Title: Design of an Extraction Unit for Salt Water Removal from CrudeOil
1Design of an Extraction Unit for Salt Water
Removal from Crude-Oil
United Arab Emirates University Faculty of
Engineering Chemical Engineering Department
CHME 2-4
Advisor Dr. Mamdouh Ghannam
Coordinator Dr. Jamaal Abou-Kassem
2Contents
- Chemical Treatment.
- Point of Application.
- Methods of Application.
- Chemical feed pumps.
- Experiments
- Three phase separator Design.
- Piping Instrumentation Diagram.
- HAZOP Study.
- Indirect Heater Design..
- Environmental Impact.
3Continue Content
- Experimental Design
- Material of Construction.
- Cost.
4Chemical Treatment
- The main idea of this treating is to add some
small amounts of surface active emulsion
breaking chemicals (reagents ) into the treated
emulsion to deactivate the water in oil (oil
soluble reagent ) - After this treating the free phases separated by
gravity exit the vessel
5- 1) Point of Application of Chemicals
- The agitation takes place when the chemicals are
sufficient for emulsion breaking . - The chemical injection pump is usually placed at
the header of the separator .
6- 2) Relationship of Chemicals to Temperature
- In General the increasing of the
- emulsions temperature decreases the
- amount of chemicals required for its
- treating
7 3) Relation of the amount of chemical to
settling time
- The amount and the type of chemicals define how
the emulsion will break out, Sometimes , in
chemical treatment , to fasten the break down
process of emulsions - 1- Faster acting chemical can be used
- 2- The temperature of the emulsion can be
increased
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9Methods of Applying Chemicals
- The chemical compounds for chemical treating ,
usually are put into the produced emulsion at any
point in the system . - Depending on the point of the application
(injection or adding ) of the compounds there are
three basic types of application in chemical
treating of oil - 1- Down hole treating.
- 2- Flow line treating.
- 3- Batch treating.
101) Down hole treating
- Emulsion becomes more viscous when it contains
water dispersed in oil by agitation. This makes
emulsion resist the flow in the system. - Applying chemical treating down hole breaks the
emulsion and makes it easier to lift.
112) Flow line Treating
- In this treatment the chemical reagent should be
- injected in flow line at a point where
sufficient - agitation and treating time are assured, usually
this point is at the well head or at the header
in multiple well systems.
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133) Batch treating
- The produced emulsion from the well moves to the
treating tank with heaters , where the chemical
reagent drips slowly through the holes of a
bucket into the emulsion to de-emulsify it.
After settling the water will be drain off . - This treating requires more chemical regents.
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15Demulsifiers
- Quality Indexes are made with the most advanced
ethoxylation catalytic polymerization technology
developed. - Packing Packed in 200kg galvanized drum or
iron drum. - Storage and Transportation nonpoisonous and can
be dealt with as common chemicals and storage
time is one year.
16Chemical Feed Pumps
- Injecting chemical reagents.
- They have adjustable stores
- Driven - operated pumps.
17Chemical Injection Pumps
18- DEMULSIFIERS
- ALKAN DEMULSIFIER
- T _at_ 60o C (140o F)
- Combustible
- 1 gallon per 20,000 gallons (50 ppm) of oil
- 1 gallon per 10,000 gallons (100 ppm) of oil
19Demulsification Experiment
- Water Concentration 20 vol..
- Time of mixing 20 min.
- 2000 RPM.
- Salt conc. 100000 ppm
- Demulsifiers conc. (10,25,50,100 ppm)
- Plot (volume precipitated vs. Time)
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21Demulsifier conc.
22Horizontal Separator Sizing
Height
Length
23Horizontal Separator Sizing
- Retention time method.
- Drop settling method.
- Design consideration.
24Horizontal Separator Sizing
- Basis
- Operating temperature 60 oC
- Operating pressure 1 atm
- Retention time 5 minutes
- Production rate 50,000 barrel/day
25Horizontal vessel design equations
- Diameter calculation
- (p/4) D2 M Leff q tr
- Volume calculation
- V C (sh1 sh2) / µw ) (D/1440)
- Length calculation
- L (4/3) D Leff
26Calculations results
27PID Contents
- 1) All process equipment are identified by an
equipment No. - 2) All pipes are identified by a line No. (pipe
size material of construction)
28- 3) All control and block valves are identified
by numbers. (type size) - 4) Pumps are identified by a code No.
- 5) All control loops instrument are with an
Identification No.
29Types of Valves
CV
Electronic
Butterfly Valve
Pneumatic
Fails Open
Fails Shut
30PID Objectives
- (I) Safe Plant Operation
- -To keep process variables within the safe
operating limits. - -To provide alarms and automatic shut-down
system, to detect dangerous situations as they
develop. - -To provide interlocks and alarms, to prevent
dangerous operating procedures.
31PID Objectives
- (II) Production Rate
- -To achieve the design product output.
- (III) Product Quality
- -To maintain the product composition within the
specified quality standards. - (IIV) Cost
- -To operate at the lowest production cost.
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33Hazards and Operability Studies (HAZOP)
- Basic Principles
- Involves systematic study of the process.
- Vessel by vessel
- Line by line
- Guide words
34Guide words
- No or Not (No part of the intention is achieved
but nothing else happens). - More (Quantitative increase)
- Less (Quantitative decrease).
35Additional guide words
- Intention
- Deviation
- Causes
- Consequences
- Hazards
36Objective of guide words
- Special words are used in a systematic fashion
(HAZOP procedure). - To investigate potential hazards and possible
solutions.
37(I) Intention- emulsion stream transfer from
knock out drum to indirect heater
38HAZOP
39HAZOP
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41(II) Intention- Outlet stream from indirect
heater to the horizontal separator
42HAZOP
43HAZOP
44Indirect Heater
- Energy needed to heat the crude Q
- Q 15 Fo DT (0.5 r 0.2)
- Q 11,790,000 Btu/hr
- Vessel size
- O.D 96
- L 30
45Indirect Heater PID
46Environmental Impact
- Burning of fuel gas causes the emission of CO2,
H2S..etc to the atmosphere
47Combustion
48Fuel Gas
49Combustion
50Indirect Heater Efficiency
- Addition of flue gas passes.
- Attending to leaks.
- Insulating Pipe work and exposed surfaces.
51Experimental Design
- The apparatus consist of
- Mixing tank
- Mixer
- Pump
- Pipes
- Separation tank
- Weir
- Valves
52Experimental Design
53Weir Separator
54Calculations
- The calculations include
- The dimensions of the separation tank.
- The height of the weir.
- The flow rates coming in and out of the
separation tank. - The location of the feed.
- Pump.
55Dimensions
- Volume 27 liters
- Oil
- Water
- Demulsifier (Alkan)
- Emulsifier (Triton X100)
56Dimensions
57Flow Rates
- Flow Rate In Rate of Water Out Rate of Oil
Out. - Residence time (t)
- Volume (V)
- Volumetric flow rate (Q V / t)
58Calculations
- Feed location (h)
- 20 x (Volume) / (Area)
- P P atm ?g h
- P 101.325 Kpa 0.08 Kpa 101.405 Kpa
59Pump calibration
60Pump calibration
61Materials of construction
- Mechanical Properties.
- Corrosion resistance.
- Sulfur Stress Corrosion.
- Temperature Corrosion.
- Pitting.
62Process Flow Diagram
63Materials of construction
- KnockOut Drum.
- Carbon Steel.
- Indirect Heater.
- Stainless Steel 316.
- Three Phase Separator
- Carbon Steel.
64Cost
- Manufacturing Companies.
- NATCO, ALFALAVAL, SOFRESID, etc.
- KnockOut Drum.
- 50,000-200,000
- Indirect Heater.
- 350,000 -750,000
- Three Phase Separator
- 100,000-300,000
65T
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