Decarbonization and Improved Energy Efficiency Using a Novel Nanocomposite Surface Treatment

Abstract

Fouling of heat exchanger equipment through the formation and attachment of hard scale, microbially induced corrosion (MIC) products, or particulate erosion is a serious challenge to reliable production in the oil and gas industry. Exchangers which become fouled in this way perform 15-30% worse than their rated ability, requiring either constant intervention to clean away biofilms, continuous injection of biocides and corrosion inhibitors, or the regular plugging of tubes to prevent leaks, representing a significant operating expense and billions of dollars in lost production time. When an exchanger is unable to provide sufficient heat due to tube fouling, additional sources of heating must be utilized to make up for this deficit and to ensure that facility processes remain within design allowances. This need for supplemental heating is a significant source of carbon emissions in the industry and represents a significant obstacle towards decarbonization efforts. However, it also represents an economically attractive way to simultaneously lower emissions while also lowering a producer's cost per barrel. This work describes an alternate strategy to control and prevent fouling in heat exchangers, through the one-time application of an omniphobic (water- and oil-repelling) nano-surface treatment. Once applied to a heat exchanger, the extremely smooth and low-surface energy material greatly reduces the ability of MIC-causing bacteria to deposit and adhere to the surface. Because it imparts functionality to the surface itself, rather than simply function as a physical barrier, it enables long lasting protection which was validated under laboratory conditions in a pressurized autoclave, as well as two pilot demonstrations. Results from both the laboratory and field evaluations of the treatment's promise showed that treated surfaces showed a corrosion rate over 36-times lower when compared to untreated surfaces, while also completely arresting the formation of corrosion pitting, tube fouling, and erosion of the tube interior. These field-validated results were then applied to the observed heating deficit of a proposed deployment site, resulting in calculated carbon emissions savings of up to 17,000 Tons CO2 per year.