Enhancing Low-Temperature Demulsification: A Hybrid Demulsifier (Organofunctional Silicone) as a Booster to Conventional Demulsifiers

Abstract Efficient demulsification of crude oil emulsions at low temperatures remains a significant challenge, particularly during winter and in offshore environments where heater-treater systems are aging and less effective. This study highlights the potential of organofunctional silicone hybrid demulsifiers (OSHD) as co-additives or performance boosters to conventional demulsifiers. Bottle tests conducted at reduced temperatures demonstrated that OSHDs enhance separation efficiency, reduce BS&W levels, and produce a sharper oil-water interface—offering a promising solution for cold-weather oilfield operations. The study involved multiple OSHD formulations tested on 38°–40° API crude oil characterized by low sulfur content (0.1%–0.3%) and high wax content (8%–10%), with a pour point of 33 °C. Due to declining heater-treater efficiency, a demulsifier solution capable of operating effectively at temperatures 8 °C to 10 °C below standard field conditions was required. A formulation containing 90% incumbent or OSHD dropper and 10% OSHD treater achieved over 65% water separation within 6 minutes and maintained BS&W below 1%. In comparison, the organic demulsifier alone delivered only 60% separation and BS&W exceeding 3%. Residual water in the oil phase was reduced from 3% to below 1%, indicating improved dehydration. Various combinations of OSHD droppers and treaters with conventional demulsifiers were evaluated. Performance was assessed based on water separation, residual water content, and separation time, with results benchmarked against standard organic demulsifier treatments. Key OSHD formulations were also tested on fresh crude, validating the positive outcomes observed in aged crude tests. The findings suggest that organosilicone hybrid demulsifiers not only improve performance at lower temperatures but also act synergistically with conventional demulsifiers. Their use as performance enhancers can reduce chemical dosage, improve efficiency, and lower overall demulsifier costs in field applications.