Abstract
The first surfactant-based pilots can be traced back to the 1960s and since then almost a hundred field tests have taken place. Interestingly, almost half of these pilots have used an alkali (ASP) and the other half has not (SP). This reflects the current status of the industry which is divided along the same lines and over the same question: do surfactant-based processes require alkali or not? This paper proposes to address this question by providing explanations and discussing case studies.
The paper will start by reminding the reader of the role of both surfactant and alkali and will review the pros and cons of alkali in terms of formulation performances, adsorption but also surface facilities and logistics. Several cases studies (lab and field) will be discussed to show when alkali can and cannot be used, and what solutions are available as alternatives to the use of alkali.
Although alkali allows reducing both surfactant concentration and adsorption, it can also cause severe scaling and requires additional facilities including water softening; in addition, the large volumes of alkali required can cause logistical challenges. On the other hand, the main challenges of formulations without alkali is finding surfactants that can develop a low enough Interfacial Tension and low adsorption, or to find an acceptable adsorption mitigation strategy such as salinity gradient or adsorption inhibitors. In the early years of SP projects, very high surfactant concentrations were used (micellar process) and the process was not economic; as a result, alkali was seen as the only realistic solution. This appears to no longer be the case due to the developments of new surfactants. Although most projects in recent years have favoured the use of alkali, it seems that a trend towards SP is growing, with recent field projects in Kuwait, Oman, China and Russia favouring the SP solution.
This paper will provide a discussion on the pros and cons of the use of alkali in surfactant-based processes. It will show that although using alkali has been a standard for many years it also entails severe surface issues such as scaling and requires additional capital for water softening and logistics. More importantly, recent developments in surfactants now seem to provide alkali-free solutions that can compete in terms of formulation performances. This now needs to be confirmed in the field.