A nanohybrid polymer as a high-performance flow improver: experimental and CFD analysis for waxy crude oil transportation

The extraction and transport of high-viscosity, high-pour-point crude oils present significant technical and cost challenges. While nanoparticle-based additives offer a promising avenue for improving flow properties, their practical application requires robust validation. This work details the synthesis of a novel nanohybrid polymer via oleic acid-functionalized nanosilica copolymerized with vinyl imidazole, icosyl acrylate, and maleic anhydride and its comprehensive evaluation as a flow improver for Indian waxy crude. Experimental analysis confirmed a substantial improvement in rheological behavior, with a 9 °C reduction in pour point and a > 60% decrease in viscosity. To assess the feasibility of field-scale application, the experimental data were further employed in a computational fluid dynamics (CFD) simulation using ANSYS Fluent 2024. The simulation results demonstrated an increase in the liquid fraction of crude oil by more than 60% and a reduction in pressure drop exceeding 78.8%. These findings underscore the efficacy of the synthesized nanohybrid polymer as a promising flow improver additive for enhancing the transportability of Indian waxy crude oils. Despite promising flow improvement, the performance of the nanohybrid additive may vary with crude oil composition and operating conditions. Future work will focus on aging studies, field-scale validation, recyclability and comprehensive environmental and lifecycle assessments.