Suez University

Faculty Of Petroleum & Mining Engineering

Refining & Petrochemicals Department

Report on:

ELECTROSTATIC
&MECHANICAL
DESALTING
Supervised By:

Dr.Walaa
Prepared By:
Yahya Moustafa Mohammed Abdelsalam
Sec.:

2013-2014
 1. Introduction

Crude oil contains mineral salts in various forms such as dispersed or emulsified drops of injection
water, solid crystals of water-soluble salts, etc. This salt is primarily dissolved NaCl (associated brines),
which are produced with crude oil.

Crude oil desalting is a process by which a dilute water source is used to reduce the salt content by
mixing salted crude oil and water, followed by coalescing of the resulting water for settling and
removal of water droplets. Crude oil salt content must typically be reduced to 10 to 20 PTB (pounds
per thousand barrel) to meet pipeline or tanker specifications, and to prevent salt deposition,
corrosion, or refinery catalyst deactivation. Crude oil typically has to meet B.S.& W. specifications that
may vary from 0.10 to 0.50 volume percent.

Coalescing is typically accomplished in electrostatic dehydrator vessels, occasionally in mechanical

coalescors, or in field Heater-treaters or Chem-electric units. Special mixing devices are used for
mixing dilution water with desalter brine water.

In rare situations, crystalline salt can exist in oil fields. Although crystalline salts are not common, it
can occur in early production when very little water is present. Crude oil emulsions or Regular
emulsions are very small water droplets suspended in a crude oil phase.
The purpose of desalting is to remove these undesirable impurities, especially salts and water, from the
crude oil prior to distillation.

The most concerns of the impurities in crude oil:

 The Inorganic salts can be decomposed in the crude oil pre-heat exchangers and heaters. As a
result, hydrogen chloride gas is formed which condenses to liquid hydrochloric acid at overhead
system of distillation column, that may causes serious corrosion of equipment.
 To avoid corrosion due to salts in the crude oil, corrosion control can be used. But the byproduct
from the corrosion control of oil field equipment consists of particulate iron sulfide and oxide.
Precipitation of these materials can cause plugging of heat exchanger trains, tower trays, heater
tubes, etc. In addition, these materials can cause corrosion to any surface they are precipitated on.
 The sand or silt can cause significant damage due to abrasion or erosion to pumps, pipelines, etc.
 The calcium naphthanate compound in the crude unit residue stream, if not removed can result in
the production of lower grade coke and deactivation of catalyst of FCC unit.

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 2. Description

Crude oil often contains water, inorganic salts, suspended solids, and water-soluble trace metals. As a
first step in the refining process, to reduce corrosion, plugging, and fouling of equipment and to
prevent poisoning the catalysts in processing units, these contaminants must be removed by desalting
(dehydration).

The two most typical methods of crude-oil desalting, chemical and electrostatic separation use hot
water as the extraction agent. In chemical desalting, water and chemical surfactant (demulsifiers) are
added to the crude, heated so that salts and other impurities dissolve into the water or attach to the
water, and then held in a tank where they settle out. Electrical desalting is the application of high -
voltage electrostatic charges to concentrate suspended water globules in the bottom of the settling
tank. Surfactants are added only when the crude has a large amount of suspended solids. Both
methods of desalting are continuous. A third and less-common process involves filtering heated crude
using diatomaceous earth.

The feedstock crude oil is heated to between 150° and 350°F to reduce viscosity and surface tension
for easier mixing and separation of the water. The temperature is limited by the vapor pressure of the
crude-oil feedstock. In both methods other chemicals may be added. Ammonia is often used to reduce
corrosion. Caustic or acid may be added to adjust the pH of the water wash. Wastewater and
contaminants are discharged from the bottom of the settling tank to the wastewater treatment facility.
The desalted crude is continuously drawn from the top of the settling tanks and sent to the crude
distillation (fractionating) tower.

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 3. Desalting process

3.1.Intro

A desalter is a process unit in an oil refinery that removes salt from the crude oil. The salt is dissolved in
the water in the crude oil, not in the crude oil itself. The desalting is usually the first process in crude oil
refining. The salt content after the desalter is usually measured in PTB - pounds of salt per
thousand barrels of crude oil.Another specification is Basic sediment and water. Desalters are also used
to treat groundwater reservoirs in areas impacted by cattle feedlots and dairies.

The desalting process is completed in following steps:

 Dillution water injection and dispersion.

 Emusification of diluted water in oil.
 Distribution of the emulsion in the electrostatic field.
 Electrostatic coalescence.
 Water droplet settling.
Crude oil passes through the cold preheat train and is then pumped to the Desalters by crude charge
pumps. The recycled water from the desalters is injected in the crude oil containing sediments and
produced salty water. This fluid enters in the static mixer which is a crude/water disperser,
maximizing the interfacial surface area for optimal contact between both liquids.

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 The wash water shall be injected as near as possible emulsifying device to avoid a first separation with
crude oil. Wash water can come from various sources including relatively high salt sea water,
stripping water, etc. The static mixers are installed upstream the emulsifying devices to improve the
contact between the salt in the crude oil and the wash water injected in the line.

The oil/water mixture is homogenously emulsified in the emulsifying device. The emulsifying device
(as a valve) is used to emulsify the dilution water injected upstream in the oil. The emulsification is
important for contact between the salty production water contained in the oil and the wash water.
Then the emulsion enters the Desalters where it separates into two phases by electrostatic coalescence.

The electrostatic coalescence is induced by the polarization effect resulting from an external electric
source. Polarization of water droplets pulls them out from oil-water emulsion phase. Salt being
dissolved in these water droplets, is also separated along the way.

The produced water is discharged to the water treatment system (effluent water). It can also be used as
wash water for mud washing process during operation.

A desalting unit can be designed with single stage or two stages. In the refineries, the two stages
desalting system is normally applied, that consists of 2 electrostatic Coalescers (Desalter).

3.2.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.

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 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 p ump, 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.

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.

Refining & Petrochemicals 4 th Year Page 5

 3.3.Safety Considerations

The potential exists for a fire due to a leak or release of crude from heaters in the crude-desalting unit.
Low boiling point components of crude may also be released if a leak occurs.

Because this is a closed process, there is little potential for exposure to crude oil unless a leak or release
occurs. Where elevated operating temperatures are used when desalting sour crudes, hydrogen sulfide
will be present. There is the possibility of exposure to ammonia, dry chemical demulsifiers, caustics,
and/or acids during this operation.

Depending on the crude feedstock and the treatment chemicals used, the wastewater will contain
varying amounts of chlorides, sulfides, bicarbonates, ammonia, hydrocarbons, phenol, and suspended
solids. If diatomaceous earth is used in filtration, exposures should be minimized or controlled.
Diatomaceous earth can contain silica in very fine particle size, making this a potential respiratory
hazard.

3.4.Corrosion Considerations

Inadequate desalting can cause fouling of heater tubes and heat exchangers throughout the refinery.
Fouling restricts product flow and heat transfer and leads to failures due to increased pressures and
temperatures. Corrosion, which occurs due to the presence of hydrogen sulfide, hydrogen chloride,
naphthenic (organic) acids, and other contaminants in the crude oil, also causes equipment failure.
Neutralized salts (ammonium chlorides and sulfides), when moistened by condensed water, can cause
corrosion. Over- pressuring the unit is another potential hazard that causes failures.

3.5.Benefits of Crude Oil Desalting

 Increase crude throughput.

 Less plugging, scaling, coking of heat exchanger and furnace tubes.
 Less corrosion in exchanger, fractionators, pipelines, etc.
 Better corrosion control in CDU overhead.
 Less erosion by solids in control valves, exchanger, furnace, pumps.
 Saving of oil from slops from waste oil.

Refining & Petrochemicals 4 th Year Page 6

 4. Types of Desalting Process

4.1.Electrostatic Desalting

Electrostatic desalting is employed for both oil field and refinery applications, to facilitate the removal
of inorganic chlorides and water-soluble contaminants from crude oil. In refinery applications, the
removal of these water-soluble compounds prevents or minimizes damage to downstream distillation
equipment.
The electrostatic desalting process consists of two important factors:
 Emulsion preparation by increasing the population density of small water droplets suspended in the
crude oil via wash water injection.
 Creating a uniform droplet size distribution by imparting mechanical shearing and dispersion of
the dispersed aqueous phase.

4.1.1. Conventional AC Electrostatic Desalter

The conventional AC (Alternating Current) electrostatic dehydration system is an efficient method to
remove high salinity formation water from the crude oil stream. This process relies on establishing a
high voltage AC electrical field in the oil phase of dehydrator/desalter vessels. The electrical field
imposes an electrical charge on water droplets entrained in the oil stream, thus causing them to
oscillate as they pass through the electrodes.

During this oscillation the droplets are stretched or elongated and then contracted during reversal of
the imposing AC electrical field. During this agitation the water droplets co-mingle and coalesce into
droplets of sufficient size to migrate, by gravity, back into the lower water phase of the vessel for
disposal.

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 Several modifications are available to enhance the conventional AC electrostatic system. These
modifications include:
 Double-hot electrode system: apply power to the two electrodes.
 Triple-hot electrode system: apply power to the three electrodes.
 Systems tailored to the project specific requirements.

4.1.2. Electrostatic AC/DC Dual Wave Desalter

GasTech's Dual Wave design utilizes both alternating and direct current through multiple plates to
promote enhanced water extraction and chloride level reduction.

GasTech's Dual Wave AC/DC system provides the client with the following benefits:
 Increased flow rates, resulting in:
o Smaller vessel footprints
o Less capital investments
 Optimized water removal:
o Lower quantities of water to the pipeline or storage.
o Less demulsifier chemical
o Less internal corrosion
 Lower operating temperatures:
o Conserves oil gravity and volume

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 STANDARD FEATURES OPTIONS

 Inlet diffuser manifold  Sand-jetting system

 Anti-vortex water collector  Inverted sand troughs
 Anti-vortex drains  Interface sludge draw-offs
 Oil collection weir baffle  Matrix packing
 Open bottom distributor  AC electrodes
troughs  Steam-out system
 Dry oil collector piping  Electrostatic
 AC/DC Plate type electrodes Heat er/ Treater

The GasTech horizontal heater-treater combines the advantages of emulsion breaking heat with
electrostatic dehydration in a single vessel package.

The unique thermal section is designed with an inlet shroud for liberating both gas and free water
from the emulsion. This flow path allows the free water to separate for disposal, without further
heating, resulting in fuel savings for the client.

The open bottom distributor troughs provide even dispersal of the heated oil across the entire
electrode section for optimum dehydration before being collected for discharge to the pipeline or
storage.

4.1.3. PROCESS DESIGN OF CRUDE OIL ELECTROSTATIC DESALTERS

A. SCOPE
This Project Standards and Specifications covers minimum process design requirements and
design considerations for electrostatic desalters.

B. REFERENCES
Throughout this Standard the following dated and undated standards/codes are referred to. These
referenced documents shall, to the extent specified herein, form a part of this standard. For dated
references, the edition cited applies. The applicability of changes in dated references that occur
after the cited date shall be mutually agreed upon by the Company and the Vendor. For
undated references, the latest edition of the referenced documents (including any supplements and
amendments) applies.

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 C. ASTM (American Society for Testing of Materials)
ASTM D4007 'Test methods for water & sediment for crude oils'

D. DEFINITIONS AND TERMINOLOGY

Water Content (of the Crude) . Water content of the crude is that water which is emulsified,
entrained or free in the crude oil, excluding the water that is in solution at the operating
temperature of the desalting system.

E. SYMBOLS AND ABBREVIATIONS

SYMBOL/ABBREVIATION DESCRIPTION

F. UNITS
This Standard is based on International System of Units (SI) except where otherwise specified.

G. DESIGN CRITERIA

 Process Requirements
1. Crude properties

The following properties have to be specified for desalter design:

- selected crude oil;
- gravity, API;

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 - BS & W, vol%;
- salt content, kg/1000 bbl (kg/159 m3);
- viscosity at two temperatures, cSt;
- sulfur content, mass %;
- pour point, °C;
- RVP at 38°C, kPa (abs.) or bar (abs.);
- delivery pressure (at inlet of the mixing valve), kPa (ga) or bar (ga).

2. Process water properties

Water to refinery desalter can be supplied from sour water stripper. Vendor shall confirm
suitability of wash water and recommend any change if necessary. Vendor shall specify
the required water rate. Other wash water sources may also be specified. The following
characteristics shall be specified for all specified types of water.
The expected water temperature at the injection point has to be specified by the Company.
A typical wash water injection rates may be between 3-7 (vol % of crude). Injection point
should be ahead of the mixing valve and /or ahead of heat exchanger train (not fired heater).
3. Operating and mechanical design conditions

The following conditions shall be specified by the Company:

a. Operating pressure of the desalter (minimum pressure must be sufficient to maintain
desalter content in liquid state).
b. Operating temperature at the inlet of the desalter (range may be specified).
c. Allowable pressure drop for the desalter (including the mixing valve). d. Design
flow rate of crude oil (bbl/sd).
e. Maximum anticipated system pressure and temperature.

 Performance Requirements

The desalter shall produce a treated crude, under steady state conditions, which conforms to the
following requirements:

a. Specified design throughput (bbl/sd).

b. The desalted crude salt content will be specified by the Company where depending
on this requirement, one or more desalter stages may be furnished.

c. In case when more than one stage is specified, facilities for series and parallel flow
should be provided.

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 d. Desalter shall be able to perform its duty with specified water types.

H. Instrumentation and Control System

Independent of safety devices like safety valves, the instrumentation and control system shall
protect all items of the system against maloperation by operators, equipment failure, etc., but
also enable the operators to undertake suitable actions during operation.

Vendor shall submit the proposed instrument and control schematic drawings, adequate to
fullfill the requirements of his process and mechanical guarantees for Company's approval.
All instrumentation shall be suitable for continuous working in the conditions of their location.

Provision shall be made for local tripping of critical equipment. The desalter
Supplier shall be responsible for the satisfactory design and operating capability of the
instruments, controls and safety equipment associated with the desalter and he shall submit
details to the Company for approval.

The type of valves/control valves shall be selected according to the service. Special valves
shall be used where cavitation, noise, flashing or erosion may occur. All shut-down
systems shall be capable of full function testing from primary sensor up to final actuation
device while the plant is on line. Test key- operated override switches shall be provided for
this function. These shall override the minimum number of function components. Alarms
shall be provided to show automatically when the trip circuit is being overriden for test. All
override test facilities shall be mechanically protected and shall be accessible only to the
personnel authorized to carry out testing.

The items listed below are regarded as the minimum required instrumentation/control
components of the electrostatic desalting system.

1. Mixing valve

The desalter shall be furnished with a suitably sized valve in the crude oil entrance line. A
local differential pressure indicator, connected to the upstream and downstream sides of
the mixing valve, shall be provided for reading of the adjusted pressure drop. Pressure drop
across the mixing valve shall also be monitored in CCR. This valve shall be manually operated
for dispersion of process water into the crude oil. This mixing shall be accomplished
with a minimum pressure drop for creating a water-in-oil emulsion.

2. Level interface controller (LiC)

Level interface controller shall receive measurement information from the level interface
transmitter. The transmitter shall be connected to the displacer at the water/oil interface. The

Refining & Petrochemicals 4 th Year Page 12

 controller uses this measurement information to control the action of the level interface
control valve and is provided with high and low level interface alarms. This control valve shall
maintain the vessel's water-oil interface at the desired level.

3. Level interface control valve (LiCV)

This control valve shall be installed in the vessels effluent water line to control the flow rate
of water leaving the vessel. Signals transmitted by the level interface controller determine
how much air is supplied to the control valve actuator.

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