Emulsion Synthesis Using Different Benchtop Ultrasonic Homogenizers
produced water; emulsion; ultrasound; acoustic cavitation; stability
Produced water is the main liquid effluent generated during oil production, composed of a mixture of water, oil, suspended solids, and distributed ions, which often form emulsions that are difficult to separate. Considering that such emulsions, when used for reinjection, can contribute to issues such as loss of injectivity and formation damage, studying the behavior of these dispersions, even in laboratory models, is essential to understanding their effects on oil recovery operations. In this work, model produced water emulsions were obtained under controlled laboratory conditions using ultrapure water, NaCl, NaOH, and oil, based on the ultrasound-assisted emulsification (UAE) technique. Three benchtop ultrasonic homogenizers classified as high-intensity ultrasound (HIU) were evaluated: UP400St (Hielscher), EcoSonics (Ultronique), and BH-2000Q (Sino Sonics). The tests sought to correlate the operational parameters of each equipment—such as power, amplitude, sonication time, operating mode, and sample volume—with emulsion stability and droplet size distribution. The best results were obtained with continuous sonication, high intensity, and a processing time of approximately 40 minutes for volumes up to 500 mL. Under these conditions, unimodal distributions with an average diameter of less than 10 µm were obtained. However, at volumes (2L), a reduction in emulsification efficiency was demonstrated, reducing the need for operational adjustments or additional strategies to maintain dispersion quality.