Dual-Voltage Electrodes for Rag Layer Control in Desalters

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Solution Overview

Problem

Existing dehydrator and desalter vessels face inefficiencies due to the formation of a stable oil and water emulsion layer (rag) at the interface, which compromises vessel performance and requires frequent shutdowns for treatment, disrupting production processes.

Innovation Solution

Implementing a low voltage electrode grid in the interface emulsion layer within the vessel, combined with a high voltage grid in the oil layer, to promote water coalescence and control rag layer build-up using variable amplitude and frequency voltage supplies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If vessel volume is increased to accommodate rag layer formation, then vessel capacity is improved, but device complexity and operational efficiency deteriorate due to requiring additional vessels and shutdowns

Engineering Contradiction:

Improvevessel volumeVSAvoidoperational efficiency

Core Design Contradiction:

Volume of stationary objectVSProductivity

Solution Approach 1:

The invention extracts the harmful rag layer from the separation process by applying electrostatic fields to coalesce water droplets within the emulsion layer, causing them to separate and rise to the oil layer where they can be continuously removed. This eliminates the need to increase vessel volume to accommodate rag layer buildup.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The electrostatic treatment system operates continuously during vessel operation, maintaining constant control over the emulsion layer without requiring shutdowns. This enables continuous removal of separated water, maintaining productivity while managing the rag layer effectively.

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If high voltage electrostatic field is applied to promote water coalescence, then separation efficiency is improved, but energy consumption increases

Engineering Contradiction:

Improveseparation efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The system applies high voltage electrostatic fields locally only to the emulsion layer where water coalescence is needed, rather than throughout the entire vessel. This targeted application maximizes separation efficiency while minimizing overall energy consumption.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The electrostatic treatment is segmented into specific zones within the vessel, with electrodes positioned to create fields only in the emulsion layer. This segmentation allows efficient water separation in the critical zone without unnecessary energy expenditure in other regions.

Inventive Principle:

Principle #1Segmentation

3Reliability

If vessel shutdown is implemented to remove and treat rag layer, then rag layer control is improved, but productivity and operational continuity deteriorate

Engineering Contradiction:

Improverag layer controlVSAvoidoperational continuity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system provides self-service rag layer management by continuously coalescing and separating water within the emulsion layer during normal operation. The separated water is automatically removed through the oil layer outlet, eliminating the need for external intervention or shutdowns to manage the emulsion layer.

Inventive Principle:

Principle #25Self-service

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

Enhances vessel performance by reducing the rag layer volume and increasing the separation efficiency of water and solids, minimizing the need for shutdowns and additional vessels.

Implementation Method 1

one set arranged to apply an electrostatic field to an oil layer residing within a separator vessel

Methodology Applied

Scientific EffectElectrostatic field: Electric Field

Implementation Method 2

promoting water coalescence and reducing the rag layer volume

Methodology Applied

Scientific EffectCoalescence: Coagulation

Implementation Method 3

the other set arranged to apply an electrostatic field to an interface emulsion layer residing within the separator vessel below the oil layer and above a water layer

Methodology Applied

Scientific EffectElectrostatic field: Electric Field

Data Source

PatentEP3277398B1System to reduce interface emulsion layer formation in an electrostatic dehydrator or desalter vessel through use of a low voltage electrostatic interface emulsion treatment system inside the vessel

Publication Date: 2026.05.20 CAMERON SOLUTIONS INC

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AI summary

A system ( 10) for separating the components of an incoming oil-water mixture includes two electrode sets (30/40), one set arranged to apply an electrostatic field to an oil layer residing within a separator vessel and the other set arranged to apply an electrostatic field to the interface emulsion layer residing within the separator vessel (12). The first set of electrodes (30) is in communication with a high voltage power source that ranges from 1 to 60 kV; the second set of electrodes (40) is in communication with a low voltage power source that is no greater than 5 kV. Each set of electrodes (30/40) may also be in communication with a second voltage source to provide increased power to promote effective coalescence. The system (10) may also include power electronics to produce a variable amplitude and a variable frequency voltage supply to one or both electrode sets (30/40).