A New Process for Manufacturing and Stabilizing High-Performance EOR Surfactants at Low Cost for High-Temperature, High-Salinity Oil Reservoirs

Abstract

Abstract An alcohol dimerization process known as the Guerbet reaction is used to create large alcohol structures for the production of the corresponding alkoxy sulfate surfactants. In the alcohol industry, Guerbet (dimer) alcohols are considered the "gold" standard for large, branched alcohols. These Guerbet alcohols tend to be more expensive than other alcohols when produced in high purity for various industrial applications. The high cost is mainly due to driving the reaction to completion and/or stripping-off of the unreacted monomer alcohol to produce high purity. However, inexpensive Guerbet alcohols (GA) can be prepared by aiming for less than quantitative conversion during the alcohol dimerization process. The resultant blend of 85-95% GA and 5-15% monomer alcohol is subsequently used in the alkoxylation process to add propylene oxide and/or ethylene oxide, followed by sulfation. Through the use of this new Guerbet process, these surfactants can be manufactured at low cost when made as sulfates as opposed to sulfonates. For example, a C32 GA can be produced from a C16 alcohol. These and other sulfate surfactants can be stabilized at high temperature with alkali. This is a surprising discovery that greatly increases the availability of low-cost, high performance surfactants for high temperature reservoirs.