Electrostatics Separation Technolgy

Process Solution Group

Description of Processes & Fundamentals

YOU DRILLED AN OIL WELL...

BUT ALSO PRODUCED.. GAS MUD SALT SAND WATER SULFUR CHEMICALS

TYPICAL PROCESS SCHEME

GAS PROCESSING BULK SEPARATION OIL TREATING WATER TREATING

CRUDE OIL TREATING CONSISTS OF . . . DEHYDRATION DESALTING

(REMOVAL OF INSOLUBLE WATER)

(REMOVAL OF MINERAL CONTAMINANTS SOLUBLE IN WATER, AND OF SOLIDS)

DEHYDRATION DESALTING
CRUDE OIL

CRUDE OIL

CRUDE OIL DEHYDRATION

WATER IN A CRUDE OIL PRODUCTION STREAM CAN TAKE SEVERAL FORMS OIL RICH WATER RICH

EMULSIFIED WATER DISSOLVED WATER FREE WATER

STREAM SAMPLE

FREE WATER
Free water is either water existing as the continuous phase, or water existing as relatively large dispersed droplets, both of which separate quickly from the oil phase

DISSOLVED WATER
MEASURED WATER-IN-OIL SOLUBILITIES

TYPICAL WATER-IN-OIL EMULSION

Seen Through a Microscope

Droplet sizes range from sub-micron to several hundred microns.

Mechanism of Oil Dehydration

A Three Step Process Coagulation Counteracting the Droplet Surface Films Flocculation Gathering the Destabilized Drops Together Sedimentation Gravitational Separation of the Phases

Mechanical Forces for Coalescence and Sedimentation

STOKES EQUATION
Describes Sedimentation Velocity

g D ( 2 - 1 ) = 181

V = Sedimentation Velocity g = gravity D = Particle (or dispersed droplet) Diameter 1= Density of Continuous Phase 2= Density of Dispersed Phase 1 = Viscosity of Continuous Phase

DEHYDRATION OF CRUDE OILS

ACCOMPLISHED BY . . .
DROP GROWTH OF THE DISPERSED PHASE SEPARATION OF THE LIQUID PHASES BY GRAVITY SETTLING

DROPLET GROWTH ACHIEVED BY COALESCENCE

Diameter = 1 mm Volume = 0.5236 mm3 Surface Area = 3.1416 mm2

+
Diameter = 1.260mm Volume =1.0472 mm3 Surface Area=4.98 mm2

TOTAL VOLUME UNCHANGED TOTAL SURFACE AREA ONLY 79% OF ORIGINAL

DROPLET COALESCENCE
So why does an emulsion not rapidly coalesce and separate into distinct phases? An emulsion is a dispersion that has been stabilized.

WHAT IS AN EMULSION?
EMULSIONS ARE TWO IMMISCIBLE PHASES, INTERDISPERSED BY MECHANICAL AGITATION, AND THE DROPLETS STABILIZED BY . . . VISCOSITY DENSITY DIFFERENCE DROPLET SIZES EMULSIFYING AGENTS STATIC ELECTRICAL CHARGE DESCRIBED BY STOKES LAW NOT DESCRIBED BY STOKES LAW

EMULSIFYING AGENTS
EMULSIFYING AGENTS OIL HEAVY PARAFFINIC COMPOUNDS HEAVY NAPHTHENIC ACIDS PETROLEUM ACIDS ASPHALTIC COMPOUNDS ORGANIC SOLIDS INORGANIC SOLIDS WATER DROP

ELECTROSTATIC CHARGE
In a flowing process stream where water exists as a dispersed phase in an organic continuous phase, the water droplets tend to acquire a positive excess charge. This causes a repulsive force between droplets.

++++ ---

++++ ---

HOW CAN WE DESTABILIZE THE EMULSION AND INCREASE SETTLING RATE?

Heat Chemistry Flow Regime Coalescing Surfaces Electrostatic Fields

Crude oil dehydration utilizes these principles to speed up the coalescence and separation of emulsified water from oil

BENEFITS OF HEATING
Viscosity Increased Differential Density Increased Film Strength Weakened Chemical Reactivity Accelerated

Heat Chemistry Flow Regime Coalescing Surfaces Electrostatic Fields

BENEFITS OF HEATING

Heating can cause problem for heavy oil

DRAWBACKS OF EXCESSIVE HEATING

FUEL COST LOSS OF VOLUME LOSS OF GRAVITY INCREASED MAINTENANCE SAFETY

CHEMICAL TREATMENT Chemical additives called demulsifiers are typically injected into the crude oil stream to weaken the stabilizing film surrounding the water droplets

Heat Chemistry Flow Regime Coalescing Surfaces Electrostatic Fields

Chemical Treatment
Requirements:
Deactivate Natural Surfactants Enhance Condensation of Interface Zone Modify Wetting of Solids Produce No Insoluble By-Products

Major Components:
Demulsifier (Primary Ingredient) Wetting Agent (Used if solids are a problem)

Selection Methods for Demulsifiers

Bottle Tests Most Common Method Measure Sedimentation Rate Estimate Resultant Oil Quality Vary Chemical Type and Dosage Electrostatic Bench Tests Measure Response of Emulsion to Electrostatic Field: Power Requirements & Sedimentation Rate Measure Resultant Oil Quality Vary Chemical Type & Dosage and Electrostatic Field Type

Bottle Test

Chemical Dossage Mixing

100 cc Emulsion
Heating to process temperature 24 hours settling evaluation

cc Oil

cc Emulsion

cc Water

t=0

t = t1

Chemical analysis: Electrical susceptibility test

Equipment for electrical susceptibility test

Chemical analysis: Electrical susceptibility test

Graphical recorder

Test cell

Chemical analysis: Electrical susceptibility test

Chemical analysis: Electrical susceptibility test

Amperage against test temperature
0.200 0.190 0.180 0.170

Amperage (mA)

0.160 0.150 0.140 0.130 0.120 0.110 0.100 0 10 20 30 40 50 60 70 80 90

Petrozuata Lagotreco Jusepn

Temperature (C)

Chemical analysis: Electrical susceptibility

test
0,0000205000 0,0000190000

Relative Electrical Conductivity against temperature

Electrical Conductivity (mA/V)

0,0000175000

0,0000160000

Petrozuata Lagotreco Jusepin

0,0000145000

0,0000130000

0,0000115000

0,0000100000 0 10 20 30 40 50 60 70 80 90

Temperatura (C)

Comparative Results 19.5API Brazilian Crude

Chemical Bottle Test Water in Oil
% By Difference

Electrostatic Bench Test BS&W

Measured %

A B C D E

2.2 4.6 5.3 5.7 6

2.12 2.01 1.62 1.20 2.35

Red: Best Performance

DEMULSIFIERS
CHEMICAL TANK AND PUMP

TREATER

WET CRUDE INLET

DEMULSIFIER IS INJECTED UPSTREAM OF THE TREATER

FLOW DISTRIBUTION

Heat Chemistry Flow Regime Coalescing Surfaces Electrostatic Fields

Flow distribution is critical to achieving uniform velocity and avoiding excessive turbulence

FLOW DISTRIBUTION
Collector Outlet Distributed Flow

UP-FLOW
Distributor

Inlet

LONGITUDINAL-FLOW

Perforated Distributor Baffles

COALESCING SURFACES CAN SPEED UP SEPARATION

Heat Chemistry Flow Regime Coalescing Surfaces Electrostatic Fields

ACHIEVABLE WATER REMOVAL

TREATED CRUDE BS&W (%)
100 FREE WATER KNOCKOUT 3-PHASE SEPARATOR TREATER or DESALTER 0.1 10 20 30 40 50 70 100 CRUDE OIL GRAVITY (DEG API)

10

USING AN ELECTROSTATIC FIELD TO CAUSE COALESCENCE

Heat Chemistry Flow Regime Coalescing Surfaces Electrostatic Fields

POLARIZATION OF DISPERSED DROPLETS

+
Dipoles Align With The Field Droplet Elongates

ELECTROSTATIC EFFECTS

DIPOLAR ATTRACTIVE FORCE BETWEEN EQUAL SIZED DROPS 2 6

F=

6 KE r 4 d

F = Force of Attraction = Dielectric Constant E = Electric Field Strength r = Drop Radius d = Interdrop Distance

Notice the Limitations: Very Sensitive to Drop Size Operates Over Short Range

Critical Voltage Gradient

Maximum Voltage at which Specified Drop Size Can Exist

Ec < ( / d )

1/ 2

y/x>1.9 y x Drop is polarized by the electrostatic field Drop is more conductive than continuum Drop deforms to a prolate spheroid Drop splits when ratio of axes becomes too large Electrical charge on the drop promotes shattering or

ELECTROSTATIC FIELDS

There are two basic types of electrostatic field:

AC FIELD DC FIELD
. . . and several possible variations of each

DROPLET BEHAVIOR IN AN AC FIELD

OPPOSITE POLES OF POLARIZED WATER DROPLETS ATTRACT, PROMOTING COALESCENCE

ELECTROSTATICALLY INDUCED FILM RUPTURE Absence of Electric Field Surface Stabilized by Film Coalescence Inhibited Drop Stretched by Field Surface Film Broken Coalescence Enhanced

AC -TYPE ELECTRODES
TRANSFORMER OIL OUT

WATER OUT OIL IN

AC FIELD BENEFITS
DIPOLAR ATTRACTION FILM STRETCHING WATER TOLERANCE

BUT THERE ARE LIMITATIONS

MINIMAL DROP MOVEMENT LOW CHARGE DENSITY LIMITS ON USEFUL FIELD STRENGTH

DROPLET BEHAVIOR IN A DC FIELD

+ +
Electrodes

+ Upward oil flow

-+

A single small water droplet

COALESCENCE IN A DC FIELD

+ -

- + UPWARD OIL FLOW

- +

COALESCING IN A DC FIELD
Opposites Attract

DC FIELD BENEFITS
MOST AC FIELD BENEFITS, PLUS . . . DROPLET TRANSPORT NET ELECTROSTATIC CHARGE BUT. . . MUST AVOID ELECTROLYTIC REACTIONS WATER TOLERANCE IS REDUCED

ELECTROSTATIC FIELDS: DUAL POLARITY

AC/DC (DUAL POLARITY) COALESCER

PLATE ELECTRODE ARRAY

INSULATOR HANGERS RAILS

ELECTRODE PLATES

DUAL POLARITY
Provides Combined AC/DC Fields For Combined Benefits
Drop Polarization Film Rupture Water Tolerance Drop Movement Drop Charge Density Minimizes Induced Corrosion

TRANSLATING PROCESS INTO EQUIPMENT

Heat Chemistry Flow Regime Coalescing Surfaces Electrostatic Fields

PROCESS EQUIPMENT DESIGN

PROCESS EQUIPMENT DESIGN

We have looked at the the principles the industry utilizes to achieve crude oil dehydration. Different equipment suppliers apply these principles in different ways. Following is an overview of NATCOGROUP equipment design, using these principles.

FREE WATER KNOCKOUT

GAS INLET

OIL

WATER

BATTERY OF VERTICAL TREATERS

VERTICAL TREATER (Cold climate options)

INTERNAL FUNCTIONS DEGASSING MIST REMOVAL FREE WATER REMOVAL HEATING SECONDARY DEGASSING EMULSION COALESCING/SETTLING

TYPICAL TREATER FIRETUBE AND DRAFT SYSTEM

STACK HEAD TURBULATOR

STACK FIRETUBE AIR INTAKE/BURNER

CONE BOTTOM VERTICAL TREATER

OPTIONAL ITEMS: CONE BOTTOM SAND JET RING HEATING BUNDLE SLOPED BAFFLES OUTSIDE LEVEL CONTROLS CROSS DRAIN

VFH TREATER (Vertical Flow Horizontal EQUALIZER GAS OUTLET Treater)

INLET

OIL OUTLET

FIRETUBE FIRETUBE SHROUD FREE WATER OUTLET

SPREADERS

EMULSIFIED WATER OUTLET

FULL BAFFLE

PERFORMAX COALESCING PLATES

COALESCING SURFACES
PERFORMAX MATRIX MATERIAL Polyvinylchlorid e Polypropylene Carbon Steel Stainless Steel

PERFORMAX TREATER (Horizontal Model)

DUAL POLARITY ELECTROSTATIC TREATER (VFH-CWW)

DUAL POLARITY ELECTROSTATIC TREATERS

SMALL OIL PRODUCTION BATTERY WITH SEPARATION AND TREATING

Dual Polarity Electrostatic Treater with Degasser

AC Field electrostatic dehydrators

Howe-Baker Electrostatic Dehydrators

AC Field electrostatic dehydrators

Petreco Electrostatic Dehydrators

AC Field electrostatic dehydrators

Kvaerner (HRI) Electrical treaters

Comparative suppliers analysis

AC Field
Proven technology in conventional desalting process Electrostatic dehydration/desalting under AC electric field Traditional desalting technology Lower comparative cost High oversizing design High sensitivity to emulsion tightness (high stability) and high water content High desalting multiple stages requirements Good technical support High control requirements

Dual Polarity
Proven technology in conventional desalting process Electrostatic dehydration/desalting under Dual polarity (AC/DC) electric field and electrodynamic desalting process (exclusive technologies) Improved desalting technologies Higher comparative cost Optimal design (low oversizing) Low sensitivity to emulsion tightness (high stability) and high water content Low desalting multiple stages requirements Excelent technical support High control requirements

ELECTROMAX TREATER

ELECTROMAX CRUDE OIL DEHYDRATOR

Combines Electrical and Mechanical Coalescence
High Flux Electrical Section Downflow Sedimentation Performax Mechanical Coalescer Dual Polarity Electrostatic Field Programmable Voltage Cycle Composite Electrodes Field Proven on Heavy and Difficult Oils

DUAL POLARITYTM DEHYDRATOR

TYPICAL ELECTRICAL ASSEMBLY

TECHNOLOGY

Following are some recent technology advancements that have significantly improved dehydration equipment performance.

Several Factors Influence Hydrodynamic Design of Separators

Inlet nozzle and momentum breaker design critical to efficient use of vessel volume Internal baffle positions improve flow distribution and prevent high fluid velocity paths Discharge nozzle designs affect fluid quality (vortex breakers may be inadequate) Computational Fluid Dynamics Provides Insight to Fluid Flow in Separators

Velocity Vectors Colored by Velocity Magnitude

Computational Fluid Dynamics State-of-the-Art Method to Solve Practical Problems

Complex Fluid Flow Analysis

Flow Visualization and Distribution Analysis

Key Separator Components for Control of Fluid Flow Patterns

Inlet nozzle geometry and location Momentum dissipation devices (e.g., splash plate, vortex tubes, ) Solid (non-porous) weirs and dams Perforated plates Outlet nozzle geometry and location Vortex breakers or other directional flow devices

TIME

Box-Type Spreader with Open Bottom

00 SECONDS

TIME

Box-Type Spreader with Open Bottom

20 SECONDS

TIME

Box-Type Spreader with Open Bottom

40 SECONDS

TIME

Box-Type Spreader with Open Bottom

60 SECONDS

TIME

Box-Type Spreader with Open Bottom

80 SECONDS

TIME

Box-Type Spreader with Open Bottom

100 SECONDS

TIME

Box-Type Spreader with Open Bottom

120 SECONDS

TIME

Box-Type Spreader with Open Bottom

140 SECONDS

TIME

Box-Type Spreader with Open Bottom

160 SECONDS

TIME

Box-Type Spreader with Open Bottom

200 SECONDS

TIME

Box-Type Spreader with Open Bottom

220 SECONDS

Perforated Plates in Separators

Establish good fluid flow distribution to reduce short circuiting Control liquid sloshing for ship-mounted systems

Perforated Plates in Separators

Design Criteria
Fraction of open area as holes Hole size Hole pattern Open area under plate for sand migration Placement and number of plates within separator

Fluid Flow Paths Upstream and Downstream of a Perforated Plate Show Turbulence and Recirculation Patterns

Dual Perforated Plates Redistribute Flow Down Length of Separator

Separators on Floating Platforms are Subjected to Six Degrees of Motion

4 5 6
1. Surge: Y 2. Sway: X 3. Heave: Z

3 1 2
4. Pitch: ZY 5. Roll: ZX

6. Yaw: XY

For CFD Simulation, Vessels Placed in Actual Position on Platform to Accurately Capture Vessel Movement Due to Wave Motion

Iso-surface Plot of Water/Oil Interface (Case #1) Iso-surface Plot of Water/Oil Interface (Case #1)

Spill-over due to Roll Motion

Time = 28.0 sec

Vessel Tail

Top of Weir Plate w/ Lip

Water Spill-over Reaches The Oil Outlet

Advanced Technology Reduces the Size of Downstream Separation Equipment

Electrostatic treaters dehydrate crude oil in ever decreasing vessel sizes CFD provides insight to vessel hydrodynamics Vessel internals designed to cope with process upsets Water Treatment Systems become smaller, more efficient Improved designs for hydrocyclones extend turn-down range and remove smaller droplets CFD-assisted column flotation design improves IGF performance Can move IGF off-platform to save weight & space

SHROUDED-PIPE SPREADER
Patented Shrouded Pipe Distributor Excellent momentum absorption Near perfect flow distribution No more than 5% flow recirculation

U.S. Patent 6,010,634

ELAPSED TIME = 30 SECONDS

MODEL RESULTS - Water Table w/ Dye

OUTLET

STANDARD PIPE DISTRIBUTOR INTERFACE

SHROUDED PIPE DISTRIBUTOR

MODEL RESULTS - Water Table w/ Dye

ELAPSED TIME = 60 SECONDS

STANDARD PIPE DISTRIBUTOR

SHROUDED PIPE DISTRIBUTOR

Shrouded Inlet Spreader

TIME 00 SECONDS

Shrouded Inlet Spreader

TIME 20 SECONDS

Shrouded Inlet Spreader

TIME 40 SECONDS

Shrouded Inlet Spreader

TIME 60 SECONDS

Shrouded Inlet Spreader

TIME 80 SECONDS

Shrouded Inlet Spreader

TIME 100 SECONDS

Shrouded Inlet Spreader

TIME 120 SECONDS

Shrouded Inlet Spreader

TIME 140 SECONDS

Shrouded Inlet Spreader

TIME 160 SECONDS

Shrouded Inlet Spreader

TIME 180 SECONDS

Shrouded Inlet Spreader

TIME 200 SECONDS

Shrouded Inlet Spreader

TIME 220 SECONDS

Effects of Arcing
Arcing is a Natural Part of the Process Arcs Momentarily Discharge a Steel Electrode Array Significant Arcing Results in Performance Loss Due to Compromise of the Field

A Means of Arc Control is Needed.

COMPOSITE ELECTRODES

Conventional electrodes are constructed of Steel. Composite Electrodes are made of plastic

COMPOSITE ELECTRODES

CONDUCTIVE STRIP

PLASTIC PLATE

COMPOSITE ELECTRODES

CONDUCTIVE STRIP TAPERED VOLTAGE FIELD

COMPOSITE ELECTRODES
PROVIDE ADDITIONAL TOLERANCE FOR WATER AND CONDUCTIVITY FIBER REINFORCED THERMOPLASTIC CONSTRUCTION RELIANCE ON SURFACE CONDUCTIVITY QUENCH ELECTRICAL ARCS PROVIDE FIELD GRADIENT INCREASE INTENSE-FIELD RETENTION TIME PROVIDE HIGHLY STABILIZED ARRAY

LOAD-RESPONSIVE CONTROLLER
POWER SUPPLY REQUIREMENTS
PROTECTION MUST PROTECT ELECTRICAL COMPONENTS IN CONDUCTIVE ENVIRONMENTS FLEXIBILITY ABILITY TO HANDLE VARYING FEEDSTOCK AVAILABILITY MINIMAL DOWNTIME IN CHALLENGING CONDITIONS

LOAD-RESPONSIVE CONTROLLER
Conventional means of transformer protection: reactor in primary circuit
R SF O TO R M C EA ER

POWER SUPPLY

TR

HI VOLTAGE TO PROCESS

LOAD RESPONSIVE CONTROLLER

Another way to control power time-based voltage chopping

Voltage

Crude Oil Conductivity Maintains Heat Dissipation Rating Functions During Process Upset Condition Preserves Coalescing Effect Microprocessor design allows field modulation

Slow Modulation Voltage Cycle

Field Control by Load Responsive Controller (LRC)

Modulated Dual Polarity Benefits

Modulation offers the Following Improvements:

Added Coalescing Power More Effective on Smaller Drops Better Drop Growth Higher Water Tolerance Increased Tolerance to Conductive Oils

Modulated Fields - Terminology

Threshold Voltage Gradient Voltage Gradient Necessary to Initiate Coalescence Critical Voltage Gradient Limiting Maximum Voltage Gradient at Which a Drop of a Specified Diameter Can Exist Modulation Frequency Affects Drop Transport Drop Relaxation Field Decay

State-of-the-Art Technology: Modulation of the Electrostatic Field

Slow Speed Modulation (as in EDD) Used to Control Drop Size Distribution Pulse Modulation Used to Energize Drop Surfaces Base Frequency Control Used to Limit Field Decay

Effects of Pulse Modulation & Base Frequency

Energizes Drops at Resonant Frequency Deformed Drops More Readily Coalesced Allows Adjustment for Physical Parameters
Interfacial Tension (Pulse Modulation) Oil Conductivity (Base Frequency) Density Viscosity

Resonant Frequency Oscillation

High frequency electrostatic field applied Marangoni Effect produces localized circulation in drop

Electrophoretic movement becomes oscillatory Drop deforms Surface free energy counters interfacial tension Drop surface becomes highly reactive Coalescence enhanced by reduced energy barrier

Field Decay in Conductive Oils

Limits Coalescence Performance

Voltage
Increasing Conductivity

Effect of Base Frequency on Voltage Decay

Increases Coalescence Performance

sin ( z )

s i nz ) (

1 0 z 20

1 0 z 20

Low Frequency
Note deep RC discharge between voltage peaks.

High Frequency
Note shallow RC discharge between voltage peaks.

Low Frequency
Note deep RC discharge between voltage peaks.

High Frequency
Note shallow RC discharge between voltage peaks.

EXAMPLE OF IMPROVED TECHNOLOGY BENEFIT

PROBLEM: Increased capacity was needed through existing desalting units in Africa, and shipping quality specifications had to be maintained. SOLUTION: AC Treaters were Retrofitted with Dual Polarity Electrode system. RESULTS: Capacity increased from 50,000 BPD to 100,000 BPD and shipping quality was maintained.

EXAMPLE OF IMPROVED TECHNOLOGY BENEFIT

PROBLEM: Existing North Sea DUAL POLARITY dehydrator designed for 60,000 BPD, but production had increased to 100,000 BPD SOLUTION: Retrofit unit with Composite electrodes Retrofit unit with Pipe/Deflector spreader RESULT: Capacity increased to 100,000 BPD

DEHYDRATION DESALTING
CRUDE OIL

CRUDE OIL

THE SALT PROBLEM

Mineral salts are often carried in solution in the water which is emulsified in the oil. In addition there are often small amounts of insoluble solids carried in the oil or water phases. OIL
SALT IN WATER

THE SALT PROBLEM

WHERE DOES THE SALT COME FROM? IN THE FIELD, IT COMES FROM THE FORMATION IN THE REFINERY IT IS EITHER RESIDUAL SALT REMAINING AFTER FIELD DEHYDRATION, OR IS SEA WATER WHICH HAS CONTAMINATED THE OIL

THE SALT PROBLEM

THE RESIDUAL WATER CONTAINS MINERAL SALTS. SALT IS A PROBLEM IN THE FOLLOWING WAYS . . . 1. IT PROMOTES CORROSION 2. IT FOULS HEATERS, HEAT EXCHANGERS, PUMPS AND TOWER TRAYS 3. IT POISONS CATALYSTS IN REFINERY UPGRADING PROCESSES

THE SALT PROBLEM

TYPICAL SALT-IN-OIL REQUIREMENTS

FOR
CORROSION SALT DEPOSIT FOULING CORROSION SALT DEPOSIT FOULING CATALYST POISONING

OILFIELD: 10 - 25 PTB REFINERY: 0.5 - 3 PTB

(PTB = pounds of salt per 1000 bbls of oil)

THE SALT PROBLEM

THE SALT PROBLEM

S/O =

0.35 x S/W x W/L 1 - W/L

S/O = salt-to-oil (PTB) S/W = salt-to-water (mg/l water salinity) W/L = water-to-total liquid (volume fraction)

THE SALT PROBLEM

DEHYDRATION ALONE IS INSUFFICIENT TO MEET THE SALT REMOVAL REQUIREMENTS IN MANY CASES
PTB (POUNDS OF SALT PER 1000 BBLS OF OIL)
200
g/ l 0 m ,0 0

20 0

100

.00 0 10

g/l 0m

/l 0 mg 0 50,0

TYPICAL FIELD REQUIREMENTS TYPICAL REFINERY REQUIREMENTS

0.1

0.2 0.3 0.4 0.5 RESIDUAL WATER (%)

0.6

DESALTING FUNDAMENTALS
0.35 x S/W x W/L 1 - W/L

S/O =

This formula suggests that there are two parameters that determine salt-in-oil: Water Salinity Water Fraction of the Stream

DESALTING FUNDAMENTALS
Water fraction can be reduced by simple dehydration, using principles already discussed. To reduce water salinity, it must be diluted.

DESALTING FUNDAMENTALS Basic desalting consists of two sub-processes: 1st - Dilution - of the dispersed brine
with a water of lesser salinity (called wash water or dilution water)

2nd - Dehydration - removal of the diluted

dispersed brine by oil dehydration

DILUTION OF DISPERSED BRINE

Desalting Chemical injection Wet Crude Oil Inlet To desalter vessel for dehydration

Wash water Injection

Mixing by Continued Rough hydraulic or hydraulic Dispersing mechanical Coalescence of wash agitation, water usually a Mixing Valve

THE MIXING VALVE

Differential Pressure Controller DPC

To Desalter Crude Flow Mixing Valve Static Mixer (Optional) is occasionally installed either upstream or downstream of the mixing valve

MIXING VS. DEHYDRATION IN DESALTING

DESALTER BASIC FLOW SCHEME

Desalted Oil Discharge

Single Stage Desalter

Crude Oil Inlet Wash Water Inlet

Mix Valve

Brine Discharge

CONSERVATION OF WASH WATER

There are several reasons why wash water must be conserved: Supply of fresh or near-fresh water is often scarce, particularly in the producing field. Disposal of effluent water is often costly, and needs to be minimized. Too much total water can cause desalter electrodes to short-circuit.

SOURCES OF WASH WATER

Refinery Condensate from towers Cooling water Utility water Field Deep fresh-water formations Shallow groundwater River water Sea water (often must be de-salinated)

DUAL POLARITY DESALTER (typical)

DOUBLE VOLT AC ELECTROSTATIC COALESCER

Power Unit 1
Phase A Phase B Earth

Power Unit 2
Phase B Phase C Earth

Power Unit 3
Phase C Phase A Earth

Grid 1

Grid 2

Grid 3

Earth

Power Unit Primary Connections

DELTA
Power Unit 3

Grid Connections
Power Unit 1

Power Unit Secondary Connections

Grid 1
Power Unit 1 Power Unit 2

Phase A
Power Unit 1

Grid 1 DELTA STAR

Power Unit 3

Phase B Phase C
Power Unit 2

Grid 3
Power Unit 3

Grid 2
Power Unit 2

Grid 3 Earth

Grid 2

TRIGRID AC ELECTROSTATIC COALESCER

Power Unit
Phase A Phase B Earth

Grid 1 Earth Grid Grid 2

Earth

Power Unit Primary Connections

Phase A

Grid Connections
Power Unit Grid 1

Power Unit Secondary Connections

Earth

Phase B Grid 2 Earth Grid 1 Grid 2

TRIVOLT AC ELECTROSTATIC COALESCER

Power Unit 1
Phase A Phase B Earth

Power Unit 2
Phase B Phase C Earth

Power Unit 3
Earth Phase C Phase A

Grid 1

Grid 2

Grid 3

Earth

Power Unit Primary Connections

Grid Connections
Power Unit 1 Power Unit 2 Power Unit 3

Power Unit Secondary Connections

Grid 1

Phase A
Power Unit 1

DELTA

STAR Grid 1
Power Unit 2

Power Unit 1 Power Unit 2

Phase B Phase C

Grid 2 Grid 3

Power Unit 3

Grid 3 Earth

Grid 2

HIGH VOLTAGE ASSEMBLY

Overflow with liquid seal Oil Level Glass Disconnect Link High Pressure Bushing Continuous Vent 10 ANSI Class 300 lb Power Inlet nozzle Vessel Wall Power Connector Rod Weight Pick-up bucket

Power Unit

Electrode Insulator Assembly

DESALTER SIZING
FLOW

OIL FLOW (BPD) AREA = DESIGN FLUX

DESIGN FLUX OBTAINED FROM...

DESIGN FLOW AREA

SIZING STANDARDS LOCAL HISTORICAL NORMS PILOT TESTS

PILOT TESTS
Natcos HTU dehydration/desalting pilot unit in the Tulsa R&D facility simulates field or refinery dehydration and desalting processes; tests conventional and state-of-the-art technologies

PILOT TESTS

LIMITATIONS OF SINGLE STAGE DESALTERS

To maintain reasonable wash water requirements, the inlet stream can contain only a small amount of dispersed brine. To reduce high inlet brine concentrations, a dehydrator is placed upstream.

DEHYDRATOR/DESALTER FLOW SCHEME

Outlet Oil

Emulsion Inlet Effluent Water Wash Water Mix Valve Effluent

Water

TWO STAGE DESALTERS

WITH INTER-STAGE RECYCLE

Brine Recycle

THREE STAGE DESALTERS WITH INTER-STAGE RECYCLE

Where extreme wash water conservation or deeper desalting is required, three stages may be used

INTERNAL RECYCLE
Single Stage Desalter with Internal Recycle
Desalted Oil Discharge

Crude Oil Inlet

Mix Valve Internal Recycle

Recycle Pump Brine Discharge

Wash Water Inlet

INTERNAL RECYCLE
Two Stage Desalters with Internal and Inter-Stage Recycle
First Stage Second Stage Desalted Oil Discharge

Crude Oil Inlet

Mix Valve

Mix Valve

Recycle Pump

Inter-Stage Recycle Brine Discharge Wash Water Inlet Internal Recycle

INTERNAL RECYCLE
Three Stage Desalters with Internal and Inter-Stage Recycle
First Stage Crude Oil Inlet Second Stage Third Stage Oil Discharge

Brine Discharge

Wash Water Inlet

REFINERY DESALTING

PRODUCER A

PRODUCER C

REFINERY

PRODUCER B PRODUCER D

FIELD DESALTERS
(3) 2-Stage Trains At Sea Side, Egypt

FIELD DESALTERS

1st and 2nd Stages, Mid-East

REFINERY DESALTERS

2-STAGE, Mid-East

DESIGN AND OPERATIONAL CONSIDERATIONS

SEPARATION OF SUSPENDED SOLIDS CHEMICAL TREATMENT WATER WASH REMOVAL OF SEPARATED SOLIDS SAND JETS (MUD WASH SYSTEM) INTERFACE SLUDGE DRAINS

DESIGN AND OPERATIONAL CONSIDERATIONS

AVOID CRYSTALLINE SALT In the producing field, it is caused by low watercontent wells being flashstripped during degassing. In the refinery it is caused by heating a low watercontent crude to where the water solubility exceeds available water.

AVOIDING SALT CRYSTALLIZATION AND DEPOSITION IN REFINERY DESALTERS

FEEDSTOCK TANKS CHARGE PUMPS HEATERS DESALTERS

SMALL AMOUNT OF WASH WATER INJECTED UPSTREAM OF HEATERS

WASH WATER SUPPLY

Solids Control
Sources of Solids Formation Fines & Precipitated Scale Precipitated Asphaltenes Solids Partitioned Between Oil and Water Phases Chemical Treatment May Help Some Remain in the Vessel Interface Sludge Bottom Sediments Removal Is Essential For: Control of Conductivity Maintenance of Flow Distribution

Solids Removal

Interface Sludge Drain

Operated As Required

Mud Wash (Sand Jet) System

Scheduled Operation

TECHNOLOGY

ADVANCED DESALTING TECHNOLOGIE S

ELECTRO-DYNAMIC DESALTER

Combines 5 Essential Process Technologies: Dual Polarity Electrostatic Dehydrator Start with a proven technology Composite Plate Electrodes Provide high water tolerance Load Responsive Controller Controls field strength Counterflow Dilution Water Process Provides multi-stage contact Electrostatic Mixing Process Focuses mixing energy only on dispersed phase

ELECTRO-DYNAMIC DESALTER

ELECTRO-DYNAMIC DESALTER
WASH WATER INLET OUTLET
OIL COLLECTOR

WASH WATER HEADER

...................................
COMPOSITE ELECTRODES SPREADER

INLET

WATER OUTLET

ELECTRO-DYNAMIC DESALTER - LOAD RESPONSIVE

CONTROLLER

ELECTRO-DYNAMIC DESALTER PC BASED LOAD RESPONSIVE CONTROLLER LOCAL MAY BE LOCAL

OR REMOTE Transformer, SCRs and Firing Board Diodes NATCO Control Board and Diagnostic Display Junction Box DEDICATED OR PORTABLE PC With LRC Program and Monitoring Software

Control Feedback AC Power

LRC Control Software

LRC Programming/ Monitoring Software

3

ELECTRO-DYNAMIC DESALTER COUNTERFLOW WASH WATER PROCESS

ELECTRODE PLATES

WASH WATER HEADER DOWNWARD WATER FLOW

UPWARD OIL FLOW

ELECTRO-DYNAMIC DESALTER

TYPICAL SINGLE STAGE EDD

COUNTERFLOW WASH WATER INLET

OIL OUTLET

CRUDE OIL INLET FIRST WASH WATER INLET MIX VALVE

BRINE OUTLET

EDD IN FAR EAST REFINERY

EDD IN FAR EAST REFINERY

EDD IN FAR EAST REFINERY

Dual Frequency Technology

Transformer
Three phase design Low reactance Increases power utilization up to 70%.

Voltage Control
Voltage levels can be optimized. Pulse waveform can be selected.

Frequency Control
Base Frequency Pulse Frequency

Dual FrequencyCompact Electrostatic Dehydrator Modulation of the Electrostatic Field

Slow Speed Modulation Used to Control Drop Size Distribution High Speed Modulation Used to Energize Drop Surfaces

Dual FrequencyCompact Electrostatic Dehydrator High Speed Modulation of Field

Energizes Drops at Resonant Frequency Deformed Drops More Readily Coalesced Allows Adjustment for Physical Parameters
Interfacial Tension Oil Conductivity Density Viscosity

Dual FrequencyCompact Electrostatic Dehydrator

Benefits: Incremental improvement, over existing best in class electrostatic technology. Allows the operator to minimize planned capital expansions: Increases processing capacity of existing vessels. Allows processing of difficult, highly conductive, viscous oils and/or oil blends. Debottleneck offshore platforms where minimization of space, weight and performance are critical.

Dual FrequencyCompact Electrostatic Dehydrator

Characteristics:
The transformer consists of three primary components, packaged in a single oil-filled enclosure (three phase, 480 volts (50 / 60 Hz)). First, the 480 volts is conditioned to produce a variable amplitude and variable frequency voltage supply for the primary of the transformer. Second, the medium frequency transformer steps up the input voltage to a secondary voltage level necessary to promote effective coalescence. Third, the secondary voltage is rectified into positive and negative half-wave outputs. These polarized, half-wave voltages are then applied to the electrodes to create the benefits of both AC and DC fields.

Dual FrequencyCompact Electrostatic Dehydrator

A PC-based process controller defines the voltage production. To highly conductive crude oils: Increasing frequency to maximize the energy delivered to the oil dehydration process. Using a medium frequency transformer overcomes the voltage decay associated with conventional 50/60 Hz transformers. Where the interfacial tension between the oil and water is low: Adjust the waveform minimize destruction of the water droplets normally caused by the application of 50/60 Hz power. Reducing the frequency of the waveform and the selection of the shape of the voltage waveform allow to achieve the best dehydration results.

Dual FrequencyCompact Electrostatic Dehydrator

In wet crude oils (low effective impedance, rapid voltage decay): Reduces voltage decay and effectively sustains the applied voltage. Seting the minimum and maximum voltage levels to increase the percentage of the entrained water that is swept by the electrostatic voltage. Maximize the droplet growth to promote a rapid sedimentation rate and reach the smallest water to develop a surface charge and promote coalescence. Reducing the voltage to a minimum level will maximize the droplet growth to promote a rapid sedimentation rate.

Dual FrequencyCompact Electrostatic Dehydrator

PC-based Dual Frequency load responsive control system can control:

The output of the transformer to produce an infinite variety of waveform configurations. The unique waveform generated is optimized to the specific oils physical properties, and enables higher treatment rates and lower BS&W levels than conventional technology.

Demulsification vs. Frequency

Demulsification, % 100 80 60 40 20 0 0 500 1000 1500 2000 Frequency, Hz 1000 V 3000 V

Data from German Researchers

International Chemical Engineering, Vol. 33, no. 1, January, 1993

Dual Frequency
The Latest Development

Combines Modulation Modes Maximum Drop Growth & Vessel Flux Optimized for Crude Oil Characteristics More Efficient Power Utilization Easy Retrofit

Dual Frequency Field Test Results

0.5

0.4

Outlet BS&W (%)

0.3

0.2

0.1

l ua D

rit ola

m Co y

sit po

e
F al Du

y nc e qu re

0 0 20000 40000 60000 80000 100000 120000

Capacity (BOPD)

Dual Frequency Results

Dual Frequency Applications

Retrofits to existing installations:

Especially Dual Polarity (External Changes) Increased performance: BS&W and/or Capacity

Refinery market where:

Highly conductive crudes cannot be desalted Space is a constraint

Offshore production facilities where:

Space is limited Weight increases deck construction & expense

Dual Frequency Advantages Reduced outlet BS&W by 30 to 95%

Tested on oils between 17 & 40 API.

Allows an increase in vessel throughput from 50 to 100%. Easy retrofit to existing Dual Polarity dehydrators or desalters
Estimated 2000 vessels currently in service.

Replaces steel and vessel volume with advanced electrostatic controls

Easily optimized to process conditions.

Dual FrequencyCompact Electrostatic Dehydrator

Dual Frequency TM Compact Coalescer Technology

Conventional A/C 14 x 65

Current State-of-the-Art Technology 12 x 40

Dual FrequencyTM 10 x 26

Coalescing Droplets

Example: 80,000 BOPD 32 API Crude 4 cps Viscosity Inlet: 5% BS&W Outlet: 0.5% BS&W