Modulated AC/DC Crude Desalting Technology Application & Best Practices

Abstract

The Modulated AC/DC Crude Desalting technology was successfully commissioned at several Saudi Aramco facilities. Enhancements to desalting performance and optimization of plant operating expenditures were realized. Benefits of the Modulated AC/DC Desalting technology, installation and operational best practices and a comparison to conventional AC technology is shared in the paper. The conventional AC desalting technology was replaced with the Modulated AC/DC Crude Desalting technology at some Saudi Aramco facilities. After the successful commissioning, the performance of the new units was tested in one of these facilities to identify operating limits, such as maximum water cut and minimum demulsifier injection at the production header, in which the stable operation is sustainable. A comparison of the performance of the technology compared to that of previous conventional AC desalting technology was conducted through analysis of grid/plate voltage stability, demulsifier injection rate, wash water rates and crude quality parameters. Some enhancements to the process were also introduced which resulted in realizing additional benefits. The technology resulted in several benefits, including: (1) A reduction in the required demulsifier injection rate during the testing period compared to the same time period from the previous year, leading to significant cost savings; (2) Ability to maintain normal operations beyond the design water cuts of the facility; (3) No major grid outages since installation; (4) Additional data that can be used to diagnose separation performance as each transformer provides a number of feedback signals to DCS that are good indicators of the separation process. Based on the observations and analysis, the Modulated AC/DC Crude Desalting Technology has several advantages over the conventional AC Crude Desalting Technology in regards to crude desalting performance and process stability. The Modulated AC/DC Crude Desalting technology at Saudi Aramco was the first installation in Saudi Arabia for Arab Light crude oil. The paper captures Saudi Aramco’s experience and best practices that other companies can find beneficial in their efforts to maintain crude quality and reduce operating expenditures.