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The present article aims to decipher the effect of preheating a segment of the pipe on the pressure propagation mechanisms and flow restart operation in a gelled pipeline. During the restart operation, shear-thinning thixotropic rheology governs the gel properties, where the viscosity is a function of shear strain and thermal history. A finite volume method is employed to solve the governing equations for a weakly compressible gel. Rheology of the initial gel incorporates the effect of temperature distribution from the preheating stage. Flow restart in the thixotropic gel involves three different timescales: namely, the compressive diffusion timescale (acoustic wave propagation timescale), the viscous timescale, and the gel degradation timescale. In an isothermal case, the flow restart occurs at the gel degradation timescale, whereas flow restart in the preheated gel takes place at the viscous timescale. Time evolution of nonlinear axial pressure profile and residual viscosity provides a theoretical understanding of the gel degradation process in the thermal diffusion-controlled and advection-controlled flow regimes, defined in terms of Peclet number (Pe). The results indicate that the gel degradation process is affected by thermal-induced melting in addition to shear melting. Partial preheating tends to dislodge the gel into plugs, and this is more significant at low Pe and high pristine gel strength. The local Nusselt number (Nu) at the heated portion of the wall during flow restart suggests that the wall-heat transfer is prominent when the pressure wavefront has not reached the outlet.

Abstract

Flow assurance challenges associated with waxy crude oil precipitation at low ambient conditions are significant concerns for oil industries during production, transportation, and storage. Numerous methods have been employed to mitigate wax deposition and gelation issues. Since wax precipitation is temperature-sensitive, heating has emerged as a promising method to enhance oil flowability. The present work intends to examine the degelation behavior of waxy oil using rheometry, differential scanning calorimetry, and microscopy techniques. In addition, a non-isothermal flow restart simulation is performed using an in-house numerical simulator consisting of a rheological model of sol–gel transition developed in the current work. A numerical simulation of a preheated gelled pipeline demonstrates the significance of the degelation temperature. The effects of the wax concentration, initial gel temperature, and aging period on the degelation temperature are examined. The observed degelation temperature is higher than the gelation temperature, leading to thermal hysteresis. The extent of thermal hysteresis reduces with a decrease in the heating rate. The numerical simulation uses the finite volume method with variables placed on a staggered grid. The gel heated above and below the degelation temperature shows a significant variation in axial velocity profiles. However, further heating does not affect the velocity profiles. A shear banding type of effect is observed in the axial velocity profile above the degelation temperature. Heating the gelled oil to the degelation temperature instead of the wax disappearance temperature saves excessive heating energy during storage and transport operations.

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