Technical Bulletin

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Down Hole Emulsification (DHE)*

Petroferm Inc. has specially developed a number of water and oil emulsions to aid in the
production, transportation and combustion of heavy, viscous hydrocarbons. Emulsions such as
these can be applied from the wellhead down hole to the pipeline and finally to the combustion
chamber. Down hole emulsifiers employ the use of water continuous emulsions that have the
characteristic viscosity of the continuous phase, water, rather than the viscosity of the
hydrocarbon that is flowing in the water.
A variety of techniques are employed to improve upon the production of heavy oil or to
assist with its transport in pipelines. Some of these techniques include use of heat, steam, and
light hydrocarbons. In wells that have a high fluid level, surfactant and water mixtures can
reduce viscosity, increase down hole pump efficiencies, diminish power consumption, and
extend overall production in the field.

Reduction in viscosity of the heavy oil will reduce the

mechanical loads and flow line pressures as well as greaten the overall ability to remove the
viscous crude oil from the field to the dehydrators. Petroferm has commercialized this technique
and is responsible for increasing the overall production of viscous crudes in Mexico by over
4000 barrels per day.
For instances in which progressive cavity pumps (e.g. Moyno pumps) are used down hole
to produce heavy oil, the reduction in viscosity of the produced fluids can have the following
positive benefits:
1.

Reduce the head loss to friction in the well tubing.

2.

Improve pump efficiency.

3.

Reduce the viscous drag on the rotating shaft thus prolonging the life of the
motor, coupling and shaft.
Petroferm Inc.
2416 Lynndale Road Fernandina Beach, Florida 32034 USA
Telephone: 904-261-8286 Facsimile: 904-261-6994

Technical Bulletin
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4.

Increase pump speed using the same size motor and rod string.

5.

Maximize production through the use of a larger pump; or alternatively, install a

smaller pump at a greater depth.

The efficiency of a progressive cavity pump is inversely proportional to the viscosity due
to the entrance effects of the pump. Although reduction of the viscosity augments the pump
efficiency, it also increases slippage to an insignificant amount. Declination in well tubing and
transfer line frictional head loss should allow for greater oil production with less pump work.
The result is diminished mechanical wear and fewer pump and flow line maintenance problems.
The purpose of the first DHE project was to show the benefits of using emulsion
technology when transporting heavy oils through pipeline systems. The goal of projects
thereafter have been to increase production of heavy oil from wells in other districts throughout
all Mexican production zones.
The first test was a pipeline section test performed in May 1991 at Sabalo. Rather than
using large volumes of water to assist in the transport of heavy oils, emulsions, specifically with
HO FLOW* 400, were used. Water was of considerable concern because of separation costs at
Cacallilao and corrosion of the pipeline system. For this reason, it was believed that reducing the
required volume of water would be of considerable interest to Pemex. At Sabalo the use of
emulsions reduced the amount of water needed by 81 percent and decreased the amount of time
required to fully close the return line.

Transportation of product to the next battery fell

significantly. Additionally, the return valve could be closed in 2.5 hours using HO FLOW
400 versus 92.5 hours required when water additions are used. The test quantity of 387 cubic
meters of emulsified crude oil could be pipelined to G. Mendes in only 16.5 hours versus the 99
necessary to pipeline an equivalent amount of heavy crude without the use of Petroferm's
emulsion chemicals. Under normal conditions the pressure of the pipeline remained at 14
2
kg/cm ; however, the average pressure during pumping was reduced to 5 kg/cm2.

*
*

DHE is a registered trademark of Petroferm Inc.

HO FLOW is a registered trademark of Petroferm Inc.

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The second test was a single well project at Ebano 3. The well, Dicha 65, responded
remarkably to the addition of water and HO FLOW chemical. The test period was comprised of
a three-day interval. In this short time, the average oil production increased ten-fold, while
decreasing the amount of gas usage. The test results indicated significant potential benefits were
available to Pemex, thus, a larger test was planned.
The third test was application of HO FLOW chemicals (and technology) to the wells of a
single battery. The water-chemical mixture was added by changing the rate of injection once a
week rather than immediately maximizing production. This afforded the opportunity to gain data
about the reservoir in addition to solving operational problems.
The first priority was monitoring the appearance of formation water which could indicate
coning. The orderly start-up allowed Petroferm to start pipeline shipments into Cacallilao in a
methodical fashion to determine whether any potential treating problems existed. It is noteworthy that the amount of salt water in the return production remained at 1-2% indicating that
water coning was not occurring. No treating problems were encountered during the test period.
2500 cubic meters of emulsified crude oil were pipelined to the dehydration plant during the 30
day test.
Significant increases in production were obtained despite some operating difficulties;
low, fluctuating gas pressure as well as the presence of high condensate volumes in the gas
supply were observed. During the last 8 days of the test, after the wells had been reasonably
optimized, the net daily production was 118+ cubic meters per day versus the pre-test net
production of 15 cubic meters per day.
The transportation benefits demonstrated during the test at Sabalo are presently occurring
at Station A-21 in addition to the notable increases in production. The transit time to pipeline
for a typical 600 cubic meter batch has fallen from about 70 hours to only 20, and the
pipeline is able to attain full pump discharge rates within a five-minute period. No extra water
(other than the 20 - 25 percent used to make the extra production) is presently being added. The
pipeline pressure is reduced significantly from normal.

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It was calculated for the test at A-21 that a benefit to cost ratio of greater than 10:1
presently exits for using HO FLOW chemicals. For every dollar spent on chemical, greater
than ten dollars will be returned to Pemex in increased oil revenues.
Due to the success of several Down Hole Emulsification (DHE) projects in Mexico for
PEMEX, Golfo Supplemento Latino, SA de CV (GSL) currently operates 300+ wells that
produce more than 4,000 additional barrels per day. GSL received a three-year contract to
operate these wells and a request for renewal of the contract has been given.

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