Process of preparing improved heavy and extra heavy crude oil emulsions by use of biosurfactants in water and product thereof

1. A process for preparing concentrated heavy crude and extra heavy crude-in-water emulsions comprising crude having between 20 and 6° API and biosurfactants in water, the process comprising the following steps:

I) premixing comprising: a) dissolving a salt in different concentrations by agitation and at room temperature to form a saline solution; and b) mixing the biosurfactant in the saline solution by using agitation and room temperature to form a surfactant premix;

II) preparing concentrated emulsion with the crude and the surfactant premix comprising: a) separately heating the surfactant premix and the crude between 30 and 90° C.; b) adding the crude to the surfactant premix with constant agitation and temperature; c) homogenizing the resulting mixture for 2 minutes and left standing another 2 minutes until completing 3 homogenizing-standing cycles to obtain a crude-in-water precursor emulsion; d) mixing with constant agitation and temperature (30-60° C.), an additional quantity of biosurfactant to said precursor emulsion to achieve a biosurfactant concentration between 100 and 10,000 ppm of biosurfactant in the total volume of the resulting precursor emulsion; e) continuing with constant agitation and temperature to obtain an emulsion-biosurfactant premix; f) separately measuring a balance of crude for preparation of the concentrated emulsion and heating between 30-60° C.; g) adding said crude to the emulsion-biosurfactant premix with constant agitation; h) then, homogenizing the resulting mixture for 2 minutes and left standing another 2 minutes until completing three homogenizing-standing cycles in order to obtain the concentrated crude-in-water emulsion having a water content of 10 to 70 vol %.

2. The process for preparing the concentrated crude-in-water emulsion according to the process of claim 1 , wherein an aqueous phase has a salt content between 3.5 and 10.5 weight % based on quantity of water in the concentrated crude-in-water emulsion.

3. The process for preparing the concentrated crude-in-water emulsion according to claim 2 , wherein the aqueous phase contains the biosurfactant in an amount of 100-400 ppm based on the total quantity of the resulting concentrated crude-in-water emulsion.

4. The process for preparing the concentrated crude-in-water emulsion according to claim 2 , wherein the biosurfactant is selected from the group consisting of an alkyl glucoside, glycerol ester, alkyl betaine surfactant, and mixtures thereof.

5. The process for preparing the concentrated crude-in-water emulsion according to claim 4 , wherein the alkyl group of the glucoside contains from 2 to 22 carbon atoms.

6. The process for preparing the concentrated crude-in-water emulsion according to claim 4 , wherein the glycerol ester is a mono-, di- or tri-ester, preferably mono- and di-ester having 2 to 22 carbon atoms.

7. The process for preparing the concentrated crude-in-water emulsion according to claim 4 , wherein the alkyl group of the betaines contain from 2 to 22 carbon atoms.

8. The process of claim 4 , wherein said alkyl group of the glucoside, the glycerol ester, and the alkyl group of the betaines have 8 to 18 carbon atoms.

9. The process for preparing the concentrated crude-in-water emulsion according to claim 2 , wherein the concentrated crude-in-water emulsion comprises 30-90 vol % hydrocarbons (6 to 20° API) and from 70-10 vol % water based on the volume of the emulsion, 100-10000 ppm of biosurfactant based on the precursor emulsion and 3.5-10 weight % salt based on the weight of the water in the emulsion.

10. A process for preparing a crude oil-in-water emulsion comprising the steps of:

forming a mixture containing water, NaCl and a biosurfactant selected from the group consisting of alkyl glycosides, glycerol esters, alkyl betaines and mixtures thereof to obtain an aqueous surfactant mixture;

admixing the crude oil with the aqueous surfactant mixture and emulsifying the mixture to obtain said crude oil in water precursor emulsion;

adding an additional amount of said biosurfactant to said precursor emulsion and adding additional crude to the resulting mixture to obtain the crude oil-in-water emulsion including about 10-30 vol % water containing 3.5-10 wt % of said NaCl, said crude oil being 8 to 16° API and said biosurfactant being present in an amount of about 100 ppm to about 10,000 ppm based on the total amount of the crude oil-in-water emulsion.

11. The process of claim 10 , wherein said precursor emulsion has a water content of 70-90% by volume and a crude oil content of 10-30% by volume, and said concentrated crude-in-water emulsion has a crude oil content of 70-90% and a water content of 10-30% by volume.

12. The process of claim 11 , wherein said biosurfactant is a C 2 -C 22 alkyl glycoside.

13. The process of claim 11 , wherein said biosurfactant is a C 2 -C 22 alkyl glycerol ester.

14. The process of claim 11 , wherein said biosurfactant is a C 2 -C 22 alkyl betaine.

15. The process of claim 1 , wherein said crude has 8-16° API.

16. The process of claim 1 , wherein said crude-in-water precursor emulsion has a water content of 70-90% by volume and a crude oil content of 10-30% by volume and where said concentrated crude-in-water emulsion has a crude oil content of 70-90% and a water content of 10-30% by volume.

17. The process of claim 1 , wherein said crude-in-water precursor emulsion consists essentially of saline solution, crude oil and said biosurfactant, where said biosurfactant is selected from the group consisting of a C 2 -C 22 alkyl glycoside, a C 2 -C 22 alkyl glycerol ester, a C 2 -C 22 alkyl betaine, and mixtures thereof.

18. A process of transporting crude oil comprising the steps of:

preparing a crude oil-in-water emulsion comprising 70-90 vol % crude oil having 8-16° API, 10-30 vol % water, about 3.5 wt % to about 10 wt % NaCl based on the amount of water, and a surfactant in an amount of about 100 ppm to about 10,000 ppm based on the amount of water in the emulsion, said surfactant being selected from the group consisting of a C 2 -C 22 alkyl glycoside, a C 2 -C 22 alkyl glycerol ester, a C 2 -C 22 alkyl betaine, and mixtures thereof, wherein said crude-in-water emulsion is prepared by the steps of:

forming a mixture containing water, NaCl and a biosurfactant selected from the group consisting of alkyl glycosides, glycerol esters, alkyl betaines and mixtures thereof to obtain an aqueous surfactant mixture;

admixing the crude oil with the aqueous surfactant mixture and emulsifying the mixture to obtain said crude oil-in-water precursor emulsion;

adding an additional amount of said biosurfactant to said precursor emulsion and adding additional crude to the resulting mixture to obtain the crude oil-in-water emulsion, said crude oil being 8 to 16° API and said biosurfactant being present in an amount of about 100 ppm to about 10,000 ppm based on the total amount of water in the crude oil-in-water emulsion; and

feeding said emulsion through a pipeline.

19. The process of transporting crude oil of claim 18 , wherein said precursor emulsion has a water content of 70-90% by volume and a crude oil content of 10-30% by volume, and said concentrated crude-in-water emulsion has a crude oil content of 70-90% and a water content of 10-30% by volume.

20. The process of claim 19 , wherein said concentrated crude-in-water emulsion consists essentially of crude oil, water and said biosurfactant.

21. The process of claim 20 , wherein said biosurfactant is a C 2 -C 22 alkyl glycoside.

22. The process of claim 20 , wherein said biosurfactant is a C 2 -C 22 alkyl glycerol ester.

23. The process of claim 20 , wherein said biosurfactant is a C 2 -C 22 alkyl betaine.