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PILOT TESTS
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Natcos HTUdehydration/desaltingpilot unit in the TulsaR&D facility simulatesfield or refinery
dehydration anddesalting processes;tests conventional andstate-of-the-arttechnologies
PILOT TESTS
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LIMITATIONS OF SINGLE STAGEDESALTERS
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To maintain reasonable wash water requirements, the inlet stream can containonly a small amount of dispersed brine. Toreduce high inlet brine concentrations, adehydrator is placed upstream.
DESALTERS
DEHYDRATOR/DESALTERFLOW SCHEME
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WashWater Effluent
Water
EmulsionInlet
Outlet Oil
EffluentWater Mix
Valve
TWO STAGE DESALTERS
WITH INTER-STAGE RECYCLE
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Brine Recycle
HREE STAGE DESALTERSITH INTER-STAGE RECYCLE
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S G C C
Whereextreme wash
water
conservationor deeper
desalting isrequired,
three stagesmay be used
INTERNAL RECYCLE
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Single Stage Desalter with Internal Recycle
Crude Oil Inlet
Wash Water Inlet
BrineDischarge
Desalted OilDischarge
RecyclePump
Mix Valve
InternalRecycle
INTERNAL RECYCLE
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First Stage Second Stage
Crude Oil Inlet
Wash Water Inlet
BrineDischarge
Desalted OilDischarge
Recycle Pump
MixValve
Internal Recycle
MixValve
Inter-Stage Recycle
Two Stage Desalterswith Internal and Inter-Stage Recycle
INTERNAL RECYCLE
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Three Stage Desalterswith Internal and Inter-Stage Recycle
FirstStage
SecondStage
CrudeOil Inlet
WashWater Inlet
BrineDischarge
OilDischargeThirdStage
REFINERY DESALTING
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REFINERY
PRODUCER A
PRODUCER B
PRODUCER C
PRODUCER D
FIELD DESALTERS
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(3) 2-Stage TrainsAt Sea Side, Egypt
FIELD DESALTERS
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1st and 2nd Stages, Mid-East
REFINERY DESALTERS
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2-STAGE, Mid-East
DESIGN AND OPERATIONALCONSIDERATIONS
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SEPARATION OF SUSPENDED SOLIDS
CHEMICAL TREATMENT
WATER WASH
REMOVAL OF SEPARATED SOLIDS
SAND JETS (MUD WASH SYSTEM)
INTERFACE SLUDGE DRAINS
CONSIDERATIONS
OPERATIONAL CONSIDERATIONSAVOID
DESIGN AND
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AVOID
CRYSTALLINE SALT
In the producing field, itis caused by low water-
content wells being flash-stripped duringdegassing.
In the refinery it is caused
by heating a low water-content crude to wherethe water solubilityexceeds available water.
AVOIDING SALT CRYSTALLIZATION ANDDEPOSITION IN REFINERY DESALTERS
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HEATERS
CHARGEPUMPS
FEEDSTOCKTANKS
DESALTERS
WASH WATERSUPPLY
SMALL AMOUNT OF
WASH WATERINJECTED UPSTREAMOF HEATERS
Solids Control Sources of Solids
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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
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Interface Sludge Drain
Mud Wash (Sand Jet) System
Operated As Required
Scheduled Operation
TECHNOLOGY
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ADVANCED
DESALTINGTECHNOLOGIE
S
Combines 5 Essential Process
ELECTRO-DYNAMIC DESALTER
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Combines 5 Essential ProcessTechnologies :
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 ProcessProvides multi-stage contact
Electrostatic Mixing ProcessFocuses mixing energy only on dispersed phase
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ELECTRO-DYNAMIC DESALTER
ELECTRO-DYNAMIC DESALTER
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. . . . . .OIL COLLECTOR
SPREADER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INLET
COMPOSITE ELECTRODES
OUTLET
WATER OUTLET
WASH WATERHEADER
WASHWATERINLET
ELECTRO-DYNAMICDESALTER -LOAD RESPONSIVE
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CONTROLLER
ELECTRO-DYNAMIC DESALTER - PC BASED LOAD RESPONSIVE
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CONTROLLER
3
LRCProgramming/Monitoring
Software
DEDICATED OR PORTABLE
Feedback
Transformer,SCRs andFiring Board
JunctionBox
NATCO ControlBoard andDiagnostic
Display
PC With LRCProgram andMonitoring
Software
LRCControl
SoftwareAC Power
LOCAL MAY BE LOCAL
OR REMOTE
Control
Diodes
ELECTRO-DYNAMIC DESALTER - COUNTERFLOW WASH WATER
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PROCESS
WASHWATER
HEADERELECTRODE
PLATES
DOWNWARDWATER FLOWUPWARD
OIL FLOW
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TYPICAL SINGLE STAGE EDD
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OIL OUTLET
BRINE OUTLETMIX
VALVE
CRUDEOIL INLET
FIRST WASHWATER INLET
COUNTERFLOWWASH WATERINLET
EDD IN FAR EAST REFINERY
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EDD IN FAR EAST REFINERY
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EDD IN FAR EAST REFINERY
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Dual Frequency Technology
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Transformer Three phase designLow reactanceIncreases power utilization up to 70%.
Voltage ControlVoltage levels can be optimized.Pulse waveform can be selected.
Frequency ControlBase FrequencyPulse Frequency
Modulation of the Electrostatic Field
Dual FrequencyCompact Electrostatic Dehydrator
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Slow Speed ModulationUsed to Control Drop Size Distribution
High Speed ModulationUsed to Energize Drop Surfaces
High Speed Modulation of Field
Dual FrequencyCompact Electrostatic Dehydrator
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High Speed Modulation of Field
Energizes Drops at Resonant FrequencyDeformed Drops More Readily CoalescedAllows Adjustment for Physical Parameters
Interfacial TensionOil ConductivityDensityViscosity
Dual FrequencyCompact Electrostatic Dehydrator
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Incremental improvement, over existing best in classelectrostatic technology.
Allows the operator to minimize planned capital
expansions: Increases processing capacity of existingvessels.
Allows processing of difficult, highly conductive,viscous oils and/or oil blends.
Debottleneck offshore platforms where minimization of space, weight and performance are critical.
Benefits:
Dual FrequencyCompact Electrostatic Dehydrator
Characteristics:
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The transformer consists of three primary components, packagedin a single oil-filled enclosure (three phase, 480 volts (50 / 60 Hz)).
First, the 480 volts is conditioned to produce a variable amplitudeand variable frequency voltage supply for the primary of thetransformer.
Second, the medium frequency transformer steps up the inputvoltage to a secondary voltage level necessary to promoteeffective coalescence.
Third, the secondary voltage is rectified into positive and negativehalf-wave outputs. These polarized, half-wave voltages are thenapplied to the electrodes to create the benefits of both AC and DCfields.
Characteristics:
A PC-based process controller defines the voltage production.
Dual FrequencyCompact Electrostatic Dehydrator
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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 Hzpower.
Reducing the frequency of the waveform and the selectionof the shape of the voltage waveform allow to achieve thebest dehydration results.
Dual FrequencyCompact Electrostatic Dehydrator
In wet crude oils (low effective impedance, rapid voltage
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decay):
Reduces voltage decay and effectively sustains theapplied voltage.Seting the minimum and maximum voltage levels to
increase the percentage of the entrained water that isswept by the electrostatic voltage. Maximize the dropletgrowth to promote a rapid sedimentation rate and reachthe smallest water to develop a surface charge andpromote coalescence.Reducing the voltage to a minimum level will maximizethe droplet growth to promote a rapid sedimentationrate.
Dual FrequencyCompact Electrostatic Dehydrator
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PC-based Dual Frequency load responsive control systemcan control:
The output of the transformer to produce an infinite
variety of waveform configurations.
The unique waveform generated is optimized to thespecific oils physical properties, and enables higher treatment rates and lower BS&W levels than
conventional technology.
100Data from German Researchers
Demulsification vs. Frequency
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0
20
40
60
80
0 500 1000 1500 2000
Frequency, Hz
D e m u
l s i f i c a
t i o n
,
1000 V
3000 V
International Chemical Engineering, Vol. 33, no. 1, January, 1993
Dual Frequency The Latest Development
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Combines Modulation Modes
Maximum Drop Growth & Vessel Flux
Optimized for Crude Oil Characteristics
More Efficient Power Utilization
Easy Retrofit
Dual Frequency Field Test Results
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0
0.1
0.2
0.3
0.4
0.5
0 20000 40000 60000 80000 100000 120000
D u a l
P o l a r i t y
C o m p
o s i t e
D u a l F r
e q u e n c
y
Capacity (BOPD)
OutletBS
&W (%)
Dual Frequency Results
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Dual Frequency Applications
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Retrofits to existing installations:Especially Dual Polarity (External Changes)Increased performance: BS&W and/or Capacity
Refinery market where:Highly conductive crudes cannot be desaltedSpace is a constraint
Offshore production facilities where:Space is limitedWeight increases deck construction & expense
Dual Frequency Advantages
Reduced outlet BS&W by 30 to 95%
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y
Tested on oils between 17 & 40 API.
Allows an increase in vessel throughput from 50to 100%.
Easy retrofit to existing Dual Polaritydehydrators or desalters
Estimated 2000 vessels currently in service.
Replaces steel and vessel volume withadvanced electrostatic controls
Easily optimized to process conditions.
Dual FrequencyCompact Electrostatic Dehydrator
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Dual Frequency TM
Compact Coalescer Technology
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Example:
Technology