dow corning oil & gas brochure
TRANSCRIPT
-
8/9/2019 Dow Corning Oil & Gas Brochure
1/20
Dow Corning Oil & Gas Industry Solutions
-
8/9/2019 Dow Corning Oil & Gas Brochure
2/20
Dow Corning Corporation
2
Table of Contents
About Dow Corning .....................................................................................................3
Oil and Gas Solutions .................................................................................................4
Section 1: Oil/Water Separation Demulsication .....................................................5
Section 2: Downhole Well Sealing Repair, Abandonment and Zonal Isolation ........ 8
Section 3: Hydrocarbon Foaming .............................................................................12
Section 4: Resin-coated Proppants Interface Modiers............................................ 13
Section 5: Sand/Fines Consolidation ........................................................................ 14
Section 6: Antifoams for Oil Production and Processing ..........................................16
How to Contact Us ....................................................................................................20
-
8/9/2019 Dow Corning Oil & Gas Brochure
3/20
Oil & Gas Industry Solutions
About Dow Corning
Dow Corning Corporation was
established in 1943 specically to
explore the potential of silicones. It
was created as a joint venture between
Corning Glass Works (now Corning,
Incorporated) and The Dow Chemical
Company. Today Dow Corning
provides performance-enhancing
solutions to serve the diverse needs
of more than 20,000 customers
worldwide. A global leader in silicon-
based technology and innovation,
offering more than 7,000 products and services, Dow Corning is equally owned by The Dow Chemical
Company and Corning, Incorporated.
Headquartered in Midland, Michigan, U.S.A., Dow Corning has more than 45 sites worldwide as well as
over 10,000 employees around the globe.
Combining client services and innovation, Dow Corning is also committed to the principles of sustainability.
The company views sustainability as fundamental to its future success in meeting the needs of customers,
employees and local communities. It has made sustainability a corporate value and is implementing
an approach that covers all three dimensions of sustainable development economic, social and
environmental. The company has long participated in the Responsible Care program, an international
initiative to advance the safe and secure management of chemical products and processes. Dow Corning
uses Responsible Care as a framework for activities including product development, manufacturing,
transportation, usage and waste disposal.
AV04923
-
8/9/2019 Dow Corning Oil & Gas Brochure
4/20
Dow Corning Corporation
4
Oil and Gas Solutions
Dow Corning has had an ongoing commitment to the oil
and gas industry since the early 1970s, resulting in many
product and application innovations.
Recently, new products have extended the application
area for silicones from traditional antifoam into broader
applications.
Dow Corning produces a variety of products for many oil
and gas applications, such as:
Oil/water demulsication
Oil well sealing for repair, abandonment and
zonal isolation
Hydrocarbon foaming
Sand consolidation
Proppant modication and processing aids
Gas/oil separation foam control
Delayed coking foam control
Dow Cornings website, dowcorning.com/oilandgas, has several informative articles and selection
guides covering some of the more established uses for silicon-based technology in the industry, including:
Silicone in the Oil and Gas Industry
Silicone Foam Control for the Oil and Gas Industry
Foam Control Methods in Delayed Cokers
Dow Corning can also offer supportive services and fully integrated solutions tailored to your specic
business needs.
The following sections give more details on some of the newer and emerging applications for silicon-
based technology in upstream oil and gas operations.
AV12208
-
8/9/2019 Dow Corning Oil & Gas Brochure
5/20
Oil & Gas Industry Solutions
Section 1: Oil/Water Separation Demulsication
Overview
As high-quality crude oil resources become depleted
and heavy crude oil reserves are tapped, the need for
new, efcient and potent demulsiers to resolve difcult
water-in-oil emulsions becomes more important.
Dow Corning provides silicone technology for oil
producers and service companies to improve their
current crude oil demulsication process.
The Dow Corning DMx line of silicone demulsiers
represents a range of different structures and molecular
weights that have been proven effective in water/oil
demulsication.
Silicone polyethers exhibit low surface tension (in some
cases down to 21 dyn/cm compared to 30 dyn/cm
for typical hydrocarbon surfactants in water) and low cohesive energy; they are surface active in both
aqueous and nonaqueous media, and show inverse temperature solubility and cloud point. Some
benets that can be achieved are rapid water drop rate, better interface denition, better water quality,
low-temperature performance and overall improved cost efciency for demulsication operations.
The effectiveness of silicone demulsiers has been demonstrated over the years in the eld, both as
stand-alone additives and as performance boosters to organic-based formulations, in levels between 10
30 wt%, based on formulation active ingredients.
Key Advantages
Rapid water drop rate
Sharp interface denition
Improved water quality
Low-temperature performance
AV12202
-
8/9/2019 Dow Corning Oil & Gas Brochure
6/20
Dow Corning Corporation
6
Case History
Dow Corning worked with a leading oil and gas company to improve their crude oil demulsication
process at their primary offshore platforms in Asia.
The traditional demulsication process involves the use of organic demulsiers at temperatures of 60 to
70C to reduce the water content in the oil stream to about 3-5 percent. These organic demulsiers are
ineffective at lower temperatures. The rm was looking for a solution that would enable them to carry out
the same process at a lower temperature with higher water reduction.
Dow Corning worked with the companys team on various eld trials to screen the DM series. The com-
pany has decided to conduct further bulk trials with one of the DM series products, which enables cleaner
and faster separation of oil and water, and reduces the water content in treated crude up to less than 0.4
percent. In addition, it works effectively at a lower temperature of 40 to 50C, thus enabling considerable
energy and cost savings to the company.
Oilelds conditions
~70 producing wells coming into 4 parallel separators
Medium oil with some wax (controlled by pigging)
Average water cut ~60%
Residence time ~3 min
Temp: 50 - 60C
Pressure: 7-8 kg/cm2
Field Trial Screen Result
Treatment detail Final water content in oil Final oil content in slop water
30 ppm glycol-based 3.0 - 7.2% 100 ppm
~8 ppm Dow Corning DM5 1.6 - 3.6% < 25 ppm
18 ppm glycol-based + 1.5 ppmDow Corning DM5 (Best)
~2% Optimized < 50 ppm
23 ppm glycol-based + 2 ppmDow CorningDM5
1% Demonstrated < 50 ppm
-
8/9/2019 Dow Corning Oil & Gas Brochure
7/20
Oil & Gas Industry Solutions
Product Information
Products Viscosity Flash Point HLB*
cSt or mm2
/s Closed Cup C Equivalent
Dow Corning DM1 1,750 71.5 6.6
Dow Corning DM2 260 113 12.3
Dow Corning DM3 280 83.3 6.6
Dow Corning DM4 40 101 11.5
Dow Corning DM5 310 67.2 9.2
Dow Corning DM6 200 80 10.5
*HLB equivalent = (molecular weight of ethylene oxide/molecular weight of total polymer) x 20.
-
8/9/2019 Dow Corning Oil & Gas Brochure
8/20
Dow Corning Corporation
8
Section 2: Downhole Well Sealing Repair, Abandonment and Zonal Isolation
OverviewCement is a common material used
in downhole sealing jobs, and while
cement is well established and
relatively inexpensive, there are
many cases where cement is either
unsuitable or has potential longer-term
problems. For example, cement can
crack or leave annular gaps uponcuring or during normal operations due
to changes in pressure, temperature,
mechanical loading or even due to corrosion. Remedial or squeeze cementing operations are difcult or
impossible due to the particle size of the cement.
Dow Corning and Shell Research developed a silicone elastomer system to help with these problems
several years ago. This work was initially described in SPE 39346 Development of a Novel Silicone
Rubber/Cement Plugging Agent for Cost Effective Through Tubing Well Abandonment by M. Bosma, et al.
This patented silicone elastomer system has many desirable characteristics. For example:
Good thermal range will remain exible and stable from 200C
Good chemical resistance
Cure prole can be varied to give desired working time at job temperature by addition of a
catalyst or cure retarder for example, to get 3 hours working time for the Dow Corning WS
4230 Well Sealant:
- At 30C, no additives are needed to the base formulation
- at 50C, you would add 2.5% Dow Corning WS 4232D Diluted Cure Retarder or 0.25%
Dow Corning WS 4233 Cure Retarder
- at 100C you would add 6.5% Dow CorningWS 4233 Cure Retarder or 0.2%
Dow Corning WS 4234C Concentrated Cure Retarder
- at 135C you would add 1.3% Dow CorningWS 4234C Concentrated Cure Retarder
Swell slightly in oil, which can lead to an even better seal
Cure is not signicantly affected by contaminants (oils, muds, etc.), at least up to the 5-10% level
AV12209
-
8/9/2019 Dow Corning Oil & Gas Brochure
9/20
Oil & Gas Industry Solutions
Supplied as a liquid, two-part, cure-in-place system. The addition cure chemistry relies on no
outside materials (such as moisture) to initiate cure and doesnt have any cure byproducts.
It is worth noting that strong acids (sulfuric, concentrated HCl, etc.) or bases (concentrated
KOH, etc.) can degrade the elastomer over time, particularly at higher temperatures. Also
at high temperatures, the elastomer is hydrolytically unstable and can degrade over time.
Since this latter case is quite common downhole, additional work was done to understand this
phenomenon.
Since degradation requires contact with destabilizing material, the rate should be diffusion controlled. A
multiyear study was undertaken to determine the diffusion coefcients and then to validate the theory with
application simulation results. The following chart illustrates the expected degradation rate based on the
diffusion coefcients. Experimental results from the exposure study match up well.
Example 2 below illustrates how this can apply in practice to a P&A application.
Example 1 below illustrates a typical operation for secondary/remedial sealing using Dow Corning
WS4235UF Unlled Well Sealant. This is an application where cement has a low success rate due to the
difculty of squeezing a solids-containing slurry. Note that this operation could also be performed with a
top-down squeeze.
Field trials to date have been a combination of these two examples, most for annular gas to the surface in
previously abandoned wells. All re-abandonments with this system were successful on the rst try. More
details on these trials are available.
Diffusion-controlled depolymerization
Time, years
Fa
ilure,meters
5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
0 5 10 15 20 25
25C
100C
200C
-
8/9/2019 Dow Corning Oil & Gas Brochure
10/20
Dow Corning Corporation
10
Example Applications
Example 1: Damaged Casing and Annular Seal (Squeeze Cementing/ Sealing)
Example 2: Theoretical Example of Hydrolytic Degradation over Time in aPlugging and Abandonment Application
A. Damaged casing
B. Through tubing squeeze ofDow Corning WS 4235UF Unlled Well Sealant
C. Circulate or drill out to resume production
A. Well plugged with 5m ofDow CorningWS 4230 Well Sealant (red) + cement (gray).
Conditions are 100C, primarily brine with residual oil left in contact with the silicone seal
B. After 10 years, the brine has penetrated about 0.75m into the seal
C. After 20 years, the brine has penetrated just over 1 m into the seal, still leaving almost
4 meters ofDow CorningWS 4230 Well Sealant to act as a positive seal to prevent
uids migration, even if the cement has cracked or otherwise failed
-
8/9/2019 Dow Corning Oil & Gas Brochure
11/20
Oil & Gas Industry Solutions
Dow CorningWS 4235UF Unlled Well Sealantready to be pumped
Well Sealing System Product Summary
Product Selection
Products Description Specication Application
Dow CorningWS4230 Well Sealant
Two-part lledsilicone elastomer
Mixed viscosity is ~2000 cSt
Specic gravity =1.35
Silica ller is nominally 5micron particle size
Sealing larger spaces,such as in plugging andabandonment
Dow CorningWS4235UF UnlledWell Sealant
Two-part lledsilicone elastomer
Mixed viscosity is ~300 cSt
Specic gravity = 0.97
Squeeze sealing, such asin zonal isolation andsecondary / remedialcementing
Dow CorningWS4232D Diluted CureRetarder
Cure retarder For use at low - moderatetemperatures to achievedesired working times
Dow CorningWS4233 Cure Retarder
Cure retarder For use at moderate - hightemperatures to achievedesired working times
Dow CorningWS4234C ConcentratedCure Retarder
Cure retarder For use at hightemperatures to achievedesired working times
Syl-Off4000 Catalyst For use at very lowtemperatures to achievedesired working times
Dow CorningQ3-3522
Cleaning solvent Clean cured/uncuredsilicone elastomers fromsurfaces
-
8/9/2019 Dow Corning Oil & Gas Brochure
12/20
Dow Corning Corporation
12
Section 3: Hydrocarbon Foaming
Overview
There are multiple applications
in the oil and gas industries
that involve the need to
generate hydrocarbon-based
foam, such as oil-based uids
for underbalanced foam drilling
and gas well deliquication.
Dow Corning technology can
be used to generate foam in a
broad range of hydrocarbons.
There are technology options
available for pure hydrocarbon systems as well as hydrocarbon/brine systems.
Key Advantages
The key advantages of silicone-based foaming agents:
Higher temperature resistance than many organic materials Ability to create foam in system with up to 100% hydrocarbon
Non-uorinated
Product Information
Dow Corning 1250 Surfactant is known in patent literature to be an effective foaming agent in oil-based
drilling uids
Developmental products now available for evaluation:
Dow Corning HCF-105 Dev Additive
Dow Corning HCF-110 Dev Additive
Dow Corning HCF-125 Dev Additive
AV12203
-
8/9/2019 Dow Corning Oil & Gas Brochure
13/20
Oil & Gas Industry Solutions
Section 4: Resin-coated Proppants Interface Modiers
Overview
Hydraulic fracturing is a technique
used in gas and oil wells to increase
the permeability of zones to enhance
production. It is a standard practice
used today as wells get older and
permeability decreases or new wells
are being drilled in less permeable
formations. The process includes
creating a fracture, or ssure, in lowpermeable zones, lling the fracture
with proppants that pack and hold the fractures open, all yielding an enhanced permeable pathway to the
wellbore for the oil or gas.
In recent years, resin-coated proppants have seen an increase in usage because they have demonstrated
a higher crush resistance and demonstrated less nes migration, which leads to improved conductivity. As
new proppants develop, resin-coated proppants continue to evolve and become more specialized to
specic wells and the geological conditions downhole. The resin technology is also being engineered to
meet the needs of deeper wells, which translate to higher pressures and temperature environmental
conditions that the proppant must be able to withstand.
Dow Corning provides silicon-based technology that can enhance the performance of the resin technology
used in proppants with targeted benets in adhesion of the resin and compressive strength enhancement,
as well as processing aids to improve ow and anticaking performance. We supply a wide range of
products with different functionalities to address the needs of our customers.
Our Key Advantages
Dow Corning brand proppants additives can enhance the performance of a resin-coated proppant.
Increase to compression strength of resin and formation
Compatibility with many resinous matrices
Improve adhesion between coating and neat proppant
Lubricity / Anticaking
AV10959
-
8/9/2019 Dow Corning Oil & Gas Brochure
14/20
Dow Corning Corporation
14
Section 5: Sand/Fines Consolidation
When hydrocarbons are recovered from subterranean formations, which are comprised of poorly consolidated
or unconsolidated sandstones, free sand and very small particles called nes can be carried away with
the hydrocarbons and transported to the surface. This often results in negative effects such as plugging of
the formations pores and/or erosion of the equipment. These adverse effects on well productivity and
equipment are costly sources of well damage that are often sought to be mitigated.
Different methods have been developed for preventing or addressing the effects linked to the migration of
nes and the related formation damage, including sand/gravel packing, screens, slotted liners, maximum
sand-free production rate, sand consolidation and various combinations of these methods.
Sand consolidation is a process involving the injection of a reactive chemical into a naturally unconsolidated
formation. The chemicals purpose is to bind the sand particles that make up the formation matrix while
maintaining sufcient permeability to achieve viable production rates.
Various sets of chemistry have been investigated for sand consolidation, among them organosilanes,
which have demonstrated benecial effects such as increased compression strength of the formation.
This class of materials can be simply ushed into a formation and due to their ability to rapidly hydrolyze
once in contact with aqueous solutions, organosilanes can easily form in-situ silanol species that will
condensate with each other and with any other hydroxyl sites on the surface of the mineral particles. This
results in a Si-O-Si network that will bind the siliceous material to the formation. Organosilane materials
also have been demonstrated to enhance the adhesion and compression performance of organic resins
used for consolidating sand formations.
In addition, their low bioaccumulation and high biodegradability prole make these chemicals
environmentally acceptable.
Dow Corning provides silicon-based technology that can chemically bind with the particles and provide
and enhance performance. We supply a wide range of organosilanes with different functionalities to
address the needs of our customers.
-
8/9/2019 Dow Corning Oil & Gas Brochure
15/20
Oil & Gas Industry Solutions
Our Key Advantages
Ease of processing
Increase the compressive strength of the formation
Lessens nes migration
Lessens nes swellability
Environmentally acceptable
Product Information
Material Functionality SpecicGravity at 25C
Viscosity(cSt)
Resin Compatibility
Dow Corning
PP-11 amino / ethoxy 1.03 5 Novolac and Resol PhenolicSystems**, Furan, UreaFormaldehyde, Epoxy
Dow CorningPP-20
amino / methoxy 0.946 1.06 Novolac and Resol PhenolicSystems**, Furan, UreaFormaldehyde, Epoxy
Dow CorningPP-40
glycidoxy / methoxy 1.07 3 Novolac and Resol PhenolicSystems, Furan, Urea
Formaldehyde, Epoxy**
** Preferential Resin System
-
8/9/2019 Dow Corning Oil & Gas Brochure
16/20
Dow Corning Corporation
16
Section 6: Antifoams for Oil Production and Processing
Foam is a Problem
From the well head, through rening, processing and even during shipment of the nished product, foam
can cause major problems in the production and rening of oil. Foam robs you of capacity and makes
your production process less efcient. It causes cavitation in pumps and excessive process fouling.
Waste, maintenance costs and processing time go up, while productivity goes down.
Silicone Foam Control is the Solution
Silicone foam control agents from Dow Corning eliminate process foam in production, renery and gas
processing plants. Eliminating process foam can increase your productivity, reduce your production costs
and, consequently, save you money.
Dow Corning has been involved in foam control for the petroleum industry for more than 50 years and has
a wide range of foam control products available for almost every foaming need. Dow Cornings website,
dowcorning.com, has several informative articles and selection guides covering some of the more
established uses for silicon-based technology in the industry, including:
Silicone Foam Control for the Oil and Gas Industry
The following are short descriptions of a few applications where silicone antifoams are commonly
used today.
AV12204
-
8/9/2019 Dow Corning Oil & Gas Brochure
17/20
Oil & Gas Industry Solutions
Gas-Oil Separation Certain crudes tend to foam while undergoing depressurization to release
entrapped gas. This tendency can severely limit output and is especially severe on offshore rigs where
vessel size is limited and special foaming problems can occur. Using as little as 1 to 5 parts per million
silicone antifoam from Dow Corning can help you maintain maximum separator capacity and well output.
There are many different options ofDow Corning brand silicone antifoams that can be used in gas/oil
separators. Most of these neat antifoams are of quite high viscosity and can be supplied as a concentrate
for ease of handling. We can customize a blend of selected silicone-based uids and solvents to meet
your needs, exactly. Save costs and time by choosing the right blend.
Typical 3-Phase Gas-Oil Separator Unit
The antifoam is typically metered into the crude oil inlet line either upstream (preferred) or immediately
downstream of the choke valve. Continuous addition at low levels is typically the most effective from both
performance and cost standpoints. Whether its for typical foam problems in low/medium GOR environments
or a more persistent foaming problem often seen in high GOR or heavy oil situations, the Dow Corning
range of silicone antifoams has proven effective in solving foaming problems.
-
8/9/2019 Dow Corning Oil & Gas Brochure
18/20
Dow Corning Corporation
18
Gas Scrubbing Gas scrubbers used to remove CO2
and H2S from gases are prone to foam. Such
processes are commonly used for natural gas, renery gas, in gas treatment as a part of reforming, in
ethylene production (steam cracking) and in the production of ethylene oxide. Trace impurities, such as
liquid hydrocarbons, well-head inhibitors, corrosion solids and valve greases in the incoming gas can
cause foam regardless of which absorbent (MDEA, DEA, TEA and DGA or carbonate solution) is used.
Foaming can cause poor separation efciency and reduced throughput, as well as loss of expensive
absorbent by carry-over. The foam can be controlled by feeding Dow Corningsilicone antifoam into the
absorber/contactor and regenerator columns.
The antifoam is typically metered into either the column reux line (after any lters) or into the column
feed line. It is generally preferred to add the antifoam into a reux stream immediately before a pump to
maximize mixing and dispersion in the system, as shown in the below system diagram. Since some of thedefoamer is removed by the lters, it is usually added to both columns.
Recommended Use of Silicone Antifoams
SWEET GAS
OUTLET
SCRUBBER
ACID
GAS
CONTACTOR
Antifoam
CHARGE
PUMP
AMINE
COOLER
BOOSTER
REFLUX
CONDENSER
REFLUXPUMP
REFLUX
ACCUMULATOR
CHARCOAL
DRAIN
REBOILER
RECLAIMER
SOLIDSFILTER
FLASH
GAS
SOUR
GAS
INLET
SCRUBBER
REGENERATOR
FILTER
PUMP
Antifoam
FLASH TANK
OR SKIMMER
-
8/9/2019 Dow Corning Oil & Gas Brochure
19/20
Oil & Gas Industry Solutions
Product Information for Gas Scrubbers:
Dow Corning 1410 / DB-110A: Recommended dose: 10 100 ppm
Dow Corning 1430 / DB-310: Recommended dose: 5 50 ppm
Dow Corning 2-3316 Silicone Organic Antifoam: Recommended dose:
-
8/9/2019 Dow Corning Oil & Gas Brochure
20/20
How to Contact Us
Dow Corning has sales ofces, manufacturing sites, as well as science and technology laboratories around the globe.
Telephone numbers of locations near you are available at dowcorning.com/oilandgas.
Chat with an expert online.
Live Help is available at: dowcorning.com/content/support
Or contact us at: dowcorning.com/ContactUs
LIMITED WARRANTY INFORMATION PLEASE READ CAREFULLY
The information contained herein is offered in good faith and is believed to be accurateHowever, because conditions and methods of use of our products are beyond our controlthis information should not be used in substitution for customers tests to ensure that ouproducts are safe, effective and fully satisfactory for the intended end use. Suggestionof use shall not be taken as inducements to infringe any patent.
Dow Cornings sole warranty is that our products will meet the sales specications ieffect at the time of shipment.
Your exclusive remedy for breach of such warranty is limited to refund of purchase priceor replacement of any product shown to be other than as warranted.
DOW CORNING SPECIFICALLY DISCLAIMS ANY OTHER EXPRESS OR IMPLIEDWARRANTY OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY
DOW CORNING DISCLAIMS LIABILITY FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.
Front Cover Photo: AV12204Dow Corningis a registered trademark of Dow Corning Corporation.
Syl-Offis a registered trademark of Dow Corning Corporation.
We help you invent the future is a trademark of Dow Corning Corporation.
All other trademarks or trade names are the property of their respective owners.
2009 Dow Corning Corporation. All rights reserved.
Printed in USA AGP9981 Form No. 26-1686A-0