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Heavy oil separation Electrostatic Coalescers

Jan Tore Klausen Stavanger 14.04.2011

Todays presentation
Overview of oil treating using electrostatic forces Presentation of the Dual Frequency Electrostatic by Cameron Presentation of the Compact Electrostatic Separator (CES) Novel separator used for heavy oil separation Presentation of lessons learned in the development of the CES

NATCO Dual Frequency Electrostatics

Fundamentals of electrostatic treating

Increasing water concentration

+
+ + _

_
Electrophoretic Force
_

_ + _ + _ + _+ _ + _+

Di-Electrophoretic Force
+

_ + _ + _+ _ + +

_ +

Dipole Force
_

_ + _+

_ + _+

_ + _+

_ + _+

_ + _+

Oil/Water Interface
PROCESS SYSTEMS

NATCO Dual Frequency Electrostatics

Effects of Frequency on Voltage Decay

Threshold Voltage

Low Frequency
Note deep RC discharge between voltage peaks. F = KV2 r6 d4

High Frequency
Note shallow RC discharge between voltage peaks.

NATCO Dual Frequency Electrostatics

600
Primary Voltage, volts

Critical Voltage

400 200 0 -200 -400 -600

Sinusoidal Wave (or trapezoidal, triangular, square, etc)

Threshold Voltage

Base Frequency

Pulse Frequency
Time

Droplet charge follows the Modulation waveform

AC, Dual Frequency and Dual Polarity

Movie showing the difference performance between AC, DF and DP Black corresponds to oil

Alternating Current

Dual Frequency

Dual Polarity

NATCO Dual Frequency Electrostatics

Comparisson to other types of treaters

Conventional A/C 14 x 65 4.2mx19.5m

Dual polarity Technology 12 x 40 3.6mx12m

Coalescing Droplets Dual Frequency 10 x 26 3mx7.8m

Example: 80,000 BOPD 32 API Crude 4 cps Viscosity Inlet: 5% BS&W Outlet: 0.5% BS&W

Cameron
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Compact Electrostatic Separator

(CES)

Basic CES Process System, design objectives

Gas < 3% Liquids Power Power Oil << 10% water

Inlet to 75% water cut

GOR to 1000 scf/bbl 180 Sm3/m3

Water < 200 ppm Oil To reinjection

Lessons learned from the EPIC inline coalescer from NATCO

In-Line Coalescer EPIC 1989 1996

EPIC In line coalescer

EPIC Between Stages, coalescer only Transformer Second Stage Separator Water First Stage Separator Oil

Oil / Water Gas

EPIC Manifold

Emulsion > 65% BS&W

Water
11

Lesson Learned

Rapid and compact coalescence is possible

Electrostatically formed water droplet are fragile. In-line coalescer must be close to separator Piping between the coalescer and the separator is critical Insulated electrodes will fail.

CES Separation System

Free Gas

Electrostatic Coalescence + Separation Free Water

Electrostatic Coalescence + Separation

Solids

Water Recovery

Solids

Separated Water

PSAT Flow Loop used for internal testing

Oil Rate 3000 bpd (~480 m3/d) Gas 10 MMscfd Water 3000 bpd (~480 m3/d) @ 200 psi (14 bar), 200F (93 deg C)

CES tested in laboratory

Following parameters checked

Synergy Angle Liquid flux Temperature / Viscosity Voltage / Frequency

Effect of Flux Rate

30,0 25,0

Critical Weber Number

% Water in Oil Outlet

20,0

Standard Dehydrator Compact Separator

15,0

10,0

Operating Flux
5,0

0,0

Liquid Flux Rate (bopd/m2)

Compact Separator works well at high flux rates. Performance drops after critical Weber number is exceeded.

Synergy 1 versus 2 stages

90 80 70 % Water Reduction 60 50 40 30

Both Stages - Actual

Both Stages - Predicted

Stage 1 Only

20 10 0
Flow Rate

Stage 2 Only Both Stages No Voltage

Effect of Vessel Angle

6 5
45 degrees Horizontal

Water in Outlet [%]

22 degrees

3 2
1

Liquid Flow rate [BOPD]

Effect of Oil Viscosity at liquid design conditions

100

90

% Recovery H2O

80

70

60

50

40 15 17 19 21 23 Viscosity, cp 25 27 29

Effect of Voltage
Rate and Voltage Sensitivity at AC, 60 Hz, 120 F
8

% Water in Oil Outlet

Base Voltage
4

Higher Voltage

0 1000 1500

Flux Rate, BFPD/m2

2000

2500

3000

3500

Higher Voltage Better Performance

Effect of Electrostatic Field

Rate and Technology Sensitivity at 120 F
8

% Water in Oil Outlet

AC, 60 Hz AC, 1000 Hz

0 1000

1500

Flux Rate, BFPD/m2.

2000

2500

3000

3500

Advanced AC performed better than AC

Results with POWER OFF

Inlet Water Outlet Water % % Test 1 Test 2 Average Test 1 Test 2 Average 34 37 35.5 75 77 76 34 33 33.5 26 22 24

Results with POWER ON

Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Average
Test 1 Test 2 Average Inlet Water % 30 31 32 34 31 31 31.5 75 73 74 Outlet Water % 3.8 3 3.2 3 3.4 4 3.4 4.5 3.5 4

POWER OFF

POWER ON

Lesson Learned

Two electrostatic stages promote increased separation.

Performance agrees with process condition variation. Pre-treatment permits wide water cut range. Advanced electrostatic field will improve performance. Can achieve water quality between 100 and 500 ppm

Liquid 3000-3500 bpd/ft2 (~ 45 m3/m2) Gas 25 MMscfd @1000 psi (~70 bar) Inlet Water to 75% Outlet water < 10% Temperature to 200 F (93 Deg C) Water Quality < 300 ppm

Any questions?