Crude oil desalting proccess in

refinery

Slides Prepared by YASIR KHAN

 Crude Oil Desalting
Principles of Crude Oil Desalting
Desalting is an integral part of refinery crude oil
processing and can be the key to controlling pipestill
corrosion, heat exchanger fouling, furnace tube
coking, and process water disposal.
Salts, which normally occur in the form of brine
suspended in the crude, promote corrosion, fouling,
and coking. The primary function of a desalter is to
remove this salt from the oil.
Other contaminants, such as sediment, which can
promote heat exchanger fouling and plugging,
erosion, and residual product contamination, can
also be removed in a desalter.
Electrostatic desalting is used to remove salts and
particulates from crude oil. The crude oilbrine
mixture is contacted with wash water using a mix
valve just upstream of the desalter vessel. Salt is
extracted from the brine into the wash water
droplets. The electric field in the desalter enhances
water droplet coalescence so that water/oil
separation requires much less residence time, and
hence a smaller vessel, than is needed for
unenhanced settling. Small quantities of desalting
aids are often added to enhance contacting
effectiveness, droplet coalescence, and water
separation. Desalted oil is removed from the top of
the desalter vessel and the briny water from the
bottom.
As indicated by the schematic presented in Figure 1
for a single stage desalting operation, chemical
desalting aid (demulsified) is typically injected at the
suction side of the crude charge pump, and wash
water (fresh water) is added at the mix valve
immediately upstream of the desalter. The treated oil
from the desalter (desalted product) is fed through
the remaining crude preheat exchangers before
entering the atmospheric pipestille.
FIGURE 1:SINGLE-STAGE DESALTING
FLOW DIAGRAM
A typical two-stage electrostatic desalting operation
is shown schematically in Figure 2. In such an
operation, fresh water is added at the mix valve for
the second stage desalter and the effluent water
from the second stage is used as wash water for the
first stage. Demulsifier injection is required
upstream of the first stage, and depending on the
nature of the demulsifier, may also be needed
upstream of the second stage as well.
FIGURE 2:TWO-STAGE DESALTING FLOW
DIAGRAM
 Process Variables and Operating Guidelines

Process Variables

Desalter operating Oil feed quality

temperature
and pressure Wash water amount
and quality
Pressure drop across
the mixing valve
Oil and water residence
times in the vessel
The electric field

Type and amount

of chemical
additive used.
Oil Feed Quality
Oil feed type and quality have a significant influence
on desalter performance.
Light (high API gravity) oils are relatively easy to
desalt.
Heavier oils are more difficult to desalt for several
reasons:

1-The density difference between the oil and water is

small and the oil viscosity is relatively high so that
the rate of water droplet settling in the desalter is
low.
2-Heavier oils also tend to contain more naturally
occurring emulsifiers than lighter crudes. These tend
to inhibit water droplet coalescence and promote the
formation of stable emulsions in the desalter.
Temperature
For every desalter installation and crude blend processed,
there is an optimum desalter operating temperature.
High temperature is required for several reasons:
The primary purpose is to lower the oil viscosity to increase
the settling rate of water droplets in the desalter.
2-In addition, higher temperature tends to promote
coalescence of the water droplets by enhancing the
drainage of the oil-surfactant layer surrounding the water
droplets. Larger water droplets thus formed settle more
rapidly in the lower viscosity oil.
Production field desalters typically operate at temperatures
between 1000F and 2000F. The operating temperature range
is typically 200- 3000F for refinery desalters. This
temperature range is high enough to melt waxes that could
hinder coalescence and water separation from the oil.
Excessively high desalter operating temperatures can
cause significant operating problems. High desalting
temperatures may increase crude conductivity, causing
high current draw and low desalting voltage that could
result in poor water droplet coalescence and desalting.
Since water solubility in the crude increases with
increasing temperature, high desalter operating
temperatures can also lead to higher water content in
the crude from the desalter.
Pressure
Desalter operating pressure must be maintained at a
sufficiently high level for vaporization not to occur. If
a vapor space develops in the vessel, a safety float
switch or low level switch will automatically de-
energize the electrodes and effectively shut down
the desalter. The required pressure depends on the
desalter operating temperature and crude type.
Desalters typically operate at pressures between 65
and 300 psig.
Wash Water Rates, Quality, Injection Points, and
Sources
Wash water rates between 4 and 8 vol% (10 to 12 vol%
maximum) of the crude throughput are required to
maintain effective desalter performance. The wash
water is normally injected just upstream of the mixing
valve. Wash water addition provides the water droplet
concentration needed to contact and rupture the
protective coating surrounding the brine and promote
coalescence to form larger, more easily separated
droplets with reduced salt concentration. This water is
essential for the desalting process.
Insufficient wash water leads to poor contacting with
brine droplets in the oil, reduces the dilution effect on
the salt
The wash water quality for refinery desalters is a key
process consideration that not only affects the desalting
Troubleshooting Desalters Operating
Inadequate Salt Removal
POSSIBLE CAUSES CORRECTIVE ACTION
Desalter capacity exceeded Decrease throughput.
by handling heavier Increase operating temperature.
oil than design basis. Blend heavy oil with lighter oil.
Insufficient wash water rate. Increase wash water rate to between
4% and 8% of oil flow
rate.
Inadequate mixing. Increase mix valve DP in 1-2 psi
increments to establish optimum.
Low operating temperature. Increase temperature of untreated
oil, close all unnecessary heat
exchanger bypasses.
Low electrode voltage. Check electrical system for operating
problems.
Insufficient demulsifier Increase demulsifier chemical injection
dosage or ineffective rate and/or change
demulsifier. type.
 Voltmeter and/or Ammeter Readings Vary Widely
and Continuously
POSSIBLE CAUSES CORRECTIVE ACTION
Water level in desalter too Check water level using interface
high. samples; decrease to lowest level that
gives good quality effluent and clear
water at 30 in. level.
Check interface level controller and
valve for proper operation; check
sensor calibration if necessary.
Stable emulsion formed in Increase injection rate and/or change
desalter. type of demulsifier chemical.
Excessive water injection. Check that wash water rate is between
4% and 6% of oil flow rate; stop wash
water injection if controller or water
flow meter operation is questionable.
Gas forming in desalter Operating temperature too high or back
vessel. pressure insufficient. Check
backpressure valve operation.
Failed entrance bushing. Check bushing and replace if necessary.
Ascertain that transformer connected to
bushing is not source of problem before
checking bushing.

Failed insulator inside Take desalter out of service. Empty and

desalter. purge the vessel. When entry is permitted,
enter vessel, determine which insulator has
failed by visual inspection and/or electrical
resistance test, and replace it.

Energized electrode has Shut down system, empty and purge vessel.
become grounded. When safe entry permitted, inspect vessel
interior and ungrounded electrode.
Sharp Increase in Current Draw (Amperage)

POSSIBLE CAUSES CORRECTIVE ACTION

Water slug entering with Reduce wash water injection rate and
crude. check off sites crude handling
procedures.

High water level in Check level controller setting by using

desalter. interface sampling system. Lower level
while retaining good effluent water
quality and clear water at 30 in. level.
 Wide Emulsion Band
POSSIBLE CAUSES
Oil feed properties - high
BS&W, low gravity, waxy
constituents, high particulate
loading, emulsifiers from oil
field recovery.
Excessive mixing valve DP.
CORRECTIVE ACTION
Slug feed chemical (e.g., 2 to 4 x
normal rate) for a maximum of 2 to
3 hours - then lower injection rate
to less than 10 ppm to stabilize
operation. Investigate offsite crude
handling procedures. Check for
alternative chemical additive
package with more effective solids
wetting agent.
Open mixing valve completely, allow
amperage to stabilize and slowly
increase DP to optimum value.