Vertical Desalter Electrode Layout for Efficient Crude Oil Dehydration

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Solution Overview

Problem

Current electrocoalescence oil processing methods using rod electrodes suffer from small surface area, gaps between electrodes, and susceptibility to corrosion, leading to reduced efficiency in desalting vessels.

Innovation Solution

A vertically oriented desalting vessel with large, rectangular electrode plates is used, applying an electric field to coalesce water droplets, forming distinct oil, emulsion, and water layers, with monitoring to prevent short circuits and maximize electrode exposure to the field.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If rod electrodes are used to form an electrical grid, then the desalting process can be performed, but the surface area is small and gaps exist between electrodes reducing efficiency

Engineering Contradiction:

Improvedesalting efficiencyVSAvoidelectrode surface area

Core Design Contradiction:

ProductivityVSArea of stationary object

Solution Approach 1:

The electrode system is segmented into multiple parallel plate electrodes arranged vertically, replacing the traditional rod electrode grid. This segmentation increases the total surface area exposed to the crude oil while maintaining the electrical field distribution needed for effective desalting.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The electrode configuration transitions from a two-dimensional grid of rod electrodes to a three-dimensional arrangement of vertical plate electrodes. This dimensional change allows for increased surface area within the same vessel volume while improving oil contact with the electrodes.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If rod electrodes are used, then the electrical grid can be formed, but corrosion susceptibility reduces overall efficiency

Engineering Contradiction:

Improveelectrode durabilityVSAvoiddesalting efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The electrode plates are constructed from corrosion-resistant materials such as stainless steel or coated metals, creating a composite structure that combines electrical conductivity with corrosion resistance. This material selection directly addresses the corrosion issue while maintaining electrocoalescence functionality.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The electrode plates are designed as replaceable components that can be easily removed and replaced when worn. This approach allows for cost-effective maintenance by replacing corroded electrodes rather than attempting to restore them, thereby maintaining continuous operational efficiency.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Area of stationary object

If large electrode plates are used, then surface area is maximized, but the risk of short circuits increases

Engineering Contradiction:

Improveelectrode surface areaVSAvoidshort circuit risk

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The electrode plates are positioned at specific vertical locations within the vessel, with careful attention to the local quality of the crude oil mixture at each height. The plates are placed in regions where the oil-water emulsion is most effective for desalting while avoiding direct contact with pure water layers that could cause short circuits.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

An intermediary insulating layer or spacing mechanism is introduced between the electrode plates and the water layer. This intermediary prevents direct electrical contact between electrodes and water, eliminating short circuit risks while allowing the electrodes to remain in the optimal position for maximizing surface area contact with the oil phase.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 system enhances efficiency and durability by maximizing electrode surface area and minimizing corrosion, allowing continuous operation with continuous production of desalted oil and brine byproduct.

Implementation Method 1

Electrocoalescence is the process by which coalescence of water droplets is accelerated by the application of an electrical field

Methodology Applied

Scientific EffectElectrocoalescence: Electrostatics

Implementation Method 2

Coalesced water droplets can then be separated from crude oil by the effect of gravity as they fall to the bottom of the vessel as they grow larger and heavier

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS20260035623A1Crude oil desalter dehydration vessel

Publication Date: 2026.02.05 SAUDI ARABIAN OIL CO

AI summary

A system for removing salt from oil includes a vertically oriented desalting vessel, a crude oil entry located at a bottom of the desalting vessel in fluid communication with the top crude oil layer, a pair of electrode plates positioned vertically in the top crude oil layer, at least one ground plate inside the desalting vessel, a water outlet located on the bottom of the desalting vessel, and a treated oil outlet located at a top of the desalting vessel. A method for removing salt from crude oil includes providing a crude oil mixture into a vertically oriented desalting vessel, applying an electric field through a pair of electrode plates, collecting treated oil from a treated oil outlet located at a top of the desalting vessel, and collecting water from a water outlet located on the bottom of the desalting vessel in fluid communication with the bottom water layer.