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Fuel 89 (2010) 1095–1100

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Fuel
journal homepage: www.elsevier.com/locate/fuel

Heavy crude oil viscosity reduction and rheology for pipeline transportation
Shadi W. Hasan a, Mamdouh T. Ghannam b,*, Nabil Esmail a
a
Department of Mechanical and Industrial Engineering, Concordia University, Montreal, Quebec, Canada
b
Department of Chemical and Petroleum Engineering, College of Engineering, United Arab Emirates University, Al-Ain, United Arab Emirates

a r t i c l e i n f o a b s t r a c t

Article history: Different methods of reducing the viscosity of heavy crude oil to enhance the flow properties were inves-
Received 3 December 2008 tigated. Experimental measurements were conducted using RheoStress RS100 from Haake. Several fac-
Received in revised form 25 May 2009 tors such as shear rate, temperature and light oil concentration on the viscosity behavior have been
Accepted 15 December 2009
studied. This study shows that the blending of the heavy crude oil with a limited amount of lighter crude
Available online 5 January 2010
oil provided better performance than the other alternatives. Experimental measurements in terms of
shear stress s–shear rate c_ ; and yield stress s0 were conducted on the mixture of heavy crude oil–light
Keywords:
crude oil (O-light). The results showed a significant viscosity reduction of 375 mPa s at a room temper-
Heavy crude oil
Viscosity reduction
ature of 25 °C. This study shows that the heavy crude oil required a yield stress of 0.7 Pa, whereas no yield
Oil/water emulsion stress was reported for the heavy crude oil–light crude oil mixture.
Alcohol Ó 2010 Elsevier Ltd. All rights reserved.
Yield stress

1. Introduction of water-in-oil (W/O) emulsions [3–5]. Such emulsions are consid-


ered as a ruthless problem within the petroleum industry due to
Crude oil is one of the most actively traded commodities in the their various costly problems in terms of production loss and trans-
world. Oil prices change daily in response to fluctuating conditions port difficulties. Heavy crudes account for a large fraction of the
that affect supply and demand. Global demand for crude oil has world’s potentially recoverable oil reserves. The viscosities of those
been intensifying steadily over the past 20 years, as world demand crudes at room temperature vary from 100 mPa s to more than
for crude has grown from 60 million barrels per day to 84 million 105 mPa s. Generally, crude oil with viscosity <400 mPa s is the
barrels per day. The market price for heavy crude oil is only about classical maximum desired pipeline viscosity [6–8].
one-half that of light crude oil, which is the price generally quoted Therefore, different methods are used in order to reduce the vis-
by the media. cosity of the heavy crude for the pipeline transportation. For in-
Oil transportation has become a complex and highly technical stance, dilution with lighter crudes or alcohols, heating, and the
operation. One of the major difficulties in the pipeline transporta- use of surfactants to stabilize emulsions are some of those com-
tion is the high viscous fluids that require efficient and economical mon methods. Heating is a common method utilized to overcome
ways to transfer the heavy crude. Heavy crude oils have a density the above noted problems of transporting heavy oil by pipeline [1].
approaching or even exceeding that of water. They are usually ex- The basis for this method lies in the fact that as heavy oil is heated,
tremely viscous, with a consistency ranging from that of heavy the viscosity of the heavy oil is reduced and thus made easier to
molasses to a solid at room temperature. Heavy crude oils are pump. Therefore it is important to heat the oil to a point where
not pumped easily through the pipelines because of the high con- the oil has a substantially reduced viscosity. A principle drawback
centrations of sulfur and several metals, particularly nickel and to the use of heated pipelines is the high capital and operational
vanadium. Crude oils are complex fluids that can cause a variety cost of such a heated pipeline over long distances [9]. In addition,
of difficulties during the production, separation, transportation underwater pipeline transportation of heavy oil through a heated
and refining of oil [1,2]. pipeline is very difficult due to the cooling effect of the surround-
The formation of emulsion is another problem that occurs in the ing water and the practical difficulty of maintaining pumping sta-
petroleum industry. Indeed, crude oil is often mixed with water tions and heating stations [10,11].
when it comes out from a well. As the oil–water mixture passes Another method utilized in the transportation of heavy crude
over chokes and valves, mechanical input leads to the formation oil is the formation of the emulsions [12,13]. In such a method
the heavy oil is suspended as micro-spheres stabilized in a water
* Corresponding author. continuous phase by the use of surfactants and detergents forming
E-mail address: mamdouh.ghannam@uaeu.ac.ae (M.T. Ghannam). an O/W emulsion, and thus achieving a reduction in the apparent

0016-2361/$ - see front matter Ó 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.fuel.2009.12.021
1096 S.W. Hasan et al. / Fuel 89 (2010) 1095–1100

viscosity [14,15]. The principle difficulty with the use of this tech- hol with purity in excess of 99% was provided from Sigma–Aldrich
nology is the selection and cost of the surfactant component of the Canada Ltd.
emulsion. Not only the surfactant must be capable of stabilizing
the emulsion during transportation, but it also must be capable 2.2. Emulsion preparation
of separation once the destination point of the pipeline is reached
[10,16]. Emulsion properties, such as stability and rheological An aqueous solution of surfactant was made initially for prepar-
properties, are governed by many variables including temperature, ing oil-in-water (O/W) emulsion. The aqueous solution of surfac-
composition and droplet size distribution. The highest level of con- tant with concentration of 0.1% was prepared with distilled
trol consists of producing monodisperse phase, i.e. narrow size dis- water. A measured volume of the aqueous surfactant solution
tributed emulsions with a tunable mean size. Conventional was transferred into a conical flask provided with a stirrer. The re-
emulsification devices, such as dispersing machines, colloid mills, quired amount of the crude oil was added gradually into the aque-
and high pressure homogenizers are used to prepare emulsions ous phase while the mixing was provided to form stable and
by applying strong shearing stresses. Other novel techniques based homogeneous emulsion by breaking large liquid drops into smaller
on the application of low shear stresses have been recently devel- drops. All surfactant solutions were prepared before mixing with
oped where the final state is determined solely by droplet frag- the crude oil. Afterwards, the emulsion was taken for the
mentation, allowing good control of the droplet size distribution measurements.
[17]. Another phenomenon that might take place is the gelling of
the emulsions due to partial coalescence through which crystals lo- 2.3. Experimental set-up
cated close to the oil/water interface can protrude into the contin-
uous phase which lead them to pierce the film and bridge the The measurements were carried out using RheoStress RS100
surfaces, causing the droplets to coalesce. However, if the crystal- from Haake [21]. This rheometer has several operating test modes.
lized fraction within the globules is enough, the intrinsic rigidity It has a universal controlled rate (CR) mode, a controlled stress (CS)
inhibits relaxation to the spherical shape driven by surface tension mode, and an oscillation (OSC) test mode. In the CS mode, shear
after each coalescence event. Large stress bearing clusters will ap- stress is applied to a test sample by means of extremely low iner-
pear and grow by the accretion of any other primary droplet or tia. The drive shaft of the RS100 is centered by an air bearing to en-
cluster until a rigid network made of partially coalesced droplets sure an almost frictionless transmission of the applied stress to the
is formed, in which the original droplet shape remains recogniz- test fluid. The resulting deformation of the sample is detected with
able [18]. Blending of heavy oils with lighter oils, hydrocarbon a digital encoder that processes 106 impulses per revolution. This
gases or alcohols are other alternatives to reduce the viscosity of resolution makes it possible to measure small yield values, strains,
the heavy oils [19]. or shear rates. The computer controlled rheometer can be easily
The proposed study focused on many significant points in order switched between both CS and CR modes, and it can provide oscil-
to come up with a good understanding of the heavy crude oil flow lating stress inputs. A controlled variable lift speed is used to posi-
properties and how to enhance it. The main theme of this investi- tion the cone on the plate. A thermal gap size is controlled to
gation is to examine the rheological properties and the character- compensate for any of the sensor generated heat. The software
ization of the heavy crude oil. This study is divided into three package ‘‘Haake Windows” controls both test routines and data
sections. The first one is to investigate the different techniques of evaluation. The rheometer is equipped with a cone and plate sen-
reducing the heavy crude oil viscosity such as forming oil–aqueous sor. This cone–plate sensor was used with a cone angle of 4°, cone
solution of surfactant emulsions, blending the heavy crude oil with diameter of 35 mm, and 0.137 mm gap at the cone tip.
alcohol, and blending the heavy crude oil with lighter crude oil at
different temperatures. The second section of the current study is 3. Results and discussion
to verify different rheological models such as Bingham, Power
law and Casson to simulate the flow behavior of the heavy crude 3.1. Rheological model
oil. The third section includes the investigation of the yield stress
of the heavy crude oil. The flow behavior of the heavy crude oil sample was investi-
gated over a wide range of shear rates at 25 °C. The measurement
test was conducted under the CR mode, and the values of shear
2. Experimental stress and shear rate were obtained. Fig. 1 shows a typical rheo-
gram in terms of shear stress and shear rate. The resulted shear
2.1. Materials stress increases gradually and significantly with shear rate. Model-

All crude oil samples used in this study were obtained from
Husky Energy – Lloydminster, Canada. The density and API gravity
of the used heavy crude oil are 995 kg/m3 and 10.71 at 15 °C, T = 25 oC
respectively. Initially, the crude oil was homogenized by shaking
it for an hour to ensure that the physical properties of the heavy 1000
Shear stress (Pa)

crude oil are the same. After homogenization, the crude oil was
used for measurements. The commercial non-ionic surfactant Tri-
ton X-100 from Sigma–Aldrich Canada Ltd., was used as an emul-
sifying agent to form oil–water emulsion. A surfactant material is
usually added into the oil–aqueous solution emulsion system as
an emulsifying agent to accomplish two functions. The first func-
tion is to lower the oil–aqueous solution interfacial tension, there-
fore assisting in the formation of the emulsion system. The second 100
10 100 1000
function of the surfactant material is to stabilize the presence of Shear rate (s-1)
the oil droplets phase within the aqueous continuous phase to
avoid the oil droplets coalescence mechanism [20,21]. Ethyl alco- Fig. 1. Heavy crude oil rheogram.
S.W. Hasan et al. / Fuel 89 (2010) 1095–1100 1097

Table 1 is the effect of temperature. Temperature has a strong effect on vis-


Modeling analysis of Eqs. (1)–(3). cosity and viscous behavior. This effect provides the flow behavior
Power law model m n R2 curve in terms of the viscosity-shear rate or viscosity-shear stress
7.438 0.892 0.994 relationships. Fig. 3 shows the effect of temperature on viscosity-
shear rate for heavy crude oil over the range of 25–75 °C in 10°
Bingham model s0 g R2
179.5 3.338 0.981 increments. The test is done using the CR mode. It is observed that
the crude oil shows non-Newtonian shear thinning behavior over
Casson model s0 g R2
21.788 0.988 0.975 the range of shear rates from 0.6 to 740 s1 in which the apparent
viscosity decreases considerably with temperature and is reduced
by one half when it is heated from 25 to 75 °C. It is also demon-
strated that the viscosity differences are larger at low shear rates
than at high shear rates. As the temperature increases, the compo-
Table 2
DVR% of heavy crude oil versus temperature. sitions of the heavy crude oil with high molecular weight, such as
asphaltenes, resins, waxes etc., do not have the chance to agglom-
Temperature, °C DVR%
erate and form aggregates, and thereby breaking the bonds be-
25 0 tween the solid particles and hence reducing the oil viscosity. To
35 20
access the extent of the viscosity reduction, the degree of viscosity
45 23
55 30 reduction (DVR) is introduced and it can be calculated using Eq. (4)
65 32 [23]
75 36
DVR% ¼ ðgr  gc Þ  100=gr ð4Þ

where gr is the reference viscosity at 50 s1 shear rate and 25 °C,


ing analysis was carried out to search for a certain rheological Pa s, and gc is the corresponding viscosity at 50 s1 shear rate and
model that fits the measurements. Three rheological models of corresponding temperature, Pa s. Table 2 reports the DVR% over
Power law, Bingham, and Casson models, according to Eqs. (1)– the temperature range of 25–75 °C. Over the examined temperature
(3), were investigated in this study. The results of the modeling range, it is noted that there is a significant increase in DVR% from 0%
analysis are reported in Table 1 and Fig. 2 as well. Where s is the to 36%. This can be attributed to several reasons. The first reason is
applied shear stress in Pa and c_ is the corresponding shear rate due to the strong effect of temperature on the viscosity of heavy
in s1, the m and n of Eq. (1) are consistency index in Pa sn and flow components in the crude oil such as wax and asphaltene. The sec-
behavior index, the so and g of Eqs. (2) and (3) are the apparent ond reason is due to the effect of high temperatures on the chemical
yield stress in Pa and the apparent viscosity in Pa s. Fig. 2 shows structure of heavy components which results in destroying the or-
that the power law model fits the flow behavior of the heavy crude dered structures of heavy components in the crude oil phase, and
oil very adequately over the tested range of shear rates. Also Table hence reducing the oil viscosity [24].
1 reports the highest regression correlation coefficient, R2, of 0.994 Moreover, it is found that the viscosity of the heavy crude oil
for the Power law model. This conclusion agrees with other work depends on the shear rate. The viscosity reaches low values at high
[22]. shear rates. This means that the flow encounters less resistance at
s ¼ mc_ n ð1Þ higher shear rates. This is due to the molecular chains found in the
heavy crude oil. As the shear rate increases, the chain type mole-
cules disentangled, stretched, and reoriented parallel to the driving
s ¼ s0 þ gc_ ð2Þ
force, and hence reduced the heavy crude oil viscosity [21,23].

s ¼ ðs0:5 _ 0:5 Þ2
0 þ ðcgÞ ð3Þ
3.3. Oil/water emulsion

3.2. Temperature effect Generally, emulsions are of great interest in many industrial
applications. The formation of oil-in-water emulsion (i.e. O/W
One of the important methods that can be used to lower the emulsion) is one of the alternatives to enhance the flowability of
heavy crude oil viscosity and enhance, therefore, the flowability crude oil through the pipelines. That is why it is very important
to study the flow behavior of the O/W emulsion. It is established

10000
11
Exprimental Data
Temperature, oC
Power Law Model 25
Bingham Model 10 35
45
Casson Model 55
Shear stress (Pa)

65
9 75
Viscosity (Pas)

1000
8

100 5
10 100 1000 0 200 400 600
Shear rate (s-1) Shear rate (s-1)

Fig. 2. Suggested rheological models. Fig. 3. Effects of temperature on the viscosity of heavy crude oil.
1098 S.W. Hasan et al. / Fuel 89 (2010) 1095–1100

10 which means that the viscosity becomes independent on the shear


Temperature, oC
25
rate and temperature.
35
8
45
55
65 3.4. Effect of ethyl alcohol addition
6 75
Viscosity (Pas)

Figs. 6 and 7 illustrate the viscosity behavior when the heavy


4 crude oil is blended with ethyl alcohol of 10% and 20% by volume.
As can be noticed from Fig. 6, the non-Newtonian behavior re-
2 ported for the 90% crude oil–10% alcohol mixture is similar for
the behavior of the heavy crude oil alone shown in Fig. 3. The pres-
0 ence of 10% alcohol causes strong viscosity reduction by almost
80% at 25 °C (i.e. from 10.0 to 2.0 Pa s). Even more viscosity reduc-
0 200 400 600 800
tion can be achieved by further addition of alcohol as reported in
Shear rate (s-1)
Fig. 7. The viscosity reduces from 10.0 to 0.95 Pa s at 25 °C in the
Fig. 4. Effect of temperature on the viscosity of 90% O/W emulsion. presence of 20% by volume of alcohol. It is suggested that the
reduction of the measured viscosity is due to the interactions be-
tween the hydroxyl functions and some functionalities of the
asphaltenes [19]. As the oil–alcohol ratio decreases, the shear thin-
that the rheological properties of emulsions and their stability are
ning behavior takes place, and the viscosity decreases as the tem-
affected by the volume fraction, and droplet structure of the dis-
perature increases. From the foregoing results, it can be concluded
persed phase, and chemical composition of each phase [23]. Emul-
that the blending of heavy crude oil with ethyl alcohol enhances
sions can be concentrated up to high volume fractions which
the flowability of the heavy crude oil and it is much better than
correspond to the close packing of an equivalent suspension of
the results obtained from the O/W emulsion technique.
hard spheres, and thus resemble in an elastic solid. By deforming
the droplets interfaces, additional surface area will be created
resulting in minimizing their total free energy. The extra surface 3.5. Effect of light crude oil addition
area determines the elastic shear modulus [17]. Surfactants are
chemical materials used as emulsifying agents in order to obtain Another alternative for viscosity reduction was investigated by
O/W stable emulsions by lowering the interfacial tension between blending the heavy crude oil with a lighter crude oil with viscosity
the crude oil–water system, and by stabilizing the presence of the around 0.300 Pa s. The objective from the blending process is to
droplets phase within the continuous phase to prevent the coales- form a less viscous and less dense crude oil which will be more
cence action of the droplets phase [17,20,21]. It is reported that the
viscosity of heavy crude oil decreases as the concentration of the
aqueous solution of surfactant increases [25]. Figs. 4 and 5 show 2.50
Temperature, oC
the viscosity behavior of O/W emulsion versus shear rate. Two dif- 25
2.25 35
ferent concentrations of aqueous solutions, 10% and 20% by vol- 45
55
ume, were examined over the temperature range of 25–75 °C. 2.00 65
75

The viscosity is found to be significantly less than that obtained


Viscosity (Pas)

1.75
for the crude oil alone, and it is reduced by 20% (i.e. from 9.97 to
8.09 Pa s) at 25 °C for the 90% O/W emulsion. Similarly, for the sec- 1.50
ond case of the 80% O/W emulsion, the viscosity decreased even by
a higher percentage of 35% from 9.97 to 6.49 Pa s at 25 °C. 1.25
Figs. 4 and 5 present two distinct regions: the low shear rate re-
1.00
gion up to 500 s1 where the viscosity of the O/W emulsions exhi-
bit a strong non-Newtonian shear thinning behavior, and the 0.75
second region of shear rates >500 s1, where the viscosity of the 0 200 400 600 800
W/O emulsions shows Newtonian profile. For the high shear rate Shear rate (s-1)
region, all curves approach each other forming one master curve,
Fig. 6. Viscosity behavior for 90% oil–10% ethyl alcohol mixture.

10 1.0
Temperature, oC Temperature, oC
25 25
35 0.9 35
8 45
45
55
55 65
65 0.8 75
6 75
Viscosity (Pas)
Viscosity (Pas)

0.7

4
0.6

2 0.5

0.4
0
0.3
0 200 400 600 800 0 200 400 600 800
Shear rate (s-1) Shear rate (s-1)

Fig. 5. Effect of temperature on the viscosity of 80% O/W emulsion. Fig. 7. Viscosity behavior for 80% oil–20% ethyl alcohol mixture.
S.W. Hasan et al. / Fuel 89 (2010) 1095–1100 1099

1.50 5
Temperature, oC
25
35
45 4
1.25 55
65

Shear stress (Pa)


75
3
Viscosity (Pas)

1.00

0.75 Temperature, oC
1 25
45
65

0.50 0
0 200 400 600 800 0.0 0.1 0.2 0.3
Shear rate (s-1) Shear rate (s-1)

Fig. 8. Viscosity behavior for 90% heavy oil–10% light oil. Fig. 10. Yield stress measurements of heavy crude oil at different temperatures.

0.50 Table 4
Temperature, oC Values of yield stress measurements.
25
0.45 35
Sample Yield stress so, Pa
45
55
65
Heavy crude oil, 25 °C 0.7
0.40
Viscosity (Pas)

75 Heavy crude oil, 45 °C 0.5


Heavy crude oil, 65 °C 0.4
0.35 10% Light crude oil mixture, 25 °C 0.0
20% Light crude oil mixture, 25 °C 0.0
0.30

0.25 takes place, which disappears when the applied stress is released.
The relationship between the elastic deformation and the applied
0.20
0 200 400 600 800 stress is linear. However, above the yield stress point, the applied
Shear rate (s-1) stress leads to unlimited deformation which causes the sample
to start flow [21,26]. The yield stress measurements for heavy
Fig. 9. Viscosity behavior for 80% heavy oil–20% light oil. crude oil samples were carried out at different temperatures
desirable and more suitable for the pipeline transportation. Figs. 8 employing RheoStress RS100 under controlled stress mode. Con-
and 9 illustrate the viscosity behavior when the heavy crude oil is trolled stress rheometers provide the most direct technique for
blended with 10% and 20% by volume of a light crude oil, respec- yield stress measurements. Shear stress in the sample is progres-
tively. The viscosity behavior of the blending mixture behaves sim- sively increased with no shear flow reported till the yield stress
ilarly as that for the heavy crude oil shown in Fig. 3. The presence is reached. For each test of the yield stress measurements, the as-
of 10% light crude oil causes a strong reduction in the heavy crude signed stress was ramped up from 0.09 to 4.0 Pa within the exper-
oil viscosity from 10.0 to 1.2 Pa s at 25 °C, which is almost ten imental period of 150 s to establish the rheogram behavior curve of
times less than the original crude oil viscosity. On the other hand, shear stress–shear rate.
the addition of 20% light crude oil leads to an even higher viscosity Fig. 10 illustrates the relationship between the assigned shear
reduction from 10.0 to 0.375 Pa s at 25 °C, which is 26 less than stress and the response of shear rate for different temperatures
that of the heavy crude oil alone. As a conclusion, this technique as a typical example for other tests through which the yield stress
is recommended more than the other viscosity reduction alterna- measurements can be conducted for the heavy crude oil. It can be
tives, since the viscosity is reduced to 0.375 Pa s at 25 °C in the observed that the yield point which is required to start the flow de-
presence of 20% light crude oil. Table 3 shows a comparison be- creases with temperature. The yield point of the heavy crude oil
tween the results of all techniques examined in this study at the reaches a value of 0.7 Pa at room temperature 25 °C and it de-
shear rate of 51.74 s1. creases to 0.4 Pa when the temperature reaches 65 °C. On the other
hand, the addition of 10% and 20% by volume of light crude oil
diminishes the yield stress value, which means that the presence
3.6. Yield stress measurements of the light crude oil within the heavy crude oil will eliminate
the need for any further stresses to be applied. Table 4 highlights
The yield stress, so, is defined as a limiting stress below which a the measured yield stress values for other samples.
sample behaves as a solid. At low stress, the elastic deformation

Table 3 4. Conclusions
Comparison between the viscosity results of all techniques at 51.74 s1.

Sample 25 °C 35 °C 45 °C 55 °C 65 °C 75 °C
The objective of this study is to investigate the different alterna-
tives of reducing the viscosity of the heavy crude oil to enhance the
Heavy oil 9.97 8.0 7.65 7.01 6.75 6.33
10% Emulsion 8.09 7.33 6.77 6.49 5.86 5.25
flow properties. The heavy crude oil exhibits non-Newtonian flow
20% Emulsion 6.49 4.67 3.90 3.73 3.39 2.94 behavior of shear thinning profile, which can be best presented by
10% Alcohol 1.97 1.71 1.61 1.40 1.27 1.10 the power law model. A wide range of temperature was covered in
20% Alcohol 0.94 0.88 0.81 0.74 0.66 0.62 this study to examine the effect of temperature on the flow behav-
10% Light oil 1.20 1.11 1.00 0.87 0.75 0.68
ior of the heavy crude oil. The heavy crude oil viscosity decreases
20% Light oil 0.37 0.35 0.30 0.28 0.25 0.23
significantly from 10.0 to 2.5 Pa s when the temperature changes
1100 S.W. Hasan et al. / Fuel 89 (2010) 1095–1100

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