Optimizing dehydration and viscosity reduction in Egyptian heavy crude oil emulsions using eco-friendly demulsifiers

Heavy viscous crude oil presents significant challenges in extraction due to increased viscosity, primarily caused by water-in-oil (W/O) emulsions and heavy fractions. This study aims to develop and evaluate environmentally friendly demulsifier additives to enhance the dehydration and reduce the viscosity of Egyptian heavy crude oil emulsions. The research focused on synthesizing polyethylene glycol (PEG) esters (mono and di esters of oleic acid, caprylic acid, and phthalate esters) and testing their performance alongside four Demtrol surfactants. Comprehensive characterization of these surfactants was carried out using FTIR, NMR, elemental analysis, and mass spectrometry. The demulsification efficacy was assessed through bottle tests and viscosity measurements, with a comparative analysis against commercial products. The results demonstrated that Demtrol 1015 reduced viscosity by 53.5 % within two hours, while PEG 600 mono oleate achieved 76 % water separation from a 37 % water-cut emulsion. The novelty of this work lies in the use of eco-friendly PEG esters that offer effective emulsion destabilization, reducing both environmental impact and operational costs. This approach significantly enhances production rates, minimizes corrosion risks, and supports sustainable heavy crude oil processing.