Maximizing enhanced oil recovery via oxidative cracking of crude oil: employing air injection and H₂O₂ with response surface methodology optimization

Abstract

The utilization of air injection as a method to enhance oil recovery in oil fields has gained prominence due to its cost-effectiveness and widespread availability, particularly in heavy oil production. This study focuses on optimizing the oxidative cracking process of Algerian crude oil by employing air injection supplemented with H2O2 and analyzing the interaction of key operating parameters like temperature and catalyst amount using response surface methodology. The predicted values derived from the response functions closely aligned with experimental data, demonstrating high accuracy (R2 = 0.9727 for liquid oil, R² = 0.9176 for residue, and R² = 0.7399 for gas phases). Using the developed second-order model, optimal conditions were determined through contour and surface plots, as well as regression equation analysis using Design software. At these optimal parameters (14.78 wt. % of H2O2, 2 L/min of air flow, 100 mL of crude oil at 354.05 °C for 40 minutes), the oxidative cracking process yielded 96.32 % liquid oil, 3.018 % residue, and 0.662 % gas products. Notably, the experimental produced liquid oil constituted 96.07 vol. %, matching well with the optimization outcomes. Physicochemical analysis of liquid product phase obtained from oxidative cracking process of petroleum confirmed the prevalence of light aliphatic compounds (C2-C11) at 70.59 %, alongside 29.41 % of C12-C36. The process also resulted in reduced viscosity, density, refractive index, and sulfur content in the liquid phase. The combination of air injection and H2O2 showcases promise in recovering residual oil effectively and contributes to the ongoing advancements in EOR techniques.