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Modular hydrodynamic cavitation processing unit.
Purpose:
Industrial continuous-duty unit. Designed for stationary installation within oilfield infrastructure.
Throughput:
2,400 barrels per day (16 m³/h)
Weight:
7,400 kg
Configuration:
Explosion-proof enclosure for use in hazardous areas (Ex db eb IIB T4)
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Prepared oil enters the inlet pipeline and is fed by a screw pump for cavitation processing. Simultaneously, a modifier — liquefied hydrocarbon gas (LPG or equivalent) — is delivered via a diaphragm metering pump, with flow rate monitored by a flow meter.
The oil and modifier enter the mixing unit for initial blending. The resulting two-phase mixture is directed into the hydrodynamic cavitator, where high-intensity cavitation fields generate localized pressure drops through instantaneous hydrocarbon vaporization, causing rupture — partial cracking — of long-chain hydrocarbons and their transformation into shorter-chain hydrocarbons.
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Date of analysis:
November 1, 2024, 09:02
Laboratory:
Laboratorio de Hidrocarburos, Calle 200 N° 10-77, Floridablanca, Sede Principal
Executor:
PSL Pro Análisis (Colombia)
Reports:
LHC-24-0482-01, LHC-24-0482-03
Applied standard:
ASTM D7169-23
Initial product:
drilling oil sludges from Crudo Blanco crude oil (Tocancipá field, Colombia), unsuitable for direct processing.
Objective of the study:
To evaluate the effect of TCH cavitation technology on the processability of oil sludges.
The initial product (Sample Fondo #14) was a blend of seven heavy crude oils with an API of 16 and a viscosity of 2,980 cSt at 30 °C, delivered to the Hidrocasanare refinery (Yopal, Colombia) via the Ecopetrol pipeline. The product was characterized as difficult to process, with low content of light fractions and a high volume of residue above 500 °C.
Laboratory tests: September 14 – October 3, 2020. Pilot tests: October 30 – November 2, 2020, using industrial cavitation unit CAV-90 (up to 1,400 bbl/day) in Tocancipá, Colombia. The oil was delivered in 220-barrel totes, preheated to 35 °C. Three totes (660 barrels) were processed.
During the tests, various operating modes were applied:
Samples 3/0 and 3/A were taken using built-in online samplers, reflecting the influence of parameters on the processing result. Sample CAV was obtained under laboratory conditions with the addition of 3% diesel-based modifier.
After applying TCH cavitation technology, fractional analysis per ASTM D7169 revealed significant compositional changes. Key outcomes:
Conclusion: laboratory and pilot tests demonstrated that TCH technology significantly improves the processability of heavy crude oil without requiring modifications to the existing refinery configuration.
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Analysis date:
November 3–7, 2020
Laboratory:
Texas OilTech Laboratories
Reports:
2377-14, 2430-01, 2457-07, 2457-08
Standard applied:
ASTM D7169-20
Feedstock:
a blend of 7 crude oil grades delivered by pipeline from various Ecopetrol fields
Research objective:
evaluating the effectiveness of TCH technology for increasing light fraction yields from heavy feedstock processed at the Hidrocasanare refinery (Yopal, Colombia).
The initial product (Sample Fondo #14) was a blend of seven heavy crude oils with an API of 16 and a viscosity of 2980 cSt at 30 °C, delivered to the Hidrocasanare refinery (Yopal, Colombia) via the Ecopetrol pipeline. The product was characterized as difficult to process, with low content of light fractions and a high volume of residue above 500 °C. Two modifying agents were simultaneously introduced: 6 vol.% LPG (density 500–550 kg/m³) and 8 vol.% naphtha (density 680–730 kg/m³).
Laboratory tests were conducted from September 14 to October 3, 2020. Pilot tests were carried out from October 30 to November 2, 2020, using an industrial cavitation unit Cav-90 (capacity up to 1,400 barrels/day) at the site in Tocancipá (Colombia).
The oil was delivered in 220-barrel totes and preheated to 35 °C. After cavitation processing, the product was discharged into clean storage tanks. A total of three totes (660 barrels) were processed.
During the tests, various operating modes were applied, including adjustments of:
Samples 3/0 and 3/A were taken using built-in online samplers and reflect the influence of parameters on the processing result. Sample CAV was obtained under laboratory conditions with the addition of 3% diesel-based modifier.
After applying the TCH cavitation technology: Fractional analysis according to (ASTM D7169) revealed significant compositional changes: post-processing, the oilcontained fractions with a boiling point below 180 °C, which were previously absent. The yield of fractions in the 180–360 °C range (diesel components) significantlyincreased, while the content of heavy residues with boiling points above 500 °C decreased from over 50% to below 15%.
The greatest effect was achieved using LPG- and naphtha-based modifiers, which provided not only physical stabilization but also chemical transformation ofhydrocarbons.
Conclusion: The conducted laboratory and pilot tests demonstrated that TCH technology significantly improves the processability of heavy crude oil without requiring modificationsto the existing refinery configuration.
Project initiator:
Ecopetrol S.A. — the national operator of oil and gas infrastructure in Colombia
Research objective:
To evaluate the effectiveness of TCH technology for reducing viscosity and increasing the API of heavy and highly viscous crude oils, with the goal of reducing the need for diluents, improving flowability, and ensuring reliable pipeline transportation through Ecopetrol’s infrastructure.
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| Oil sample | API before treatment | API after treatment | Viscosity at 30°C before, cSt | Viscosity at 30°C after, cSt |
|---|---|---|---|---|
🇵🇪 Jibarito | 8.5° | 11.5° | 99,600 | 22,000 |
🇵🇪 SanJacinto | 9.2° | 14.7° | 75,000 | 21,000 |
🇨🇴 Girasol | 10.9° | 13.5° | 7,500 | 1,600 |
🇨🇴 Jazmin | 11.3° | 14.2° | 8,350 | 1,800 |
🇨🇴 Rubiales | 12.8° | 16.0° | 5,700 | 800 |
🇨🇴 Castilla | 10.7° | 14.6° | 12,000 | 1,700 |
🇨🇴 Chichemene | 9.5° | 14.7° | 58,180 | 11,400 |
In all tested samples, a significant reduction in oil viscosity was observedfollowing TCH treatment — averaging 70–85%. This enables pipelinetransportation without the use of traditionally high volumes of diluents orany additional heating.
Simultaneously, an increase in API gravity by 3–5 degrees was recorded,indicating a reduction in density and improvement in the physicochemicalproperties of the crude, bringing it closer to specifications required forstandard transportation and refining.
The achieved effect remained stable for 60–120 days, confirming the longterm stability of the treated feedstock during storage and throughout thelogistics chain.
The use of TCH technology enables a 10–15% reduction in distillatecomponent consumption (diesel or naphtha) compared to the baselinepreparation scheme, thereby reducing operating costs.
Additionally, the technology helps reduce the load on pipeline and pumpingequipment, simplifies flow management, and allows for the integration ofpreviously marginally transportable residual streams into the system.
Conclusion: The conducted tests demonstrated that TCH technology effectively reducesthe viscosity and density of heavy oil to levels that enable stable pipelinetransportation.As a result, the need for diluents is significantly reduced, and preheating isno longer required, which lowers operational costs and simplifies theintegration of heavy fractions into the existing logistics chain.This technology can be implemented within the current infrastructure withoutthe need for major modifications.
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Description:
Mechanical blending of a heavy residual component — typically HFO No. 6 orvacuum residue — with up to 25% of lighter fractions (diesel fuel, gasoil) toachieve the required fuel specifications.
Limitations:
Description:
Deep processing of heavy fractions using hydrogen and catalysts. The resultingproduct is stable, low in metals and sulfur, and has predictable performancecharacteristics.
Limitations:
Description:
Blending only pre-verified and compatible components — such as hydrotreatedresidues, deasphalted oils (DAO), and low-sulfur gasoils. This method excludesthe use of unstable fractions like vacuum bottoms or visbreaking residues.
Advantages:
Limitations:
Prior to the implementation of TCH technology, the Refiantioquia refinery inMedellín (Colombia) specialized in the production of IFO 180 marine fuel usingdirect component blending.
The process flow involved residual mazut (HFO No. 6) diluted with up to 25%diesel fuel to adjust viscosity, density, and pour point in accordance with ISO8217 (RMG/RME) specifications.
The finished fuel was delivered to the port of Buenaventura on the Pacificcoast, where it was used for bunkering commercial and transit vessels —including bulk carriers, container ships, and tankers.
However, mechanical blending failed to ensure adequate fuel stability andflowability, complicating the bunkering process and increasing operational costsdue to high distillate consumption.
In 2022, an automated industrial unit based on TCH cavitation technology witha capacity of 1,500 barrels per day was commissioned at the Refiantioquiarefinery.The new module was integrated into the existing infrastructure and designedfor the deep physico-chemical processing of residual mazut (HFO No. 6),partially replacing the conventional mechanical blending process.
Controlled cavitation enabled thorough molecular dispersion and activation ofhydrocarbon bond redistribution, resulting in: