Journal of the Taiwan Institute of Chemical Engineers 58 (2016) 141147

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Journal of the Taiwan Institute of Chemical Engineers

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Modeling electrostatic separation for dehydration and desalination of

crude oil in an industrial two-stage desalting plant
E. Aryafard a, M. Farsi a, M.R. Rahimpour a,b,, S. Raeissi a
a
Department of Chemical Engineering, School of Chemical and Petroleum Engineering, Shiraz University, Shiraz, Iran
b
Department of Chemical Engineering and Materials Science, University of California, Davis, One Shields Avenue, Davis, CA 95616, United States

a r t i c l e i n f o a b s t r a c t

Article history: The aim of present study is to develop a mathematical model to predict water and salt separation eciencies
Received 20 February 2015 in an industrial two stages crude oil desalting process. The considered process consists of mixing valve and
Revised 12 June 2015
electrostatic drums connected in series. The desalting plant is modeled based on the population balance
Accepted 21 June 2015
method considering water droplet breakage and coalescence terms to predict droplet size distribution. The
Available online 29 July 2015
class method as a common mathematical technique is selected to solve population balance equation. The
Keyword: accuracy of the developed mathematical model and considered assumption is evaluated using taken data
Crude oil emulsion from an industrial desalting plant. Then, the effect of mixing valve pressure drop, ow rate of fresh water and
Mixing valve strength of electric eld is studied on the desalting and dehydration eciencies. The simulation result shows
AC electrostatic desalting that increasing ow rate of fresh water from 3% to 6% decreases salt content in the treated crude oil from 2.06
Population balance to 0.71 PTB.
2015 Taiwan Institute of Chemical Engineers. Published by Elsevier B.V. All rights reserved.

1. Introduction polarity, electro-dynamic, and dual frequency are different common

The extracted crude oil from reservoir contains some compo-
nents like gas, water, salt, solid particles and so on. The salts that
are often present in crude oil are calcium, sodium and magne-
sium chlorides. Salt can cause severe problems such as corrosion
in equipment, fouling by salt deposition, and poisoning of cata-
lysts in downstream units. Mineral salts may be present in the
crude oil in several forms such as dispersed and emulsied water
drop and crystal. Thus, crude oil is dehydrated and desalted be-
fore being charged to the renery units. Oil desalting and dehy-
dration systems are industrial processes for removing water-soluble
salts from an oil stream. The primary objective for a crude oil
desalting process is to achieve sucient product purity in terms
of salt removal and water cut eciencies. A conventional oil de-
salting plant consists of separator, coalescer tank and electrostatic
drum that are connected in series. The free water droplets are
settled and separated from crude oil in the coalescer tank. Then,
fresh water is mixed with crude oil to dilute base brine and
decrease salt concentration. The prepared emulsion is fed to the elec-
trostatic desalting drum and brine is separated from crude oil. Among
different desalination methods, the common method is electrostatic
desalting that use electric eld. AC, DC, dual polarity, modulated dual
Corresponding author. Tel.: +98 713 6133787; fax: +98 713 6287294.
E-mail address: rahimpor@shirazu.ac.ir (M.R. Rahimpour).
methods in electrostatic desalting.
Many researchers have focused on prediction of water droplet col-
lision and coalescing in crude oil desalting. Berg et al. studied de-
formation of water droplets in an electric eld in hydrocarbon liq-
uids [1]. Abdul-Wahab et al. developed simple inferential estimator
to predict product quality in the crude oil desalting process [2]. In
this study, temperature, settling time, mixing time, chemical dosage,
and dilution rate were considered as input variables to predict wa-
ter and salt removal eciencies. Chiesa et al. studied the effect of
continuous phase viscosity on coalescing of water in oil emulsion in
presence of an electric eld, experimentally [3]. Pruneda et al. simu-
lated the crude oil desalting in an industrial plant based on a sim-
ple mathematical model and calculated the optimum temperature
[4]. The results showed the maximum prot is attainable at 135 C
for Maya crude oil. Mahdi et al. experienced effect of emulsier con-
centration, temperature, fresh water rate, settling time and mixing
time on the dehydration eciency in the crude oil desalting [5]. The
results showed that salt removal eciency approaches to 93.28% at
the optimal condition. Vafajoo et al. studied effect of temperature,
rate of chemical injection and crude oil pH on the salt removal in
an electrostatic desalting plant, experimentally [6]. The experimen-
tal results showed that injection of 50100 ppm demulsier and pH
912 result in maximum separation of water and salt from crude
oil. Meidanshahi et al. modeled a pilot plant electrostatic desalting
drum based on the population balance method at steady state condi-
tion [7]. They calculated droplet size distribution at the outlet of the

http://dx.doi.org/10.1016/j.jtice.2015.06.028
1876-1070/ 2015 Taiwan Institute of Chemical Engineers. Published by Elsevier B.V. All rights reserved.
142 E. Aryafard et al. / Journal of the Taiwan Institute of Chemical Engineers 58 (2016) 141147

Nomenclature

Bi bond number
Ca capillary number
d diameter
E0 electric eld strength
eij collision eciency
f daughter drop size distribution function
g gravity
g(v) breakage frequency
K a constant Fig. 1. Flow diagram of two-stage electrostatic desalting.

m number of fragments formed per breakage of a

Table 1
droplet Specication of feed, mixing valve and electrostatic de-
n(v,z) continuous number density salting drum.
Ni(z) discrete number density
Property Value
P pressure
PTB pounds of salt per thousand barrels of crude oil Feed
u velocity Crude oil rate (bbl/day) 55,000
Crude oil temperature (C) 51
uc continuous phase velocity
API 33
v volume Water cut (%) 12
Vij (0) relative velocity Crude oil salt content (PTB) 9443.26
w volume Fresh water
Flow rate 3% of crude oil rate
We Webber number
Temperature (F) 40
z length Mixing valve
Pressure drop (psi) 25
Greek letters
Mixing eciency (%) 100
(v,w) coalescence frequency Desalting drum
ratio of the radius of the small drop to that of the large Length (m) 13.72
drop Diameter (m) 3.05
oil permittivity Electrodes length (m) 0.3
Electrical eld (kV/cm) 1.5
viscosity
kinematic viscosity
rate of turbulent dissipation
decreasing salt concentration in the emulsion. The size distribution
density
of outlet droplets from valve is function of mixing pressure drop, the
interfacial tension
residence time of emulsion in valve, temperature and feed property
such as viscosity and density. Then, feed is entered to the rst desalt-
desalting drum considering an arbitrary inlet size distribution for wa- ing drum and distributed uniformly through a distributor. Emulsion
ter droplet. Mohammadi et al. studied collision and coalescence of bi- move toward the top of horizontal drum and is entered to the alterna-
nary water droplets falling in stagnant uid in presence of AC eld [8]. tive current (AC) electric eld section. An electrical system connected
The experimental results proved that the stronger electric eld and to the electrodes generates an electrostatic eld at potential about
the skew angle of the electric eld decelerate the electro-coalescence 20,000 volts and induces dipole attractive force between neighboring
of droplets. Raikar et al. modeled the water droplet breakage based on water droplets. AC electric eld causes a dipolar attraction force be-
population balance model [9]. Mitre et al. experienced and modeled tween droplets and improves collision and coalescence eciency of
the water and crude oil mixing in a valve to predict droplet size distri- water droplets. Smaller droplets move up with the crude oil as con-
bution. The simulation results proved the accuracy of the considered tinuous phase and the larger drops move down because of the domi-
mode [10]. nant gravitational force compared to upward drag force. Outlet crude
The aim of present work is to develop a mathematical model to from top of the rst desalting drum is mixed with fresh water to di-
predict water and salt removal eciencies in an industrial two stages lute the brine so the target salt content can be achieved by the crude
crude oil desalting based on the population balance model. In the oil dehydration [11]. In the second stage, the drops coalesce and large
considered process, mixing valve and electrostatic desalting drums drops move downward, while treated crude oil leaves via the top of
have been connected in series. The accuracy of the developed math- the vessel. In addition, the settled sediment at the bottom of drums
ematical model and considered assumption is evaluated using data is withdrawn as sludge. Fig. 1 shows the schematic diagram of a do-
taken from a domestic oil processing plant. In addition, effect of mix- mestic two-stage crude oil desalting plant.
ing valve pressure drop, ow rate of fresh water and electric eld The required information to complete the developed mathemati-
strength on the desalting and dehydration eciencies is studied at cal model such as specication of feed, fresh water, mixing valve and
steady state condition. electrostatic drums can be found in Table 1.

2. Process description 3. Process modeling

After free water removal from crude oil, there are a few unwanted
salts in residual water cut that need to be reduced to 510 pounds
of salt per thousand barrels of crude oil (PTB). Crude oil desalting
technology has been developed to remove residual salt from crude
oil. In two-stage desalting technology, outlet water from second de-
salting drum is mixed with crude oil to dilute the base brine and
Dispersed two-phase ows are one of the most common ow
types followed in the industrial processes. The researches show that
single droplet size models cannot properly describe behavior of a dis-
persed phase in a continuous phase [12]. Thus, population balance
model is used to study the characteristics of dispersed ow process
such as crystallization, liquidliquid extraction, solidliquid leaching,
 E. Aryafard et al. / Journal of the Taiwan Institute of Chemical Engineers 58 (2016) 141147 143

and wateroil emulsion separation. Population balance equations de- of drum, smaller droplets move up with the continuous phase, while
scribe the rate of change of the particle number density on a macro- larger drops move down because of the dominant gravitational force
scopic level. In this section, the mixing valve and electrostatic de- compared to upward drag force. Therefore, desalting drum is divided
salting drum are modeled based on population balance equation at to some segments. Each segment contains two inlet and two out-
steady state condition. By simplication the general population bal- let streams. The settled droplets from upper segment and upward
ance equation, the one-dimensional form of population balance is as droplets from below segment are inlet streams to each part. The pop-
follows [13]: ulation balance equation is simplied to:
 v  v
n(v, z) 1 n(v, z) 1
u = g(v)n(v, z) + (v, w)n(w, z)n(v w, z)dw u = (v, v w)n(w, z)n(v w, z)dw
z 2 w=0 z 2 w=0
 
+ m(w) f (v, w)g(w)n(w, z)dw n(v, z) n(v, z) (v, w)n(w, z)dw (5)
w=v w=0

where collision frequency, , is expressed as follows [15]:
(v, w)n(w, z)dw (1)
w=0
(di , d j ) = K (di + d j )2Vi(j0) ei j (6)
In right side of equation, rst and fourth terms present death
of droplets with volume v because of breakage and coalescing with ( + 1)|d c |di2 (1 2 )g
Vi(j0) = (7)
other droplets, respectively. The second and third terms show the 6(3 + 2)c
birth of droplet with volume v from coalescing the smaller droplets,
Manga and Stone suggested an empirical correlation for aggrega-
and birth of droplet with volume v from breaking of the larger
tion eciency in absence of electric eld as follows [16].
droplets, respectively.
1
ei j = 0.3 1/2 + Bi 6 (8)
3.1. Mixing valve modeling 2
When, the droplets move through a horizontal eld, collision rate
To create an accurate model for simulation of crude oil desalt- increases because of dipoledipole force between droplets. Zhang
ing process, break up frequency, coalescing frequency and daughter et al. studied droplets behavior in an electric eld [17]:
drop size distribution functions are inserted in the population bal-
0.55
ance equation. The main challenge about population balance models 2 (1 )gdi
ei j = 0.45 (9)
3 (1 + ) E02
is determination of unknown drop breakage and coalescence func- 2

tions through experimental data. Mitre et al. suggested a breakage

frequency function that predicts breakup of droplets against external 4. Numerical solution
forces [10].
    There are many numerical methods to solve population bal-
2.2 d 4/5
K 63.927 Ca if CaCacrit ance such as classes, Monte Carlo, method of moments, quadrature
g(d) = 11/5
Wecrit 2 (2)
0 if Ca Cacrit method of moments and direct quadrature method of moments. In
this study, the class method as a simple and accurate mathemati-
The effect of pressure drop and residence time in the mixing valve cal technique is selected to solve the population balance equations.
is appeared in the turbulent dissipation rate, , as follows: The discrete counterpart of the population balance equation is carried
P out with the xed pivot technique in method of classes. In the class
= (3) method, the continuous size distribution is converted to discretized
tres
classes as follows [18].
In uid mechanics, the ratio of viscous force to interfacial tension  vi+1
is dened as Capillary number. When Capillary number is larger than Ni (z) = n(v, z)dv (10)
its critical value, droplet breaks to the smaller drops [10]. In breakage vi
frequency function, Wecrit is critical value of Weber number. Weber Applying the class method on the integral form of population bal-
number is dened as external hydrodynamic stress to surface tension ance equation converts the original integral form equation to a series
ratio. When the applied external stress on a droplet is larger com- type equation as follows:
pared to surface tension force, the droplet breaks to smaller one. In
dNi (z)  1
jk 
this study, an empirical Gaussian shape function is considered to cal-
u = gi Ni + 1 j,k j,k N j Nk
culate the breakage distribution function that predicts the number of dz 2
j,k
formed drops with diameter d from breakage of d0 [14].
  2  
M 
M

2.4 2d3 d03 + ni,k gk Nk Ni i,k Nk (11)

f (d, d0 ) = 3 exp 4.5 (4) k=i+1 k=1
d0 d06
where,
 xi+1 
xi+1 v xi
v xi1
3.2. Modeling of horizontal AC electrostatic desalting ni,k = m f (v, xk )dv + m f (v, xk )dv (12)
xi xi+1 xi xi1 xi xi1
The mixed fresh water and crude oil in the mixing valve is fed  xi+1 v
to the electrostatic desalting drum. Electric eld increases collision xi+1 xi
xi v xi+1
rate between dispersed droplets in the continuous phase and results
= vxi1 (13)
xi xi1
xi1 v xi
larger droplet formation. Desalting drum could be divided in two sec-
tions based on the electric eld. In the rst section in absence of The literatures show that rate of fresh water, mixing valve pres-
electric eld, the rate of drops collision and coalescence is low, so sure drop, and strength of electric eld have a considerable effect on
this section has an insignicant effect on the size distribution. In the the crude oil desalting performance. The developed model can in-
second section in presence of electric eld, rate of drop collision in- vestigate effect of these variables on the eciency of salt and water
creases signicantly and large droplets are formed. In each section separation.
144 E. Aryafard et al. / Journal of the Taiwan Institute of Chemical Engineers 58 (2016) 141147

Table 2 droplets along the mixing valve. As mentioned previously when

Comparison between simulation results and data taken from one-
stage desalting plant in Iran.
Modeling result Industrial data
Dehydration eciency 96.48 96.77
Desalination eciency 96.09 94.15
PTB 3.19 4.78
5. Results and discussion
To develop an accurate and detailed mathematical model as a ref-
erence point to predict droplet size distribution through crude oil de-
salting, 110 droplet classes were considered in range of 15000 m.
In this study, the results are presented in four sections involving
model validation, simulation results of mixing valve, one and two
stages electrostatic desalting followed by operability analysis of crude
oil desalting in the two-stage process. The accuracy of the developed
mathematical model and considered assumption is evaluated using
industrial data from a domestic oil processing plant.
5.1. Model validation
To prove the accuracy of the considered model, predicted desalt-
ing and dehydration eciencies are compared to taken data from
an industrial one-stage plant. The desalting eciency is explained as
pounds of salt treated in a thousand barrels of crude oil (PTB). Table 2
shows comparison between simulation results and industrial data at
steady state condition. The results show that predicted dehydration
eciency is close to industrial unit value. In this study, it is assumed
that fresh water and emulsion are mixed completely, while mixing
eciency do not exceed 85%. It inuence PTB prediction and results
in a difference between predicted PTB and industrial data.
5.2. Mixing valve
In this section the results of developed mathematical model for in-
dustrial mixing valve is presented at steady state condition. Fig. 2(a)
and (b) shows the size distribution and volume fraction of water
droplet experience an external stress, it breaks to smaller droplets
and it makes emulsion more stable. Fig. 2(a) illustrates droplet size
distribution along the mixing valve; it shows that droplet size distri-
bution curve shifts from large droplets to smaller one, so picks of size
distributions in the inlet and outlet ows appears at 370 m, and
126 m, respectively. Fig 2(b) presents volume fraction of each
droplet size in the outlet ow from mixing valve. Comparison be-
tween Fig. 2(a) and (b) shows that prole of droplet volume frac-
tion and number presents a different behavior. Although maximum
droplet number occurs at 126 m, droplets with diameter 158 m
present the largest volume fraction.
Increasing pressure drop in the mixing valve, increases droplet
breakage rate and results production of smaller droplets. At higher
shear rates, large droplets break to smaller one. Fig. 3 presents the
effect of pressure drop on the droplet size distribution at the out-
let ow. Increasing pressure drop from 20 to 30 psi increases rate of
droplet breaking, which increases the number of small droplets sig-
nicantly. Although increasing pressure drop makes emulsion sepa-
ration dicult, it improves mixing eciency. Mixing eciency is de-
ned as a part of injected fresh water mixed with emulsion to dilute
the base brine. Thus, there is an optimum pressure drop that results in
maximum plant eciency to remove water and salt. In other words,
although decreasing pressure drop reduces the ability of shear stress
to breaks droplets and makes water separated easily, it decreases
mixing eciency and increases salt concentration in the brine.
5.3. One stage electrostatic desalting
In this section, the simulation results of an electrostatic desalting
drum is presented at steady state condition. In this research, the de-
salting drum was divided into two sections based on electric eld.
In rst section the uid ows in the gravitational section in absence
of the electric eld. The collision between falling and rising droplets
causes droplet coalesce with a low rate. After that, in second section,
uid ows through the AC electric eld. When a water droplet en-
ters an electric eld, a dipolar attraction force is created between
droplets. This electrical attraction improves effective collision be-
tween droplets. Fig. 4 shows the droplets size distribution along the

8
x 10
Inlet of Valve
2.5 0.12
Middle part of Valve
Outlet of Valve

2 0.1
Volume Fraction
Droplet Number

0.08
1.5
0.06
1
0.04

0.5
0.02

0 0
1 2 3
(a) 10 10 10 (b) 101 102 103
Diameter (m) Diameter (m)
Fig. 2. (a) Droplets size distribution along the mixing valve; (b) Volume fraction of droplets in outlet ow from mixing valve.
 E. Aryafard et al. / Journal of the Taiwan Institute of Chemical Engineers 58 (2016) 141147 145

8 valve and settled droplets from upper segment that ow toward the
x 10
4 bottom of desalting drum because of gravitational forces. The outlet
P=20 psi water cut from rst stage is mixed by fresh water through the mixing
3.5 P=25 psi valve and prepared emulsion is fed to the second stage. The inserted
P=30 psi feed to the second stage contains lower salt concentration. Since the
3 main part of brine cut is separated from crude oil in the rst stage,
the number of droplet in the second stage decreases and it reduces
Droplet Number

2.5 the water removal eciency. Fig 5(b) shows the droplets size distri-
bution along the second electrostatic drum.
2 Table 3 shows the water cut and salt concentration in the outlet
of the rst and second stages. In addition, it presents a comparison
1.5 between simulation results and industrial data at steady state condi-
tion. The results show that predicted dehydration eciency and PTB
1 are close to industrial unit value in two stages unit.

0.5 5.5. Operability of two stages desalting

0 As mentioned previously, increasing ow rate of fresh water de-

1 2 3
10 10 10 creases salt concentration in the water in oil emulsion, and increases
Diameter (m)
salt removal eciency. Increasing ow rate of fresh water from 3% of
Fig. 3. Size distribution of outlet ow from mixing valve in different pressure drops. crude oil ow rate to 6% increases number of droplets in the emul-
sion and decreases salt concentration in the water cut, so salt content
in the treated crude oil decreases. On the other hand, it decreases
8
x 10 deference between density of brine and crude oil and makes dehy-
3
Inlet dration dicult. Table 4 shows the effect of fresh water on the water
x=0.5 m cut and salt content of treated crude oil. The simulation result shows
2.5 x=1.0 m that increasing ow rate of dilution water from 3% to 6% decreases
Outlet salt content in the outlet crude oil from 2.06 to 0.71 PTB, respectively.
Strength of electric eld is one of the main features in the crude oil
2
Droplet Number

desalting process that inuence salt and water separation eciency.

1.5
1
0.5
0 to 97.8% in the treated crude oil. In addition, it decreases salt con-
1 2
10 10
Diameter (m)
Fig. 4. Droplet size distribution along the desalting drum.
electrostatic desalting drum. Dashed green curve shows droplets dis-
tribution in entrance of gravitational section. The calculated droplets
distribution in entrance of drum is sum of the mixing valve output
droplets and settled one from upper segment that fall down toward
the bottom of drum because of gravitational forces. Since, collision
between falling and rising droplets controls droplet coalescence in
absence of electric eld, this section has an insignicant effect on co-
alescence of the ne droplet. In this electrostatic part, collisions be-
tween polarized droplets increases, the ne droplets are coalesced
and large droplet are produced. The large droplets are settled and
entered the gravitational section. Thus, water content and salinity of
crude oil decreases signicantly.
5.4. Two stages electrostatic desalting
In this section, the simulation results of the two stages electro-
static desalting is presented and analyzed at steady state condition.
As mentioned, the separated water from crude oil in the second stage
is used as dilution water in the rst stage. Fig 5 (a) shows the droplets
size distribution along the electrostatic drum. The calculated droplets
distribution in entrance of drum is sum of inlet droplets from mixing
Fig. 6 shows the effect of electric eld on the outlet droplet distribu-
tion from rst and second stages. In a stronger electric eld, below
critical eld that causes droplet breakage and makes emulsion stable,
attractive force between polarized droplets increases and it improves
coalescence rate. Therefore, number of outlet droplets from desalting
drum decrease. Increasing the strength of electric eld in the second
stage from 1.5 to 2 kV/cm has a signicant effect on the water re-
moval eciency, so it increases water removal eciency from 96.4%
3 tent from 2.06 to 0.66 PTB in the treated crude oil. The simulation
10
results show that increasing electric eld strength has a signicant
effect on the rate of droplet collision and coalescence, so number of
large droplet in the treated crude oil has been decreased.
As mentioned, although increasing pressure drop in the mixing
valve improves collision between dilution and emulsion droplets, it
shifts droplet size distribution toward smaller droplets and makes
emulsion to be more stable. Fig. 7 shows the effect of increasing pres-
sure drop in the mixing valve of second stage on the outlet water
cut from top of electrostatic drums. Increasing mixing valve pres-
sure drop from 25 to 30 psi in the second stage, increases number
of droplets that are smaller than 160 m, in the treated crude oil.
Since collision probability between small droplets is signicantly less
than large droplets, it increases number of ne droplet in the sys-
tem. It decreases water removal in the second stage and lower water
ow rate is fed to the rst stage, which increases salt content in the
treated crude oil in the rst stage. Table 5 shows the effect of pressure
drop in the second stage on the dehydration and desalting eciency
of rst and second stages. Increasing pressure drop from 20 to 30 psi
in the second stage decreases dehydration eciency about 0.14%. In
addition, it increases salt content in the treated crude oil from 2.06
to 2.14 PTB. As mentioned, dehydration eciency is dened as per-
centage of separated water from treated oil compared to entered wa-
ter cut. The simulation results shows that increasing pressure drop
in the second stage has an insignicant effect on the specication of
treated crude oil in the rst stage, so dehydration eciency remain
constant.
146 E. Aryafard et al. / Journal of the Taiwan Institute of Chemical Engineers 58 (2016) 141147

8 First Stage
x 10 8 Second Stage
12 x 10
Inlet 3
Inlet
X=0.5 m X=0.5 m
10 X=1.0 m 2.5 X=1.0 m
Outlet Outlet

Droplet Population
Droplet Population

8 2

6 1.5

4 1

2 0.5

0 0
1 2 3
1 2 3 10 10 10
10 10 10
(a) Diameter (m) (b) Diameter (m)
Fig. 5. (a) Droplet size distribution in rst stage desalting drum; (b) Droplet size distribution in second stage desalter drum.

Table 3 6
x 10
Comparison between simulation results and data taken from a two- 6
stage desalting plant in Iran. P=25 psi
P=30 psi
Modeling results Industrial data 5
Dehydration PTB Dehydration PTB
eciency eciency
Droplet Population

4
First stage 99.54 52.26 99.21 71.18
Second stage 96.39 2.06 96.77 4.78
3

Table 4
Effect of fresh water rate on desalting and dehydration ecien- 2
cies of rst and second stages.

First stage Second stage 1

Dilution Dehydration PTB Dehydration PTB
water eciency eciency
0
3% 99.54 52.26 96.39 2.06 0 50 100 150 200 250 300
6% 99.63 43.13 98.53 0.71 Diameter (m)

Fig. 7. Effect of second stage mixing valve pressure drop on size distribution of outlet
6 water drops from second stage.
x 10
6
E0=1.5 kv/cm Table 5
E0=2.0 kv/cm Effect of pressure on the dehydration and desalting eciencies
5 of rst and second stages.

First stage Second stage

Droplet Population

4 Pressure Dehydration PTB Dehydration PTB

drop eciency eciency
3 25 (psi) 99.54 52.26 96.39 2.06
30 (psi) 99.54 52.52 96.26 2.14
2
6. Conclusion
1
In this research, an industrial two stage crude oil desalting pro-
0 cess was modeled based on the population balance equation and
0 50 100 150 200 250 300 operability of the process was investigated. This plant is an integrated
Diameter (m)
process that separated water from crude oil in the second stage, re-
Fig. 6. Effect of second stage electric eld strength on size distribution of outlet water cycled and mix with crude oil in the rst stage as dilution water.
drops from second stage. The accuracy of the developed mathematical model and considered
 E. Aryafard et al. / Journal of the Taiwan Institute of Chemical Engineers 58 (2016) 141147
assumptions were evaluated against industrial data from a domestic
oil processing plant. Then, the effect of pressure drop in the mixing
valve, ow rate of fresh water and electric eld strength on the de-
salting eciency was studied. In a strong electric eld, the attractive
force between polarized droplets increases and it improves the coa-
lescence rate. Simulation results showed that increasing the strength
of electric eld in the second stage from 1.5 to 2 kV/cm increases wa-
ter removal eciency from 96.4% to 97.8% in the treated crude oil. In
addition, it decreases salt content from 2.06 to 0.66 PTB in the treated
crude oil. In addition, it was shown that increasing ow rate of fresh
water from 3% to 6% decreases salt content in the outlet crude oil
from 2.06 to 0.71 PTB. Increasing pressure drop from 20 to 30 psi in
the second stage decreases dehydration eciency about 0.14%. In ad-
dition, it increases salt content in the treated crude oil from 2.06 to
2.14 PTB.
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