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Formulation of Water in Paraffin Emulsions: Latin American Applied Research - An International Journal April 2011
Formulation of Water in Paraffin Emulsions: Latin American Applied Research - An International Journal April 2011
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Carlos Morales,
Ulrich Riebel, riebel(at)b-tu.de
1 INTRODUCTION
A B 1 , (1)
η is the so-called apparent viscosity that would indicate
the resistance to flow under some specific conditions;
Emulsions world is wide enough. In Venezuela there are
more than 11,000 lagoons of waste oil emulsions. Due is the shear rate; A is called Consistency Index and B
to environmental regulations, these materials require Power Law Index. The viscosity increases within the
processing and/or disposal, but their characteristics and internal phase content. Many studies have reported
properties are quite variable. The problem has been empirical relationships to describe this behavior (Becher
extensively handled by petroleum engineers with little et al., 1974; Becher, 1977; Becher, 1982; Shinoda and
success and the existence of a single approach for the Aria, 1964; Arai and Shinoda, 1967; Shinoda et al.,
treatment and separation is far from possible. 1985; Bourrel et al., 1980; Antón et al. 1997), but none
The extraordinary stability of these waste oil emulsions of them are valid in the general case, because many
is due to a combination of high viscosity, low density other effects, as the non-Newtonian behavior, have to be
difference, and presence of solids and natural considered as well (Shinoda et al., 1990; Graciaa et al.,
emulsifiers in part formed by the oxidation of crude oil 1984).
components during the ageing process. Griffin (1949) introduced the Hydrophilic-Lipophilic
The scope of this work was to develop highly stable Balance or HLB concept, which is a surfactant
synthetic emulsions with reproducible properties, characteristic parameter used as a measure of the
serving as a model to study several techniques for relative affinity of the surfactant for the water and oil
emulsion destabilization that could be also used in crude phases. The HLB concept has been extensively used
oil emulsions. Although comparisons between synthetic (Davies, 1957; Lin, 1980; Becher and Griffin, 1970;
and crude oil emulsions is not the objective of this Becher et al., 1974; Becher, 1982; Becher, 1996). For
work, ranges of water content, density and viscosity of cost and efficiency reasons, a mixture of several
synthetic emulsions are in agreement with the available surfactants is generally used as emulsifier.
data of the crude oil emulsion samples.
The effect of different variables was studied in one-
dimension scans and as result, an emulsion providing 3 MATERIALS AND METHODS
emulsions with maximum stability is obtained.
Surfactant suppliers maintain that to obtain a W/O
emulsion, the HLB value should be between 4 and 6,
1
approximately. Therefore, a mixture of Sorbitan Vw + Vp + Ve) (see Fig. 1-c). The emulsions with
Monooleate (Span 80®) with a HLB=4.3 and acceptable stability were defined as those in which the
Nonylphenol Polyglycol Ether 4 EO (Arkopal N 040®) total separation was lower than 10% in 30 days.
with a HLB=8.7 (both highly soluble in oil), were used. The emulsion type was inferred by observing what
Paraffin and surfactants were mixed. Then, distilled happened when a drop of each emulsion was added to a
water was added slowly (using a burette) during 5 volume of either pure paraffin or pure water.
minutes, while it was mixed with a Braun stirrer model After finishing the experimental tests, the formulation to
MR-5550, at 13400 rpm. After adding all the water, the produce the most stable emulsion for each water content
components were mixed for 5 more minutes. 100 mL of was defined. The emulsions were prepared in triplicate
emulsion (water plus paraffin) were prepared in each to validate the reproducibility of the proposed
run in a 600 mL volumetric flask (see Fig. 1-a and 1-b). formulation protocol. Emulsions density and apparent
viscosity were experimentally determined. The density
(a) was calculated from the ratio between the emulsion
weight and volume and the apparent viscosity was
measured with a LVF model Brookfield dial reading
viscometer. For the viscosity measurement, it was
necessary to prepare batches of 500 mL emulsion.
Apparent viscosity was fitted by the power law;
therefore, parameters A and B were obtained from a plot
of apparent viscosity as a function of shear rate. A
polynomial adjustment of A and B, was obtained as a
function of water content.
(b)
Experimental plan
One-variable scan was used to study the effect of the
main variables on the emulsion properties. The
variables and ranges were: surfactant content (0.5 - 10%
v/v), water content (25 - 75% v/v), HLB value (4.5 -
6.5), alcohol content (Octanol 0 - 4% v/v), salinity (0 -
16 g/dL water), mixing velocity (6100 - 13400 rpm),
mixing time (5 -20 min), mixing type (continuous or
intermittent), and batch emulsion volume (50 – 500
mL). Finally, emulsions with Sodium Dodecyl Sulphate
(c ) were also formulated to allow comparison between a
nonionic and an ionic surfactant. The range of variation
Separated paraffin (Vp) of each parameter was established taking into account
theoretical considerations, previous experience in
formulation and available capacities and resources.
All tests were carried out at room temperature (25±1
°C). Surfactant and co-surfactant content are given in
Emulsion (Ve) relation to the water plus paraffin volume. Salinity is
given as NaCl in water. Mixing time is defined after all
water addition. Surfactant mixtures HLB values were
calculated from the Span 80® and Arkopal N040® HLB
Separated water (Vw)
values assuming ideal mixture behavior.
S e p a ra tio n (% )
of 4.0 and 8.0 %v/v. 50
40
10
9 30
8 20
S e p a ra tio n (% )
7
10
6
5 0
4 0 10 20 30
3
2
Time (days)
1
0 70
0 5 10 15 20 25 30 60
T im e (d a y s) S e p a ra tio n (% )
50
40
Figure 2. Surfactant Content Effect on Emulsion
Stability. fw = 0.50, HLB = 5.5 with a mixture of Span 30
80® and Arkopal N 040®, vm = 13400 rpm, tm = 5 min., 20
T = 25°C. Cs = 0.5-10% v/v: () 0.5%, () 1.0%, () 10
1.5%, 2.0 (), (+) 4.0%, () 8.0%, () 10.0%
0
Although the highest stability was obtained for 0 10 20 30
surfactant content of 10% v/v, the most appropriate Time (days)
formulation value should also take into account the
costs; therefore, a surfactant content of 2% v/v was Figure 3. HLB Effect on Emulsion Stability. fw =
selected for the rest of the formulations. In practical 0.25 (above) and fw = 0.50 (below), Cs = 2% v/v, vm =
applications, a surfactant concentration between 0.2-3% 13400 rpm, tm = 5 min., T = 25°C. HLB = 4.5-6.5 with
is used, which corresponds with our selection. a mixture of Span 80® and Arkopal N 040®: () 4.5,
Stability of the emulsions can be explained based on () 5.0, () 5.5, () 6.0, () 6.5
surfactant concentration which is, in all cases, above the
mixture critical micelle concentration and the surfactant
solubility. The CMC of pure Span 80 at room
temperature, for example, is 0.026% w/v (Foyeke et al.,
HLB = 6.5
HLB = 4.5
HLB = 5.0
HLB = 5.5
HLB = 6.0
1998).
The second variable studied was the surfactant HLB. A
range of HLB from 4.5 to 6.5 was selected. Outside this
range W/O emulsion stability is very low or the
formulation results in a O/W emulsion. HLB describes
the surfactant affinity to the water and oil phases, and its
influence on emulsion stability depends strongly on the
volumetric proportion of the phases. Three scans of
HLB were made for emulsions with water contents of
fw = 0.25, 0.50 and 0.75, respectively.
Figures 3 and 4 show HLB effect on emulsion stability.
In these tests, not all the emulsions were stable enough.
In some cases a separation up to 60% was obtained
within 30 days after preparation.
3
70 6100 rpm. Separation decreases from 6% at 13400 rpm
to 4% at 9500 rpm. Reduction in mixing velocity is
60
favorable not only in terms of stability, but also in
S e p a ra tio n (% )
50 operational cost. Two other stirrers with velocities up to
40 2000 and 4000 rpm, respectively, were tested before
30 selecting the Braun stirrer model MR-5550, but in both
20 cases emulsion stability was not satisfactory. Figure 6-b
shows the mixing time effect on emulsion stability. The
10
best results were obtained for 5 and 10 minutes of
0
agitation, but for 10 minutes both coalescence and
0 10 20 30 sedimentation were observed.
T im e (d a y s ) Figure 6-c shows the mixing type effect on emulsion
stability. During the first 25 days, all three emulsions
Figure 4. HLB Effect on Emulsion Stability. Picture showed approximately the same stability; however, after
after 30 days. fw=0.75, Cs = 2% v/v, vm = 13400 rpm, 30 days, a lower separation was obtained with the
tm = 5 min., T = 25°C. HLB = 4.5-6.5 with a mixture of intermittent mixing at variable velocity.
Span 80® and Arkopal N 040®: () 4.5, () 5.0, ()
5.5, () 6.0, () 6.5
With the HLB scan, at least one emulsion with high
(a) fw = 0.25
stability was obtained for low, medium and high water
content, but the study of new variables could lead to an 100
improved formulation and would help to understand the
variables which exert higher influence on stability. HLB 80
S e p a ra tio n (% )
scans were repeated with 2% Octanol dissolved in the 60
paraffin before adding the water. Octanol does not act as
good co-surfactant, and in all cases the stability is 40
reduced when alcohol is used, observing both 20
coalescence and sedimentation.
Figure 5 summarizes alcohol content effect on emulsion 0
stability for HLB = 5.5 and fw = 0.25, 0.50 and 0.75. 0 10 20 30
The higher the water content and/or the Octanol content,
the lower the emulsion stability with coalescence. T im e ( d a y s )
Reduction of emulsion stability with sedimentation can
be explained by a change in the required hydrophilic- (b) fw = 0.50
lipophilic balance in presence of Octanol. The higher 100
the fw the higher the octanol dissolved in the oil (for the
same alcohol content on the total emulsion), that 80
S e p a ra tio n (% )
S e p a ra tio n (% )
80
S e p a ra tio n (% )
10
60 8
6
40
4
20 2
0 0
0 10 20 30 0 10 20 30
Time (days)
T im e ( d a y s )
Figure 6. Mixing Conditions Effect on Emulsion
Stability. fw = 0.50, HLB = 5.5 with a mixture of Span
80® and Arkopal N 040®, Cs = 2% v/v, T = 25°C. (a):
Co = 2% 2% Octanol
= 4% 4% Octanol
Co = 4% 4% Octanol
fw=0.50, 0% Octanol
Co = 2% 2% Octanol
Co = 0%
Co = 2%
Co = 4%
Effect of mixing velocity with continuous mixing for 5
min: () 6100 rpm, () 9500 rpm, () 13400 rpm.
(b): Effect of mixing time with continuous mixing at
13400 rpm: () 5 min, () 10 min, () 20 min. (c):1
fw=0.25,
fw=0.50,
Co = 0%
fw=0.25,
fw=0.50,
12
10
8
6
4
2
0
0 10 20 30 1
Intermittent I: 5 min at 13400 rpm + 5 min pause + 5
T im e (d a y s ) min at 13400 rpm, Intermittent II: 5 min at 8000 rpm +
5 min pause + 5 min at 13400 rpm
(c)
5
7
6
Separation (%)
5
4
3
2
100 mL
250 mL
500 mL
1
50 mL
0
0 10 20 30
16 Time (days)
14
Figure 8. Emulsification Protocol Validation. W/O
S e p a ra tio n (% )
12
10 emulsions stabilized by a Span 80 ® and Arkopal N 040®
mixture, Cs = 2% v/v, vm = 9100 rpm, tm = 5 min., T =
8 25°C. fw: () 0.25, () 0.50, () 0.75
6
4 Emulsion properties
2 All the emulsions formulated with Span 80® and
0 Arkopal N 040® were W/O type. This behavior is in
agreement with the theoretical background, since the
0 10 20 30
HLB values used were between 4.5 and 6.5. In this case,
T im e (d a y s) the surfactant is highly soluble in the oil phase and this
affinity favors the formation of W/O emulsion. The
Figure 7. Batch Volume Effect on Emulsion average surface diameter of the droplets was obtained
Stability. Picture after 30 days. fw = 0.50, HLB = 5.5 by microscopy (Morales et al., 2008) and varies
with a mixture of Span 80 ® and Arkopal N 040®, Cs = between 3 and 6 microns, but it could not be determined
2% v/v, vm = 13400 rpm, tm = 5 min., T = 25°C. Batch in all cases.
Volume: () 50 mL, () 100 mL, () 250 mL, () Emulsion density was measured in all tests. Density
500 mL values varied from 840 to 930 kg/m 3 (measured at 38
°C), basically depending on the water content. The
The ionic surfactant sodium dodecyl sulphate was also influence of surfactant content, HLB, Octanol content
tested. A salinity scan in the range from 0 to 16 g and water salinity on density was not considerable, and
NaCl/dL water was made, for fw = 0.25 and 0.50. In mixing conditions did not affect density.
both cases emulsions were unstable. For fw =0.25 the Figure 9 shows water content effect on emulsion
phase separation was complete within few hours, viscosity. Viscosity depends on the shear rate,
whereas for fw = 0.50 the emulsions were highly foamy indicating that the emulsions are pseudoplastic fluids:
and O/W type. the higher the shear rate, the lower the apparent
viscosity. The experimental points demonstrate that
Emulsification Protocol increasing the water content produce a more
After the scans were made, the emulsification protocol pseudoplastic emulsion. For a constant shear rate,
was fixed as follows: 250 mL emulsions were prepared apparent viscosity depends strongly on the water
at 9500 rpm during 5 minutes. Reproducibility and total content; for a shear rate of 0.63 s-1, for example,
phase separation lower than 10% was ensured. To apparent viscosity increases from 200 to 30000 cP,
validate the proposed protocol each emulsion was when water content changes from 25 to 75% v/v.
prepared in triplicate and the stability was evaluated Although the viscometer operational range is up to 60
during a month. Average standard deviations in the s-1, this study includes only measurements up to 6 s -1,
separation were ±0.28, ±0.25 and ±0.14% for the according to the available data for crude oil emulsions
samples of fw = 0.25, 0.50 and 0.75, respectively. for future comparisons.
Figure 8 shows the validation results. At low water content, drops are too far apart to interact
among each other and the only interaction beyond the
homogeneous fluid case is that of each drop with its
surrounding fluid. When the number of drops increases,
drop-drop interactions become predominant, and the
resulting frictional effects drive the viscosity increase.
Apparent viscosity was fitted by the power law (see Eq.
1). Consistency index A[cP.sB-1] and Power Law Index
6
B[dimensionless] were calculated for each emulsion at Consistency Index A[cP.sB-1] and Power Law Index B
different water content values (see Table 1). were calculated from Eqs. 2 and 3, respectively.
100000 100000
10000 10000
V is c o s ity (c P )
V is c o s ity (c P )
1000 1000
100 100
10 10
20 30 40 50 60 70 80 0 2 4 6
-1
W a te r C o n te n t (% ) S h e a r R a te (s )
Figure 9. Water Content Effect on Emulsion Figure 10. Effect of Shear Rate on Apparent
Apparent Viscosity. W/O Emulsions Stabilized by a Viscosity. W/O Emulsions Stabilized by a mixture of
mixture of Span 80® and Arkopal N 040® .HLB = 5.5, Span 80® and Arkopal N 040® .HLB = 5.5, Cs = 2% v/v,
Cs = 2% v/v, vm = 13400 rpm, tm = 5 min, T = vm = 13400 rpm, tm = 5 min, T = 25°C. Symbols
25°C.Shear Rate γ: () 0.63 s-1, () 1.26 s-1, () 3.14 correspond to the experimental values and lines
s-1, () 6.28 s-1 correspond to the modeled ones, fw: () 0.25, ()
0.35, () 0.50, () 0.65, () 0.75
Table 1. Power Law Constants for water-in-oil
emulsion stabilized by Span 80® and Arkopal N 040® Octanol content and water salinity effect on apparent
Water Consistency Index, Power Law viscosity was also measured. Results are shown in
Content, fw A[cP.sB-1] Index, B Figures 11 and 12, respectively. The higher the alcohol
0.25 164.26 0.595 content, the lower the apparent viscosity; the opposite
0.35 522.62 0.429 effect is obtained for the water salinity, where the
0.50 1243.2 0.383 salinity effect is much stronger. The Octanol effect on
0.65 5391.1 0.293 emulsion viscosity can be explained by a reduction in
0.75 20300 0.226 the external phase viscosity.
In Figure 11, for a shear rate of 0.63 s -1 for example,
Our results agree with the general experience that viscosity diminishes by 200 cP when octanol content
demonstrates that the emulsion viscosity increases with increases from 2 to 4%, but when salinity increases
the internal phase content. Although many empirical from 8 to 16 g/dL (see Figure 12) viscosity increases by
relations have been proposed, their precision cannot be 800 cP. Although in this experiment the droplet size
determined since these equations do not take into could not be measured regularly for all salt
account the pseudoplastic behavior of the emulsion concentrations, a decrease in the average surface
which can be very significant for high fw values diameter xs from 5 microns to no detectable values was
(Salager, 1999). For this reason, a polynomial demonstrated. The reduction in droplet size and a
adjustment of A [cP.sB-1] and B [dimensionless], based probable narrow size distribution explain the increase in
on the internal phase content, is proposed, viscosity.
1800
A = 1691505.33fw4 – 2781930.33fw3 + 1600
1673741.30fw2 – 430342.25fw + 40001.21 (2) 1400
V is c o s ity (c P )
1200
B = 35.691fw4 – 78.541fw3 + 62.487fw2 – 21.719fw 1000
+ 2.2082 (3) 800
600
Thus, the apparent viscosity of fresh emulsions can be 400
determined with a model that simultaneously includes 200
the internal phase content effect and the emulsion 0
pseudoplastic behavior. 0 2 4 6
Figure 10 shows shear rate effect on apparent viscosity. -1
Experimental and modeled values are presented. S h e a r R a te (s )
Modeled values were obtained from the Power Law; Figure 11. Octanol Content Effect on Emulsion
Apparent Viscosity. W/O Emulsions Stabilized by a
7
mixture of Span 80® and Arkopal N 040®. HLB = 5.5, NOMENCLATURE
Cs = 2% v/v, fw = 0.50, vm = 13400 rpm, tm = 5 min., A consistency index (cP.sB-1)
T = 25°C, Co: () 0%, () 2%, () 4% B power law index (-)
Co octanol concentration (%v/v)
1400 Cs surfactant concentration (%v/v)
fw water fraction (-)
1200
HLB hydrophilic lipophilic balance
V is c o s ity (c P )
8
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