DESALTERS

SECTION 3: DESALTERS
Benefits Of Crude Oil Desalting

Crude oil is most often produced as a water-in-oil emulsion containing large quantities of dissolved salts
and suspended solids. The salts are mostly chloride, sulfate and carbonate salts of calcium, magnesium
and sodium. The solids are typically silt, sand, clay, iron oxides, and iron sulfides. Crystalline salts may
also be present.
The contaminants frequently found in crude oil arise from several sources:
Brine contamination in the crude is a result of the brine associated with the oil in the ground,
Most minerals, clay, silt, and sand found in the oil come from the formation around the oil well bore,
and
Iron sulfides and oxides are the result of corrosion during production, transport, and storage.
Though most of these impurities are removed in normal field treating operations there are trace
quantities of water and oil-wetted solids present which are either difficult or uneconomical to remove at
the production site. Crude oil can also become contaminated during shipping. For example, solids can
be picked up in pipelines and terminal storage facilities or the oil can become contaminated with sea
water ballast in ocean-going vessels. Waste oils and other unknown chemicals can also be added to the
crude at the production site or during transportation without the refinery's knowledge.
Crude oil desalting is accomplished by mixing fresh water with the incoming crude to "wash" salts and
solids from the crude. The addition of fresh water does several things:
It helps coalesce small water droplets into larger ones that are more easily removed,
It reduces the total salt content of the crude, and
In conjunction with the addition of demulsifier and/or wetting agents provides a medium for their
removal.
If the contaminants are not removed before the crude oil enters the crude unit preheat system they can
cause corrosion and fouling. Effective crude oil desalting can help minimize the effects of these
contaminants on the crude unit and downstream operations. Proper desalter operations provide the
following benefits to the refiner:
Reduced Crude Unit Corrosion. At the high temperatures found in crude unit
atmospheric and vacuum furnaces the chloride salts of calcium and magnesium can
hydrolyze, forming gaseous hydrogen chloride (HCl). The chemistry of this process is as
follows:
Heat
MgCl2 + 2H2O ===> Mg(OH)2 + 2HCl
Heat
CaCl2 + 2H2O ===> Ca(OH)2 + 2HCl
3.1
The HCl gas will dissolve in water to form highly corrosive hydrochloric acid. This
problem can be found in the overhead condensing systems of distillation towers, where
the steam is allowed to condense. Proper desalting will minimize the amount of HCl
generated, and will greatly reduce corrosion potential in the crude unit.
Reduced Crude Preheat System Fouling. Solid particles can deposit in crude unit
preheat exchangers or furnace tubes reducing heat transfer rates and/or cause plugging
of the tubes. Also, if sodium is not removed from the crude oil it can act as a catalyst for
coke formation in heat exchangers, furnace tubes and transfer lines. A good desalting
operation will reduce fouling potential by removing a high percentage of crude oil solids
and by minimizing the amount of sodium in desalted crude.
Reduced Potential for Distillation Column Damage. Water slugs in the crude charge
can cause damage in the crude distillation tower. Pressure surges created when this
water is vaporized to steam often disrupt tower internals. Properly designed desalters
will significantly reduce carryover of water in the incoming crude oil.
Reduced Energy Costs. Excess water in the desalted crude oil also requires more
energy to heat in the crude furnace. An efficient desalter will provide energy savings by
minimizing the amount of water in the desalted crude.
Reduced Downstream Process and Product Contamination. Certain impurities such
as sodium and potassium can poison catalysts in downstream processes. Excess sodium
and iron in petroleum coke can reduce its market value. A good desalting operation will
reduce the amount of sodium, potassium and iron in desalted crude, minimizing the
deleterious downstream effects of these contaminants.
When properly operated, the desalter should provide a crude oil containing 0.1 - 04% basic sediment and
water (BS&W) with a salt content often less than 1 lb of salt/1000 barrels of oil (PTB). An exception to
this would be on the West Coast where many of the heavy crudes are difficult to desalt to less than 4
PTB. A refinery which is not meeting these levels at the present time provides an opportunity for an
improved program using chemical demulsifiers.
A single stage desalter should provide 90-95% salt removal for a typical crude oil. The efficiency of
filterable solids removal is usually 50-75%. In instances where high efficiency is required, a second
desalter is added after the first. Overall two-stage desalting efficiency can be as high as 98%. Two
stage desalting is becoming more prevalent as refiners strive to control the contamination of downstream
processes and reduce crude unit down time due to corrosion and fouling of equipment.
3.2
Description Of The Crude Oil Desalting Process

Desalting of crude oil is accomplished by injecting 3% to 9% wash water into the crude, thoroughly
mixing the water and crude oil, and then providing efficient separation of the two phases. The
emulsification or washing step is accomplished primarily through a mixing valve which causes emulsion
formation due to the high energy dissipation (pressure drop) across the valve. Separation of the water
from the crude oil is accomplished in a "desalter" which is a pressure vessel. The normal gravity
separation of water from the crude oil in the vessel is accelerated with the use of an electrical field, heat,
and emulsion breaking chemicals.
Here is a brief review of the desalting process, starting with the crude oil as it enters the refinery crude
storage area.
Crude Storage Tanks

Crude oil can enter the refinery via pipeline or from ships and barges. The crude oil is sent to large steel
storage tanks in an area of the refinery known as the tank farm. The tank farm is a storage area for crude
oil and intermediate and finished products. Figure 3.1 is a diagram of a typical refinery crude storage and
single stage desalting operation.
R e finery C rude O il H a n d lin g S y s tem

Barge or Tanker
Crude Oil
Refinery Tank Farm

Tank 1
Pipeline
Crude
Oil
Tank 2
Pipeline
Terminal
Crude
Storage
Crude Oil
Booster
Pump
Crude Oil Desalter
Tank Farm
Crude Pump
Tank 3
To Hot Crude
Preheat
Exchangers
BIC
Emulsion
Breaking
Chemical
Cold Crude
Preheat
Exchangers
Mix
Valve
Interface
Level
Controller
Crude
Charge
Pump
Desalter
Effluent Water
Pump
Desalter
Wash Water
Figure SECTION 3: .1
Crude storage tanks vary in size from 40,000 to 500,000 bbls each. Storage tank designs also vary, but
most tanks have some kind of floating roof design. In this type of tank the roof floats on the crude oil so
the level of the roof rises and falls with the level of crude oil in the tank. Most floating roof tanks are
external, that is there is no fixed steel roof covering the top of the tank and its floating roof. Rain water is
removed from the top of the external floating roof by a drainage system that empties into a sewer outside
the tank.
3.3
Crude tanks can have separate lines and nozzles for filling and removing crude oil from the tank, or
there may be a common suction/fill line and nozzle. Tank suction nozzles are usually fixed at a height of
2-4 feet from the tank bottom. Occasionally a crude tank will have a floating suction line. This means that
the suction line is flexible and the nozzle is suspended from the bottom of the floating roof. There are
sumps and drain lines in the bottom of the tanks to allow draining of settled brine to a sewer. Some
tanks have internal mixers to prevent stratification of the tank contents and to keep solids from collecting
in the bottom of the tank. Some storage tanks also have internal steam coils and external insulation to
keep the crude oil warm enough to pump.
The way the refinery handles the crude oil in the storage area can significantly affect the quality of the
crude charged to the crude unit. Some refiners will transfer oil to a tank, allow the brine to settle for a few
days, drain the brine to a sewer, and then send well-dehydrated crude to the unit. Other plants may fill a
tank on one side while pulling suction on the other, with all mixers on and the sump drain valve
permanently closed. This operating mode will obviously result in higher BS&W levels in the crude oil sent
to the crude unit.
Crude Unit Charge Pumps and Preheat Exchangers

Figure 3.2 is a schematic of a single-stage desalter operation. Crude oil is transferred from the storage
tank through the crude preheat exchangers and into the desalter with a centrifugal pump. These pumps
can be located at the crude unit or in the tank farm. Wash water is added to the crude oil upstream of the
desalter. Wash water can be injected ahead of the preheat exchanger train or the mix valve. Some
operations utilize both water injection locations. The crude oil and water mixture passes through the mix
valve ahead of the desalter vessel.
Single Stage Electrical Desalter

Crude Oil to
Hot Crude Preheat
Exchangers
Crude Oil
Storage Tank
Transformer
Emulsion Breaker
Interface
Level
Controller
Crude
Charge
Pump
Mix Valve
Wash Water
to Mix Valve
Desalter
Wash Water to Cold

Crude Preheat Exchangers
Wash Water
Desalter Effluent Water to
Waste Water Treatment Plant
The preheat exchangers are shell and tube heat exchangers that recover heat from various crude tower
side-streams. The crude oil is usually on the tube side of these exchangers. Streams such as naphthas,
top pumparound, and kerosene are typically used to heat the crude oil to the desired desalting
temperature.
3.4
The desalter temperature is determined by its location in the crude preheat system. The characteristics
of the crude oil that the unit was designed to process determine where in the preheat system the desalter
is located. These characteristics include the amount of heat recovery anticipated from the various
distillation cuts and the temperature-viscosity behavior of the oil. These effects are described in more
detail in the section on emulsion breaking.
Wash Water Injection

Wash Water Injection Locations
Wash water is usually injected into the crude oil ahead of the mix valve. However, under certain
conditions it may be beneficial to add part of the wash water upstream of the crude preheat exchangers.
Many crudes contain dissolved calcium carbonate and other salts in the brine which exhibit inverse
solubility. As the temperature of the crude increases, these salts can precipitate from solution and form
a heavy scale in the preheat exchangers. This scaling reduces heat transfer, increases exchanger
cleaning costs, and can limit crude unit capacity. Adding wash water ahead of the preheat exchangers
reduces the scaling tendencies of these compounds by diluting the scale forming salts. Wash water will
also help remove some particulate solids that may foul the exchanger.
Adding wash water ahead of the preheat system may also be beneficial where the crude being processed
is particularly sensitive to mixing. If the crude oil emulsion created by normal mix valve pressure
differentials cannot be effectively resolved in the desalter, a more gentle mixing can be achieved by
adding a portion of the wash water ahead of the preheat exchangers and decreasing the mix valve
pressure drop. Salt removal efficiency can be maintained because of the longer water/oil contact time
when water is added ahead of the preheat. Because of the higher process pressures at the front end of
the preheat train, an additional wash water pump is sometimes required.
Wash water should not be added to the suction of the crude charge pump because the high mixing
energy created by centrifugal pumps will form a very tight emulsion that is difficult to separate.
The dissolved mineral content of the wash water should be checked to make certain it will not contribute
to scaling at the elevated temperatures in the preheat system.
Wash Water Rates
The amount of wash water used depends on the characteristics of the crude and the capabilities of the
equipment on the unit. Occasionally the wash water rate is limited by the availability of suitable wash
waters or by environmental constraints on the amount or quality of waste water leaving the plant.
Refiners normally add 4-6 volume percent wash water to the crude oil. Lower gravity crude oils (i.e. 1524 API) typically require 6-9 volume percent wash water for optimum performance. This is because a
higher droplet population density is needed to provide adequate coalescence in the more viscous lowgravity crudes. This is discussed in more detail in the section on emulsion characteristics.
If too little wash water is used, desalting efficiency can be reduced. This is because the water droplets in
the emulsion formed by the mix valve will be too far apart to collide with other droplets and coalesce in
the electrical field. The result is less water removed from the crude. There is also less of a dilution effect
on the brine that does remain in the crude.
If too much wash water is used, the resulting emulsion can become conductive enough to cause current
to flow between the grids, with a resulting decrease in voltage gradient. This reduces the driving force for
droplet polarization, coalescence in the electrical field, and reduces desalting efficiency.
3.5
Wash Water Sources

Common sources of desalter wash water include:
stripped sour water.
unstripped process waters, such as preflash, atmospheric, and vacuum

tower overhead condensates; and
municipal water (soft water only);
settled or filtered surface water (soft water only);
well water;
The kind of wash water used depends on the relative quality, cost, and availability of potential wash
water sources. Municipal water and treated surface waters are usually good sources of wash water
because they contain few contaminants. Well waters are usually suitable but can cause brine exchanger
scaling if the hardness levels are too high. Stripped and unstripped process waters are cheaper sources
of wash water. These are often used to help remove contaminants such as phenols from the water.
The disadvantage of using process water is that it can contain contaminants such as iron sulfide which
can accumulate at the desalter interface and stabilize the emulsion. Emulsion stabilization can also
occur if the pH of these process waters is high. High pHs are common in process waters due to the
presence of ammonia and the addition of caustic at the sour water strippers to improve tower stripping
efficiency. High pH emulsion stabilization is particularly troublesome with crudes high in naphthenic acid
content. Naphthenate salts can be formed. They are strong surfactants and can cause high water
carryover and oily effluent water. Some vacuum tower condensates also contain tight oil-in-water
emulsions that can be difficult to break in the desalter.
Desalter Mix Valve

Purpose
The mix valve is designed to provide enough shear energy to overcome the oil/water interfacial surface
tension and ensure thorough contact between the wash water and the crude oil. This is accomplished by
the energy dissipation (pressure drop or P) taken across the valve. The higher the pressure drop the
greater the mixing energy and the smaller the water droplets become.
P Settings
Mix valve pressure drop is an important operating parameter in the desalting system. The pressure drop
or energy input directly affects the washing efficiency and the ability to separate water and oil in the
desalting vessel. If the mix valve P is too low, the contact between wash water and crude oil will be
insufficient to achieve adequate desalting and solids removal. If the P is too high, the water will be
emulsified into the crude oil to such a degree that it becomes difficult to separate the oil and water
phases in the desalter. Again, desalting efficiency is reduced and more oil can be present in the brine.
3.6
Desalter Vessels
As mentioned earlier, desalting is a gravity separation of oil and water aided by heat, chemicals, and an
electrical field. This separation occurs in the desalting vessel, which is usually an insulated horizontal
cylindrical pressure vessel with hemispherical or ellipsoidal heads. These vessels are usually 10-14 feet
in diameter and typically range from 20-140 feet in length. Some spherical desalters vessels are also in
use.
Electrical Grids
Most desalters utilize an electrical field to promote the coalescence of water droplets from the emulsion
layer in the desalting vessel. The effects of an electrical field in breaking crude oil emulsions are
explained in Section IV of this manual under Electrical Field.
In desalters, this electrical field is established between horizontal steel grids that cover most of the crosssectional area of the vessel where the grids are located. The physical size and layout of these electrodes
determines the size of the treating field in each vessel. The treating field size limits the maximum
effective desalting unit throughput for a given crude oil.
Grid separation usually ranges between 6 and 12 inches. Each hot grid has a transformer that increases
the voltage of the normal plant AC power supply (usually 440 V) to the secondary or grid voltage. This
secondary voltage will reach 12 to 23 kV, depending on unit design. Voltage and amperage indicators for
each grid are mounted on a panel next to the desalter and provide an indication of the condition of
electrical fields within the vessel. A decrease in voltage accompanied by increased current draw is an
indication that the conductivity of the crude oil between the grids is increasing.
Vessel Size
Each desalter vessel design provides a certain range of emulsion treating capacities, expressed as
barrels per day (BPD) emulsion treated per square foot of treating area. The treating area is proportional
to vessel length and diameter. The maximum treating capacity for a given desalter vessel is limited by
treated oil viscosity and gravity at desalter operating temperatures:
Vessel treating capacity, low-velocity vessels (BPD/ft2)
d
=
=
=
45.5 log (d/) + 64.4

the difference in brine and oil density at operating temperature
crude oil bulk viscosity at operating temperature
The higher the viscosity and lower the gravity, the lower the maximum treating capacity. This is why
crude units (using similar desalter designs) processing lower gravity crudes need larger desalters than
units charging lighter crudes at similar throughputs. This formula also shows why desalters on units
changing to heavier crude slates may be within design specifications on crude rate, but can exceed
design specifications on treating capacity.
Common Vessel Designs

Most refinery desalters are designed by either Howe-Baker or Petreco. In Howe-Baker vessels or Petreco
low velocity vessels the crude oil/wash water emulsion enters the desalting vessel through a distribution
header below the mid-line of the desalter. This header provides equal distribution of the emulsion
throughout the length of the vessel. The emulsion flows up through the electrical grids; dehydrated oil
flows to the top of the vessel and is removed through a crude outlet header. Water droplets coalesce and
fall to the bottom of the vessel. The brine is removed through the effluent water header or via effluent
water nozzles on the bottom of the vessel.
With Petreco high velocity designs (Cylectric and Bilectric) the emulsion is introduced horizontally
between the electrical grids. These designs allow more oil to be treated per unit area of grid. The
3.7
advantage of the high velocity designs is that a smaller less expensive desalter vessel can be used. A
disadvantage is higher operating cost due to the increased current flow. Some of the more important
features of the various designs are summarized here.
Howe-Baker Low Velocity
Howe-Baker low velocity desalters utilize an emulsion distribution header that is typically located 2 ft.
below the bottom grid (see Figure 3.3). This distributor consists of a pipe with holes along each side.
There are two electrical grids. The bottom hot grid is located near the mid-line of the vessel. The upper
grid is the ground grid. The distributor pipe can also act as a ground, providing a weak treating field
below the hot grid.
Howe-Baker Desalter
(Internal Design)
END VIEW
DESALTED
CRUDE
SIDE VIEW
DESALTED
CRUDE
TRANSFORMER
HOT
GRID
CRUDE OUTLET
HEADER
( _)
(+)
H2 O LEVEL
MUD
WASH
RAW
CRUDE
MUD WASH
HEADER
CRUDE
INLET
HEADER
EFFLUENT WATER
EFFLUENT WATER
HEADER
MIX VALVE
RAW
CRUDE
MUD WASH
EFFLUENT WATER
WASH WATER
WASH
WATER
These vessels tend to perform best when the emulsion layer is maintained approximately 6 inches below
the level of the crude inlet distributor. Higher water levels may allow portions of the stable emulsion layer
to be forced up into the grid area by the incoming crude. This can cause excessive amperage draw and
reduced desalter performance. It also means that the water level in Howe-Baker vessels should be
controlled to a maximum of 24-36 inches, depending on vessel diameter.
Howe-Baker Tri-Electric
The design of this vessel is similar to the Howe-Baker low velocity design except three grids are used to
increase the size of the treating field. The top and bottom grids are hot, with a middle ground grid.
Petreco Low Velocity
Petreco's low velocity vessels utilize an inverted trough design for the inlet distribution header (Figure
3.4). Emulsion flows out of the distributor through holes in the sides of the trough. The bottom electrode
grid is hot, and the upper grid is the ground grid. Two treating fields are provided a weak field between
the upper and lower grids, and a strong field between the lower hot grid and the grounded distributor
pan.
3.8
Petreco Low Velocity Desalter

(Internal Design)
END VIEW
SIDE VIEW
DESALTED
CRUDE
DESALTED
CRUDE
GROUND
GRID
TRANSFORMER
CRUDE OUTLET
HEADER
( _)
(+)
MUD WASH
HEADER
HOT
GRID
H2O LEVEL
MUD
WASH
EFFLUENT
WATER
H 2O
LEVEL
CRUDE
INLET
DISTRIBUTOR
MUD WASH
RAW
CRUDE
RAW
CRUDE
WASH
WATER
MIX VALVE
EFFLUENT
WATER HEADER
MIX VALVE
EFFLUENT WATER
WASH WATER
Petreco recommends that the water level be maintained 6-12 inches above the top of the distributor to
ensure even distribution of emulsion throughout the length of the vessel. The water level should never be
lowered below the holes in the side of the distributor. Petreco claims that additional crude oil washing
and emulsion coalescence are obtained by introducing the emulsion into the water phase. By carrying a
higher water level in the vessel, the average water phase retention times are generally higher with
Petreco designs. This fact may help these vessels maintain better effluent water quality relative to other
designs, especially during upset conditions.
Petreco Cylectric
Cyelectric desalters use cone-shaped inlet nozzles that are designed to distribute the emulsion radially
between the upper and lower electrode grids. There are typically 2-8 nozzles per vessel, depending on
vessel length. Some Cylectric units use spherical vessels with a single cone distributor. Both grids are
hot and are operated 180 out of phase. A flow baffle plate is located above the top grid over each
distribution nozzle to help keep the emulsion flowing horizontally between the grids. There is a weak
treating field below this baffle plate. The strong treating field is between the two hot grids.
Additional mixing of the emulsion is provided across the gap between the inlet distributor bodies and the
inside parabolic distributor cones. The spacing of this gap can be adjusted using external hand wheels.
The Petreco design calls for a 3-7 psi D across the distributors. This D target can be achieved by
opening all of the distributors, then closing all of them the same number of turns until 3-7 psi is measured
between the mix valve and the vessel.
Water levels in Cylectric desalters should be held at 12-24 inches below the bottom grid, this also
provides a long water phase retention time.
3.9
Petreco Bilectric
Bielectric desalters use circular plate inlet manifolds that direct the emulsion toward the walls of the
vessel between upper and lower sets of grids (Figure 3.5). All three grids are energized and are operated
120 out of phase. This three-tiered electrode design doubles the effective size of the treating field for a
given vessel size. In practice, Petreco claims that Bilectric desalters have about 1.75 times the treating
capacity as low-velocity desalters of the same size.
Water levels in Bilectric desalters should be held at 12-24" below the bottom electrode grid.
PETRECO BIELECTRIC DESALTER

(INTERNAL DESIGN)
END VIEW
SIDE VIEW
DESALTED CRUDE
TRANSFORMERS
FLOW BAFFLE
TRANSFORMER
LC
TRANSFORMER
HOT GRIDS
FLOW BAFFLE
LC
DESALTED
CRUDE
CRUDE OUTLET HEADER
DISTRIBUTOR HEADER
DISTRIBUTOR HEADER
MUD
WASH
MIX
VALVE
MUDWASH
HEADER
RAW
CRUDE
MUDWASH
PUMP
WASH WATER
RAW
CRUDE
MUD WASH
HEADER
EFFLUENT
WATER
EFFLUENT WATER
MIX VALVE
WASH WATER
Level Controllers
Desalting vessels are operated liquid-filled, but it is important to be able to control the level of the
oil/water interface in the vessel. If the level is too high, the amperage draw between the grids can
increase due to the higher quantities of water. This will lower the voltage drop in the electrical field which
adversely affects water droplet coalescence. Higher BS&W and salt levels in desalted crude will result.
If the level is too low, excess oil may be drawn out of the vessel through the effluent water header. The
interface level in the vessel is easily verified by checking the desalter trylines or by using a swing arm
device. However, an interface level detection and control system must also be installed in order to
provide effective automatic control of the desired interface level.
Interface detection is accomplished by either displacement-type float devices, capacitance
probes, or by microwave devices. Displacement devices are weighted to float at the oil/water interface
and are calibrated to operate within a specific crude oil gravity range. These devices are usually used in
units processing higher gravity crudes because of the relatively large density differences between the
crude and the water phase. Capacitance probes work by detecting differences in electrical capacitance
between water and oil. They are not affected by swings in crude oil gravity and are more often used in
units processing a wider range of crude gravities.
A recent technological development is microwave detectors or Agar probes, which are gaining popularity
in heavy crude desalting applications. These probes measure differences in energy absorption between
3.10
oil and water. They can be tuned to detect relatively small amounts (e.g. 0.5% volume) of water in oil or
oil in water. Two probes are usually used to monitor the emulsion level in a vessel.
The electrical signal generated by the level detection device is sent to a transducer where it is converted
to a pneumatic signal. The desalter interface level is controlled by a flow control valve installed on the
effluent water outlet line. This valve will open or close depending on the level indicated. If the flow
control valve is sized correctly and the reset interval on the feedback loop is set correctly, the interface
level can be controlled effectively with little fluctuation in the effluent water flow rate.
Mud Wash Systems

All crude oils contain a certain amount of solids such as silt, sand, clay, and iron particles. Many of these
solids are removed in the desalter and leave the vessel with the effluent water. A portion of the solids
can also accumulate in the bottom of the vessel to form mud or oily sludge. The sludge layer may build
to a point where it plugs parts of the effluent water header or significantly decreases water phase
residence time in the vessel. Many desalters utilize a mud wash system to keep this sludge from
accumulating. A mud wash injection header is located in the bottom of the vessel. This header contains a
number of injection nozzles that direct the flow of water down toward the bottom surface of the vessel.
The water is injected through these nozzles at high velocities, stirring up the solids so they can be
removed with the effluent water.
The water used for mud washing is normally recirculated desalter effluent water, as shown in Figure 3.6.
Some units use desalter wash water for mud washing. In some units, the wash water to the desalter
must be blocked in while mud washing. The rate of water used for mud washing can be controlled
manually with block valves or automatically with flow control valves. Desalter manufacturers design the
mud wash system to deliver 5-10 gpm per nozzle.
Design of a Typical Desalter

Mudwash System
INTERFACE LEVEL
IN VESSEL
MUDWASH HEADER
&
NOZZLES
LEVEL
CONTROLLER
DESALTER EFFLUENT
WATER HEADER
TO SEWER &
WASTE WATER
TREATMENT PLANT
MUDWASH
PUMP
ALTERNATE MUD WASH

WATER SOURCE
3.11
Howe-Baker recommends mud washing a minimum of three minutes per day for a typical mud washing
system, while Petreco suggests mud washing for one hour once per week. However, the frequency and
duration of mud washing is best determined through operating experience. The appearance of the
desalter effluent water should be checked before, during, and after the mud wash procedure. In general,
if the effluent water stays dirty or oily for more than 10 to 20 minutes after mud washing, the frequency of
mud washing should be increased. If the effluent water stays clear or turns clear immediately after mud
washing, then the frequency or duration should be decreased.
Two-Stage Desalting
Some crude units use two-stage or double desalting in order to improve overall desalting efficiency.
Installation of a second stage of desalting typically will increase overall desalting efficiency by 5-6%. The
added expense of the extra stage can be justified based on the reduced fouling and corrosion seen in the
crude unit and in lower sodium levels in residual fuel, in coke, and on FCCU catalyst.
Figure 3.7 shows a schematic of a simple two-stage desalting system. Fresh desalter wash water is
added ahead of the second stage mix valve. Second stage desalter effluent water is then used for wash
water in the first stage of desalting. This is called a counter-current water washing process. Desalting
efficiency is maximized by using the fresh water in the second stage. Desalted crude salt contents of 1
PTB or less often can be achieved with two-stage desalting.
Two Stage Electrical Desalting System

DESALTED CRUDE
FROM 1st STAGE
DESALTED CRUDE
FROM 2nd STAGE
RAW CRUDE
FEEDSTOCK
1st STAGE VESSEL
2nd STAGE VESSEL
CRUDE PREHEAT
EXCHANGERS
CRUDE
CHARGE
PUMP
BIC
EMULSION
BREAKING
CHEMICAL
MIX VALVE
MIX
VALVE
WASH WATER/
BRINE EXCHANGER
2nd STAGE
EFFLUENT
WATER
TO 1st
STAGE
FRESH DESALTER
WASH WATER TO
2nd STAGE
1st STAGE EFFLUENT

WATER TO SEWER
Brine Recycle
Desalter effluent water or brine can be recycled for use as desalter wash water in single-stage desalting
operations. This is usually done when fresh wash water is scarce. By recycling a portion of the brine the
refinery can provide the total volume of wash water needed to achieve sufficient crude oil washing and
optimum water droplet coalescence in the desalter. In this way acceptable desalting and dehydration
efficiencies can be maintained using fewer gallons of fresh wash water.
Figure 3.8 shows the design of a typical brine recycle system. Brine from the discharge of the effluent
water pump is re-routed to the main water injection line ahead of the mix valve. In this case 3% of the
3.12
total wash water used is recycled. The actual amount of brine recycled depends on the water availability
and/or the volume of water that can be discharged.
Design of a Typical Brine Recycle System

DESALTED CRUDE
RAW CRUDE
CHARGE
LEVEL
CONTROLLER
MIX VALVE
BRINE RECYCLE
RECYCLE WASH WATER
FLOW INDICATOR
CONTROL VALVE
EFFLUENT
WATER
TO WASTE
WATER
FRESH WASH WATER
TREATING
PLANT
FLOW INDICATOR
FRESH DESALTER
WASH WATER
Recycled brines have a higher salt content than fresh wash water, so the recycling of brine will cause the
water droplets remaining in the desalted crude to have a higher concentration of dissolved salts. This
means that after a certain level of crude washing and dehydration efficiency has been achieved, the
desalted crude salt content will increase with the proportion of brine used as wash water. The costs of
these incremental losses in desalting efficiency must be considered when determining the recycle rate to
be used. The relationship between desalting efficiency versus percent recycle should be determined by
actual experience on the crude unit.
3.13
Sample Points
Several sample points are usually provided so that conditions in the desalter and the desalter
performance can be monitored. All of these sample points should be located and verified when initially
surveying a desalter system:
1. raw crude;
2. desalted crude for all vessels;
3. desalter wash water;
4. desalter effluent water (also called desalter brine, tailwater, or
outlet water, etc.), and
5. vessel trylines or swing arm interface sampler.
When collecting samples it is always important to flush out the sample line thoroughly so that
representative samples are obtained. This is especially important with long sample lines or when
common sample systems are used. Sample coolers are sometimes installed to prevent flashing of hot
crude oil samples. Check the sample coolers to make sure that cooling water isn't leaking into the
sample line.
Desalter Chemical Feed Points

The most commonly used crude unit demulsifying chemicals are oil soluble and are added to the crude
oil ahead of the desalter. Typical dosages for these desalting aids are 6 to 18 ppm with heavier crudes
requiring more chemical than lighter ones.
It is important that the oil-soluble demulsifiers be well-mixed into the crude oil charge. These products
are usually injected into the suction of the crude charge pump because of the good mixing provided by
the pump. Occasionally the crude charge pumps are located in the tank farm and not on the crude unit. If
this is the case, it is preferable to inject the demulsifier at the crude unit ahead of the preheat
exchangers. This will provide the crude unit operators with easier access to the chemical injection
system and allow them to have better control of the chemical injection rates.
The chemical injection location should be well ahead of any wash water additions so that the demulsifier
will be uniformly dispersed before the wash water is emulsified into the crude charge. If the chemical is
not being added to the crude pump suction, it should be fed with an injection quill into the center of the
crude line to provide better dispersion.
Due to the processing of heavier, higher solids, crudes and increased restrictions on oil-in-brine, many
desalters now require the addition of wetting agents and polymers. The wetting agents will help deoil
solids removed with the wash water. Polymers will break any reverse emulsion (oil-in-water) which may
appear in the brine, giving a more consistent oil free tail water.
Wetting agent dosages can vary from as little as 0.5 ppm to as high as 6 ppm based on the oil
throughput. The amount required will depend on the nature and quantity of filterable solids present in the
oil. Wetting agents have been traditionally injected into the wash water at rates up to 3 ppm. More
recently, we have been very successful injecting higher rates into the oil. This is most often done during
the mud wash cycle to aid in solids removal but can be done on a longer term basis if very high solids
are present in the crude.
3.14
If added to the wash water, the wetting agent should be injected on the suction side of the wash water
pump to insure adequate mixing. The injection point for adding wetting agents directly into the oil is at
the crude charge pump. It can be injected with the demulsifier if pumped only a short distance after
mixing, however a separate injection point is preferred. If unable to inject it at the charge pump, it can
be injected downstream as long as it is mixed with crude before wash water addition.
Polymer is best injected on the discharge side of the wash water pump. This will avoid any shearing of
the polymer by the pump. When adding polymer to a two stage desalter it must be injected after the
second stage as the water cascades to the first stage. Again the discharge side of the interstage pump is
the preferred spot. In two stage desalting, polymer is normally added only to the first stage to clarify the
brine prior to discharge to the sewer. While cationic emulsion polymer is typically the product of choice,
cationic solution polymers have also been used successfully. It is not necessary to predilute the polymer
if it can be adequately mixed with the wash water prior to contacting the crude. Do Not inject neat
emulsion polymer directly into the crude oil. This has caused problems with polymer coating desalter
internals necessitating unit shutdown. Typical dosages are 0.5-1.0 ppm based on the crude rate. While
polymer can be fed continuously it is most often fed as needed.
Chemical treatment of crude in tankage to improve desalter operation is becoming more common. This
is best accomplished by adding demulsifier to the crude as it is off loaded from a tanker or to the pipeline
as the crude enters the refinery tank farm. Treatment dosages will range from 4 to 25 ppm based on the
quality of the crude oil.
For additional information about chemical injection refer to the section titled "Desalter Program Trials".
Characteristics Of Crude Oil Emulsions

The desalting process involves the formation of an emulsion of wash water in crude oil and then breaking
the emulsion in the desalter. An understanding of the physical and chemical properties of emulsions will
help explain the significance of the chemical and operational variables that affect desalter performance.
Definition of an Emulsion
By definition, an emulsion is a stable dispersion of two immiscible liquids. Every emulsion has a
continuous external phase and a dispersed internal phase. Emulsions that have oil as the continuous
phase and water as the dispersed phase are called water-in-oil, W/O emulsions. The crude oil/wash
water emulsion formed by the mix valve in the desalting process is an example of a water-in-oil
emulsion. Emulsions where water is the continuous phase and oil is the dispersed phase are called oilin-water O/W, emulsions. An example of an oil-in-water emulsion is oily desalter effluent water where oil
droplets are dispersed into a continuous water phase.
Emulsion Formation
When pure water and uncontaminated oil are carefully poured into a container the two liquids will not mix
together, i.e. they are immiscible. The hydrocarbon will float on top of the water because of its lower
specific gravity. Due to the high interfacial tension between the oil and water it is unlikely that a stable
emulsion will form under these conditions. Two conditions must occur to form an emulsion from
immiscible liquids. First, some kind of mixing energy must be applied to the system to overcome the
interfacial tension. Second, an emulsion stabilizing agent must be present to prevent the emulsion from
separating after the mixing energy has been removed from the system.
Mixing or Shear Energy
In desalting applications the shear energy is provided by the mix valve located ahead of the desalter.
The amount of shear energy applied to the crude oil/wash water mixture is controlled by adjusting the
energy dissipation or pressure drop across the mix valve. When the crude/water mixture passes through
3.15
the high shear of the mix valve, the energy expended in the pressure drop disperses the water into small
droplets. Unit operators can increase the desalter mix valve pressure drop to provide better contact
between the crude oil and wash water for efficient desalting, or decrease the P to prevent a stable
emulsion from building in the desalter vessel.
In cases where wash water is added ahead of the crude preheat train, some additional shear energy is
provided as the crude/water mixture passes through pipe fittings, heat exchangers, and flow control
valves. This source of mixing energy is generally not controllable.
Emulsion Stabilizers
The other requirement for forming a stable emulsion is the presence of emulsifying agents or emulsion
stabilizers. There are several sources of these emulsifying agents in desalting systems. Crude oil
contains a number of naturally occurring organic emulsifying agents such as asphaltenes, organic acids
and porphyrins, plus finely divided solid materials such as clay, sand and silt. Synthetic emulsifiers such
as sulfonates may also be added to the crude oil during production. Any slop oils added to the crude
charge can also contain species such as suspended solids and surfactant chemicals that will stabilize the
emulsion in the desalter.
Surface active molecules have a lipophilic (fat-loving) portion which tends to be soluble in hydrocarbons
such as crude oil, and a hydrophilic portion (water-loving) that tends to be soluble in water. The general
structure of surfactant molecules is shown in Figure 3.9. These molecules tend to concentrate at the
interface between the oil and water phases in the emulsion. These agents stabilize the interface making
it more difficult for coalescence and separation to occur. Figure 3.10 depicts how these surface active
agents are oriented in the interfacial area surrounding a water droplet suspended in a continuous oil
phase. Solid particles are also shown in the stabilized film around the water droplet.
Generalized Structure of a
Surfactant Molecule
OIL SOLUBLE
WATER SOLUBLE
HYDROPHOBIC END
HYDROPHILIC END
(WATER-FEARING;
RELATIVELY NON-POLAR)
TYPICALLY A LINEAR OR
BRANCHED HYDROCARBON
FUNCTIONAL GROUP
(WATER-LOVING;
RELATIVELY POLAR)
CAN BE AN ANIONIC,
CATIONIC OR NON-IONIC
FUNCTIONAL GROUP
3.16
Solids and Surfactant Molecules Stabilizing

The Oil - Water Interface
Emulsion - Stabilizing
Solids
Emulsified
Water
Droplet
OIL
Emulsion Stabilizing Molecules
Surface active agents are usually classified according to the type of hydrophilic functional groups they
contain:
Anionic surfactants contain functional groups that have a negative
charge in polar solvents. An example is a carboxylic acid (R-COO-).
Cationic surfactants contain functional groups that have a positive charge in polar
solvents. An example is a quaternized amine compound (R3-NH+).
Nonionic surfactants contain functional groups that have no charge but
will hydrogen bond to water molecules in aqueous solutions.
Among the most troublesome emulsion stabilizers in crude oil desalting applications are naphthenic
acids. Naphthenic acids are naturally occurring high molecular weight organic acids that are found in
varying amounts in all crude oils. Naphthenic acids are saturated five membered ring compounds
containing mono-carboxylic acid side chains of varying lengths. Naphthenic acids are particularly strong
surfactants when they are present as their sodium or potassium salts. These salts can be formed when
the pH of the desalter wash water is above 7.5. This is why units processing crudes containing high
levels of naphthenic acids can have severe emulsion problems, especially when high pH wash water is
used.
Emulsion Resolution
The shear or mixing energy imparted by the desalter mix valve emulsion disperses the wash water into
the crude oil in the form of very small droplets. Figure 3.11 is a diagrammatic representation of the
physical and chemical mechanisms involved in demulsification of the water-in-oil emulsion. The
demulsification is the resolution of the emulsion to a lower free energy state where a continuous layer of
a less dense fluid (oil) floats on a continuous layer of a more dense fluid (water). There are several steps
3.17
involved in splitting the W/O emulsion into two layers. In simplest terms, the small water droplets are
turned into larger drops which are then able to undergo gravitational settling.
Physical Process of Emulsion Breaking

FLOCCULATION
SEDIMENTATION
COALESCENCE
COALESCENCE
SEDIMENTATION
O IL
COALESCENCE
WATER
Flocculation is the process by which individual small droplets stick together to form agglomerates
containing several droplets. Coalescence occurs when droplets that are touching each other come
together to form a single larger droplet. Sedimentation is the gravitational settling of the dense water
droplet through the emulsion. Generally less important in desalting applications is Oswald Ripening
which involves the diffusion of molecules from small drops to large drops. All of these steps hasten
emulsion resolution by making bigger droplets.
In this model of emulsion resolution the result of the collision between droplets is an important
consideration. If the droplets bump into each other and bounce off, the emulsion will not be broken. If
the droplets stick to each other (flocculate) when they collide, they can then coalesce, or form bigger
drops and fall below the hydrocarbon phase. Surface active emulsifying agents can have a significant
effect on the outcome of these collisions. If emulsifying agents are sufficiently stabilizing the oil/water
interface around the droplets, the droplets will not coalesce and the emulsion will not be easily broken.
Emulsion breaking chemicals help break crude oil emulsions by counteracting the effects of emulsion
stabilizing agents at the oil/water interface.
3.18
Gravitational Force and Stokes' Law

Emulsions break when water droplets settle out of the oil phase.
The separation of the two liquids is best described by Stokes' Law.
V = K (
w - o ) G d2
o
where:
V
K
w
o
G
d
o
=
=
=
=
=
=
=
Velocity of falling water drop

A constant
Density of water
Density of oil
Gravitational acceleration
Diameter of water droplets
Viscosity of bulk media (oil)
The velocity of the falling water droplet or the speed of the separation can be altered by changes in the
physical characteristics of the liquids. Crude oil desalting units are designed to provide optimum physical
conditions for fast resolution of specific crudes. This means that the desalters' electrical grids provide a
high intensity electrical field to promote droplet coalescence into larger drops (increased "d"). The
relatively high temperature of the unit (200-300F) reduces crude oil viscosity (o).
3.19
Control Of Desalter Operational Variables

As indicated throughout this manual, there are a number of factors that affect emulsion stability in a
desalter. Some of the most influential factors include:
Crude oil density
Desalter temperature
Status of electrical grids
Wash water rate
Wash water pH
Mix valve P
Desalter interface level
Desalter pressure
Emulsion stabilizers in the crude oil or wash water
Emulsion breaking chemicals
The following sections discuss the impact of these key operating variables on crude oil desalter
performance.
Crude Oil Density
Emulsions can break into separate oil and water phases because water has a higher density than crude
oil. Stokes' Law shows that the greater the difference in the density between crude oil and wash water (w
- o), the faster the separation.
The oil/water density differential term in Stokes' Law has important implications for desalting. First, it
explains why higher density or lower gravity crude oils are usually more difficult to desalt. When the
density of the crude oil approaches the density of water the water droplets fall through the emulsion at a
much lower velocity. Viscosity is also a factor because low gravity crudes are usually more viscous than
high gravity crudes. In order to obtain the desired dehydration efficiency in the desalter, the velocity of
the rising oil phase in the vessel cannot exceed the velocity of the falling water droplets. The oil phase
velocity can only be decreased by reducing the rate of oil charged to the vessel or by increasing the size
of the vessel. This is why crude units designed to process high density, lower gravity crudes must have
larger desalting vessels than units processing low density, higher gravity crudes at equivalent
throughputs.
Though it has a large impact on emulsion separation, the gravity of the crude oil is usually not a variable
within the control of refinery operations. However, some refiners that process very low gravity crudes add
recycled light hydrocarbon into their crude charge in order to increase the oil/water density differential
and the speed of the emulsion separation.
Desalter Temperature
Although temperature does not appear in Stoke's Law, it does have an effect on the rate at which the
emulsion breaks. The viscosity of crude decreases with increasing temperature. This relationship is
shown graphically in Figure 3.12. You can see in Stokes' Law that the velocity of the falling water droplet
(V) is inversely proportional to the crude oil's viscosity. As a result, lower crude viscosity makes it easier
for water droplets to separate from the hydrocarbon phase.
3.20
1200
450
5000
2000
1000
10 API
120
12 API
500
200
16 API
20.0
100
22 API
60.0
45.0
5.5
30 API
36 API
35.0
80.0
100
130
210
TEMPERATURE - F
VISCOSITY - CENTISTOKES
VISCOSITY - SAYBOLT SECONDS
Characteristic Temperature - Viscosity

Relationship for Crude Oils
2.5
300
Higher desalter temperatures promote emulsion breaking or more efficient droplet coalescence by:
increasing the solubility of some naturally occurring emulsion stabilizers such as Nathenic acids
in the oil phase,
increasing the frequency of collisions between droplets, and
diffusing emulsion breaking chemicals to the oil/water interface faster.
Desalter temperatures can also have an effect on the density differential between crude oil and water.
The relationship between crude and water densities vs. temperature is shown in Figure 3.13. This graph
shows that for crude gravities of approximately 35API and higher, increases in desalter temperature
above 200F will increase the crude/water density differential. For crude oil gravities of about 20API and
less, increases in desalter temperature above 200F will narrow the density differential.
3.21
Temperature - Density Relationship

For Oils, Water and Brine
20,000 ptb NaC
l Brine
4.5 API
10,000 ptb NaC
l Brine
7.0 API
FRESH WATE
R
SPECIFIC GRAVITY
1.00
10 API
16 API
22 API
0.90
30 API
36 API
0.80
100
200
300
TEMPERATURE - F
The effect of desalter temperature on crude oil and water densities has a minimal impact on most
refinery desalter operations. However, when desalting very low gravity crudes desalter temperatures
above 250F are needed to reduce crude oil viscosity to an acceptable level. In these cases it is
sometimes necessary to use heavy brine for desalting to ensure that the wash water is more dense than
the crude oil.
Crude oil is brought up to desalter operating temperature in the crude preheat exchangers ahead of the
desalter. Any decreases in the heat recovered in the crude preheat exchangers can reduce desalter
performance. Decreased heat recovery can be caused by exchanger fouling, changes in tower
pumparound rates, by changes in feedrates, or changes in unit feed characteristics.
There are also upper limits on desalter operating temperatures. Crude oil becomes more conductive at
higher temperatures. This can decrease the effectiveness of the electrical grids. High temperatures can
also cause vaporization of lighter components in the crude oil. The resulting turbulence in the desalter
vessel will reduce emulsion breaking efficiency.
Electrical Field
The effect of the electrical field in desalters is to induce a polarization of the water droplets in the
emulsion. As shown in Figure 3.14, the part of the droplet nearest the positive electrode will have a
negative charge and the part near the negative electrode will have a positive charge. Since opposite
charges attract, the droplets will become attracted to each other and can coalesce into larger droplets.
This electrically induced flocculation and coalescence of water droplets greatly increases the rate of
emulsion breaking in the desalting vessel because large droplets separate faster than small droplets.
Operation of the electrical grids is typically trouble-free, though shorts can occur. Problems can usually
be detected with the voltage and amperage indicators. Voltage and amperage readings will vary from
unit to unit but should be nearly equal for each grid. They should not fluctuate under normal conditions.
3.22
Coalescence of Water Droplets

In an Electrical Field
(_)
(_)
+ + + +++ +
+
+ +
d1
__ _ _
_ __ _
O IL
O IL
O IL
+ + + +++ +
+ +
+
_ _ _
__ _ _
_
d1
__ _ _
_ __ _
++ +
+ +++ +
O IL
LARGER DIAMETER DROPLET

SETTLES FASTER THAN SMALLER
DROPLETS
O IL
(+)
O IL
(+)
Wash Water Rate

As mentioned in the discussion of desalting parameters, the amount of wash water added ahead of a
desalter is critical to maintain good desalting efficiency. Higher volumes of fresh wash water provide a
greater dilution of the crude oil salts. However, water wash rates also affect the efficiency of crude oil
emulsion resolution because of the relationship between wash water rate and water droplet population
density within the emulsion.
The water droplet population density can be expressed in terms of d, the distance between droplets in
the electrical field. The effect of d on water droplet flocculation and coalescence in an electrical field is
related by the formula:
F =
Where F
K
E
a
d
=
=
=
=
=
K E2 a6
d4
the force of attraction between water droplets in an electrical field,
a constant,
the voltage gradient between grids,
the radius of adjacent water droplets, and
the distance between droplets in the electrical field.
When desalter water wash rates are low, the population density of water droplets is also low. As the
distance between water droplets (d) increases, the induced polarization of the droplets in the electrical
field becomes too slight to effectively promote droplet coalescence. The efficiency of emulsion
separation in the desalter decreases, resulting in high desalted crude BS&W and salt content. Better
droplet coalescence and emulsion separation can be achieved by increasing the water droplet population
density, i.e. by increasing the wash water rate.
However, if the wash water addition rate is too high, the crude emulsion can become too conductive.
When this happens, the voltage cannot be maintained on the desalter electrodes and the droplets will not
be effectively polarized. This will also result in high desalter crude BS&W's and salt content.
3.23
Wash Water pH
Desalter wash water pH can have a significant effect on desalter performance. It is usually best to
maintain desalter wash water pHs in the near-neutral range of about 5.5 to 7.5. Lower wash water pHs
can result in desalter corrosion problems. However if there is a wash water pH problem it is more likely to
be from high pHs. High pH wash waters are more common in most units because of the use of process
waters that can contain high levels of ammonia. Sometimes caustic is added to the sour water stripper
feed water in order to elevate the pH to increase ammonia stripping efficiency. Occasionally, spent
caustic is injected into desalter wash water as a means of disposal and can also increase the pH of wash
water.
If desalter wash water pH is above 7.5 it can promote emulsion stabilization, greater oil undercarry and
poor crude oil dehydration. At higher pH's naturally occurring naphthenic acids in the crude oil become
ionized and form sodium or potassium naphthenate soaps which are powerful emulsion stabilizers. In
some cases high pH wash waters can also cause iron sulfide formation in the desalter, resulting in
increased filterable solids content in the desalted crude.
If the water in the emulsion contains high levels of calcium, and magnesium carbonate or sulfate, high
wash water pHs can also cause sludge buildup in the desalter and scaling in the effluent water piping and
brine exchangers. The water solubility of carbonate and sulfate salts of calcium and magnesium
decreases with increasing temperature and pH.
Some refiners use acid injection to control the wash water pH. This reduces scaling and emulsion
stabilization problems caused by high wash water pH.
Mix Valve P
The mix valve setting is one of the most important operating parameters in a desalting system. Mixing
energy is controlled by adjusting the desalter mix valve pressure differential or P. This pressure drop is
used to disperse the wash water into small droplets within the crude oil. This provides the intimate
contact between the crude and wash water that is necessary for desalting. If the P is too low, desalter
efficiency will decrease. If the mixing energy is too high, the emulsion formed may be too stable to
break.
This effect can be illustrated by looking at the formulas describing the attraction between droplets in an
electrical field and in Stokes' Law. In these expressions, the tendency for droplets to flocculate in an
electrical field and the velocity of droplet separation by gravity are both reduced with decreasing droplet
diameter.
Figure 3.15 shows the relationship between mix valve pressure drop and the desalted crude salt and
BS&W content. The desalter mix valve P should be adjusted so that the efficiency of both salt and
BS&W removal is maximized. In general, desalters processing lower gravity crudes (15-24 API) will use
pressure drops of 5 to 12 psi. Emulsions of higher gravity crudes (25-45 API) are generally easier to
break. As a result, higher mixing energies are used in these systems, usually in the 10 to 20 psi range.
3.24
Desalter Mix P vs. Desalted Crude

Salt and BS&W Content
60
40
20
1.0
SALT CONTENT
OPTIMUM
MIXING
PRESSURE
80
0.6
0.4
0.2
BS & W
0
0.8
% BS&W IN DESALTED CRUDE
% SALT IN DESALTED CRUDE
100
INCREASING MIXING PRESSURE
The optimum range of mix valve pressure drops not only varies from unit to unit but will even vary on a
single unit, depending on unit throughput and crude and wash water characteristics. The optimum
pressure drop setting is determined by unit experience. However, it is sometimes necessary to
reestablish the optimum mix valve P setting due to changing process conditions or in an effort to
optimize desalter performance. To do this, open the mix valve to reduce the P to its minimum. After 2
hours, sample the desalted crude, test for salt and BS&W content, and check the condition of the effluent
water. Increase the pressure drop in 2 or 3 psi increments, allowing at least 2 hours between changes for
the system to reach equilibrium. Recheck the desalted crude and effluent water quality. Repeat these
steps until a P vs. BS&W profile similar to Figure 3.15 can be established. Keep increasing the
pressure drop until the desalted crude BS&W and salt content both increase. Reduce the P to the
level where the salt and BS&W levels are minimized.
Desalter Interface Level

Experience usually tells where the optimum level of the desalter should be. In Howe-Baker vessels, the
water level should be held 6 to 12" below the inlet distribution header. For Petreco low-velocity desalters,
the water level should be held about 6 inches above the top of the crude inlet header to ensure even
distribution of emulsion in the vessel. Petreco Cylectric and Bilectric designs call for the water level to be
held 12 to 24" below the bottom electrode grid.
Petreco high-velocity desalters can also be operated at relatively high interface levels since most of the
emulsion treating takes place between the electrical grids. Running a higher water level increases the
retention time of the water phase. This can improve effluent water quality.
3.25
Desalter Pressure
The operating pressure of desalter vessels is an important parameter. Most desalting vessels operate
between 50 and 250 psig, depending on the crude charge pump discharge pressure and location of the
vessel in the preheat train. Desalter pressure must be sufficient to prevent vaporization of the anticipated
crude oil blends at the normal range of desalter operating temperatures. Howe-Baker recommends
operating pressures of at least 20 psi above the vapor pressure of the crude/water mixture at the
operating temperature.
If vaporization does occur, the resulting turbulence in the vessel will decrease emulsion breaking
efficiency and desalter performance. A high degree of vaporization can cause a vapor space to form in
the top of the vessel. If this happens, the vessel's low level switch will cut power to the electrical grids,
resulting in significant desalter performance problems.
3.26
Demulsifier Product Chemistry

The components formulated into Baker Petrolite demulsifier products contribute to good desalter
performance in many ways:
1. Surface active components displace emulsifying agents at the oil/water interface and
promote the coalescence of water droplets.
2. Wetting agents "wet" the surface of solid particles so that they can be removed from the oil
phase or the oil/water interface and be dispersed into the water. This reduces the solids
content of desalted crude and promotes flocculation and coalescence of water droplets.
3. Flocculants draw droplets and particles together to form large agglomerates. They also
reduce emulsion layer volume at the oil/water interface.
4. Some emulsion breaker components help break oil out of the wash water, thus producing
cleaner tailwater.
Other demulsifier components promote more complete dehydration of the crude oil leaving the desalter.
The combined effect of all these demulsifier chemistries is a reduction of oil in the desalter effluent water
and lower crude salt and solids content. The quicker emulsion break afforded by use of emulsion
breaking chemicals also allows the mix valve P to be held at higher settings. This increases salt
removal efficiency.
The major types of demulsifiers used in desalting applications are alkoxylated alkyl-phenol/formaldehyde
resins. There are also several other classes of compounds commonly utilized in demulsifier
formulations in lesser amounts.
Just as emulsion-stabilizing agents have differing water/oil solubilities, demulsifiers must have varying
solubilities to counteract these forces. Because the exact nature of the emulsifying agents present in a
given crude are usually unknown, it is always necessary to conduct bench tests to select the demulsifier
or blend of demulsifiers best suited to resolve a particular emulsion. The procedures used and the
criterion on which to base the final product selection are discussed in the Baker Petrolite Field Emulsion
Breaker Screening Procedure included in the appendix. However, demulsifier screenings and selection
are best done in a laboratory setting by experienced emulsion breaking chemists using bench scale
electrostatic precipitators designed for this purpose. Whenever possible, crude oil and wash water
samples should be sent to Sugar Land for complete emulsion breaker testing.
3.27
Desalter Troubleshooting
Most desalters experience periodic performance problems, and as chemical suppliers we are usually
involved in and are often responsible for troubleshooting the problem. The problems are sometimes
obvious and it pays to first check basic parameters such as chemical feed rate and desalter temperature,
pressure and level. Many problems are also caused by feedstock changes, especially changes in slop oil
addition rates or crude feed tank switches. This section provides some more specific troubleshooting
guidelines to follow when looking for the solution to desalter operating difficulties.
3.28
Problem: High Crude BS&W

Possible Causes
I.
High raw crude BS&W
Remedial Measures
1.
2.
3.
4.
5.
6.
7.
8.
9.
Check raw crude BS&W.

Check feed slate for changes.
Check desalter efficiency.
Check wash water rate go to VI.
If wash water rate is high cut-off entirely
or reduce back to the normal level.
If necessary, reduce mix valve delta P go to III.
Check wash water and brine pH
Allow system to equilibrate.
Check desalter outlet crude BS&W.
II. Chemical dosage is too low.
1.
2.
3.
4.
5.
Check demulsifer dosage.

If necessary, increase demulsifier dosage.
Repeat steps 1, 2, 3 & 4 until
BS&W removal improves.
III. Mix valve delta p is too high
1.
2.
3.
4.
Reduce mix valve delta P by 2 psi.

Repeat steps 1, 2, & 3 until
IV. Desalter interface level is too high. 1.

2.
3.
4.
5.
Verify desalter interface level.

If necessary, decrease desalter interface level.
Check the condition of the interface controller.
V. Emulsion layer is building.
1. Check emulsion layer with trycocks or swing

arm sampler.
2. Check mix valve delta P.
3. Check demulsifer dosage.
4. Check wash water & brine pH.
5. If necessary, reduce mix valve delta P go to III.
6. If necessary, increase demulsifier dosage go to II.
7. If pH is high, identify and correct the problem.
8. Allow system to equilibrate.
9. Check desalter outlet crude BS&W.
VI. Incorrect wash water rate.
Low wash water rate.

1. If necessary, increase wash water rate.
2. Allow system to equilibrate.
3.29
Problem: High Crude BS&W

Possible Causes
Remedial Measures
3. Check desalter outlet crude BS&W.
4. Repeat steps 1, 2, & 3 until
1.
2.
3.
4.
VII. Electrical system problem.
High wash water rate.

If necessary, decrease wash water rate.
1. Check voltage on desalter.

2. Check amperage meters.
3. If necessary, see section on electrical problems.
3.30
Problem: High Salt Content

Possible Causes
Remedial Measures
1. High BS&W
1. Refer to Problem: High Crude BS&W.
2. Mix valve delta p is too low
1.
2.
3.
4.
Increase mix valve delta P by 2 psi.

salt efficiency removal improves.
3. Low wash water rate.
1.
2.
3.
4.
Increase wash water rate.

salt efficiency removal improves.
3.31
Problem: Oily Effluent Water

Possible Causes
I.
Chemical dosage is too low.
Remedial Measures
1.
2.
3.
4.
5.

If necessary, increase demulsifier dosage.
Check desalter effluent water quality.
Repeat steps 1, 2, 3, & 4 until
effluent water improves.
II. Desalter interface level is too low.
1.
2.
3.
4.
5.
Verify desalter interface level.

If necessary, increase desalter interface level.
III. Mix valve delta p is too high
1.
2.
3.
4.

IV. High raw crude BS&W
1.
2.
3.
4.
Check feed slate for changes. Determine if

changes will be long-term requiring a change
in the chemical program.
Check for addition of slop oil.
Stop the addition of slop oil if possible.
Refer to Problem: High Crude BS&W.
V. Increased chemical emulsion

stabilizers in feed.
1.
2.
3.
4.

Check for increased slop oil feed rate.
If found, increase chemical dosage go to I.
If necessary, reduce slop oil feed.
VI. Sludge accumulation in vessel
1.
Check temperature of all effluent water

outlet lines. Cool lines indicate pluggage.
Remove sludge from the vessel with mud wash.
Check desalter outlet effluent water.
2.
3.
4.
5.
3.32
Problem: High Interface Build-up

Possible Causes
Remedial Measures
I.
Chemical dosage is too low.
1.
2.
3.
4.
5.

Increase demulsifier dosage.
Check interface level.
interface level improves.
II.
Mix valve delta p is too high
1.
2.
3.
4.

Check interface level.
interface level improves.
IV.
High raw crude BS&W
1.
2.
3.
4.
Check feed slate for changes. Determine if

changes will be long-term requiring a change
in the chemical program.
Check for addition of slop oil.
Stop the addition of slop oil if possible.
Refer to Problem: High Crude BS&W.
V.
Increased chemical emulsion

stabilizers in feed.
1.
2.
3.
4.

Check for increased slop oil feed rate.
If found, increase chemical dosage go to I.
If necessary, reduce slop oil feed.
VI.
High wash water pH
1.
2.
3.
Check wash water pH.

If high determine cause.
If necessary change wash water source
to correct problem.
1.
2.
Check brine pH.

If wash water pH is normal but brine pH
high, determine source in crude oil
causing high pH.
VII. High brine pH
3.33
Problem: Fluctuating Voltage

Possible Causes
I.
High water level in the vessel.
Remedial Measures
1.
2.
3.
4.
II.
A stable emulsion layer is building. 1.

2.
3.
4.
5.
6.
7.
8.
Check emulsion layer with trycocks or swing

arm sampler.
voltage remains steady.
Check emulsion layer thickness.
Check emulsion layer water content.
If overmixing is evident, go to III.
Allow system to get to equilibrate.
Check system voltage.
III. Mix valve delta P is too high
1.
2.
3.
4.

IV. High wash water rate.
1.
2.
Check wash water rates.

Check water content of emulsion after mix valve,
if possible, to check water flow meter accuracy.
Repeat steps 1, 3 & 4 until
3.
4.
5.
6.
3.34
Problem: High Current Flow

Possible Causes
I.
Remedial Measures
1.
2.
3.
4.
5.
Check emulsion layer with trycocks or swing

arm sampler.
Check system current.
current rate improves.
II. A stable emulsion layer is building. 1.

2.
3.
4.
5.
6.
7.
8.
Check emulsion layer thickness.

Check emulsion layer water content.
If overmixing is evident, go to III.
III. Mix valve delta P is too high
1.
2.
3.
4.

IV. High wash water rate.
1.
2.
Check wash water rates.

Check water content of emulsion after mix valve,
if possible, to check water flow meter accuracy.
Repeat steps 1, 3 & 4 until
3.
4.
5.
6.
V. Water slug in crude charge.
1.
2.
3.

Investigate the source of incoming water.
Monitor system to maintain the proper incoming
water rate.
VI. High operating temperature.
1.
2.
3.
4.
5.
Check desalter inlet crude temperature.

If necessary, decrease the temperature.
3.35
Problem: High Current Flow

Possible Causes
Remedial Measures
3.36
Problem: Electrical Failure

Possible Causes
Remedial Measures
I.
Vaporization in vessel.
1.
2.
3.
4.
5.
6.
7.
Low level switch will shut off power to the grids.

Check desalter inlet crude temperature.
If necessary, decrease the temperature.
Check desalter pressure.
If necessary, increase pressure.
Repeat steps 2, 3, 4, 5, & 6 until
until the system is back on spec.
II.
1. Check emulsion layer with trycocks or swing

arm sampler.
2. Check the condition of the interface controller.
3. If necessary, decrease desalter interface level.
4. Check system current.
5. Repeat steps 1, 2, 3 & 4 until
III.
Water slug in crude charge.
1.
2.
3.
4.
IV.
A stable emulsion layer is building. 1. Check emulsion layer thickness.

2. If a stable emulsion exists, turn off wash water
for one hour.
3. When the voltage returns to normal levels,
open the mix valve all the way.
4. Reintroduce water wash injection.
5. Slowly increase mix valve delta P by 2 psi
until the desired performance levels are achieved.
V.
Interrupted flow of crude oil.
VI.
Interrupted power supply.

Damage to the power transformer
or entrance bushing.
Failure of internal insulators.
Electrical grid has grounded.

If necessary, block in wash water.
Investigate the source of incoming water.
Monitor system to maintain the proper incoming
water rate.
1. Low level switch will shut off power to the grids.

2. Check low level switch status.
3. Re-establish flow.
Have a plant electrician investigate these
problems.
3.37
Desalter Program Trials

In this section, we will discuss the three phases of a desalter trail.
Phase 1:
Pre-trial preparation
Phase 2:
Trial
Phase 3:
Post-trial performance evaluation
For a successful trial, all phases must be carefully thought out, planned, and executed. A trial entered
into without preparation is an invitation to failure. A trial which is not executed according to accepted
engineering practices is not given every chance to succeed. A trial, whether a success or a failure, may
never be fully understood without a complete data base for analysis. The following are necessary steps
for every trial:
1.
2.
3.
4.
5.
Develop a thorough understanding of the unit

Develop a trial plan/agenda and follow it
Document unit performance
Document changes made to affect the unit performance
Develop and adhere to contingency response plans
The following is intended to represent an outline for desalter trials.
Pre-trial Preparation
Know The Unit History
Desalter trials require a great deal of planning and organization prior to injecting the first quantity of
chemical. A complete understanding of the historical performance of the desalter is not only good
engineering practice, it is critical to analyzing the performance once the trial has started. A desalter
survey form included in this manual is an extremely useful tool for assembling unit information.
The performance history of a unit will be your guide to its expected performance. Refiners expect the
desalter's performance during the trial to at least equal its past performance. It is imperative to
thoroughly understand that past performance.
How frequently do upsets occur?
What causes the majority of desalter upsets?
What is the operators' typical response to unit upsets?
What problems do desalter upsets cause in other parts of the refinery such as the waste
water treatment plant, atmospheric and preflash distillation columns and NESHAPS
strippers?
Answers to many of these questions will be available from the Engineering and Operations groups.
Engineering can usually provide manufacturer's operating manuals and drawings of the vessel internals.
These documents usually include the original desalter design basis and may clarify many performance
aberrations when compared to present day operating conditions. The Engineering group will also be the
likely repository for historical performance data. The Operations group should be able to describe the
3.38
practical response guidelines to typically encountered operating problems. Further, the Operations group
will be more familiar with the details of the frequency, duration, and severity of desalter upsets.
Knowing the operating history of the desalter will allow you to prepare for events that might otherwise
cause a serious unit upset. Interview the Oil Movements group to determine the tank de-watering
procedures.
Are any additives being added in the tank farm?
Have there been any operational problems connected with any particular tanks?
Understanding the answers to all of these questions will better position your trial for success.
Know The Crude(s)
Planning and/or Oil Movements will be able to describe the crude slates for a given crude unit. It will be
essential to determine what crudes will be run during the trial and whether they represent a departure
from "standard" crudes. How these crudes are handled once they have been delivered to the refinery will
vary, but there will be established guidelines most refiners follow regarding blending, storage, and line-up
to the crude unit. This information will allow you to prepare for difficult operating scenarios such as tank
switches, changes to heavier or higher solids crudes, and tank farm water slugs.
Oil Movements or the Planning group should also be able to provide crude assays. The technology group
is also a good source of information on crude oil types. This information may allow you to plan and
prepare for changes in crude quality that could have an effect on desalter performance or on the type
and quantity of demulsifier required.
It is also critical to determine the source, quality, and quantity of any slop oil being charged to the unit.
Know if there is a set schedule for processing this material and how it is added to the charge. Know if it
is added to the crude rundown line, or blended into the crude tanks, and if it is added at a constant rate
or sporadically.
Crude oil and slop oil quality should be measured first hand in advance of the trial. Analyses should
include gravity, BS&W, and filterable solids. These analyses will provide confirmation of the crude
assays obtained from the Oil Movements group, and will give you an idea of how running slop oil may
affect desalter operation.
Know The Products To Be Trailed
Collect untreated representative crude samples as far in advance of the trial as possible for product
selection lab testing. Do not assume that raw crude oil from the regular sample point is untreated. Trace
down the demulsifier injection line and verify whether the sample you collect contains chemical.
Determine when the unit is running distinct crudes and obtain samples of the different feedstocks. Try to
collect your sample when typical slop oil rates and types are being processed. Also check desalter
performance when your sample is collected. Is it in an upset condition? If so, this may not be a
representative sample.
It is crucial for the employees screening the crudes (and for the success of your trial) that adequate time
for their evaluation is provided. The trial will not have the best chance to succeed without representative
crude samples and adequate time for evaluation. Coordination of these activities with Technical Group
is essential to ensure availability of resources to meet your objectives.
Know The Desalter

Collect historical data regarding the wash water source(s), rates, standard injection locations, and quality.
Determine the mud-wash frequency, duration and schedule. Obtain a copy of the actual mud-washing
procedure if possible. It should contain information regarding line-up, demulsifier rate adjustment
3.39
guidelines, polymer or wetting agent practices, etc. Test the wash water and brine for pH, chlorides, and
solids and note its appearance. Test the raw and desalted crude for salt, BS&W and filterable solids.
Record and report a solids and salt removal efficiency. This pre-trial work will give you the basis for
evaluating your products once the trial starts.
Know and Practice Careful Laboratory Techniques
Utilize the same laboratory procedures used by the refiner. Results from those methods will be more
familiar and more readily accepted by the refiner than unfamiliar methods. Obtain the refiner's
procedures and have copies available for all personnel staffing the trial. Collect sufficient quantities of
all necessary laboratory equipment and reagents ahead of time. Confirm in advance adequate
laboratory space will be available for your test requirements.
Secure Special Supplies for the Trial
Know the proper protective equipment required by the refiner. Gloves, hard hats, safety glasses, rags,
glass or clear plastic measuring cups, notebooks, hand cleaner and liquid cleanser are but a few of the
items which may be needed once the trial starts. Obtain these items in advance.
Plan and Schedule Trial Manpower
Determine what manpower will be required to adequately cover the trial. Coordinate with Technology and
the district manager well in advance to make sure people resources will be available, then publish a work
schedule so that everyone knows when they will be needed.
Trial
It is important not to lose sight of the primary objective during the trial:
1)
Maintain control of the desalter operation,
2)
Get the unit running smoothly as soon as possible, and
3)
Optimize desalter operation only after the ability to maintain operational control and avoid
upsets has been demonstrated.
The refiner has approached the supplier(s) requesting a trial with a specific objective. Understanding the
objective and making every effort to demonstrate that capability will allow you to conduct a successful
trial. However, first and foremost in the refiner's assessment of your performance will be the ability to
control the desalter.
The refiner will specify the primary objective of conducting the trial. It may be looking for a cost benefit
or a performance advantage. Whatever the objective, listen closely and make every effort to provide
that improvement in performance. There should be no misunderstanding what constitutes success or
failure in the trial.
Start of trial
Adequate preparation has positioned you for a successful trial. During the trial it will be necessary to
document the actions and performance of the product(s) in a way that is clear and concise. While there
may be many ways of accomplishing this objective, the way which has provided consistent success is
outlined as follows:
1)
Determine the product(s) to be used at the start of the trial and their initial dosages. Calculate
how long it will take for the new product to get into the crude oil or wash water and into the
desalter. It is critical to know exactly when the desalter can be expected to respond to changes
in product chemistry.
2)
Develop a clear plan for responding to potential unit performance deterioration. This plan
should include exact responses to typical upset conditions. What should be the initial response
3.40
to excessive oil in the brine? What should be the first response to an increasing rag layer? If
the BS&W in the desalted crude is increasing, what should be done first? What will be the
indication(s) that it may be time to try a different demulsifier or begin using a wetting agent?
All of these questions should be defined, answered and agreed to in writing before starting the
trial.
3)
Identify and tag all sample points clearly. Review sampling techniques with all members of
the trial team. When you are two days into the trial and struggling to decipher senseless
data,you dont want to discover an inconsistency in sample points and/or techniques.
4)
Keep a continuous record of the desalter's performance and operational variables plus any
changes that you make to improve any substandard or unacceptable conditions. Note the
time and nature of any problems that develop and the time that any adjustments are made.
One person per shift should be designated to record events and results during that shift. A
"stenographer's" type spiral binder makes a good Trial Notebook. This format allows you to
readily carry the notebook with you while on the unit and provides a clear data "time-line" of
events and responses.
5)
Two additional data logs are attached to ensure all of the necessary data is collected. These
logs are titled Desalter Trial Laboratory Results and Desalter Trial Operational Log.
Again, they are not intended to be a substitute for the Trial Notebook, but rather an adjunct
data collection format to enhance the Notebook.
6)
The refiner should be provided with reports (at least daily) on the status of the trial. Be sure
that you highlight performance parameters that coincide with the refiner's trial objectives. At a
minimum, the reports should include:
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
Report on the unit's stability

Salt removal efficiency
Solids removal efficiency
BS&W in the raw and desalted crude
Brine quality, appearance, and % oil
Grid amps and volts
Crude rates during the period
Wash water source, quality and rate(s)
Crude gravity and source (e.g., Tk number)
Additive dosage(s)
3.41
Post-trial Evaluation
Post-trial assessment of the performance should be done immediately after the trial has been concluded.
Waiting any significant length of time will only diminish the accuracy of the evaluation. Assemble the
data in a chronological format and plot pertinent information. Focus clearly on unit stability and
accomplishing the customer's stated objectives. Where possible, provide direct comparisons to the
incumbents' performance. This can be done using the performance data collected prior to the start of the
trial or by comparing trial data with that supplied by the refiner. State clearly and unequivocally the
performance advantages of your products and services. This is the time to highlight your value to the
refiner.
Present the data in a short executive summary including tables and graphs outlining the performance
advantages demonstrated during the trial. The majority of the data will be included as a supplement for
deeper review if the refiner is so inclined. Attach all trial data including a copy of the Trial Notebook so
your efforts are evident.
It is critical that your assessment of the trial's success concur with the refiner's perception. Discussing
the trial with the refiner as it is being conducted will help establish this perception. As the trial is winding
down, review your successes and advantages with the refiner prior to publishing your final report. There
should be no divergence on the opinion of the trial's success.
Once your trial is over, competitor's trials may follow. Maintain contact with the refinery personnel to
monitor the competition's performance. Ask whether you can continue to sample the desalter to evaluate
their performance first hand. This information will allow you to assess the competition's strengths and
weaknesses, and will provide you with the data needed to sell the merits of your treatment program.
BAKER PETROLITE CRUDE UNIT

DESALTER SURVEY
Date: __________________
Surveyed By: ___________________
Company: _________________
Location: _________________
Unit: ________________
DESALTER
First Stage
Type: Electrical
Chemical _________________
Manufacturer: Petrolite
Design:
Howe-Baker
Throughput
Other ________________
MBPD API Gravity ___________________
Level Control - (Y / N)
Automatic - (Y / N) Type: Float
Capacitance
Microwave ____
Second Stage
Type: Electrical
Chemical _________________
Manufacturer: Petrolite
Design:
Howe-Baker
Throughput
Other ________________
MBPD API Gravity ___________________
Level Control - (Y / N)
Automatic - (Y / N) Type: Float
Capacitance
Microwave ____
Attach a process flow diagram of the desalter. Include all piping, pumps, mix valves and wash water and chemical injection points. If
possible obtain a copy of the manufacturers operating manual and design specs.
Crude Charge
Charge Rate:
MBPD API Gravity:
Are Crudes Blended?
% Salt:
PTB Filt. Solids:
Recovered Oil Processed - (Y / N) Continuous

Recovered Oil Charge: MBPD ______
CRUDE
Wash Water
Charge Rate:
Source(s)
%
pH
Injection Point(s)
MBPD
PTB
Intermittent _____
% CHARGE
API GRAVITY
pH
Spent Caustic Added - (Y / N)
High Ammonia - (Y / N)
Operating Parameters
Desalter Temperature
Pressure
Water Level (Inches) 1st Stage
2nd Stage
Mix Valve P (psi)
2nd Stage
1st Stage
Mud Wash: 1st Stage - (Y / N)
2nd Stage - (Y / N)
3.43
Source
COMMENTS
Frequency: 1st Stage
2nd Stage
Typical Results/Test Methods

BS&W(%) In
1st Stage Out
2nd Stage Out
Salts(PTB) In
1st Stage Out
2nd Stage Out
Filt. Solids(PTB) In
1st Stage Out
2nd Stage Out
Wash Water pH In
1st Stage Out
2nd Stage Out
O&G/Solids (% or PPM)
Volts 1st Stage
2nd Stage
Amps 1st Stage
2nd Stage
Test Methods
BS&W Heated
Salts: Conductivity
Titration/Method
Potentiometric
Comments (Observation about consistency of results e.g. any seasonal variation, high water carryover, periods of oily brine, problem
crudes or crude blends, etc.)________________________________________________________________________________
_______________________________________________________________________________________________________
Tank Farm
Crude Receipts:
Tanker
Pipeline
Blended In:
Tank
Pipeline
Crude Tank Mixers - (Y / N)
Run Continuously
Water Drained from Tanks - ( Y / N)
How Often?
Tanks Vented - (Y / N)
Crude Suction Fixed
Intermittent
Fixed Roof
Floating Roof
Floating
Pretreatment Program - (Y / N)
Comments: (How long is crude stored before it is run? How consistently is water drained? Does the refinery fill and draw from a tank at
the same time? i.e. any observations about practices which could affect desalter operation.)
__________________________________________________________________________________________________________
__________________________________________________________________________________________________________
__________________________________________________________________________________________________________
__________________________________________________________________________________________________________
Competitive Information
Current Vendor_____________
Product
Dosage
Wetting Agent - (Y / N) Product
Dosage
Polymer - (Y / N)
Dosage
Product
Continuous
Service Frequency
Intermittent
_____
______________
Testing Performed By Competition/Frequency _____________________________________________________________________

__________________________________________________________________________________________________________
Comments: (Customer perception of results, service, local representative who will be involved in decision to award Baker Petrolite tank
business, etc.) __________________________________________________________________________________
____________________________________________________________________________________________________________
____________________________________________________________________________________________________________
3.44
FORMULAS AND CONVERSION FACTORS
Measures of Desalter Performance:

% Salt Removal =
PTB salts in - PTB salts out x 100

PTB salts in
% Solids Removal =
PTB solids in - PTB solids out x 100

PTB solids in
Where 1 pound of salt or solids per 1000 bbls (PTB) = 2.86 ppm (or mg/liter)
Desalter Mixing Efficiency E (%)
SRF X 100
SRCalc.
Where SRF = Field Salt Removal Efficiency:
SRF =
Si - So
Si
Si
So
Raw crude salt content (PTB)

Desalted crude salt content (PTB)
=
=
And SRCalc. =
SRCalc.
Theoretical Salt Removal Efficiency (Dehydration Efficiency):

=
W
wi
wo
W + wi - wo
W + wi
=
=
=
Wash water added (%)

BS&W in raw crude (%)
BS&W in desalted crude (%)
Other Useful Conversion Factors:

Specific gravity =
141.5
API + 131.5
One petroleum barrel = 42 U.S. gallons

1.0 quart/1000 bbls = 5.95 ppm (or mg/liter)
1.0 pound per 1000 bbls (ptb) = 3 ppm
1.0 gallon per minute (gpm) = 34.3 Barrels per day (BPD)
gallon of water weighs 8.33 pounds
3.45
GLOSSARY OF DESALTING TERMS
API Gravity - Used by the oil industry to refer to the specific gravity of a crude oil at 60 F. The API
gravity is determined by the following formula:
sp. gr.
141.5
131.5 + API
Bottom Grind Out - Centrifuging the bottom 50 ml of oil from laboratory bench tests to determine the
quantity of water, emulsion and solids present.
BS&W - Refers to the Basic Sediment and Water present in a crude. This generally includes emulsion
(BS), water (W) and solids.
Chemical Desalter - Unit which desalts refinery crude feedstock by the use of chemical, heat and gravity.
Chemical Ratio - The amount of chemical used to resolve an emulsion. In laboratory studies, this
number is expressed as p.p.m. In plant operations, it is given as qts. chemical/1000 Bbls. crude.
Coalesce - to cause small water droplets to combine into larger ones.
Continuous Phase - The external phase of an emulsion. Oil is the continuous phase in desalting.
Crude Charge Pump - A centrifugal pump ahead of the desalter which feeds the crude to the process
train.
Crude Slate - Refers to the particular crude or blend of crudes a refinery is feeding to the desalter.
Desalter - The first unit in the crude processing stream. Its function is to remove both soluble and
insoluble impurities from the oil before it is refined.
Dispersed Phase - The internal phase of an emulsion. In desalting applications, water is the dispersed
phase.
Distribution Header - A slotted pipe running along the bottom of the desalter. This pipe insures the
incoming emulsion is evenly distributed throughout the unit.
Effluent Water - The brine and solids laden water leaving the desalter. It is also referred to as tailwater.
Electrical Desalter - The unit which desalts refinery feedstock by applying an electrical voltage as well as
heat, chemical and residence time to aid in the separation of oil and water.
Emulsion - A stable dispersion of two immiscible liquids. All emulsions contain both a continuous and a
dispersed phase.
Emulsion Pad - The unresolved emulsion found between the oil and water layers in a desalter.
Emulsion Breaking - The resolution or separation of an emulsion into its individual components.
3.46
Glossary - Continued
Emulsifying Agent - A substance which acts to stabilize an emulsion. Typical emulsifying agents found
in crude are asphaltenes, organic acids and clay, sand or silt.
Filterable Solids - Any solid materials contained in a crude oil that can be removed by a filter.
Filterable Solids Removal Efficiency - Efficiency of solids removal in a desalting system, expressed as:
Efficiency (%) = [(Solids In Solids Out) (Solids In)] X 100
Grind Out - The centrifuging of an oil sample to determine the emulsion, water and solids content.
Hydrophilic - Water soluble.
Interface - The area of contact between the two components of an emulsion.
Lipophilic - Oil soluble. Also referred to as hydrophobic.
Mix Valve - A globe valve found ahead of the desalter. It provides the oil/water contact necessary in the
desalting process.
Naphthenic Acids - Mono-carboxylic acids mainly having a ring structure with side chains of varying
length. The rings are predominantly C5 but C6 have been identified. They are oil soluble, water
insoluble organic acids. They are found in most crude oils in a range of 0.02% to 2% by weight of the
crude.
Neutralization Number - Quantity (in mg) of KOH required to neutralize all the acidic components present
in a 1 gram crude sample (ASTM D-664). Typical range is 0.1-0.5 for low "neut. number" crudes, 0.5-1.5
for medium neut. number crudes and 1.5-8.0 for high neut. number crudes. Also known as acid number.
Potentiometric Titration - A titration using a potentiometer to determine the chloride content of a solution
(used to measure salt content after an extraction procedure). The inflection points of a plot of millivolts
vs volume of titrant is taken as the end point and used to calculate the salt content.
Primary Desalter - The first desalter in a two stage desalter system.
Residence Time - The amount of retention time the oil has in the desalting vessel. It is calculated by
taking the volume in the desalter occupied by oil and dividing it by the charge rate in bbls/hour. Typical
design residence times in electrical desalters are 15-30 minutes.
Salt Content - The amount of chlorides contained in the oil. The results are expressed as the amount of
sodium chloride in pounds/1000 bbls. crude.
Salt Removal Efficiency - The efficiency of salt removal in a desalting system, expressed as:
Efficiency (%) = [(Salt In - Salt Out) (Salt In)] X 100
Stabilizing Agent - See emulsifying agent.
3.47
Stokes' Law - States that the settling rate of a small droplet in a viscous fluid is inversely proportional to
the viscosity of the fluid and directly proportional to both the density difference between the fluids and to
the square of the droplet radius. The formula is:
V = K (
w - o ) G d2
o
where:
V
K
w
o
G
d
o
=
=
=
=
=
=
=
Velocity of falling water drop

A constant
Density of water
Density of oil
Gravitational acceleration
Diameter of water droplets
Viscosity of bulk media (oil)
Surface Active Agent - A material which affects surface tension properties. Also known as detergents or
surfactants.
Tail Water - See effluent water.
Top Cut - The top portion of the oil in bench desalting studies that also may contain water, emulsion and
solids.
Total Solids - See filterable solids.
Treating Plateau - The range in p.p.m. or qts/M bbls over which a demulsifier effectively resolves an
emulsion.
Wash Water - Fresh water, either potable or process, which is added to the crude to reduce the salt
content.
Water Level - The height of the water or interface layer in the desalter.
3.48

DESALTERS

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DESALTERS

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SECTION 3: DESALTERS

Benefits Of Crude Oil Desalting

It reduces the total salt content of the crude, and

Description Of The Crude Oil Desalting Process

Crude Storage Tanks

R e finery C rude O il H a n d lin g S y s tem

Refinery Tank Farm

Crude Oil Desalter

Crude Unit Charge Pumps and Preheat Exchangers

Single Stage Electrical Desalter

Wash Water to Cold

Wash Water Injection

Wash Water Sources

stripped sour water.

unstripped process waters, such as preflash, atmospheric, and vacuum

municipal water (soft water only);

settled or filtered surface water (soft water only);

Desalter Mix Valve

45.5 log (d/) + 64.4

Common Vessel Designs

Petreco Low Velocity Desalter

PETRECO BIELECTRIC DESALTER

CRUDE OUTLET HEADER

Mud Wash Systems

Design of a Typical Desalter

ALTERNATE MUD WASH

Two Stage Electrical Desalting System

2nd STAGE VESSEL

1st STAGE EFFLUENT

Design of a Typical Brine Recycle System

FRESH WASH WATER

Desalter Chemical Feed Points

Characteristics Of Crude Oil Emulsions

Solids and Surfactant Molecules Stabilizing

Physical Process of Emulsion Breaking

Gravitational Force and Stokes' Law

Velocity of falling water drop

Control Of Desalter Operational Variables

VISCOSITY - SAYBOLT SECONDS

Characteristic Temperature - Viscosity

Figure SECTION 3: .12

increasing the frequency of collisions between droplets, and

diffusing emulsion breaking chemicals to the oil/water interface faster.

Temperature - Density Relationship

Coalescence of Water Droplets

LARGER DIAMETER DROPLET

Wash Water Rate

Desalter Mix P vs. Desalted Crude

% BS&W IN DESALTED CRUDE

% SALT IN DESALTED CRUDE

INCREASING MIXING PRESSURE

Desalter Interface Level

Demulsifier Product Chemistry

Problem: High Crude BS&W

High raw crude BS&W

Check raw crude BS&W.

II. Chemical dosage is too low.

Check demulsifer dosage.

III. Mix valve delta p is too high

Reduce mix valve delta P by 2 psi.

IV. Desalter interface level is too high. 1.

Verify desalter interface level.

V. Emulsion layer is building.

1. Check emulsion layer with trycocks or swing