Desalting Technical Training

Sugar Land, TX
May 4-8, 2009 0
 Speakers
• Sam Lordo, Regional IDM

• Dennis Haynes, ITC

• Brad Mason, Global IDM

• Research: Mike Braden Byron Strickland

John Garcia Keith Gawrys
Thomas Oliver

1
 Agenda
1 Desalting Market Analysis
2 Benefits of Desalting
3 Glossary and Crude Oil Composition
4 Desalting Theory
5 Desalter Design
6 Desalting Operation
7 Desalter Troubleshooting
8 Product Application/Information
9 Tankage Dehydration
10 Waste Oil Recovery
11 Opportunity Crudes
12 Resolv Toolkit

2
 Desalting Market Overview
 655 Refineries
 85.6 M bbls/day processed 2008
 Nalco treats over 220 Systems
 World Refining Capacity to grow to
106 M bbls/day by 2030

Global RESOLV Market

20% Desalting Systems
37%
Nalco
Baker-Petrolite
Ge Betz
18% Others

25%
Note: Does not include Russia CIS, China, Ukraine and Cuba

3
Process Business Activity

+3.3%

+5.6% +11.2%

4
 How Do We Compare?
Market Share - North America Desalters

5
 Volume Growth
Heavy “D” >50% growth since
9,000 Introduced introduction of Heavy “D”
8,000

7,000

6,000
K LBS

5,000

4,000

3,000

2,000

1,000

-
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008

6
Benefits of Desalting

7
Crude Oil Desalting

8
 Closer Look at the Vessel

Oil Effluent

Electrical
Grids
Emulsion
Header

Mix Valve

Aqueous Effluent
95% Oil + EB
5% Wash Water

Desalter animation 9
 Why Desalt?

• To Remove
Contaminants from
Raw Crude Oil

• To Reduce Corrosion
and Improve Reliability
in Downstream Units

• To Reduce the Total

Cost of Refinery
Operations

10
 Crude Oil Contaminants

• Chloride Salts

• Inorganic Solids

• Water
SEM photo from
Mike Poindexter / Dick Cloud

11
 Chloride Salts
Hydrolyze to form Hydrochloric Acid

• MgCl2 + 2H2O Mg(OH)2 + 2HCl 120 °C (248 °F)

• CaCl2 + 2H2O Ca(OH)2 + 2HCl 200-230 °C (392-446 °F)

• NaCl + H2O NaOH + HCl > 500 °C (932 °F)

Hydrochloric Acid is the primary cause of crude unit corrosion equipment failures 12
 Inorganic Solids
• Iron sulfide, sand, clay,
drilling muds
• Not soluble in crude oil
or water
• Promote oil undercarry
in desalter effluent
water
• Inorganic solids are the
second largest cause of
crude unit exchanger
and heater fouling, and
cause foaming in
downstream vacuum
towers and cokers 13
 Water
• Brine from crude oil production field

• Typical raw crude specification is 1-3% Water

• Un-desalted water reduces crude charge, increases

energy costs, causes downstream equipment corrosion,
and increases waste water production

Water Phase

Emulsified Crude Oil Resolved Emulsion

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 Benefits of Desalting
• Protect Downstream Equipment
• Reduced Corrosion
• Reduced Fouling
• Maximized Throughput
• Extended Run Length
• Stabilized Unit Operations
• Reduced Energy Costs
Corrosion
Increased energy
crude consumption
oil
HCl
Fouling & H2O

H2O

H2O
Brine Poor Product
NaCl
heat Mg(OH)2 Specification
exchanger Ca(OH)2
furnace
increased oil to wwtp

Mg Cl2 + 2H2O Mg(OH)2 +2HCl

Ca Cl2 + 2H2O Ca(OH)2 +2HCl 15
 RESOLV Engineered Approach
Phase IV Optimization/ Phase I
TSC/TCO Analysis Scope Development
Interface (RAG) Build-Up

Chemical Off
Check Pump; Start or Repair
Pump

On

Mix High Reduce

Valve

Normal

BS&W High Increase desalting aid by 25%

in Raw Increase RESOLV by 3-5gpd
Crude

Normal

Flexibility
Desalter Low

Increased Processing
Raise to Normal
Temp

Normal

Increase desalting aid by 25%

Increase RESOLV by 3-5gpd
Contact NEEC Representative
Reduced Corrosion
Reduced Fouling
Phase III Reduction in TCO! Phase II
Implementation Design

Untreated
Water separation profiles for demulsifier dosages of 13 ppm
EC2133A

100 EC2040B

% Water Separation
EC2043
80 B
EC2045A

60 EC2117A

40

20

0
0 10 20 30 40

Shock = 2.5 min @ 3000 V Time /minutes Wash water = 5.0%

16