The Hidden Risks of Blending Production Chemicals
In production operations, chemical blending is often viewed as a practical way to simplify chemical management. By combining multiple treatments into a single blend, operators can reduce the number of tanks and pumps required in the field, lowering installation costs and streamlining servicing.
On paper, it makes sense. In practice, however, chemical blending can introduce challenges that are not immediately visible.
At LCO Technologies, we are seeing a growing number of cases where blended chemicals react after they have been placed into field tanks. The result is often the formation of precipitates, clouding, or particulate matter that was not present when the blend was originally prepared.
While the chemicals may appear chemically compatible during laboratory testing, they can still create mechanical issues once deployed in the field.
When Compatibility Doesn't Mean Reliability
One of the biggest misconceptions surrounding blended chemicals is that compatibility and performance are the same thing.
A blend may remain chemically stable during initial testing, yet still create conditions that compromise pumps, packing, seals, and other soft goods over time. As particulate matter forms within the tank, operators can experience increased wear, plugging, and maintenance requirements throughout the chemical delivery system.
More importantly, the chemical itself may no longer perform as intended driving up chemical consumption.
When precipitates form, the composition of the chemical blend changes. This can reduce the effectiveness of the treatment and ultimately impact the results operators expect to achieve.
In other words, even if a blended chemical appears acceptable at first glance, its long term performance may tell a different story.
The Cost of Separation Is Smaller Than You Think
When compatibility concerns arise, the solution is often straightforward: separate the chemicals.
Some operators hesitate because they assume separating treatments will require significantly more equipment in the field. In reality, the cost difference is often minimal.
LCO's chemical injection systems can support multiple injection points from a single pump platform. With four pumping heads available on many configurations, separating chemicals does not necessarily mean installing additional pumps.
The result is better control over each treatment while preserving the intended effectiveness of the chemicals being injected.
Rather than compromising performance for convenience, operators can maximize the value of their chemical programs by keeping incompatible products separate.
Why Field Conditions Matter
A common challenge when investigating compatibility issues is that supplier samples do not always reflect real operating conditions.
Chemical producers and blenders may test products in sealed containers where little or no oxygen exposure occurs. In the field, however, storage tanks are vented to atmosphere. This introduces oxygen that can influence chemical behavior over time.
As a result, a blend that appears perfectly clear in a laboratory sample may begin forming particulates after exposure to real operating conditions.
This is why field validation is so important.
Building Confidence Before Installation
The Chemical Testing Kit was created to give operators that missing layer of visibility before deployment. Instead of discovering incompatibility in the field, the kit allows users to test chemical behavior in advance using controlled samples and real material comparisons.
The kit evaluates how a chemical interacts with LCO O-Ring materials and whether reactions such as sediment formation occur under exposure conditions. This helps operators identify potential issues early and adjust filtration requirements or material selection before installation.
Each kit includes:
- 1 × 500 mL jar
- 2 × 2 oz jars
- 2 × XF1 O-Rings
- 2 × XF2 O-Rings
- 2 × Teflon O-Rings
- 1 × One N' Done sample cut in half
Your chemical supplier may say, “Our samples look fine.” Tell them to take the lid off the bottle. Your tanks are vented, and everything changes in the presence of oxygen.
Operators can also perform oxygen exposure testing to determine whether a chemical remains stable or begins to form constituents after being exposed to air. If changes occur, you could identify the issue before it reaches the field, potentially saving your employer a significant amount of time and money.
While installing a filter before the pump may help protect the equipment, it only addresses the symptom rather than the root cause. In these cases, a different approach to chemical management may be required.
Verify Before You Deploy
Chemical compatibility issues are not always obvious until they begin affecting equipment performance and treatment effectiveness in the field.
Rather than relying solely on supplier data or laboratory samples, operators can validate chemical behavior under conditions that more closely reflect real world operations.
By testing before deployment, identifying incompatibilities early, and separating chemicals when necessary, operators can protect equipment, maintain chemical performance, and avoid costly surprises down the road.
At LCO, our goal is simple: help operators get the maximum value from every chemical treatment by providing the tools and insights needed to prevent compatibility issues before they impact operations.
As Steve Froehler puts it:
“There is no chemical known to our industry that will produce longitudinal striations on a nitrided 17-4 PH plunger. If there are striations its mechanical not chemical. If you figure it out you will use less chemical AND have lower maintenance costs, guaranteed.”
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