DESALTER TROUBLESHOOTING

PROBLEM DEFINITION
ANALYSIS
RECTIFICATION
 DESALTER TROUBLESHOOTING

Problem Definition

• POOR SALT REMOVAL

• DEHYDRATION EFFICIENCY LOW
• GROWTH OF INTERFACE “RAG” BPG-043

• OIL IN THE EFFLUENT BRINE BPG-032

• HIGH AMPERAGE / LOW VOLTAGE

 DESALTER TROUBLESHOOTING
Analysis
• OPERATIONAL CONSIDERATIONS
• CRUDE QUALITY / QUANTITY
• SLOP ADDITION
• WATER QUALITY / QUANTITY
• VOLTAGE / AMPERAGE
• TEMERATURE
• CHEMICAL RATE
• MUD WASH
 DESALTER TROUBLESHOOTING

Typical Desalter Performance - Removal Efficiency

CRUDE SINGLE DOUBLE
API STG STG
34 - 38 96 - 98 % 98 - 99 %
30 - 34 94 - 96 % 97 - 98 %
28 - 30 92 - 94 % 96 - 97 %
22 - 26 90 - 92 % 95 - 96 %
18 - 22 88 - 90 % 94 - 95 %
14 - 18 86 - 88 % 93 - 94 %
SOLIDS 60 - 75 % 80 - 90 %
 DESALTER TROUBLESHOOTING

Operational Considerations

• CRUDE CHARGE RATE • MIXING VALVE PRESSURE

• CRUDE TANK SHIFTS • VESSEL LEVEL CONTROL
• SLOP OIL ADDITION • MUD WASH
• WASH WATER INJECTION • CHEMICAL INJECTION
 DESALTER TROUBLESHOOTING

Crude Quality / Quantity

• CRUDE COMPOSITION
NATURAL EMULSIFYING AGENTS
PRODUCTION TECHNIQUES
EMULSIFIERS ADDED IN TRANSIT
• CRUDE GRAVITY / VISCOSITY
• DESALTER DESIGN CAPACITY
• CRUDE IMPURITIES
SALT CONTENT
BS&W
FILTERABLE SOLIDS
 DESALTER TROUBLESHOOTING

Wash Water Quality / Quantity

• WASH WATER QUALITY
SOURCE OF WATER
IMPURITIES, pH, AMMONIA, OIL CONTENT
• WASH WATER QUANTITY
SUFFICIENT TO DILUTE BRINE IN CRUDE
SUFFICIENT TO WET IMPURITIES IN CRUDE
OPTIMUM DROPLET DENSITY IN ELECTRIC FIELD
TYPICAL 3-8%
HIGH RATES PROMOTE CARRYOVER
• INJECTION POINTS AND RECYCLE
 DESALTER TROUBLESHOOTING
Rectification

• FIX WHAT YOU CAN

• ONLY ONE MOVE AT A TIME

– Wait at least 4 crude turnovers in the desalter before
checking/testing…
PRODUCT APPLICATIONS

RESOLV™ Applications
(Reverse Emulsion Breaker)
Inversion of Resolv Dispersion Polymer

Process Water

Bulk Water Phase

Process Water
RESOLV Dispersion Polymer Application

Optimum Desalting/Dehydration
BENEFITS
Optimum
Solids Removal

Collapses Rag

RESOLV Dispersion Clear Effluent

Polymer injection Water
Interstage
Wash Water
 Case History

Background
• XOM, Fawley

• Increased high TAN crudes to increase

refinery profitability

• Limited throughput due to emulsifying

tendency of high TAN crudes - naphthenates
strong emulsion stabilizers
 Case History

Actions & Results

• Introduced Dispersion polymer at 10 ppm based on
wash water rate.
• Oil undercarry and desalting performance returned to
“normal” values.
• High TAN crude feed increased from 5 to 25% of total
charge
• Refinery profitability increased
 Dispersion Polymer
Field Results
Begin Dispersion
Polymer Injection

35
28 28.5
30 25
24
25 22
$ / MB -- 20
20 17.5 17
Desalting 14.5 14 13.8
15 9.6 9.5 9.7
Chemical 7.1 7
9
10 6 5.5 6
5 0.5 0.6 0.2 0.2 0.2 0.5 0.2 0.1 0.4 0.2
0

Total Dispersion

BPG-033

CS-100 CS-107 CS-110

CS-104 CS-109 CS-148

 Resolv Dispersion Polymer -
Performance Advantages

• Improves Cost Effectiveness

• Improves Oil Undercarry Control
• Maintains Effective Solids Removal
• Maintains or Improves Desalting Efficiency
• Proven in Desalting, Slop Systems, and Oil
Field Applications
 Preconditioning Chemical

Asphaltene Dispersant Application

BPG-049 CH-849 CS-287

 Metals Removal (CRA)
• Opportunity crude focus
• Significant $$$ Impacts:
– FCC catalyst, Fuel specs, Overheads corrosion
(neutralizer consumption), WWTP impacts, CDU
preheat fouling, increased maintenance costs/reduced
unit runlength……
• Handling high Ca, Fe, Hg crudes
• EC2483A
• EC2047A (running a dirty bleed)
Nalco Calcium Removal Guidelines
 SELECT
Ysold NA LA EAME AP Description

EC2425A x x x x Primary emulsion breaker-heavy crude

EC2452A x x x x Primary emulsion breaker-heavy crude
EC2134A x x x x Primary emulsion breaker-lighter crude
EC2498A x x x Primary emulsion breaker-paraffinic crude
EC2472A x x x x Primary emulsion breaker-heavy crude
EC2048A x x x Dewatering aid
EC2045A x x x x Dewatering aid
EC2043A x x x x Dewatering aid
EC2447A x x x x Asphaltene stabilizer
EC2449A x x x x Asphaltene stabilizer
EC2055A x x x Reverse emulsion breaker-polymer
EC9239A x x Reverse emulsion breaker-polymer
EC2345A x x x Wetting agent
EC2483A x x x x Contaminant removal
EC1417A x x x x Corrosion inhibitor for CRA
EC2111A x x x x Contaminant removal - Acetic acid
NEW TECHNOLOGIES
DESALTING: Opportunity Crude EBs
• High Polarity Crude Oil
– Sources of polarity in crude oil are resins, aromatics or
surfactants in slop.
– Manifests itself as a crude oil with low interfacial tension
– SJV is a good example
• Heavy Asphaltic Crudes
– New demulsifier types have enhanced asphaltene interactivity
– Many Canadian crudes like Cold Lake & WCS are good
examples
• High Paraffinic
– Heavy gasoil, waxy resid is a good example
 Desalting Research Tools
Dynamic Visual Desalter Portable Electric Desalter Critical Electric Field

Kruss K100 Tensiometer Drop Shape Analyzer

 Desalting-Related Research Projects
• Emulsion Characteristics & Demulsifier performance
• Small Angle Neutron Scattering (SANS) at Argonne Labs
• Critical Electric Field (CEF) Development
+ + + + + + + +

CRITICAL VOLTAGE
Current

_ _ _ _ _ _ _ _

+ + + + + + + +
Critical Electric Field
+ + + + + + + +

_ _ _ _ _ _ _ _

_ _ _ _ _ _ _ _

Voltage
 Early CEF Results
1
12.5 ppm EC2472A
0.9 12.5 ppm EC2452A
12.5 ppm EC2425A
0.8 12.5 ppm EC2045A
12.5 ppm VX8324
0.7 12.5 ppm EC2498A
Blank
0.6

0.5

0.4

0.3

0.2

0.1

0
60 65 70 75 80 85 90 95 100
8 ml Maya Crude Oil: 2 ml Brine (1 % NaCl)
Voltage (V)
Emulsified 15000 rpm for 3 minutes
Crude Oil Data Base
 Neostar Capabilities

• Screen >700 crudes

• Indicate potential problems
• Aid in troubleshooting
• Facilitate product selection
• Forewarn of incompatibilities,
• Catalyst poisons, and overhead chlorides

• Needs input from the field on new issues and

problems arising from crude blending and
opportunity crudes….
TANKAGE DEHYDRATION
 TANKAGE DEHYDRATION

INADEQUATE DESALTING CAPACITY

• ADD DESALTING SYSTEMS

• INCREASE CRUDE STORAGE TANKS

(GREATER SEPARATION TIME)

• USE TANKAGE DEHYDRATION

 TANKAGE DEHYDRATION

• EXTENSION OF DESALTING PROCESS

• RAW CRUDE PRE-TREATMENT

• PRODUCES HIGHER QUALITY CRUDE

• GIVES DISTINCT OIL/ WATER INTERFACE

 TANKAGE DEHYDRATION

WHEN TO USE TANKAGE DEHYDRATION

• INCONSISTENT RAW CRUDE FEED QUALITY

– BARGE OR TANKER SHIPMENTS
– GREATER THAN 0.5% BRINE IN RAW CRUDE

• UNATTAINABLE SALT LIMITS ON DESALTED CRUDE

• POOR OIL / WATER SEPARATION IN TANK FARM

 TANKAGE DEHYDRATION

• SURVEY TOTAL SYSTEM

• EVALUATE CRUDE OILS AND FEEDS

• ESTABLISH PROGRAM SPECIFICATIONS

• ESTABLISH APPLICATION PROCEDURE

• OPERATOR TRAINING
 TANKAGE DEHYDRATION

APPLICATION

BPG-058
• CHEMICAL
CS-183

• TEMPERATURE CS-188

• SETTLING TIME
 TANKAGE DEHYDRATION
TREATMENT GUIDELINES
ASPHALTIC / NAPHTHENIC CRUDES
API GRAVITY DOSAGE TEMP TEMP SETTLING
(PPM) (oC) (oF) TIME (HRS)

30+ 4.5 18 - 27 65 - 80 24

25-30 6.0 27 - 38 80 - 100 36

20-25 9.0 38 - 43 100 - 110 54

16-20 12.0 43 - 52 110 - 125 72

 TANKAGE DEHYDRATION

TREATMENT GUIDELINES
PARAFFINIC CRUDES

GRAVITY DOSAGE TEMP SETTLING

(API) (PPM) TIME (HRS)
25 - 40 9 20 – 25 oF 48
10 – 14 oC
(above pour point)
 TANKAGE DEHYDRATION
Application Methods

Treated Crude

PORTAFEED

Free Water

PIPELINE

Treated Crude

PORTAFEED

Free Water
 TANKAGE DEHYDRATION
Tank Bottoms Method

Untreated Crude

Unresolved Emulsion

Recovered Oil

PORTAFEED

Free Water
 TANKAGE DEHYDRATION

BENEFITS
• IMPROVE PROFITABILITY
• ACHIEVE FEEDSTOCK REQUIREMENTS
• ENHANCE DESALTING PROCESS
• MINIMIZE CRUDE SYSTEM UPSETS
• SMOOTHER DESALTER OPERATION
• CONSERVE FUEL COST
• PROTECT DOWNSTREAM PROCESSES
• SHARPER OIL/WATER INTERFACE
• REDUCE POLLUTION CONTROL COSTS
 WASTE OIL TREATMENT

SIMPLIFIED PROCESS FLOW

LIGHT PRODUCT
ENDS

RAW TANK CRUDE WASTE

CRUDE FARM UNIT PRODUCT

HEAVY
ENDS PRODUCT

WASTE WASTE WASTE

 WASTE OIL TREATMENT
EMULSION BREAKING METHODS
Emulsion breaking requires counteracting the stabilizing
effects of emulsifiers at the interface.
Methods include:
• Decomposing the emulsifiers
• Chemically reacting the emulsifiers
• Increase the solubility of emulsifiers in either bulk phase
• Disrupt the orientated structure of the emulsifiers at the
interface
 WASTE OIL TREATMENT

TWO WASTE OIL CATEGORIES

Slop oils
Oily water
 WASTE OIL TREATMENT

SLOP OIL APPLICATIONS

• Batch treatment

• Transfer treatment

• Continuous treatment
 WASTE OIL TREATMENT
BATCH TREATMENT APPLICATION

• Slop treated in same tank

• Inefficient way to SLOP TANK
break emulsions
• May cause much more
stable emulsions EMULSION

CHEMICAL
 WASTE OIL TREATMENT
BATCH TREATMENT APPLICATION

• Heat enhances
emulsion resolution
• Ensure only emulsion is
removed from tank HYDROCARBON
EMULSION
WATER

CHEMICAL
 WASTE OIL TREATMENT
TRANSFER TREATMENT APPLICATION
• Method involves moving
SLOP TANK emulsion from one tank to another
• Ensure only emulsified
material is transferred
EMULSION

RESOLVING TANK

CHEMICAL
 WASTE OIL TREATMENT
TRANSFER TREATMENT APPLICATION
• Provides sufficient mixing
and uses less chemical
SLOP TANK • The emulsion passes through
the pump only once

RESOLVING TANK

HYDROCARBON
EMULSION
CHEMICAL
WATER
 WASTE OIL TREATMENT
CONTINUOUS TREATMENT APPLICATION
• Waste streams are continuously
pumped to a resolving tank
API • Requires close monitoring
SEPARATOR

RESOLVING TANK

HYDROCARBON
EMULSION
CHEMICAL
WATER

CS-154
 WASTE OIL TREATMENT

INCENTIVES FOR WASTE OIL TREATMENT

• Minimize waste
• Reduce pollution control costs
• Reduce disposal costs
• Reduce operating costs
• Restore storage tank capacity