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<p>Separation of water emulsions in crude oil, especially under salinity conditions and operating temperatures, remains one of the key challenges in the oil and wastewater treatment industries. In this study, a hybrid system based on activated bentonite and sodium dodecyl sulfate (SDS) as a combined demulsifier was introduced and systematically optimized. The results showed that the mixing ratio plays a decisive role in the performance of the system, such that the optimal formulation of 75% bentonite/25% SDS produced the highest synergy. This combination achieved a separation efficiency of about 93.6% at a dosage of 25 g/L and a temperature of 60 °C. The study of the effect of salinity showed that increasing the NaCl concentration to 1–2% led to a slight improvement in the efficiency (up to about 95.8%), while no significant decrease in performance was observed at higher salinities, indicating the operational stability of the system. FTIR analysis confirmed the stable adsorption of SDS on the bentonite surface via ion exchange, leading to an amphiphilic character: the outward-oriented hydrophobic alkyl chains impart partial hydrophobicity, while residual hydrophilic sites (e.g., –OH, Si–O) remain accessible. This dual nature underpins a synergistic demulsification mechanism involving controlled reduction of interfacial tension and enhanced particle bridging [33,36]. This hybrid system with lower surfactant consumption, high efficiency, and good stability in saline conditions is introduced as a cost-effective and reliable option for industrial applications. This study provides a comprehensive parametric evaluation of a hybrid bentonite-SDS demulsifier under industrially relevant conditions, identifying the optimal formulation and operational window through systematic experimental screening.</p>

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Synergistic demulsification of water-in-crude oil emulsions by bentonite-sds blends: mechanism and performance characterization

  • 期刊论文

  • 发表日期：

    2026年4月20日

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  • Ali Hasan Abdulla,
  • Mohammad Ghorbanpour,
  • Hamid Erfan-Niya

摘要

Separation of water emulsions in crude oil, especially under salinity conditions and operating temperatures, remains one of the key challenges in the oil and wastewater treatment industries. In this study, a hybrid system based on activated bentonite and sodium dodecyl sulfate (SDS) as a combined demulsifier was introduced and systematically optimized. The results showed that the mixing ratio plays a decisive role in the performance of the system, such that the optimal formulation of 75% bentonite/25% SDS produced the highest synergy. This combination achieved a separation efficiency of about 93.6% at a dosage of 25 g/L and a temperature of 60 °C. The study of the effect of salinity showed that increasing the NaCl concentration to 1–2% led to a slight improvement in the efficiency (up to about 95.8%), while no significant decrease in performance was observed at higher salinities, indicating the operational stability of the system. FTIR analysis confirmed the stable adsorption of SDS on the bentonite surface via ion exchange, leading to an amphiphilic character: the outward-oriented hydrophobic alkyl chains impart partial hydrophobicity, while residual hydrophilic sites (e.g., –OH, Si–O) remain accessible. This dual nature underpins a synergistic demulsification mechanism involving controlled reduction of interfacial tension and enhanced particle bridging [33,36]. This hybrid system with lower surfactant consumption, high efficiency, and good stability in saline conditions is introduced as a cost-effective and reliable option for industrial applications. This study provides a comprehensive parametric evaluation of a hybrid bentonite-SDS demulsifier under industrially relevant conditions, identifying the optimal formulation and operational window through systematic experimental screening.