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A. BAHADORI
University of Masjed-Soleiman
Abstract
New equations covering a wide range of oil types are developed to estimate the treating rate and treating temperature for
dual polarity electrostatic desalters and AC conventional electrostatic desalters in Iranian oil fields. Production of wet crude had
been a growing problem that affected the quality of produced oil
in Iran. Application of the correct technology and the installation
of proper desalting facilities were required to solve this problem.
Therefore, it was decided to install electrostatic desalting plants
progressively in Iranian oil fields. By the end of 2004, more than
20 desalting plants with a total capacity of 207,000 standard
cubic metres per day of treated crude have been installed. The
performance of the majority of these desalting plants have been
tested and found satisfactory. It is expected that the rate of wet
crude production will increase to 366,000 standard cubic metres
per day in 2007.
This study shows that a dual polarity electrostatic desalter may
operate at a minimum crude oil inlet temperature, resulting in
extra fuel savings and eliminating the need for a heating system
in the vessel. In addition, the treating rate for a dual polarity electrostatic desalter is more than for an AC conventional electrostatic desalter.
Introduction
The production of salty wet crudes had affected the quality of
Iranian crudes and a number of wells had to be shut in for lack of
treatment facilities(1). The water produced with crude in Iranian oil
fields contains salts in concentrations of 150,000 to 220,000 ppm.
In almost all cases, the salt is found dissolved in the water that is
dispersed in the crude oil. This salt water is present in the crude in
the form of emulsion and its separation is not an easy task.
The installation of current desalting plants within the existing
facilities in Iran called for considerable changes in the facilities
and other utility systems. These changes have been successfully
carried out and the performance of the majority of the desalting
plants have been tested and found satisfactory(1, 2).
When the produced formation water is highly saline as in the
case of Iranian fields, then straight dehydration is not the solution and the crude has to be desalted as well. Dehydration means
removing only that water which is in the crude when crude is produced. The term desalting means the addition of comparatively
fresh water to the crude. This addition of fresh water dilutes the
original brine so that the salt content of the water that remains after
treatment is within acceptable limits. In general, the dehydration
system can be divided into three classes: gravity, electrical, and
chemical, or a combination thereof(3). Therefore, the process adopted in Iran for treating wet crude is a combination of dehydra-
THIS PAPER IS BEING PUBLISHED AS A TECHNICAL NOTE AND HAS NOT BEEN PEER REVIEWED.
22
It is often necessary to adjust more than one of these process parameters when adjusting the system for optimum performance.
stripper; the remaining oxygen shall be removed by oxygen scavenger up to 0.01 mg/kg to prevent corrosion.
Mixing Intensity
Mixing intensity refers to the degree of oil and water mixing
that is achieved in a mixing valve due to the pressure drop across
the valve. The greater the pressure drop, the greater the mixing intensity. Undermixing or overmixing can occur. Undermixing (an
insufficient pressure drop) results in insufficient salt removal and
low water carryover. Overmixing (too great pressure drop) can also
occur. Too great a pressure drop at the mixer can result in a tight
water-in-oil emulsion, which cannot be broken readily by the electric field in the desalter. Indications that overmixing is occurring
include unusually low voltage at the electrode zone and a higher
than normal carryover of water into the treated oil.
Process Temperature
Heating of crude oil influences the treating process in several
ways. It reduces the viscosity of the oil, resulting in greater force
during collision of water droplets; it increases the free falling velocity of water droplets into less viscous oil; and it enhances the
gravity separation process by increasing the difference in densities. However, it may reduce the volume and the gravity of produced oil. Treating temperatures normally range from 55 to 100
C. In treating heavy crudes, the temperature may be as high as 167
C. The system operating temperature should be maintained within
the range for which the system is designed. A loss in desalting efficiency may be experienced outside this range. In other words, if
the desalter plant experiences a higher than normal system temperature which causes gassing to occur in the vessel, desalting efficiency may be reduced. If the operating temperature is too low,
emulsion resolution will not be as complete. Operation temperature should be above the melting point of the asphaltenes.
Process Pressure
The backpressure valve for the system will normally be set to
maintain a pressure at the vessel which is at least 140 kPa above
the vapour pressure of the oil and water mixture in the vessel.
This prevents the oil and water from vapourizing, expanding, and
forming gas in the vessel. If system backpressure decreases for any
reason, gassing may occur in the vessel. Symptoms of excessive
gassing are excessive water in the treated oil and poor salt removal.
The normal operating values for system backpressure should prevent gassing.
Desalting Voltage
Production unit desalters are sometimes designed for variable desalting voltage. In this case, this parameter can be used to
24
AC conventional
Dual polarity
100
Practical data
Treating Temperature ( C)
280
120
80
60
40
20
0
0.75
0.80
0.85
0.90
0.95
1.00
240
Equation results
200
160
120
80
40
0
0.75
0.80
0.85
0.90
0.95
1.00
AC conventional
Dual polarity
120
Practical data
0.80
0.85
0.90
0.95
1.00
Practical data
Equation results
100
80
60
40
20
0
0.75
120
0.80
0.85
0.90
0.95
1.00
Equation results
Treating Temperature ( C)
Treating Temperature ( C)
330
300
270
240
210
180
150
120
90
60
30
0
0.75
100
80
350
Practical data
60
40
20
0
0.75
0.80
0.85
0.90
0.95
1.00
......................................................... (5)
300
Equation results
250
200
150
100
50
0
0.75
0.80
0.85
0.90
0.95
1.00
Now we can compare the rate of fuel gas consumption for two
main types of desalters. For example, in the case of Maruns oil
field desalting plants, the operational conditions and the crude oil
properties are as follows:
qo = 8,745 m3/day;
Oil specific gravity = 0.855;
Water specific gravity = 1.15;
Inlet temperature = 44.5 C;
Inlet to AC conventional = 65 C; and,
Inlet to dual polarity = 58.9 C
25
REFERENCES
25,000
AC conventional
Dual polarity
20,000
15,000
10,000
5,000
0
0.75
0.80
0.85
0.90
0.95
1.00
Assuming that the free water has been separated from the emulsion and the remaining amount of water is less than 10% of the oil,
then the calculated duties are 4,719 and 3,312 kilo Watts for the AC
conventional electrostatic and dual polarity electrostatic desalters,
respectively. Figure 12 shows the reduction of required energy to
preheat the crude oil for dual polarity electrostatic desalters in a
case at which the inlet temperature is 38.9 C and the crude oil rate
is 8,745 m3/day.
Conclusions
1. New equations covering a wide range of oil types are developed to estimate the treating rate and treating temperature
for dual polarity electrostatic desalters and AC conventional
electrostatic desalters.
2. The dual polarity electrostatic desalter is designed to operate
at temperatures 6 C to 10 C lower than a conventional electrostatic desalter, and up to 34 C cooler than ordinary heater
treater.
3. It is concluded that the dual polarity desalters are more economically beneficial because:
It provides for more complete dehydration. As a result,
it can process at higher viscosities, which means less heat
is required to lower the viscosity of the oil at processing
conditions;
It may operate at the minimum crude oil inlet temperature, resulting in additional fuel savings and eliminating
the need for a heating system in the vessel. It achieves a 7
C reduction in temperature (Figure 6);
Its treating rate is higher than the AC conventional electrostatic desalter (Figure 7); and,
It provides considerable savings in fuel costs for any
gravity of crude oil. Figure 12 reveals the reduction in preheater load for the dual polarity compared with the AC
conventional electrostatic desalter.
Acknowledgements
The authors would like to acknowledge the Department of Petroleum Engineering at the National Iranian South Oil Company
(NISOC) for giving permission to publish this work.
NOMENCLATURE
q
qo
qw
ao
aw
T
Q
T
26
=
=
=
=
=
=
=
=
Authors Biographies
Khalil Zeidani is a Ph.D. candidate in petroleum engineering at the University of Alberta, Edmonton, Canada. He received his
M.Eng. in reservoir engineering from the
University of Calgary in 2002 and his B.Sc.
degree in chemical engineering from the
Petroleum University of Technology of Iran
in 1998. He also holds a diploma in control instrument services (C.I.S.) from the
National Iranian Oil Companys (N.I.O.C.)
Technical School. Previously, he worked
four years as a C.I.S. technologist and three years as a process engineer for the N.I.O.C. His research interests include emulsion
flow through porous media, multi-phase flow in fractures, thermal
recovery methods, and process design.
Alireza Bahadori is a process engineer
with the National Iranian South Oil Company in Ahwaz City, Iran. His expertise
includes artificial lift design, production
optimization, and facilities engineering.
Bahadori has a diploma in control instrument services (C.I.S.) from the National
Iranian Oil Companys (N.I.O.C.) Technical School (1991), a B.Sc. in chemical
engineering from the Petroleum University
of Technology, Abadan, Iran (1998), and an
M.Sc. in chemical engineering from the University of Shiraz, Iran
(2000). He is a member of the Iranian Petroleum Institute and the
Iranian Association of Chemical Engineers. Bahadori is the author
or co-author of 12 conference and journal technical papers.
Journal of Canadian Petroleum Technology