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BUT ALSO PRODUCED.. GAS MUD SALT SAND WATER SULFUR CHEMICALS
DEHYDRATION DESALTING
CRUDE OIL
CRUDE OIL
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
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
+
Diameter = 1.260mm Volume =1.0472 mm3 Surface Area=4.98 mm2
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.
++++ ---
++++ ---
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
BENEFITS OF HEATING
CHEMICAL TREATMENT Chemical additives called demulsifiers are typically injected into the crude oil stream to weaken the stabilizing film surrounding the water droplets
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)
Bottle Test
100 cc Emulsion
Heating to process temperature 24 hours settling evaluation
cc Oil
cc Emulsion
cc Water
t=0
t = t1
Graphical recorder
Test cell
Amperage (mA)
Temperature (C)
0,0000175000
0,0000160000
0,0000145000
0,0000130000
0,0000115000
0,0000100000 0 10 20 30 40 50 60 70 80 90
Temperatura (C)
A B C D E
DEMULSIFIERS
CHEMICAL TANK AND PUMP
TREATER
FLOW DISTRIBUTION
Flow distribution is critical to achieving uniform velocity and avoiding excessive turbulence
FLOW DISTRIBUTION
Collector Outlet Distributed Flow
UP-FLOW
Distributor
Inlet
LONGITUDINAL-FLOW
10
+
Dipoles Align With The Field Droplet Elongates
ELECTROSTATIC EFFECTS
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
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
AC FIELD DC FIELD
. . . and several possible variations of each
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
AC FIELD BENEFITS
DIPOLAR ATTRACTION FILM STRETCHING WATER TOLERANCE
+ +
Electrodes
-+
COALESCENCE IN A DC FIELD
+ -
- +
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
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
OIL
WATER
OIL OUTLET
SPREADERS
FULL BAFFLE
COALESCING SURFACES
PERFORMAX MATRIX MATERIAL Polyvinylchlorid e Polypropylene Carbon Steel Stainless Steel
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
TECHNOLOGY
Following are some recent technology advancements that have significantly improved dehydration equipment performance.
TIME
TIME
TIME
TIME
TIME
TIME
TIME
TIME
TIME
TIME
TIME
Fluid Flow Paths Upstream and Downstream of a Perforated Plate Show Turbulence and Recirculation Patterns
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)
Vessel Tail
SHROUDED-PIPE SPREADER
Patented Shrouded Pipe Distributor Excellent momentum absorption Near perfect flow distribution No more than 5% flow recirculation
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
COMPOSITE ELECTRODES
Conventional electrodes are constructed of Steel. Composite Electrodes are made of plastic
COMPOSITE ELECTRODES
CONDUCTIVE STRIP
PLASTIC PLATE
COMPOSITE ELECTRODES
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
Voltage
Crude Oil Conductivity Maintains Heat Dissipation Rating Functions During Process Upset Condition Preserves Coalescing Effect Microprocessor design allows field modulation
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
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
Electrophoretic movement becomes oscillatory Drop deforms Surface free energy counters interfacial tension Drop surface becomes highly reactive Coalescence enhanced by reduced energy barrier
Voltage
Increasing Conductivity
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.
DEHYDRATION DESALTING
CRUDE OIL
CRUDE OIL
FOR
CORROSION SALT DEPOSIT FOULING CORROSION SALT DEPOSIT FOULING CATALYST POISONING
S/O =
S/O = salt-to-oil (PTB) S/W = salt-to-water (mg/l water salinity) W/L = water-to-total liquid (volume fraction)
20 0
100
.00 0 10
g/l 0m
/l 0 mg 0 50,0
0.1
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)
Mixing by Continued Rough hydraulic or hydraulic Dispersing mechanical Coalescence of wash agitation, water usually a Mixing Valve
To Desalter Crude Flow Mixing Valve Static Mixer (Optional) is occasionally installed either upstream or downstream of the mixing valve
Mix Valve
Brine Discharge
Power Unit 2
Phase B Phase C Earth
Power Unit 3
Phase C Phase A Earth
Grid 1
Grid 2
Grid 3
Earth
Grid Connections
Power Unit 1
Phase A
Power Unit 1
Phase B Phase C
Power Unit 2
Grid 3
Power Unit 3
Grid 2
Power Unit 2
Grid 3 Earth
Grid 2
Earth
Grid Connections
Power Unit Grid 1
Power Unit 2
Phase B Phase C Earth
Power Unit 3
Earth Phase C Phase A
Grid 1
Grid 2
Grid 3
Earth
Grid Connections
Power Unit 1 Power Unit 2 Power Unit 3
Phase A
Power Unit 1
DELTA
STAR Grid 1
Power Unit 2
Phase B Phase C
Grid 2 Grid 3
Power Unit 3
Grid 3 Earth
Grid 2
Power Unit
DESALTER SIZING
FLOW
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
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.
Brine Recycle
INTERNAL RECYCLE
Single Stage Desalter with Internal Recycle
Desalted Oil Discharge
INTERNAL RECYCLE
Two Stage Desalters with Internal and Inter-Stage Recycle
First Stage Second Stage Desalted Oil Discharge
Mix Valve
Mix Valve
Recycle Pump
INTERNAL RECYCLE
Three Stage Desalters with Internal and Inter-Stage Recycle
First Stage Crude Oil Inlet Second Stage Third Stage Oil Discharge
Brine Discharge
REFINERY DESALTING
PRODUCER A
PRODUCER C
REFINERY
PRODUCER B PRODUCER D
FIELD DESALTERS
(3) 2-Stage Trains At Sea Side, Egypt
FIELD DESALTERS
REFINERY DESALTERS
2-STAGE, Mid-East
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
TECHNOLOGY
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
...................................
COMPOSITE ELECTRODES SPREADER
INLET
WATER OUTLET
ELECTRODE PLATES
ELECTRO-DYNAMIC DESALTER
OIL OUTLET
BRINE OUTLET
Voltage Control
Voltage levels can be optimized. Pulse waveform can be selected.
Frequency Control
Base Frequency Pulse Frequency
Energizes Drops at Resonant Frequency Deformed Drops More Readily Coalesced Allows Adjustment for Physical Parameters
Interfacial Tension Oil Conductivity Density Viscosity
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.
Dual Frequency
The Latest Development
Combines Modulation Modes Maximum Drop Growth & Vessel Flux Optimized for Crude Oil Characteristics More Efficient Power Utilization Easy Retrofit
0.5
0.4
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
Capacity (BOPD)
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.
Conventional A/C 14 x 65
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