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Impact of Crude Oil Emulsion on Pipeline Corrosion

Article · October 2021

DOI: 10.36959/901/249

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Vol 1 | Issue 1 | Pages 11-19

Journal of Petrochemical Engineering

Research Article DOI: 10.36959/901/249

Impact of Crude Oil Emulsion on Pipeline Corrosion

CA Silva*, DRN Filho, MHA Zanin and Z Panossian
Technological Research Institute, Brazil Check for
updates

Abstract
The objective of this work is to study the effect of emulsion formation on steel corrosion in a sweet environment in a
laboratory scale. Field experience shows that improper sizing of pipelines in the petroleum industry is often caused by
a lack of understanding of three-phase flows which are characterized by a gas phase flowing together with a brine-oil
liquid phase. The emulsion formation in these systems plays an important role on the corrosion rates of steel pipelines.
Therefore, the corrosiveness and stability of the brine-oil mixtures with different water cuts are systematically studied.
The necessity to reduce costs in handling fluids requires a high flow rate with an inherent risk for turbulence influencing
the stability of the brine-oil mixtures and the corrosion process of steel pipes. These conditions occur especially in
offshore environments, in oil and gas productions, in chemical processes and in energy production industries. In previous
work, multiphase-flow-loop tests were conducted for thirty hours using a centrifugal pump for promoting a mixture of
20% of light oil crude oil or heavy crude oil + 80% of deionized water, containing 15% of sodium chloride, at 40 °C under
a CO2 partial pressure of 2.0 bar. In this work, emulsion tests were conducted with heavy, medium, and light crude oil
with a water cut of 80% at 40 °C for thirty hours, under 1200 rpm stirring, in the presence of CO2. The emulsion stability
evaluation was performed by Turbiscan Stability Index (TSI) based on multiple light scattering methods. A comparison
between the obtained results in the multiphase-loop and in the Turbiscan Stability Index (TSI) tests showed that the
higher emulsion stability contributed to the increase in the corrosion rates.

Keywords
Flow-induced corrosion, Emulsion systems, Pipeline corrosion, CO2 corrosion, Crude oil

Introduction Oil wells produce single-phase crude oil at first, but it is

common for water to occur after some time of production.
Emulsions are dispersions with one liquid phase in another The water content can be as high as 90% or more before
and can exhibit stability in the presence of surfactants, the well becomes uneconomical and is shut down. Under
macromolecules and solid particles adsorbed at the interface these conditions, the two liquids can form emulsions with
of both. At least two immiscible liquid phases must be present high viscosity. The result can be a gel with non-Newtonian
to form an emulsion. Therefore, it is important to know the properties, and its transportation can be as difficult as very
behavior of a system constituted by a surfactant and two viscous oil. Predicting whether such emulsions are likely
immiscible liquids, generally referred to as oil (O) and water to occur and evaluating whether they can cause serious
(W) [1-3]. There are three types of emulsions: water-in-oil problems typically involve both chemical analysis and flow
(W/O) emulsion, oil-in-water (O/W) emulsion and multiple calculations [5].
emulsions [2,4].
In general, there are two important factors that cause
In emulsion studies, the main attention is focused emulsion formation in the petroleum industry: turbulent
on interparticle forces or colloid interactions and on the flows and pressure changes in choke valves and other
emulsion stability, in terms of demulsification. The work valves during crude oil extraction. As a consequence, the
(thermodynamic) for emulsification can be defined as the
product between the interfacial tension and the variation of
the area generated by the process. This energy must remain *Corresponding author: CA Silva, Technological Research Insti-
stored for some time until the system follows the natural tute, 05508-901, Sao Paulo, Brazil
path of minimizing it by decreasing the interfacial area and Accepted: October 19, 2021
consequent destruction of the dispersion. Despite their
Published online: October 21, 2021
thermodynamic instability, many emulsions are kinetically
stable and do not change for long periods. This happens Citation: Silva CA, Filho DRN, Zanin MHA, et al. (2021) Impact
because the barrier potential which prevents aggregation of of Crude Oil Emulsion on Pipeline Corrosion. J Petrochem Eng
the particles is high [2]. 1(1):11-19

Copyright: © 2021 CA Silva, et al. This is an open-access article distributed under the terms of
the Creative Commons Attribution License, which permits unrestricted use, distribution, and S CHOLARS. D IRECT
reproduction in any medium, provided the original author and source are credited.

Open Access | Page 11 |

Citation: Silva CA, Filho DRN, Zanin MHA, et al. (2021) Impact of Crude Oil Emulsion on Pipeline Corrosion. J Petrochem Eng 1(1):11-19

cost of transportation and pumping of crude oil as well as °C for thirty hours, with stirring at 1200 rpm, in the presence
the corrosion risks of the crude-oil processing equipment of CO2. The emulsion stability evaluation was studied through
increase. This is one of the biggest problems in the petroleum tests performed by Turbiscan Stability Index (TSI) based on
industry, especially for mature oil fields for which water multiple light scattering methods. The obtained results were
quantity accompanying crude oil extraction is high [6]. compared with the results of corrosion tests performed in a
multiphase-flow loop described in a previous work [1] aiming
The presence of CO2 can change the properties of crude
at contributing to flow-induced corrosion (FIC) understanding.
oil. The solubility of CO2 in crude oil is often many times
greater than in water. The incorporation of CO2 can induce Methodology
an expansion in the volume of crude oil. The viscosity of
crude oil decreases enormously with increasing pressure and Multiphase-flow tests
temperature. It should also be noted that, in W/O emulsions,
The multiphase flow corrosion loop was built using UNS
a lower viscosity can lead to easier separation of phases a
S31603 austenitic-stainless steel tubes, with a nominal
condition that increases the risk of corrosion [7].
diameter of 38.10 mm for a working pressure of up to 10
In Brazil, about 20% of the oil reserves comprise heavy oil bar and temperature of up to 40 °C. The construction was
with a viscosity ranging from 20 cP to 400 cP under reservoir designed in order to make it possible to carry out simultaneous
conditions. The extraction of heavy oil is more complex and tests in the horizontal (0°) and in the 45° inclination direction
more expensive than that of light oil because the challenges [13]. API 5L X80 steel was used for the preparation of the
are greater; the refining is more difficult, and the generated corrosion-loop test specimens which were made with the
derivatives are of lower added value. A significant portion diameter dimensions of 15.90 mm by 9.5 mm in height. These
of Brazilian reserves is located in deep or ultra-deep waters. specimens were fixing in the test section according to Figure
A greater depth of the well tube can result in higher partial 1 [13] which shows more details of multiphase flow and the
pressure of CO2. Therefore, heavy oils associated with high pumping processes to which the mixture of water and oil
CO2 partial pressure may indicate a higher corrosion risk for (liquid phase) was subjected for thirty hours of testing.
pipelines and equipment of deeper wells [8].
The liquid phase for the test was composed of light oil
In this scenario, the flow assurance in production is (LO - 10 cP) or heavy oil (HO - 150 cP) and a saline solution
a crucial factor considering the high pressures and low containing 15% of NaCl. Water cut of 80% (WC 80) of the NaCl
temperatures. The main challenges are to reduce production solution and 20% of LO or HO under a CO2 partial pressure
losses by improving operational practices to properly handle of 2.0 bar was used. The procedure of the O2 removal from
highly viscous emulsions, hydrates and paraffin depositions. the liquid and gaseous phases is necessary to guarantee an
The characterization of W/O type emulsions is important to environment with no oxygen (< 10 ppb) and to promote the
improve the confidence in the predictions of the necessary tests under the action of CO2 gas.
pressures for the flow of emulsions formed mainly by heavy
and viscous oils. These problems are aggravated when the Emulsification tests
fields operate in low temperatures and reach mature ages
[9,10]. Tests were conducted with the light oil and the heavy oil
used in the multiphase-flow test plus a medium crude oil, all
In Oil and Gas industry, centrifugal pumps are widely of them with a water cut of 80% at 40 °C for thirty hours,
employed to lift fluids from wells to topside facilities. under stirring, with a CO2 pressure of 2.0 bar. For stirring the
Nowadays, it is estimated that approximately 10% of the oil mixture, an impeller with a rotation of 1200 rpm was used.
supply in the world is produced with centrifugal pumping The adopted stirring represents the mean values of the
installations. In these systems, the high shear and turbulence rotation of the electric motor of the centrifugal pump used in
also can promote the breakup of the phases into small the multiphase-flow corrosion loop [14,15].
drops, producing dispersions and emulsions which can be
O/W or W/O types [11]. Many variables can influence the Figure 2 shows the emulsion test cell (2) which holds up
emulsification process. For instance, the phase viscosity to 3 bar pressures. As can be seen, the cell is provided by gas
is an important factor since it is related to the efficiency of inlets and outlets (3) to perform conditions similar to those
the stirring process. It is well known that if the difference of observed in the loop with constant test gas pressure. The
the viscosity between the water phase and the oil is high, system pressure was checked by a manometer (1) and a rotor
the emulsification process could be considerably changed. with magnetic coupling (4) was coupled in order to transmit
A change in the phase viscosity ratio can produce a change 1200 rpm to the impeller mounted inside the pressure vessel
in an emulsion standard inversion line [12]. The increase which was manufactured from a borosilicate tube with Teflon
in emulsion viscosity is due to the large number of small flanges at both ends (2). For guaranteeing the efficiency of
water droplets often leading to increasing the cost of the O2 removal, an optical sensor (5) model Mettler Toledo In
operation condition [6]. By means of specific emulsification Pro6970i was used. A maximum limit of the oxygen of 10 ppb
tests, it is possible to better understand the phenomenology was adopted. A thermostat with an internal bath was used to
of emulsions [12]. This knowledge can be used for corrosion maintain the test temperature at 40 °C for thirty hours.
assessment and management of pipelines carrying brine-oil Emulsion microstructure characterization
mixtures. In this work, emulsion tests were conducted with
heavy, medium, light crude oils plus water cut of 80% at 40 The microstructures of obtained emulsions both in the

Silva et al. J Petrochem Eng 2021, 1(1):11-19 Open Access | Page 12 |

Citation: Silva CA, Filho DRN, Zanin MHA, et al. (2021) Impact of Crude Oil Emulsion on Pipeline Corrosion. J Petrochem Eng 1(1):11-19

Figure 1: Multiphase flow corrosion loop.

Figure 2: Emulsion test cell.

loop test and in the emulsion test cell shown in Figure 1 optical turbidimetry studies were performed based on a
and Figure 2 were obtained through a stereomicroscope multiple light scattering method by a TURBISCAN Lab Expert
examination (Leica Fusion Optics M205C). analyzer to monitor the optical properties which allow a more
reliable and accurate analysis. The Turbiscan takes readings
Analysis of emulsion instability by optical at various pre-programmed time intervals and superimposes
turbidimetry the curves on a graph to show the emulsion's destabilization.
In this work, the scans were scheduled to be done for one
As emulsions are thermodynamically unstable systems,
day for each hour continuously at 40 °C. The final result of
the dispersed phase can coalesce and flocculate. The
this analysis is presented by two different graphs, one by a
formed floccules can sediment or float at the surface. All
transmitted light (T) profile and the other by a backscattered
these processes directly influence the turbidity and the
light (BS) profile. A sample was previously collected from
opacity of the emulsion. In this case, it is important to define
the emulsion cell and placed in a quartz glass cell. The
which destabilization mechanisms are taking place. Thus,
measurements were done by scanning vertically the sample
immediately after the emulsification cell test is done, the
bottle up to the height of 50 mm, for 24 hours.

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Citation: Silva CA, Filho DRN, Zanin MHA, et al. (2021) Impact of Crude Oil Emulsion on Pipeline Corrosion. J Petrochem Eng 1(1):11-19

Figure 3: Corrosion specimens after the LO test performed in the multiphase-flow loop [1].

Results and Discussion covered with a thick oil film with appearance and viscosity
quite different from the original HO (Figure 4). The corrosion
Multiphase loop test rates of these specimens were the highest values among the
After loop tests are completed for light and heavy oils, tests performed in the loop under different conditions (values
the specimens in the test section both in the horizontal (0°) of more than 170 mm/y were obtained). After the cleaning
and inclined position (45°) were disassembled and subjected with a suitable soap, no visible layer of iron carbonate was
to visual inspection and examination by Scanning Electron observed which means that the specimens were under an
Microscope (SEM) and Optical Microscopy (OM). erosion-corrosion process, i.e., the formed iron carbonate
layer was removed under the adopted flow regime. For the 0°
Figure 3 shows the appearance and the SEM images of condition, the surface of the specimen showed a significant
the specimens the tested with light oil. The corrosion rates mass loss up to the point of removing its flat original surface
of these specimens reached values in the order of 67 mm/y. due to the highly aggressive corrosion-erosion process.
After the cleaning with as a suitable soap, no visible layer
of iron carbonate was observed which indicate that the The SEM and OM images Figure 4 after cleaning
expected iron carbonate formed due to the presence of CO2 the specimens tested in heavy oil illustrate the strong
were removed by the hydrodynamic effect. hydrodynamic effect associated with corrosion. This behavior
may be related to the fluid characteristics and the distribution
For heavy oil tests, the corrosion test specimens, both of stresses on the surfaces of the specimens in the horizontal
installed at a horizontal position and at a 45° position were and inclined positions.

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Citation: Silva CA, Filho DRN, Zanin MHA, et al. (2021) Impact of Crude Oil Emulsion on Pipeline Corrosion. J Petrochem Eng 1(1):11-19

Figure 4: Corrosion specimens after the HO test performed in the multiphase-flow loop [1].

Figure 5: The microstructures of heavy oil in water with CO2 partial pressure of 2.0 bar, 40 °C, emulsified after 30 h of testing in the multi-
phase loop. Stereomicroscope examination (Leica Fusion Optics M205C) with a maximum magnification of 160x in 1.0x objective lens.

Silva et al. J Petrochem Eng 2021, 1(1):11-19 Open Access | Page 15 |

Citation: Silva CA, Filho DRN, Zanin MHA, et al. (2021) Impact of Crude Oil Emulsion on Pipeline Corrosion. J Petrochem Eng 1(1):11-19

After the loop test performed with the heavy oil, a phenomenon to find out possible causes of such high
significative increase of the viscosity of the liquid phase was corrosion rates.
verified. For this reason, a sample of the liquid phase was
taken. The same procedure was not done with the liquid Emulsification Tests
phase of the light-oil test. The visual inspection of this sample Immediately after the emulsification test, samples of
(heavy oil and water) showed three different phases: water each type of oil were collected. One part is kept at rest to
at the bottom; emulsion at the middle (transition phase) and observe the separation process and the other part is sent to
oil phase at the top. A small sample of the transition phase
the beginning of the analysis on the Turbiscan.
was taken from the liquid-phase sample. Figure 5 shows
the transition phase microstructures obtained through a Figure 6 shows the images obtained through a
stereomicroscope. Figure 5A shows that there are oil droplets stereomicroscope examination of the (a) heavy oil, (b)
in the water (O/W emulsion). A greater magnification view of medium oil and (c) light oil after 30 h stirring, at 40 °C, in the
one of the oil droplets is shown in Figure 5B. The presence of emulsion-test cell.
small water droplets (SWD) within the observed oil droplet
(OD) can be perceived a W/O emulsion. From Figure 6A, heavy oil, we can verify the presence of
water droplets in the oil phase indicating a W/O emulsion
For many crude oils, the presence of a water cut greater which is also known as “chocolate mousse” or “mousse”
than 35% will result in a continuous water phase for a fully among oil spill workers [3]. In Figure 6B, medium oil, we
mixed oil/water system such that corrosion then becomes a can observe a similar behavior with water droplets in the oil
potential risk [16,17]. phase indicating a W/O emulsion. Studies show that a W/O
Therefore, it was decided to better understand this emulsion presents the highest value of viscosity at the critical

Figure 6: The emulsion microstructures of (a) heavy oil, (b) medium oil and (c) light oil after the emulsion test with CO2 partial pressure
of 2.0 bar, 80% water cut stirred (1200 rpm) for 30 h at 40 °C. Stereomicroscope (Leica Fusion Optics M205C) images with a maximum
magnification of 100x in 1.0x objective lens.

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Citation: Silva CA, Filho DRN, Zanin MHA, et al. (2021) Impact of Crude Oil Emulsion on Pipeline Corrosion. J Petrochem Eng 1(1):11-19

water cut (60% to 80%), i.e., at the inversion point [4]. For The most important detail of the visual observation is
light oil, you can see drops of water inside the oil but in a that the heavy and medium oils were much more viscous and
different distribution mode as shown in Figure 6C. stable, with an aerated aspect and with retention of almost all
water volume (Figure 7A and Figure 7B). The higher viscosity
Figure 7 shows the images of the visual aspect of the oils
was perceived during the manipulation of the sample.
after the emulsification tests and after the analysis on the
Turbiscan, respectively: (a) and (a1) for the heavy crude oil; The light oil presented a different behavior with a quick
(b) and (b1) for the medium crude oil and (c) and (c1) for the separation soon after the sample collection, leaving the water
light crude oil. a little whitish and the oil lighter, but without major visible

Figure 7: Visual aspect of the samples after emulsification test (a) HO (b) MO (c) LO and after analysis on the Turbiscan (a1) HO (b1) MO
(c1) LO.

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Citation: Silva CA, Filho DRN, Zanin MHA, et al. (2021) Impact of Crude Oil Emulsion on Pipeline Corrosion. J Petrochem Eng 1(1):11-19

Figure 8: TSI values of crude oil emulsions as a function of time at 40 °C.

changes in viscosity and aeration (Figure 7C). It is important to mention that the measurement in
the Turbiscan considers not only creaming but also the
From Figure 7A1, it is possible to observe that the heavy
flocculation and the coalescence phenomenon.
oil presents greater stability in the formed W/O emulsion.
When compared the heavy oil with the medium (Figure 7B1) Conclusions
and the light oil, (Figure 7C1) clearly light oil is more unstable.
For light oil, soon after the emulsification test, the rapid The results of emulsion cell test in the laboratory with
separation of the O/W emulsion can already be observed. In light oil, medium oil and heavy oil + water cut 80%, under
the literature the corrosiveness of the W/O emulsion strongly 2.0 bar of CO2 pressure and 40 °C allowed us to conclude that
depends on its stability and a method is suggested to avoid the behavior of the emulsion system (stability of emulsion)
pipeline corrosion by keeping the emulsion stable [18]. is strongly correlated with the type of crude oil type. Heavy
Additionally, researchers have observed in multiphase-slug- oil formed the most stable emulsion followed by the medium
flow experimental studies that an increase in the viscosity and light oil.
and the flow rate (higher shear stress) promote the removal The corrosion rate obtained with the heavy oil in the
of corrosion products and thus the increase in corrosion multiphase-loop test was higher than that obtained with light
damage [4]. oil. In both tests an iron carbonate layer was not detected on
the surface of the tested specimens showing that the erosion
Analysis of emulsion instability by optical corrosion process is the main corrosion mechanism. This
turbidimetry difference can be ascribed to the higher stability of HO/W
The emulsion stability was characterized using the emulsion.
Turbiscan to evaluate the kinetic of Stability Index (TSI). The
TSI value is calculated based on Equation 1 [19].
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TSI =∑
∑ h |scani( h )− scani−1( h )| (1)
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i H
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DOI: 10.36959/901/249
Copyright: © 2021 Silva CA, et al. This is an open-access article distributed under the terms of
the Creative Commons Attribution License, which permits unrestricted use, distribution, and S CHOLARS. D IRECT
reproduction in any medium, provided the original author and source are credited.

Silva et al. J Petrochem Eng 2021, 1(1):11-19 Open Access | Page 19 |

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