The
processing, production, and transport of heavy crude oils are
big challenges for the petroleum industry. Central to this challenge
is the fluid viscosity: the key variable responsible for the oil fluidity
throughout the entire production process. From the reservoir to delivery
conditions, oils undergo large variations in temperature and pressure,
which may cause important phase behavior and physicochemical changes,
directly affecting the fluid’s thermophysical properties. In
the case of heavy oils, such a broad change of conditions categorically
results in several orders of magnitude viscosity span, including the
possible Newtonian to non-Newtonian rheological behavior transitions.
It is, therefore, of primary importance that heavy oils be rheologically
well-characterized to ensure their production process is successful
and viable. The viscosities of heavy and extra-heavy crude oils in
extreme conditions (high pressure, high to low temperature, high to
low shear rate) are, however, difficult for most service laboratories
to fully measure directly. Several lapses may occur when measuring
the full range of required conditions using traditional rheometers;
for example, for such viscous fluids, the development of laminar-flow
structural anomalies (eddies) and magnetic decoupling in the high-pressure
cell are common practical problems. In an attempt to pragmatically
address these problems, in this work, a methodology that may allow
for the rheological characterization of heavy and extra-heavy oils
within the full field operational range, but based on limited laboratory
measurements, is proposed. The proposed approach does not follow from
a simple extrapolation but is rather derived from the concept of control-variable
shifting. For achieving this, the superposition principle is applied
to shear-temperature and shear-pressure reliable measurements to construct
master curves to rheologically characterize the fluid within conditions
that may be too severe for direct laboratory measurements. This methodology
has been successfully applied to a database of 20 Mexican fluids,
going from extra-heavy to light fluids. The rheologies of the samples
were originally studied using three different types of equipment:
(1) a strain-controlled rheometer (for the measurement of the fluid
rheology at ambient pressure and different temperatures), (2) a sliding
piston viscometer for high-pressure and low-shear-rate viscosity measurements,
and (3) a hybrid rheometer coupled with a pressure cell for the estimation
of the fluids rheological behavior under pressure and high shear rate.
The rheological behavior of crude oils could then be obtained at conditions
as severe as the equipment allowed (up to 1000 bar and, in some cases,
shear rate up to 1000 s–1). The master curves allowed,
however, to extend the rheological characterization of the fluids
within conditions that were beyond the laboratory capabilities.