the integrity of these assets since V6 is non-acidic. V6 is possibly maybe one of the few enhanced neutral sludgebreaker available in the market. Acid have been used for tank cleaning and desludging for ages. The discharged produced water pH is neutral (6 to 7.5), and the recovered crude is of export quality (BS&W less than 0.5% per ExxonMobil/PETRONAS specification), with no re-emulsification tendency.|
|7||Other technical aspects?||Over treatment with chemical can show up as stratified crude with a high volume of interface solids (like hanging solids). We checked these with the tank profiling work to map the tank. We did not see any sludge build-up in the tank or interface issues. Hence we conclude, the dosage window of 30 to 400 ppm will not cause any over treatment of the crude, which can lead to re-emulsification issues or incomplete desludging.|
|8||Is all sludge can be recovered using V6?||Only organic(hydrocarbon) sludge can be recovered using V6|
|9||What is V6 percentage recovery?||The crude recovery is up to 95%|
|10||Where can V6 be applied?||Any crude storage facilities. Including Terminal, Refinery, FPSO/FSO, crude Tanker, Tank Farm & Production Platform|
|11||Is V6 has been deployed in other locations?||Yes. V6 has been deployed at TCOT, PPM, MCOT, BCOT|
|12||How long the process of V6 recovery?||2 weeks per storage tank (500 Kbbl storage capacity)|
|18||What are the advantages of using V6?||Quick turnaround time (only 2 weeks)
Easy deployment (Minimal mechanical intervention)
Industrial Hygiene (Non acidic solution, minimal manpower exposure & no special PPE required)
Cost effective solution ( Low dosage application, optimum dosage is 100 – 200 ppm)
Online cleaning (No shutdown required)
|19||How much V6 chemical required per treatment?||Optimum dosage is between 100 – 200 ppm, 50 drums per tank|
|20||What is the equipment required for V6 treatment?||2 chemical pumps (1 for standby ) & 2 tote tank per operation|
|21||How many manpower required for V6 operation?||Total 5 manpower required per operation.1 supervisor, 2 technicians to operate chemical pump and 2 lab chemists for testing|
|22||What is the quality of crude recovered?||Export quality, <0.5 %BS&W, tested by independent lab (SGS)|
|23||Is there any side effect on the facilities?||V6 is non-acidic solution to ensure no integrity issue after the treatment. Based on previous work, the crude quality gets better over time when soak with V6(act as demulsifier).|
|24||Is there any residue after the treatment?||After the treatment of non-oily sand (safe for landfill) and water (pH 7, can be discharged) left. Tested by independent lab (SGS)|
|25||How sludge volume is measured?||By gauging the sludge level from multiple sampling point at the tank roof top.|
|26||How recovered crude volume calculated?||Recovered crude is metered during the transfer process to the other tank.|
|27||Is V6 works for sweet or sour ?||V6 has been tested for sweet(<0.5% sulfur) & sour crude. It works for both type of crude.|