New Insights Into The Removal of Calcium Sulfate
New Insights Into The Removal of Calcium Sulfate
New Insights Into The Removal of Calcium Sulfate
Sulfate Scale
Authors: Dr. Mohammed H. Al-Khaldi, Ahmad M. Al-Juhani, Dr. Saleh H. Al-Mutairi and Dr. M. Nihat Gurmen
ABSTRACT
Calcium sulfate is one of the major scales that cause many
significant and serious operating problems in producing oil
and gas wells and in water injectors. Impermeable hard scale
deposits of calcium sulfate can severely impair the formation
permeability or lead to downhole equipment failure. Typically,
preventive treatments, such as the use of scale inhibitors, are
the most economical methods for calcium sulfate mitigation;
however, application of a cost-effective treatment is needed in
case of emergency, when calcium sulfate precipitation occurs.
A comprehensive lab investigation was conducted to assess
the effectiveness of several remedial methods for calcium
sulfate removal. This article shows the amount of calcium
sulfate dissolved after its exposure to different reactive fluids
at 25 C and 50 C. In addition, it discusses the effect of
different factors on the efficiency of each remedial treatment.
These factors include pH, temperature, reactive fluid
concentration and presence of magnesium/iron ions.
Based on obtained results, several new findings were
identified. The presence of gypsum (CaSO4.2H2O) has a
negative impact on the performance of mud acid treatments.
After the initial dissolution of gypsum in live mud acid,
dissolved calcium will precipitate as both calcium fluoride and
calcium sulfate in spent hydrochloric (HCl)/hydrofluoric (HF)
acid solutions. Gypsum has a higher solubility limit in live
HCl acid compared to its spent solutions, which results in the
reprecipitation of calcium sulfate in spent HCl. This solubility
of gypsum in acidic solutions could result in severe formation
damage. Live acids can initially dissolve any precipitated
calcium sulfate solids in wellbore areas, but the calcium sulfate
will reprecipitate in the formation rocks as the acid is spent.
Gypsum has a higher solubility limit in ethylene diamine
tetra-acetic acid (EDTA) solutions, compared to acidic
solutions. No reprecipitation of calcium sulfate occurred in
these solutions due to the fact that calcium ions exist as
complex ions and are not free to interact with other ions. The
dissolving power of EDTA was found to be a function of the
solution pH value. The dissolving power of EDTA for gypsum
was higher at high pH values. The presence of both magnesium and iron (III) ions had a negative effect on gypsum
dissolution in the EDTA fluid. Compared to magnesium, iron
(III) ions resulted in a significant decrease in gypsum solubility
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INTRODUCTION
Calcium sulfate has been cited in the literature as one of the
major scales that cause many significant and serious operating
problems in producing oil and gas wells and in water injectors.
Impermeable hard scale deposits of calcium sulfate can severely
impair the formation permeability, thereby decreasing the well
injectivity or productivity1-4. In addition, calcium sulfate can
also negatively impact the well economics when it precipitates
in downhole equipment, such as electrical submersible pumps
(ESPs). This precipitation leads to pump failure due to overloading that causes serious damage to the pump components,
and as a result, costly workovers are required.
Calcium sulfate has two main stable crystal forms.
Gypsum, CaSO4.2H2O, is formed at low temperatures (i.e.,
T < 98 C), while anhydrite, CaSO4, is the predominant form
produced at high temperatures5. Gypsum, the most common
oil field calcium sulfate scale, is very difficult to remove. This
is mainly because it has relatively low solubility limits in
water, almost 2.36 kg in 1 m3 of water at 25 C. At higher
temperatures, calcium sulfate becomes more insoluble in water
as low as 1.69 kg in 1 m3 of water at 90 C. Besides temperature, other factors affect gypsum solubility, such as the
solutions pH value and pressure. In general, calcium sulfate is
more soluble at low pH values and high pressures4, 6.
Many publications have reported on the precipitation of
calcium sulfate during different oil field operations, such as
water injection, acid stimulation and commingled hydrocarbon/water production. The main cause of calcium sulfate
scaling during these operations is the chemically incompatible
mixing of two fluids. For example, mixing injected seawater,
which is high in sulfate ions, with formation water, which
is high in calcium ions, will result in calcium sulfate precipitation once its solubility limit is exceeded. Similarly,
calcium sulfate precipitation can result from the incompatible
mixing of spent acid solutions with overflush fluids. It has
been reported7 that calcium sulfate precipitation occurred in
and around the ESPs of the Farida/Zelda reservoir wells
mainly after acid stimulation treatments. This was found to be
THEORY
Equation 1 shows how calcium sulfate, gypsum, and scaling
can be expressed:
(1)
The potential for gypsum scaling measured thermodynamically
by the saturation index (SI). A positive SI value indicates that the
mixture solution is supersaturated and there is a potential for
scaling, while a zero or negative SI value shows that the mixture is
undersaturated and there is no scale tendency. The SI for gypsum
is the logarithm of the ion activity product of its two ion
components, calcium ions and sulfate ions, divided by its
solubility product, Eqn. 29:
(2)
where g Ca2+ is the activity coefficient of the calcium ion,
g SO42- is the activity coefficient of the sulfate ion, Ci is the
concentration of the specie i (mole/L), and Ksp is the solubility
product of calcium sulfate salt, which is a function of
temperature and pressure. The ion activity coefficient in
electrolyte solutions can be calculated using solution ionic
strength and ion interaction coefficients. For example, the
calcium activity coefficient can be calculated using Eqns. 3
and 413:
(3)
(4)
where Im is the ionic strength, z is the valence (or oxidation)
number of the calcium ion, B is the ion interaction coefficient
and mj is the molality of interacting ion j (mol/kg). In the case
of the calcium ion, the interacting ion in the HCl acid solution
will be the chloride ion. In calculating a specie activity
coefficient, the ion interaction coefficients are zero for ions
with the same charge or unchanged ions. Many studies have
reported ion interaction coefficients for various ion pairs14.
HCl acid and HCl/HF acids dissociate to produce H+ ions.
In these acidic solutions, calcium sulfate is dissolved due to H+
attack on sulfate crystal sites, Eqns. 5 to 7:
(5)
(6)
(7)
The interaction of dissolved calcium ions with fluoride ions
can result in the precipitation of calcium fluoride, Eqn. 8:
(8)
Calcium fluoride precipitation is dependent on the
solutions pH value as will be discussed later. The EDTA is
a weak acid that dissociates stepwise as follows, Eqns. 9
to 12:
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(9)
(10)
(11)
(14)
The calcium sodium EDTA complex is stable because of the
chelation bonds, Fig. 317. Similar to calcium, EDTA is also an
excellent chelating agent for both magnesium and iron, Eqns.
15 and 16:
(12)
(15)
The distribution of the acid species is dependent on both
the pH value and the dissociation constants, as shown in Fig.
215, 16. The dissociation constants of EDTA are: Ka1= 1.02
E-2, Ka2 = 2.14 E-3, Ka3 = 6.92 E-7, Ka4 = 5.5 E-1115, 16. The
first dissociation constant of EDTA, Ka1, is expressed in Eqn.
13 as:
(13)
The mechanism of calcium sulfate dissolution in the EDTA
solution is different from that in acidic solutions. Calcium
sulfate is mainly dissolved due to calcium chelation at pH > 4.
Equation 14 shows the reaction of tetrasodium EDTA with
calcium sulfate:
(16)
The chelating agent affinity for an ion is defined by the
formation constant, KF, Eqns. 17 and 18:
(17)
(18)
The larger the formation constant is, the stronger is the
chelating agent-ion complex. Table 118 lists the formation
constants of EDTA with calcium, magnesium and iron (III)
cations. The presence of magnesium and iron will affect the
calcium sulfate dissolution in the EDTA solutions as will be
discussed later.
Calcium, Ca2+
Formation Constant,
Log KF18 at 25 C
10.70
Magnesium, Mg2+
8.69
Ion
Iron (III), Fe
3+
25.7
EXPERIMENTAL STUDIES
Fig. 2. Distribution of EDTA species as a function of the solutions pH value at
25 C15, 16.
Materials
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Fig. 9. XRD analysis of solid material reprecipitated in filtered HCl acid solutions
after reaction with gypsum. Reprecipitation occurred when the pH value was raised.
Fig. 10. Gypsum solubility in 15 wt% HCl acid as a function of the solutions pH
value at 50 C and atmospheric pressure.
Fig. 11. Gypsum solubility in live 15 wt% HCl acid as a function of dissolved
magnesium ion concentration at atmospheric pressure.
Fig. 12. Gypsum solubility in live 15 wt% HCl acid as a function of dissolved iron
(III) ion concentration at atmospheric pressure.
Fig. 13. Calcium sulfate reprecipitation in live 15 wt% HCl acid containing (a)
iron, and (b) magnesium ions, at different concentrations as a result of the
decrease in the solutions temperature value.
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Fig. 14. XRD analysis of solid material reprecipitated due to temperature change
in live HCl/gypsum mixture solutions containing (A) 1 wt% MgCl2.6H2O and
(B) 1 wt% FeCl3.6H2O.
Fig. 15. Solubility product of gypsum in 15 wt% HCl acid as a function of the pH
value.
containing iron (III) ions, Fig. 20. This was clearly indicated,
Fig. 17, where the concentration of iron (III) in the EDTA
before gypsum dissolution (theoretical) is equal to gypsum after
soaking for 8 hours.
CONCLUSIONS
The interaction between gypsum and different reactive fluids
(HCl/HF acid, HCl acid and EDTA) was studied in detail. The
effects of different parameters, such as solution pH value,
temperature and presence of iron (III) and magnesium ions were
investigated. The following conclusions can be drawn:
1. The presence of gypsum (CaSO4.2H2O) has a negative
impact on the performance of mud acid treatments. After
the initial dissolution of gypsum in the live mud acid,
dissolved calcium will precipitate as both calcium fluoride
and calcium sulfate in spent HCl/HF acid solutions.
2. Gypsum has a higher solubility limit in live HCl acid
compared to its spent solutions. This will result in
reprecipitation of calcium sulfate in spent HCl acid.
3. The reprecipitation of calcium sulfate in spent solutions of
HCl acid and HCl/HF acids could result in severe
formation damage. Live acids initially can partially
dissolve any precipitated calcium sulfate solids in the
wellbore area, but the dissolved calcium and sulfate ions
will reprecipitate in the formation rocks as the acid is spent.
Fig. 18. Gypsum solubility in 8 wt% EDTA as a function of dissolved iron (III)
ion concentration at 50 C and atmospheric pressure.
ACKNOWLEDGMENTS
REFERENCES
1. Fulford, R.: Effects of Brine Concentration and Pressure
Drop on Gypsum Scaling in Oil Wells, SPE paper 1830,
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BIOGRAPHIES
Dr. Mohammed H. Al-Khaldi joined
Saudi Aramco in 2001 as a Research
Engineer working in Saudi Aramcos
Exploration and Petroleum
Engineering Center Advanced
Research Center (EXPEC ARC).
During this time, he was responsible
for evaluating different stimulation treatments, conducting
several research studies and investigating several
stimulation fluids. In addition, Mohammed was involved in
the design of acid fracturing treatments. As an award for
his efforts, he received the Vice Presidents Recognition
Award for significant contributions to the safe and
successful completion of the first 100 fracturing treatments.
Mohammeds research interests include well stimulation,
formation damage mitigation and conformance control.
He received his B.S. degree in Chemical Engineering
(with First Class Honors) from King Fahd University of
Petroleum and Minerals (KFUPM), Dhahran, Saudi Arabia.
Mohammed also received his M.S. and Ph.D. degrees in
Petroleum Engineering (with First Class Honors) from
Adelaide University, Adelaide, Australia.
He is an active member of the Society of Petroleum
Engineers (SPE). Mohammed has published more than 15
SPE papers and seven journal articles, and has two patents.
In 2011, he received the SPE Best Technical Paper Award,
winning first place in the 2nd GCC SPE paper contest.
Ahmad M. Al-Juhani is a Chemical
Engineering student at King Fahd
University of Petroleum and Minerals
(KFUPM), Dhahran, Saudi Arabia. He
is scheduled to graduate in August
2011.
Ahmad did his training with the
Formation Damage and Stimulation Unit, Operation
Support Division, at the Exploration and Petroleum
Engineering Center - Advanced Research Center (EXPEC
ARC). During this period, he worked on several studies
involving pipe dope removal, calcium sulfate scale removal
and H2S scavenger evaluation.
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