MEASUREMENT AND TESTING
up to 70 minutes to less than 30 minutes – while also preventing the heat exchanger fouling issues that can arise when solid- laden emulsions pass through. This improvement helps maintain high thermal efficiency in heat exchangers, thereby reducing the need for additional fuel and operational costs. (Mani, V. 2024)
A major European refinery, which had been struggling with iron (Fe) contamination being carried downstream to their FCCU, praised the EmulsionSENS system, stating, “Perfect design and excellent results. It works like a dream! Many, many thanks to everyone for staying focused and making it happen. Goodbye, iron!!!” This enthusiastic feedback underscores the critical importance of accurate management and measurement in refining processes, as they have a direct impact on operational efficiency and reliability. A user highlighted the long-term benefits of using EmulsionSENS technology, stating: “Both desalters are operating in auto-control as usual. The low-level operation helps us remove particulates containing iron, which can poison our Resid FCC catalyst.” This testimony underscores how maintaining optimal levels and properly controlling the desalter’s operation can significantly improve refinery performance, reduce corrosion, and prevent catalyst degradation. Another satisfied user commented, “The levels in our desalters are the best thing we’ve done for that unit in a long time,” emphasizing the operational improvements enabled by automatic control. This ensures the desalter operates within the ideal range, preventing both excessively high and low levels. It highlights the importance of precise monitoring and control in the desalter unit, which has a profound impact on refinery performance by enhancing separation efficiency, reducing fouling, and lowering maintenance costs.
Density profiles in operation
When operating correctly, a desalter should exhibit a clear transition from 100% water at the bottom of the vessel to 100% oil at the top. This transition is reflected in density readings, which smoothly decrease from bottom to top. However, when a desalter loses coalescence, a rag layer, a mixture of water, oil, surfactants, and solids, can form on top of the water, disrupting this transition. The presence of a rag layer reduces the desalter‘s efficiency by diminishing.
The tables and corresponding graphs below illustrate the differences in density profiles during normal operation versus when a rag layer is present.
Unveiling the invisible: the EmulsionSENS advantage
Berthold‘s EmulsionSENS is not only theoretically advantageous; real-world refinery operations demonstrate its genuine benefits. The ability to accurately assess and control desalter performance results in substantial improvements in operational efficiency and sustainability. By maintaining optimal water levels and precisely managing transition zones, refineries can reduce energy consumption, prevent fouling, and extend the lifespan of critical equipment. As highlighted in the case study from Veolia at a Southeast Asia refinery, traditional measurement technologies, such as capacitance probes, have limitations in accurately detecting both the interface between water and oil and the rag layer when present. Capacitance-based instruments rely on differences in dielectric properties to differentiate between oil and water phases. However, they struggle in the presence of emulsified layers, where the mixture of oil, water, and solids disrupts the dielectric contrast, making it difficult to reliably detect the boundary between the rag layer and the water. Consequently, capacitance probes may provide a steady reading even as the rag layer grows, failing to alert operators to changes in the desalter’s internal conditions.
In contrast, more advanced technologies like Berthold’s EmulsionSENS, which measure density at various elevations, are better suited for this application. These systems provide accurate, real-time data on both water levels and rag layer positioning, a capability critical for effective desalter management. By offering precise measurements, they enable refineries to optimize separation efficiency, minimize fouling risks, and enhance overall process stability. (Mani, V. 2024)
The EmulsionSENS system is highly effective in detecting not only the interface between oil and water within the desalter but also in accurately monitoring the mud layer at the bottom of the vessel. This dual capability is essential for implementing an optimized mud washing program, which ensures the periodic removal of accumulated solids before they can impair the desalter’s performance. By effectively reducing the concentration of solids, the mud washing process helps prevent the formation of emulsions that could disrupt oil-water separation. Emulsions take up critical volume, diminishing residence time and compromising separation efficiency.
With real-time data from EmulsionSENS, refineries can adjust mud washing frequency by monitoring the effectiveness. Increased mud washing frequency plus introducing solids wetting agents, achieving up to 50-60% solids removal efficiency, as demonstrated in a Southeast Asian refinery case study by Veolia. This consistent removal of solids prevents downstream fouling of heat exchangers, which often results from solids carryover. In this case, the optimized mud wash process, along with wetting agents, reduced wash durations significantly – from
WWW.P
ETRO-ONLINE.COM Figure 4: Density profiles with rag layer Revolutionizing desalter operations
The push for green energy and sustainability presents both a challenge and an opportunity for the refining industry. To stay competitive in a resource-constrained world while meeting global environmental targets, refiners must prioritize energy efficiency and reduce their carbon footprint. A key strategy for achieving this is optimizing the operation of critical units like the desalter. Fouling in heater tubes and heat exchangers – often resulting from suboptimal desalter performance – can significantly reduce efficiency in crude oil refineries. By enhancing performance through effective level control, temperature management, and the use of advanced technologies like Berthold‘s EmulsionSENS,
refineries can significantly mitigate these inefficiencies and move toward more sustainable operations.
The ability to accurately measure and manage the water/transition zone, oil/transition zone interfaces, and mud levels is essential for optimizing the desalter‘s efficiency. Berthold‘s EmulsionSENS technology offers this capability, enabling real-time monitoring and precise control, which translates into significant advantages for refinery operations. By adopting these advanced technologies and best practices, refiners can position themselves for long-term success in an increasingly competitive and environmentally conscious industry. Installing EmulsionSENS not only enhances refinery performance and reduces maintenance costs but also supports sustainability efforts by lowering energy consumption and minimizing environmental impact.
As the refining industry navigates the transition to a greener, more sustainable future, optimizing desalters becomes a critical pillar in this journey. Through precise measurement, data-driven management, and advanced technologies, refineries can position themselves to meet the evolving demands of the energy landscape. Embracing these innovations not only ensures their continued competitiveness but also contributes to the global movement toward energy efficiency and environmental stewardship. As H. James Harrington aptly put it, “Measurement is the first step that leads to control and eventually to improvement.” Through accurate measurement, effective control, and a commitment to continuous improvement, refineries can thrive, both profitability and a positive environmental impact.
References
Bain, J. de S., García, D., Cigala, F., & Rivolta, T. (2019, March 20) – How refiners can capture the benefits of the energy transition and digitalization. Bain & Company – Retrieved from
https://www.bain.com/insights/how- refiners-can-capture-the-benefits-of-the-energy- transition-and-digitalization/
Boughaba, A., & Bouziane, M. (2020) – Influence of key parameters on crude oil desalting: An experimental and simulation approach. ScienceDirect – Retrieved from
https://www.sciencedirect.com
Cahill, J. (2018). Refinery Desalter Efficient and Reliable Operation – Emerson Automation Experts – Retrieved from https://www.
emersonautomationexperts.com/2018/industry/ downstream-hydrocarbons/refinery-desalter-efficient-reliable-operation/
Mani, V. (2024). – Desalter optimisation strategies: Part I. PTQ Q4 2024, 89-97. Veolia Water Technologies and Solutions. Retrieved from https://
www.digitalrefining.com
Figure 3: Density profiles under normal conditions
Berthold Technologies GmbH & Co. KG Calmbacher Straße 22, 75323 Bad Wildbad, Germany Email:
industry@berthold.com Web:
www.berthold.com
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