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ABSTRACT: Wax removal by pigging is costly in sub-sea oil production. Cost-effective scheduling of pigging can be achieved
based on the deposition rate predicted by wax deposition models. Conventional wax deposition models predict wax deposition
rates on the basis of Newtonian fluid mechanics. Such an approach can become invalid for highly waxy crude oils with non-
Newtonian rheology. In this investigation, different simulation techniques, including large eddy simulation, Reynolds-averaged
Naiver−Stokes equations, and the law of the wall, were applied to model non-Newtonian pipe flow. It was discovered that the
law of the wall method is the best method to calculate the velocity profile, shear stress and the turbulent momentum diffusivity in
turbulent non-Newtonian pipe flow of waxy oil. An enhanced wax deposition model considering the non-Newtonian
characteristics of waxy oil using the law of the wall method was developed and applied to predict wax deposition rates in a field-
scale pipeline.
1. INTRODUCTION wax deposition modeling studies have been carried out based on
1.1. Wax Deposition in Sub-sea Pipelines and Wax oils with relatively low wax contents, e.g., <5 wt%.5−7 As a result,
Deposition Modeling. During sub-sea oil transportation, the the non-Newtonian flow characteristics are not significant in the
crude oil is cooled by the seawater. Dissolved wax molecules published investigations. However, some crude oils can have a
contained by the crude oil will precipitate when the temperature wax content >15 wt%, and it is expected that such waxy oils can
of the fluid is below the wax appearance temperature (WAT). become highly non-Newtonian due to the precipitation of wax at
Precipitation of wax is expected to be the most profound at the temperatures below the WAT.9 The effect of the non-Newtonian
pipe wall where the lowest temperature is encountered among all fluid characteristics on the modeling of flow, heat transfer, and
radial locations, generating a radial concentration gradient of the mass transfer is not well-understood.
dissolved wax and a net flux of dissolved wax toward the wall.1 Applications of wax deposition models to real-world oil
Radial diffusion of wax molecules causes wax to deposit on the transportation pipelines are extremely rare in published
inner pipe wall, reducing the effective pipe diameter and posing investigations. Moreover, a large number of adjustable
severe risks to oil production. Wax remediation techniques parameters are usually required to achieve reasonable predictions
including mechanical removal, thermal insulation, chemical at field scale due to the large uncertainties associated with field
treatment, etc. need to be implemented to address the wax operations.9,10 Continuing efforts have been dedicated to
deposition issue during production.2 The design of these wax improving wax deposition modeling capabilities, especially
remediation techniques, such as the pigging operation, is a upscaling from laboratory-scale predictions to field applications.
nontrivial task. It should be noted that frequent pigging will 1.2. Non-Newtonian Characteristics of Waxy Crude Oil.
generate significant operational costs while insufficient pigging A dynamic yield stress and shear thinning characteristics can be
will lead to thick and hard deposits that are impossible to observed for waxy crude oils when the temperature is below the
remove.3 Therefore, determination of a proper pigging frequency WAT. Such unique non-Newtonian characteristics originate
is crucial to sub-sea oil production. Determination of a proper from the precipitation of wax at temperatures below the WAT
pigging frequency relies on estimated wax deposition and aging and the resulting wax-in-oil suspension. The complex rheology of
rates during the design phase of oil field development. Wax waxy crude oil below the WAT has been extensively studied.11−15
deposition is a process depending on various parameters, These investigations show that various constitutive equations,
including the oil flow rate, oil and ambient temperatures, shear including the Cross model,16 the Casson model,17 and the
stress, oil composition, and so on.4 In order to investigate the Herschel−Bulkley model,18 can usually be used to fit the non-
effects of the interplay between these parameters on the wax Newtonian flow curves of waxy crude oils. Furthermore, it has
deposition rate, wax deposition models need to be constructed. been found that the non-Newtonian rheology of waxy crude oil
Academic wax deposition models have been developed on the has a significant impact in the modeling of pipeline restart.19,20
basis of the mechanism of molecular diffusion.1 Virtually all
exiting wax deposition models simulate the heat loss of the oil Received: February 18, 2017
flow to the ambient and the radial diffusion of wax in order to Revised: March 24, 2017
predict the wax deposition rate in pipelines.5−8 A majority of the Published: March 27, 2017
Unfortunately, the role of non-Newtonian fluid characteristics of the wall shear stress of both Newtonian and non-Newtonian
waxy crude oil in wax deposition modeling is not well- fluids can be analytically derived as a function of the pipe
understood. The next subsection discusses the steps involved diameter, the flow rate and the rheological parameters of the fluid
in wax deposition modeling and the potential roles of non- of interest. However, transportation of crude oil in sub-sea
Newtonian fluid characteristics in these steps. pipelines usually occurs in turbulent flow regime. Therefore, it is
1.3. Wax Deposition Modeling Considering Non- imperative to establish reliable methods to calculate the wall
Newtonian Fluid Mechanics. A wax deposition model shear stress for industrial-scale field pipeline transporting waxy
consists of three steps: (1) hydrodynamic calculations and (2) crude oils. At temperatures above the WAT, a waxy crude oil
heat and mass transfer calculations, which then allow for (3) behaves as a Newtonian fluid23 and the calculation of wall shear
calculation of the deposit thickness. The hydrodynamic stress for Newtonian turbulent pipe flow can be readily achieved
calculation predicts the pressure drop along the pipeline. using a friction factor correlation such as the one by Blasius,24
Pressure drop predictions can be used to compare with the shown in eq 1.
measured pressure drop in experiments/field operations to
benchmark the wax deposition model. In addition, hydro- fD = 0.316Re−1/4 (1)
dynamic calculations predict the radial velocity profile and the
eddy momentum diffusivity to be used in the subsequent heat where
and mass transfer calculations. Heat and mass transfer
calculations simulate the heat loss from oil to the surroundings fD = Darcy friction factor
and the radial molecular diffusion of wax, followed by
calculations of deposit growth and aging. These steps in the Re = Reynolds number
wax deposition modeling algorithm need to be enhanced to
capture the non-Newtonian characteristics of waxy crude oil. The wall shear stress can then be calculated using the friction
Benallal et al. and Zheng et al. first attempted to model wax factor defined in eq 1:
deposition with non-Newtonian fluid mechanics in laminar flow
regime.21,22 In this investigation, we analyzed non-Newtonian ρoil U 2
turbulent characteristics to enable turbulent applications such as τwall/interface = fD
8 (2)
industrial-scale pipe flow.
The following section, i.e., section 2, discusses two existing where
numerical techniques, including large eddy simulation (LES) and
Reynolds-averaged Navier−Stokes (RANS) simulation, for:
τwall/interface = shear stress imposed by the fluid at
• hydrodynamic modeling to calculate the shear stress at the
wall/deposit‐fluid interface (Pa)
wall/deposit-fluid interface as well as the radial velocity
profile and eddy diffusivities ρoil = density of the oil (kg/m 3)
• heat and mass transfer modeling
U = superficial velocity of the oil (m/s)
Predictions from the theoretically advanced LES are used as
benchmarks to assess the more commonly used RANS. It was
Unfortunately, methods to calculate the wall shear stress of
found that RANS cannot be used to model non-Newtonian
turbulent non-Newtonian pipe flows are not well-established.25
turbulent flow.
The most common approach is to calculate the shear stress at the
In section 3, we will develop a method to model hydro-
wall on the basis of friction factors correlations. However, friction
dynamics, heat transfer, and mass transfer by adapting the law of
factor correlations are available only for non-Newtonian fluids
the wall method. The predictions from the modified law of the
whose flow curves follow simple rheological models such as the
wall agree well with those from LES. Section 4 discusses the
power law model26,27 and the Herschel−Bulkley model.28,29 The
modeling of wax deposit formation based on first principles of
complexity of the rheological behavior of a waxy crude oil can be
the rheology of waxy oil. It should be noted that this workflow
developed for non-Newtonian flow, heat and mass transfer beyond these classical rheological models.11,30 Friction factor
modeling is based on single-phase oil flow. Extension of the correlations for non-Newtonian fluids with complex rheological
methodology to multiphase flow regimes is beyond the scope of behaviors do not exist at this time. In addition, different friction
this investigation. Finally, the wax deposition model developed factor correlations can give drastically different predictions for
by combining findings from sections 2−4 will be applied to the wall shear stress, even for the same non-Newtonian fluid.
simulate deposit build-up in a real-world field pipeline, discussed Under extreme conditions, the prediction of the wall shear stress
in section 5. obtained from one correlation can be twice as high as the
prediction from another correlation.25 Therefore, it is imperative
2. HYDRODYNAMIC MODELING WITH to develop reliable methods to model the hydrodynamics of non-
Newtonian turbulent pipe flow.
NON-NEWTONIAN CHARACTERISTICS
The turbulent characteristics of non-Newtonian pipe flow can
The hydrodynamic calculations will predict the pressure drop be modeled from first principles with direct numerical simulation
and the radial velocity profile as well as the eddy momentum (DNS). This simulation can be achieved by numerically solving
diffusivity. The pipeline pressure drop, or equivalently, the shear the Navier−Stokes equations, shown in eq 3.
stress at the pipe wall/deposit-fluid interface, is a critical
parameter for pipeline design. Moreover, as will be discussed ∂U
in section 4, the prediction of the deposit growth rate is achieved ρoil + U ·∇U = −∇p + ∇·τ
∂t
by comparing the shear stress imposed by the fluid and the
dynamic yield stress of the deposit. In the laminar flow regime, = −∇p + ∇·μ[∇U + (∇U)T ] (3)
Figure 1. Snapshot of the instantaneous velocity magnitude generated from turbulent non-Newtonian pipe flow simulation performed with rheological
parameters at location 3.
Figure 3. Predicted radial profile of temperature/concentration with Moreover, the nonfluctuating velocity profile predicted by LES
RANS and LES. corresponds well with the analytical solution for the radial
velocity profile of laminar Herschel−Bulkley fluid pipe flow. It
A dimensionless number, Δ, characterizing the relative rate of should be noted that a plug is predicted in the center region of the
convective and diffusive transfer, defined in eq 7, is also pipe. Different from the artificial “plug” predicted due to
calculated on the basis of the temperature/concentration profiles numerical artifacts associated with RANS, this plug in laminar
predicted by RANS and LES, respectively. Note that Δ is flow can be observed in laminar pipe flow experiments.38
identical to the Nusselt number in the context of heat transfer It should be noted that being able to capture the transition
and Sherwood number for mass transfer. from turbulent to laminar flow along the axial direction is critical
∂ϕ
in the modeling of heat and mass transfer as turbulent flow has
h D − ∂r |wall D significant lower heat/mass transfer resistance than laminar flow.
Δ = int = In order to understand the impact of flow regime prediction on
Γ ϕbulk − ϕwall (7) heat and mass transfer modeling, two heat transfer simulations
where were performed with (Case 1) a Newtonian viscosity model and
(Case 2) a non-Newtonian viscosity model. Table 1 shows the
Δ ≡ Nu, Nusselt number for heat transfer parameters used in these two simulations.
Δ ≡ Sh, Sherwood number for mass transfer
Table 1. Input Parameters for Heat Transfer Simulation with
h int = internal convective transfer coefficient (m/s) Newtonian and Non-Newtonian Approaches
D = pipe diameter (m) Case 1 Case 2
approximately 700% over-estimation in the internal heat transfer This friction factor correlation is first utilized to predict the
coefficient is observed by neglecting the transition from flow regime. The transition point is defined as the intersection of
turbulent to laminar discussed above. This over-estimation can the wall shear stress−mean velocity relationship generated by
translate into an over-estimation in the rate of heat transfer. As a assuming laminar and turbulent flows, respectively. The
result, it is essential to incorporate the modeling of non- rheological parameters taken at location 5 of the pipeline were
Newtonian fluid mechanics in wax deposition modeling. used to generate an example for the flow pattern prediction,
shown in Figure 5.
3. A COMPUTATIONALLY EFFICIENT METHOD FOR
HYDRODYNAMIC MODELING TO BE USED IN WAX
DEPOSITION MODELING
As was discussed in the previous section, neither LES nor RANS
can be applied to model wax deposition in a pipeline. LES is
unacceptably time-consuming, and RANS can generate numer-
ical artifacts. Therefore, it is imperative to develop a reliable and
computationally efficient method to predict the wall shear stress,
velocity, temperature and concentration profiles to be used to
predict wax deposition. This desired method should be able to
capture the flow characteristics uncovered by LES simulations,
recapitulated below:
• a flow pattern that can transit from turbulent to laminar
flow due to the increase in viscosity
• a plug in the near center line region that can be expected in
the laminar flow regime but is likely to be broken up by Figure 5. Prediction of wall shear stress based on the laminar and
turbulent eddies in the turbulent flow regime turbulent Chilton−Stainsby friction factor correlations and the
• a laminar boundary layer that can be observed in the definition of the onset for turbulent−laminar transition.
vicinity of the wall in the turbulent flow regime, while the
local velocity fluctuates with time outside this boundary A sensitivity analysis was also performed to understand the
layer effect of rheological parameters, τy, n, and K, on the prediction of
We now propose a reliable and computationally efficient laminar−turbulent transition. It was found that the transition
method to perform hydrodynamic, heat transfer, and mass occurs at a higher mean velocity with larger values of τy and K and
transfer modeling of non-Newtonian pipe flow. This method with smaller values of n. Details with respect to this sensitivity
consists of three steps: analysis are included in Appendix G.
Table 2 shows the flow pattern predictions (laminar or
• prediction of flow regime
turbulent) based on the Chilton−Stainsby friction factor
• calculation of velocity profile
correlation as well as predictions by LES.
• calculation of turbulent diffusivity for heat and mass
transfer modeling
Table 2. Predictions of Flow Regime with LES and Chilton−
These three steps will be discussed individually in the three Stainsby (C-S) Friction Factor Correlation
subsections to follow.
3.1. Prediction of Flow Regime. Chilton and Stainsby flow pattern
developed a friction factor correlation that can predict the wall location LES C−S axial location (% total length)
shear stress based on the fluid rheological parameters, the 1 turbulent turbulent 0
pipeline diameter and the flow rate,29 shown in eq 8. 2 turbulent turbulent 16
⎡ R ⎤−0.25 3 turbulent turbulent 21
fHB = 0.079⎢ 2 HB 4 ⎥ 4 laminar laminar 38
⎣ n (1 − X ) ⎦ (8) 5 laminar laminar 55
where
ρoil UD 3.2. Calculation of Velocity Profile. For the laminar flow
RHB = regimes, an analytical solution for the velocity profile and
μwall ( 3n4+n 1 )( 1 − aX −1bX − cX )
2 3 pressure drop can be obtained. Therefore, we will now focus on
developing a computationally efficient approach for the hydro-
τy 1 2n dynamic modeling of turbulent flow. In this subsection, we will
X= , a= , b= ,
τwall 2n + 1 (n + 1)(2n + 1) explore modifications of the conventional law of the wall that are
necessary in order for it to be applicable to non-Newtonian pipe
2n2 flow. The conventional law of the wall can be expressed with eqs
c=
(n + 1)(2n + 1) 9 and 10.
fHB = friction factor for a Herschel−Bulkley fluid ⎧ y+ y+ ≤ 5
⎪
⎪
RHB = Reynolds number for a Herschel−Bulkley fluid U z+ = ⎨ 5 ln y+ − 3.05 5 < y+ ≤ 30
⎪
⎪ 2.5 ln y+ + 5.5 y+ ≥ 30
μwall = viscosity of oil at wall (Pa·s) ⎩ (9)
Figure 13. (a) Evolution of solid volume fraction in the immediate vicinity of the wall. (b) Evolution of dynamic yield stress of wax-in-oil suspension in
the immediate vicinity of the wall to the point of deposit formation.
Figure 14. Comparison between the predicted pressure drop evolutions and that observed in field.
Figure 13a shows the predicted increase of the solid volume 5. APPLICATION OF THE ENHANCED WAX
fraction in the oil in the immediate vicinity of the wall in a field- DEPOSITION MODEL ON A FIELD-SCALE PIPELINE
scale simulation. In order to calculate the change of dynamic The enhanced wax deposition model is applied to predict wax
yield stress as a function of time, the solid volume fraction at each deposition in a real-world field-scale pipeline off the shore of
time step shown in Figure 13a is entered into the relationship Indonesia.9 This pipeline transports waxy crude oil from a central
between the dynamic yield stress and the solid volume fraction. processing platform to floating production storage offloading.
The relationship between the dynamic yield stress and the solid The sub-sea pipeline has an inner diameter of 12 in. and a length
volume fraction was obtained by fitting of the viscosity− of 23 km. The pressure drop across the entire pipeline is
temperature curves measured at different shear rates using the monitored over the production period. It was observed that wax
Herschel−Bulkley equation. The increase in the dynamic yield deposition causes the pressure drop to increase from ∼200 to
stress of the wax−oil suspension is shown in Figure 13b. This ∼300 psi over a production period of 7 days.9 Detailed
field-scale simulation will be described in detail in the following description of this field as well as the monitored operating
Section 5. variables, such as flow rate, temperature, and pressure drop can
As can be seen from Figure 13a, the solid volume fraction of be found in the article by Singh et al.9 The simulation parameters
the wax-in-oil suspension in the immediate vicinity of the wall and configurations are summarized in Appendix I.
continuously increases as time elapses due to accumulation of The wax deposition model is first used to calculate the pressure
drop along the pipeline without wax deposit attached to the pipe
solid wax, leading to a continuous increase in the dynamic yield
wall. The calculated pressure drop, 180 psi, corresponds well with
stress of the solid−liquid suspension, shown in Figure 13b. This
the pressure drop recorded right after pigging, ∼200 psi, thereby
layer gels to form a deposit when the dynamic yield stress reaches validating the hydrodynamic calculation. The heat transfer
or exceeds the shear stress imposed by the fluid at the interface of simulation predicts an average outlet temperature of 30 °C,
∼3.5 Pa. which corresponds well with the field observation of an outlet
At this point, the modeling of hydrodynamics, heat transfer, temperature varying from 27 to 29 °C during production.9 Wax
and mass transfer as well as the deposit formation was enhanced deposition modeling was then performed after the hydrodynamic
with non-Newtonian fluid mechanics. In the following section, and heat transfer calculations were validated by comparison
the enhanced wax deposition model will be applied on a real- between predictions and field observations. Figure 14a shows the
world field-scale pipeline. predicted pressure drop−time trajectory by assuming two
5020 DOI: 10.1021/acs.energyfuels.7b00504
Energy Fuels 2017, 31, 5011−5023
Energy & Fuels Article
Table 3. Summary of Non-Newtonian Model Predictions and shown in Table 3. Figure 15 shows the predicted average wax
Field Observations deposit thickness over the entire length of the pipeline as well as
the axial deposit thickness profile.
field
prediction observation It should be noted that predictions such as those shown in
pressure drop right after pigging (psi) 180 200
Figure 15 are virtually impossible to measure in a field-scale
pressure drop with Newtonian approach (psi) 160 200
pipeline. Therefore, such insights on the average deposit
pipeline outlet temperature (°C) 30 27−29
thickness evolution and the axial deposit thickness profile are
deposit wax content (wt%) 24 27 ± 2
extremely valuable for pigging design. In order to highlight the
difference between the Newtonian and non-Newtonian wax
deposition models, the change of pressure drop as a function of
limiting scenarios for the bulk precipitation kinetic constant, i.e., time as well as the axial deposit thickness profile were generated
the Chilton−Colburn approach9 and the solubility approach.43 with the Newtonian wax deposition model, shown in Figure 16.
As can be seen from Figure 14a, the Chilton−Colburn analogy It should be noted that exact same input parameters, except the
significantly over-predicts the pressure drop build-up rate while viscosity, used for wax deposition modeling with the non-
the solubility method is more representative for the bulk Newtonian model are also used in the Newtonian model. An
precipitation kinetics in this field-scale simulation. The bulk Arrhenius temperature dependency was used for the viscosity in
precipitation kinetic constant is adjusted to achieve agreement the Newtonian model without the consideration for the increase
between the predicted pressure drop−time trajectory and that in viscosity due to suspended solid.
observed in the field, shown in Figure 14b. As can be seen from As can be seen from Figure 16a, the Newtonian model
Figure 14b, the predicted pressure drop matches the observed significantly under-estimates the pressure drop increase over
pressure drop evolution with an adjusted bulk precipitation time due to the under-estimation in the viscosity. Misinter-
kinetic constant of 2 × 10−2 s−1. This value is consistent with the pretation of this under-estimation of the pressure drop build-up
range of bulk precipitation kinetic constant reported by Lee et al., generated from the Newtonian model can lead to overly
i.e., 10−2−1 s−1.44 It is noticed that the predicted starting pressure optimistic assessment of the wax deposition risk. As can be
drop is slightly lower (10%) than the observed pressure drop. seen from Figure 16b, the Newtonian model also significantly
This discrepancy is likely due to the fact that a certain amount of under-predicts the deposit thickness. This under-estimation is
wax deposit remains attached to the pipeline after the pigging, due to the fact that the Newtonian model assumes the solid
therefore leading to a higher pressure drop right after the pigging fraction of the deposit to be always greater than total wax content
than the pressure drop associated with a completely bare of the oil, i.e., 17 wt% for this particular crude, while based on
pipeline. This enhanced wax deposition model is the first model analysis from rheology, it takes only ∼6 wt% of solid wax to
that can generate reasonable field predictions from first principles immobilize the wax-in-oil suspension and form a deposit.
of fluid mechanics, transport and rheology. The enhanced wax
deposition model predicts a wax content of 24 wt%, which
6. CONCLUSIONS
corresponds well with the wax content of the pig return deposit,
i.e., 27 ± 2 wt%. Table 3 summarizes the comparisons between In this investigation, we assessed the role of non-Newtonian
predictions and field observations. characteristics on wax deposition modeling. Non-Newtonian
As can be seen from Table 3, excellent agreement between the hydrodynamics as well as heat and mass transfer modeling were
model predictions and field observations of pressure drop, investigated with large eddy simulations (LES). With LES, the
temperature as well as the wax content presented in this section effects of non-Newtonian turbulent characteristics on hydro-
indicate that the enhanced wax deposition model can provide dynamics as well as heat and mass transfer models were studied
wax deposit predictions with a high level of confidence. If the from first principles. The computational cost of applying LES to
Newtonian approach is used to predict the pressure drop right model wax deposition in a field-scale pipeline was calculated. It
after pigging, a more severe under-prediction can be observed, as was discovered that LES is too computationally intensive for the
Figure 15. (a) Predicted average deposit thickness evolution over a production period of 7 days. (b) Predicted axial deposit thickness profile after 7 days
of production.
Figure 16. (a) Comparison between the pressure drop−time trajectories predicted by non-Newtonian and Newtonian approaches. (b) Comparison
between the axial deposit thickness profiles predicted by non-Newtonian and Newtonian approaches.
■
of the flow.
Key point 5: The modified law of the wall approach can ACKNOWLEDGMENTS
generate rapid and accurate predictions for the velocity profile,
The authors would like to thank Total for the permission to
temperature and concentration profiles. Therefore, the modified publish this work. The authors acknowledge financial support
law of the wall approach is used for wax deposition modeling. from the University of Michigan Industrial Affiliates Program
The enhanced wax deposition model is applied to predict wax sponsored by Assured Flow Solutions LLC, Chevron, Con-
deposition in a real-world field-scale pipeline. The wax ocoPhillips, Multichem a Hallibruton Service, Phillips66, Statoil,
deposition model generates reliable predictions for the increase and Total. The authors would also like to thank Prof. Ronald G.
of pressure drop due to deposit build-up over time, the Larson for the helpful discussion during the preparation of this
manuscript.
■
temperature at the outlet of the pipe as well as the wax content
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