US20180334621A1 - Crude hydrocarbon fluids demulsification system - Google Patents

Crude hydrocarbon fluids demulsification system Download PDF

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Publication number
US20180334621A1
US20180334621A1 US15/601,491 US201715601491A US2018334621A1 US 20180334621 A1 US20180334621 A1 US 20180334621A1 US 201715601491 A US201715601491 A US 201715601491A US 2018334621 A1 US2018334621 A1 US 2018334621A1
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US
United States
Prior art keywords
fluid
heating coils
pipe
process fluid
separator
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US15/601,491
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English (en)
Inventor
Kamarul Ariffin Amminudin
Nagoorpitchai S. Meeranpillai
Sultan H. Owaidhi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Saudi Arabian Oil Co
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Saudi Arabian Oil Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saudi Arabian Oil Co filed Critical Saudi Arabian Oil Co
Priority to US15/601,491 priority Critical patent/US20180334621A1/en
Assigned to SAUDI ARABIAN OIL COMPANY reassignment SAUDI ARABIAN OIL COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MEERANPILLAI, NAGOORPITCHAI S., AMMINUDIN, Kamarul Ariffin, OWAIDHI, SULTAN H.
Priority to PCT/US2018/033850 priority patent/WO2018217719A1/en
Priority to CN201880034055.0A priority patent/CN110678243B/zh
Priority to EP18733718.3A priority patent/EP3630327A1/en
Publication of US20180334621A1 publication Critical patent/US20180334621A1/en
Priority to US17/208,668 priority patent/US11873454B2/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G33/00—Dewatering or demulsification of hydrocarbon oils
    • C10G33/06—Dewatering or demulsification of hydrocarbon oils with mechanical means, e.g. by filtration
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D17/00—Separation of liquids, not provided for elsewhere, e.g. by thermal diffusion
    • B01D17/02—Separation of non-miscible liquids
    • B01D17/04—Breaking emulsions
    • B01D17/042—Breaking emulsions by changing the temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D17/00—Separation of liquids, not provided for elsewhere, e.g. by thermal diffusion
    • B01D17/12—Auxiliary equipment particularly adapted for use with liquid-separating apparatus, e.g. control circuits
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G33/00—Dewatering or demulsification of hydrocarbon oils
    • C10G33/08—Controlling or regulating
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/78—Heating arrangements specially adapted for immersion heating
    • H05B3/82—Fixedly-mounted immersion heaters
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2203/00—Aspects relating to Ohmic resistive heating covered by group H05B3/00
    • H05B2203/021—Heaters specially adapted for heating liquids

Definitions

  • This disclosure relates to the demulsification of multiphase fluids, for example, fluids flowing through flowlines in a hydrocarbon processing facility.
  • This disclosure describes technologies relating to a crude demulsification system.
  • An elongate, horizontally level, pipe includes a circumferential wall.
  • the pipe flows, within the circumferential wall, process fluid that includes a first fluid and a second fluid immiscible with the first fluid.
  • the first fluid and the second fluid are separated by an interfacial layer.
  • Heating coils are disposed within the pipe. Each heating coil passes through an interior region of the pipe between the circumferential wall at a respective height from a bottom of the pipe.
  • the heating coils generate heat.
  • a controller is connected to the heating coils.
  • the controller triggers at least one of the heating coils that is nearest to a location of the interfacial layer within the interior region to apply heat to the interfacial layer.
  • the heat is sufficient to at least partially demulsify the interfacial layer.
  • the heating coils pass through the interior region of the pipe between the circumferential wall at different heights along an entire axial length of the pipe.
  • the heating coils can include an electrical heating coil and an electrical power supply.
  • the heating coils can include a first heating coil passing through the interior region at a first height from the bottom of the pipe that is substantially one-third of a radius of the pipe, a second heating coil passing through the interior region at a second height from the bottom of the pipe that is substantially one-half of the radius of the pipe.
  • Each of the heating coils can be encased in a protective and heat-conductive sheath configured to protect the heating coils.
  • the process fluid can include water and hydrocarbon liquids.
  • the heat generated by the heating coils is sufficient to at least partially demulsify the water and hydrocarbon liquids.
  • a separator with a separator inlet is fluidically coupled to an outlet of the pipe.
  • the separator receives the fluid with a heated interfacial layer at the separator inlet.
  • a demulsifier can at least partially demulsify the interfacial layer.
  • a demulsifier inlet can receive the demulsifier.
  • the demulsifier inlet can be positioned on the pipe.
  • a process fluid comprising a first fluid and a second fluid immiscible with the first fluid is received in a flowline.
  • the first fluid and the second fluid are separated by an interfacial emulsion layer.
  • the flowline includes heating coils. Each heating coil passes through an interior region of a pipe between a circumferential wall at a respective height from a bottom of the pipe.
  • the heating coils generate heat.
  • at least one of the plurality of heating coils within a pre-heater is selectively triggered to heat the interfacial layer based at a height of the interfacial layer from the bottom of the pipe.
  • the process fluid can include water and hydrocarbons.
  • the process fluid is at least partially demulsified in response to applying heat to the interface height of the process fluid.
  • Each of the heating coils can be positioned at a different height within the pre-heater.
  • the heating coils can include an electrical heating coil.
  • the heating coils include two heating coils.
  • the process fluid is sent from the pre-heater to a separator.
  • the process fluid can be further demulsified within the separator.
  • the process fluid is demulsified within the separator using demulsifying chemicals, electrostatic grids, ultrasonics, or sand jetting.
  • a process fluid receiving by a pre-heater One or more heating coils are selecting to power from out of a set of heating coils. Heat is applied to an interface of the process fluid by a selected heating coil. the process fluid is at least partially demulsified in response to applying heat to an interface height of the process fluid. The process fluid is sent from the pre-heater to a separator. The process fluid is further demulsified within the separator.
  • FIG. 1 is a side cross-sectional schematic diagram of a separator with an inlet pre-heater.
  • FIGS. 2A-2B show detailed cross-sectional views of the inlet pre-heater.
  • FIGS. 2C-2D show detailed cross-sectional views of the inlet pre-heater.
  • FIGS. 2E-2F show detailed cross-sectional views of the inlet pre-heater.
  • FIGS. 2G-2H show detailed cross-sectional views of the inlet pre-heater.
  • FIGS. 2I-2J show detailed cross-sectional views of the inlet pre-heater
  • FIG. 3 is a flowchart showing an example method for at least partially demulsifying a fluid.
  • crude-oil When producing and processing hydrocarbons, for example, crude-oil, water is often emulsified within crude-oil and should be separated from the crude-oil before being transported through pipelines to separate facilities. That is, the crude-oil must be dried or dehydrated. A low-water content in the crude-oil is essential for crude-oil transportation, particularly in pipelines, as to prevent hydrate formation. Many pipeline companies have specifications limiting the allowable amount of water within crude-oil to prevent such a hydrate formation from occurring within the pipeline. Dry crude-oil can also be less corrosive than wet crude-oil and can be easier to process in refining operations. For example, crude fluid can be produced on an off-shore platform. That is, crude-fluid is produced from a completed production well.
  • the crude-oil from the crude-fluid produced on the off-shore platform Before the crude-oil from the crude-fluid produced on the off-shore platform can be transported to a refinery onshore, the crude-oil must be sufficiently dehydrated. Proper separation, demulsion, and dehydration can take place on the offshore platform before the dehydrated crude-oil enters the pipeline. In winter months, when the ambient temperature is lower, demulsifying the crude oil can become more difficult. The lower ambient temperatures can create bottlenecks in processing plants due to increased retention times necessary to separate the water from the oil.
  • This disclosure describes partially demulsifying and separating water that has emulsified into oil before the fluid has entered the separator.
  • the separation is achieved by applying heat with a pre-heater to an interface layer between the water and the oil within the flowline upstream of the separator to initiate and accelerate the demulsification and separation process.
  • the targeted heating is more effective and requires less energy than traditional demulsification and separation methods.
  • the in-line separator can consume 20% of the power used by a separator.
  • FIG. 1 shows a flowline fluid demulsification and separation system 100 that is capable of separating and demulsifying water and crude-oil or water and other hydrocarbon liquids, such as condensate.
  • the separation system 100 can be located in any production or refining facility that processes crude-fluids.
  • the crude-fluid can be from a wellbore, an upstream separator, or an upstream facility.
  • the separation system 100 includes a flowline 122 through which a process fluid 102 flows.
  • the process fluid 102 can include crude fluids including water and crude-oil.
  • a flowline such as flowline 122 , transports fluid between different sections of a single facility while pipelines transport fluid between different facilities.
  • the flowline 122 is an elongate, substantially horizontally level, pipe with a circumferential wall 130 .
  • the flowline 122 can be sufficiently level to allow for a consistent emulsion layer to form within the flowline 122 .
  • the process fluid 102 flows, within the circumferential wall, a process fluid 102 that includes a first fluid and a second fluid immiscible with the first fluid.
  • Such fluids can include water and hydrocarbon liquids, such as crude-oil.
  • the process fluid 102 can include gas as well.
  • the first fluid and the second fluid are separated by an interfacial layer 132 .
  • the flowline 122 can be of sufficient length to allow bulk separation to occur within the flowline 122 . That is, an upper portion of the flowline 122 is filled predominantly with crude-oil and a lower portion of the flowline 122 is filled predominantly filled with water with an emulsion layer in between the two portions.
  • the pre-heater 104 can include heating coils, such as heating coils 202 ( FIGS. 2A-2D ) that generate heat; the heating coils can be disposed within a pipe.
  • the heating coils can be placed at a height approximately equal to the interfacial layer 131 to specifically heat the emulsion layer and to at least partially demulsify the process fluid 102 . If electrical heating coils are used, they can be made of any heating coil material, such as nichrome.
  • a controller 128 can be connected to the heating coils.
  • the controller 128 can trigger at least one of the heating coils that is nearest to the location of the interfacial layer 131 within the interior region or the pre-heater 104 to apply heat to the interfacial layer 131 .
  • the targeted application of heat is sufficient to at least partially demulsify the heated interfacial layer 131 .
  • a demulsifier 126 (a chemical designed to demulsify process fluid) can be injected into either the pre-heater or the separator 108 .
  • FIGS. 2A-2B show a side cut-away view and a front view of an example pre-heater 104 , respectively.
  • the pre-heater 104 can include heating coils 202 positioned at a set height along the pre-heater 104 .
  • the heating coils 202 passes through an interior region of the pipe between the circumferential wall 130 at a respective height from a bottom of the pipe. The height is set to match the height of the interface level within the pre-heater 104 .
  • the heating coils 202 can pass through the interior region of the pipe along an entire axial length of the pre-heater 104 .
  • the length of the heater coils can be dependent upon the diameter of the flowline.
  • the heating coils 202 are encased in a protective and heat-conductive sheath 204 that protects the heating coils 202 from the process fluid 102 .
  • the protective sheaths 204 protect the heating coils 202 from the process fluid 102 .
  • the sheaths 204 can be made of metal, ceramic, or any other material suitable to protect heating coils in a flowline.
  • FIGS. 2C-2D show a side cut-away view and a front view of an example pre-heater 104 , respectively.
  • the pre-heater 104 can include multiple layers of heating coils 202 positioned at different heights.
  • each heating coil 202 passes through an interior region of the pipe between the circumferential wall 130 at a respective height from a bottom of the pipe.
  • the varying heights allow individual coils to be used in the event of a process upset or slugging event; such an event can affect the height of the interface level within the pre-heater 104 .
  • FIGS. 1 such as the implementation illustrated in FIGS.
  • the heating coils 202 can pass through the interior region of the pipe along an entire axial length of the pre-heater 104 .
  • the heating coils 202 can extend only partially along the length of the pre-heater 104 .
  • the pre-heater 104 can include two heater coils 202 : a first heating coil 202 a and a second heating coil 202 b. In some implementations, more than two heating coils can be used.
  • the first heating coil 202 a passes through the interior region at a first height from the bottom of the pipe that is substantially one-third of a radius of the pipe, and the second heating coil 202 b passes through the interior region at a second height from the bottom of the pipe that is substantially one-half of the radius of the pipe.
  • Each of the heating coils 202 is encased in a protective and heat-conductive sheath 204 that protects the heating coils 202 from the process fluid 102 .
  • the first heating coil 202 a is encased in a first protective sheath 204 a while the second heating coil 202 b is encased in a second protective sheath 204 b.
  • the protective sheaths 204 protect the heating coils 202 from the process fluid 102 .
  • the sheaths 204 can be made of metal, ceramic, or any other material suitable to protect heating coils in a flowline.
  • FIGS. 2E-2F show a side cut-away view and a front view of an example pre-heater 104 .
  • the pre-heater 104 can include heating coils 210 .
  • the heating coils 202 can pass through the interior region of the pipe laterally across the pre-heater 104 .
  • the heating coils 210 can be encased in a protective and heat-conductive sheath 212 that protects the heating coils 210 from the process fluid 102 .
  • the sheath 212 can be made of metal, ceramic, or any other material suitable to protect heating coils in a flowline.
  • FIGS. 2G-2H show a side cut-away view and a front view of an example pre-heater 104 .
  • the pre-heater 104 can include multiple heating coils 210 positioned at different heights.
  • each heating coil 210 passes through an interior region of the pipe between the circumferential wall 130 at a respective height from a bottom of the pipe.
  • the varying heights allow individual coils to be used in the event of a process upset or slugging event; such an event can affect the height of the interface level within the pre-heater 104 .
  • FIGS. 1 such as the implementation illustrated in FIGS.
  • the heating coils 210 can pass through the interior region of the pipe laterally across the pre-heater 104 .
  • the pre-heater 104 can include multiple heater coils 210 : a first heating coil 210 a and a second heating coil 210 b.
  • Each of the heating coils 210 can be encased in a protective and heat-conductive sheath 212 that protects the heating coils 210 from the process fluid 102 .
  • the first heating coil 210 a is encased in a first protective sheath 212 a while the second heating coil 210 b is encased in a second protective sheath 212 b.
  • the protective sheaths 212 protect the heating coils 210 from the process fluid 102 .
  • the sheaths 212 a and 212 b can be made of metal, ceramic, or any other material suitable to protect heating coils in a flowline.
  • FIGS. 2I-2J show a side cut-away view and a front view of an example pre-heater 104 .
  • the pre-heater 104 can include multiple heating coils 210 .
  • the heating coils 202 can pass through the interior region of the pipe laterally across the pre-heater 104 .
  • the pre-heater 104 can include multiple heater coils 210 : a first heating coil 210 a, a second heating coil 210 b, and a third heating coil 210 c.
  • each of the heating coils 210 is positioned at the same height along the length of the pre-heater.
  • Each of the heating coils 210 is encased in a protective and heat-conductive sheath 212 that protects the heating coils 210 from the process fluid 102 .
  • the first heating coil 210 a is encased in a first protective sheath 212 a
  • the second heating coil 210 b is encased in a protective sheath 212 b
  • the third heating coil 210 c is encased in a third protective sheath 212 c.
  • the heating coils can include an electrical heating coil.
  • an electrical power supply 206 provides current to heat up at least one of the heating coils 202 or heating coils 210 .
  • different numbers heating coils 210 can be activated based on a temperature of a process fluid 102 .
  • a sensor can send a signal to a controller. The controller then activates the necessary number of coils based on the desired load.
  • the heating coils 202 or 210 can include coiled tubing through which heat media can be flowed to heat up the heating coils 202 or 210 .
  • a heat media pump flows the heat media through the heating coils and a temperature regulator controls the temperature of the heat media fluid.
  • a separator 108 can be positioned downstream of the pre-heater 104 .
  • the separator 108 has a separator inlet 124 that is fluidically coupled to an outlet 124 of the pre-heater 104 .
  • the separator inlet 124 and the pre-heater outlet 124 can be the same opening.
  • the separator 108 receives the process fluid 102 that has had the interfacial layer 132 heated by the pre-heater 104 prior to entering the separator 108 .
  • As the process fluid 102 enters the separator it can hit a deflector plate 106 .
  • the deflector plate helps release entrapped gasses from the process fluid and confines turbulent fluid flow to one end of the separator.
  • a different inlet can be used.
  • a spreader inlet can be used.
  • the process fluid 102 further separates into an upper layer of oil 120 and a lower layer of water 118 .
  • the separator 108 can contain a demulsion apparatus 116 that can further separate and demulsify the process fluid 102 .
  • Such a demulsion apparatus can include demulsifying chemicals, electrostatic grids, ultrasonic emitters, sand jets, heaters or any other apparatus that can further demulsify the process fluid.
  • the oil phase is directed into an oil bucket 110 and out an oil outlet 112 to either further refining or a pipeline while the water 118 phase is directed out the bottom water outlet 114 where the water can be cleaned and released to the environment.
  • FIG. 3 is a flowchart showing a method 300 for partially demulsifying a process fluid prior to the process fluid entering the separator.
  • process fluid that include a first fluid and a second fluid immiscible with the first fluid is received in a flowline.
  • the first fluid and the second fluid are separated by an interfacial emulsion layer.
  • the height of the interfacial emulsion layer from the bottom of the pipe can be determined, and at 304 at least one of the plurality of heating coils is selectively triggered to heat the interfacial layer 132 based on a height of the interfacial layer 131 from the bottom of the pipe.
  • the heating coil can be selected manually by an operator.
  • Each of the plurality of heating coils can be positioned at a different height within the pre-heater.
  • the process fluid is at least partially demulsified in response to applying heat to the interface height of the process fluid.
  • the process fluid is sent to a separator where the process fluid can be further demulsified.
  • Demulsifying the process fluid within the separator can involve using demulsifying chemicals, electrostatic grids, ultrasonics, sand jetting, or any other apparatus or method to demulsify the process fluid.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
  • Devices And Processes Conducted In The Presence Of Fluids And Solid Particles (AREA)
US15/601,491 2017-05-22 2017-05-22 Crude hydrocarbon fluids demulsification system Abandoned US20180334621A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
US15/601,491 US20180334621A1 (en) 2017-05-22 2017-05-22 Crude hydrocarbon fluids demulsification system
PCT/US2018/033850 WO2018217719A1 (en) 2017-05-22 2018-05-22 Crude hydrocarbon fluids demulsification system
CN201880034055.0A CN110678243B (zh) 2017-05-22 2018-05-22 原油烃流体反乳化系统
EP18733718.3A EP3630327A1 (en) 2017-05-22 2018-05-22 Crude hydrocarbon fluids demulsification system
US17/208,668 US11873454B2 (en) 2017-05-22 2021-03-22 Crude hydrocarbon fluids demulsification system

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CN113620486A (zh) * 2021-08-23 2021-11-09 塔里木大学 一种有机化学实验污水处理装置
CN115445248A (zh) * 2022-09-16 2022-12-09 江苏理工学院 一种集成多种破乳技术的高效污油处理装置及其处理方法
US20230279299A1 (en) * 2022-03-01 2023-09-07 Saudi Arabian Oil Company Microwave assisted oil-water separator

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US12049594B2 (en) 2022-02-28 2024-07-30 Saudi Arabian Oil Company Natural material for separating oil-in-water emulsions

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US20210207040A1 (en) 2021-07-08
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