INTRODUCTION AND CLIENT CONTEXT
In the dynamic and competitive landscape of the oil and gas sector, operational efficiency and product quality are fundamental pillars for success and profitability. A leading and independent company in its industry, with onshore operations in Brazil, consolidated its position in 2021 by acquiring 100% of the operations of a major oil company in the region.
With production distributed across four strategic stations, continuity and optimization of its operations are crucial, with Stations 1 and 2 accounting for 90% of production.
| PROPERTIES | TYPICAL VALUES |
| Average H₂S Concentration | 47 |
| Gross Production (m³/day) | 1000 |
| API Gravity (°API) | 19 |
| BSW % | 75 |
| System Type | Liquid Phase |
| PROPERTIES | TYPICAL VALUES |
| Average H₂S Concentration | 11 |
| Gross Production (m³/day) | 6200 |
| API Gravity (°API) | 13 |
| BSW % | 83,9 |
| System Type | Liquid Phase |
Dorf Ketal, renowned for its innovative solutions in specialty chemicals, established a strategic partnership with this company, supplying products such as triazine and holding the contract for primary processing products.
This deep and continuous collaboration enabled Dorf Ketal to gain a thorough understanding of the operational challenges and optimization needs of its partner.
OPERATIONAL AND MARKET CHALLENGES
The referenced leading company was facing multiple complex challenges that directly affected the quality of the oil produced, the integrity of its assets, and its commercial flexibility. The main issues identified were:
1. Problems with Triazine Application: The use of triazine in the processing system caused significant adverse effects, including corrosion and scaling, and contributed to the formation of carbon disulfide (CS₂) during the oil refining process. Mitigating these problems was essential to ensuring equipment integrity and refining efficiency.
2. Hydrogen Sulfide (H₂S) Generation in Storage Tanks: The Storage Terminal (TNC) operated with a high residence time (around 30 days), creating an environment conducive to the proliferation of sulfate-reducing bacteria (SRB). These bacteria are largely responsible for the continuous generation of H₂S — a highly toxic and corrosive gas that not only poses safety risks but also devalues the final product.
3. Need to Increase Market Value and Commercial Flexibility: The high H₂S content in the oil limited sales options and posed challenges in meeting the specifications of different refineries. Improving oil quality by reducing H₂S content was a direct strategy to add market value to the product and provide greater commercial flexibility with various clients.
DORF KETAL’S INNOVATIVE SOLUTION: H₂S SCAVENGER + BIOCIDE COMBO
Faced with these multifaceted challenges, Dorf Ketal developed and implemented an integrated and highly effective solution: the H₂S Scavenger and Biocide Combo product. This combined technology was designed to act on two critical fronts: neutralizing existing H₂S and controlling its biological generation.
Dorf Ketal’s product development approach focused on key components:
1. H₂S Scavenger (Seq. H₂S): A product specifically formulated to neutralize and remove H₂S from the system.
2. High-Performance Biocide: The biocide was carefully selected to target sulfate-reducing bacteria primarily. Dorf Ketal ensured that the biocide was effective in continuous treatment, with attention to optimal concentration versus dosage, and that it operated synergistically with the H₂S scavenger.
Fig.1 – SRB Biofilm Image
The compatibility between the two products was carefully validated, considering a slightly acidic pH and solvent stability, ensuring a shelf-life of 6 months.
The application of the H₂S Scavenger and Biocide Combo was strategically implemented at the company’s main production and transfer stations, aiming to treat the oil at critical points before storage at the TNC.
This continuous and targeted application was crucial to addressing the root cause of H₂S generation and accumulation.
RESULTS AND TANGIBLE BENEFITS
The implementation of Dorf Ketal’s H₂S Scavenger and Biocide Combo produced remarkable results, exceeding expectations and delivering significant value:
1. Reduction in H₂S Levels: Daily H₂S monitoring graphs showed a substantial and consistent decline at measurement points.
The results are shown below, based on measurements at strategic points.
Outlet of TqO – Station 1 and Transfer from Station 1 to TNC: Daily average H₂S levels, which previously ranged from 15 to 20 ppm, were reduced to values close to 0–5 ppm.
Outlet of TqO – Station 2 and Transfer from Station 2 to TNC: H₂S concentration, which reached 50–80 ppm, was controlled and consistently remained in the 0–10 ppm range.
Storage Terminal (TNC): The most critical point, which showed H₂S levels between 5 and 7 ppm, achieved impressive results, with H₂S content reaching zero ppm.
2. Improved Oil Quality and Commercial Flexibility: With H₂S elimination and the mitigation of triazine-related issues (corrosion, scaling, and CS₂), the quality of the produced oil improved significantly. This advancement enabled the company to meet stricter market specifications, increasing its commercial flexibility to negotiate with various refineries and consequently raising the market value.
3. Reduction of Nitrogen Compounds: The process optimization and removal of triazine resulted in reduced nitrogen compounds, a common issue in refining that can lead to fouling and other operational problems, ensuring a higher-quality feedstock for customers.
4. Economic Impact: Dorf Ketal’s successful solution translated into a direct and significant financial benefit for the company. Process optimization, improved oil quality, and greater commercial flexibility generated savings and revenue increases totaling over US$1,830,000.00 per year. This is a concrete testament to the return on investment and the value added through partnership with Dorf Ketal.
CONCLUSION
This case study demonstrates how Dorf Ketal’s integrated and specialized approach — through the development and application of the H₂S Scavenger and Biocide Combo product — was fundamental in solving complex operational challenges faced by a leading company in the oil and gas sector. The ability to efficiently control H₂S generation, optimize triazine removal, and improve final product quality allowed the company not only to overcome operational bottlenecks but also to achieve a significant competitive advantage in the market.
Quantitative results, including the elimination of H₂S at critical points, and financial benefits exceeding US$ 1.8 million per year, reaffirm Dorf Ketal as a strategic partner capable of delivering high-impact solutions that generate sustainable value and position its clients at the forefront of efficiency and profitability in the oil and gas sector. Continuous collaboration and the application of cutting-edge technologies are key to resilience and success in an increasingly demanding business environment.
