Mechanistic Study of Water Droplet Coalescence and Flocculation in Diluted Bitumen Emulsions with Additives Using Microfluidics

Synthetic crude oils derived from mined oil sands processed via the Clark hot water extraction process do not meet current specifications for pipeline transport and are corrosive to upgrader equipment by virtue of the high residual water content (2–5%) and salts. Formulated chemical additives used in this process can improve the oil quality by accelerating and enhancing the separation of water from oil. The identification and selection of these formulated additives is typically based on performance data collected in field testing for each component or blend. Herein, two methods are reported to study the effect of chemical additives on the phase separation behavior of water in diluted bitumen emulsions prepared in microfluidic devices. First, water droplets in diluted bitumen were created in the presence of chemical additives and the kinetics of droplet coalescence were compared for various additives and concentrations. Second, using a custom-made device geometry, water droplets in diluted bitumen were formed and aged prior to the addition of chemical additives. The treated droplets were observed to calculate the kinetics of droplet coalescence. The frequency of coalescence events was the same order of magnitude in both studies. The effectiveness of various additives can be determined by measuring the coalescence time, which is dominated by film drainage in the case of the best chemical additives