Integrated Crude Oil Separation Control for Salt and Water Specs
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Solution Overview
Problem
Current gas oil separation plants (GOSP) face inefficiencies in crude oil desalting, dehydration, and stabilization, particularly due to the lack of effective and inexpensive online analyzers for real-time monitoring of salt content, leading to frequent off-spec crude production and high operational costs.
Innovation Solution
Integrated GOSP systems with innovative process control strategies that utilize real-time monitoring of salt-in-crude content through total dissolved solids (TDS) and basic sediment and water (BS&W) measurements, allowing for continuous control and optimization of the desalting process, reducing the need for multiple processing units and minimizing chemical and water usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple processing units are used for desalting, dehydration, sweetening, and stabilization, then crude oil separation specifications are met, but device complexity and operational costs increase
Solution Approach 1:
The patent combines multiple processing functions (desalting, dehydration, sweetening, and stabilization) into a single integrated crude oil separation unit. This merging of functions reduces the number of separate processing units while maintaining compliance with crude oil separation specifications, directly addressing the contradiction between meeting manufacturing precision requirements and reducing device complexity
Solution Approach 2:
The integrated separation unit is designed to perform multiple functions simultaneously - removing salt, water, and volatile components in one device. This multi-functionality allows a single unit to replace what would traditionally require multiple specialized processing units, reducing overall system complexity while maintaining specification compliance
2Measurement precision
If online analyzers are deployed for real-time salt content monitoring, then crude oil quality control improves, but operational costs and maintenance requirements increase
Solution Approach 1:
The patent employs inexpensive, disposable test strips for salt content measurement instead of expensive, complex online analyzers. These test strips are simple to use, require no maintenance, and can be discarded after a single use, eliminating the operational burden and high maintenance costs associated with sophisticated analytical instruments while still providing adequate measurement precision for quality control
Solution Approach 2:
The system enables operators to perform self-service quality monitoring using simple test strips that require no specialized training, calibration, or maintenance. Operators can independently verify salt content compliance without relying on complex automated analyzers, reducing operational complexity and maintenance requirements while maintaining adequate measurement capability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables precise control of salt and water content in crude oil, meeting export specifications with reduced costs and energy consumption, while efficiently handling high water cuts and tight emulsions, thereby improving product quality and operational efficiency.
Implementation Method 1
The system includes an electrostatic coalescer to attract fine water droplets
Implementation Method 2
a heated mixer to mix the crude oil with wash water
Implementation Method 3
a separator to separate the water from the oil
Data Source
AI summary
Systems and methods for controlling desalting and dehydration of crude oil, one method including monitoring total dissolved solids (TDS) content at an outlet stream from a crude oil separation unit, the outlet stream comprising water; monitoring basic sediment and water (BS&W) content at an outlet stream from the crude oil separation unit, the outlet stream comprising processed crude oil; determining pounds per thousand barrels (PTB) salt content and volumetric water content of a dried, desalted crude oil product stream using the TDS content and BS&W content; and controlling a process input to the method from a comparison between the PTB salt content and volumetric water content of the dried, desalted crude oil product stream versus a maximum set value for PTB salt content and volumetric water content of the dried, desalted crude oil product stream.