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Table of content

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Definition Theory Why desalt crude? Description Safety consideration Corrosion consideration

DESALTING

Desalting and dewatering of crude oil upstream of the crude distillation unit is a key process operation for the removal of undesirable components from crude oil before it reaches any of the major unit operations. The operation of a desalting system can be very challenging due to changing process variables. At best, it is a process of measuring trade-offs and compromises. The main function of the Desalter is to remove salt and water form the crude oil. However, many other contaminants such as clay, silt, rust, and other debris also need to be removed. These can cause corrosion and fouling of downstream equipment when deposited on heat transfer surfaces. Also, there are metals that can deactivate catalysts used in the process of 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, When extracted from an oil reservoir the crude oil will contain some amount of saltwater and particulate matter known as sediment or mud.. The bulk of the water and sediment is usually separated at the field to minimize the quantity that needs to be transported further. The residual content of unwanted these impurities is measured as BS&W. Oil refineries, may either buy crude to a certain BS&W specification or may alternatively have initial crude oil desalting process units that reduce the BS&W to acceptable limits.

Desalter Theory
The Desalter removes contaminants from crude oil by first emulsifying the crude oil with chemicals and wash water to promote thorough contact of the water and oil. The salts containing some of the metals that can poison catalysts are dissolved in the water phase. After the oil has been washed and mixed as an emulsion of oil and water, demulsifying chemicals are then added and electrostatic fields are used to break the emulsion. Desalters are sized to allow the water and oil to settle and separate according to Stoke's Law. In addition, solids present in the crude will accumulate in the bottom of the desalter vessel. The desalter must be periodically washed to remove the accumulated solids. A "mud washing" system is installed in the bottom of the vessel to periodically remove the solids. Mud washing consists of recycling a portion of the desalter effluent water to agitate the accumulated solids so that they are washed out into the effluent water. These solids are then routed to the wastewater system. Desalter effluent or "undercarry" is a combination or many things including the mud wash done at periodic intervals, produced water that came with the crude, and the brine wash water resulting from the dilution and removal of salts and other contaminants.

Why Desalt Crude?

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The salts that are most frequently present in crude oil are Calcium, Sodium and Magnesium Chlorides. If these compounds are not removed from the oil several problems arise in the refining process. The high temperatures that occur downstream in the process could cause water hydrolysis, which in turn allows the formation of hydrochloric acid. Sand, Silts, Salt deposit and Foul Heat Exchangers Water Heat of Vaporization reduces crude Pre-Heat capacity Sodium, Arsenic and Other Metals can poison Catalysts Environmental Compliance, i.e., By removing the suspended solids, which might otherwise become an issue in flue gas opacity norms, etc.,

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.

Electrostatic Desalting Flow Chart The feedstock crude oil is heated to between 150 and 350F 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.

Desalting Process
Feedstock Crude oil From Storage Process Treating Typical products - to - unit

 

Desalted crude to Atmospheric distillation tower Waste water to Treatment

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.

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.

TYPES OF DESALTING SYSTEMS

Single-Stage Dehydrator Single-Stage Desalter Two-Stage Desalter Three-Stage Desalter

DESALTER COMPONENTS
Process Vessel Distribution System Electrodes and Transactors Mud Wash Level Control Devices

DESALTER DESIGN CONSIDERATIONS

Vessel Size Number of Stages Transactor Size and Power Consumption Crude Properties

FACTORS THAT AFFECT DESALTER OPERATION AND PERFORMANCE

Crude Oil Feed Rate and Quality Temperature/Viscosity/Density Relationships Electrical Field Intensity Wash Water Rate, Quality and Flow Configuration Emulsion Formation (Pumps, Exchangers, Valves, Mixers) Control of Water Level and Emulsion Layers Demulsifier Technology

Resources
www.petroleumrefining.com www.setlaboratories.com www.waterandwastewater.com www.wikipedia.com