Modelling droplet size distribution in inline electrostatic coalescers for improved crude oil processing

Water-in-oil emulsions pose significant challenges in the petroleum and chemical industrial processes, necessitating the coalescence enhancement of dispersed water droplets in emulsified oils. This study develops a mathematical model to predict the evolution of water droplet size distribution in inline electrostatic coalescers (IEC) as a promising means to improve the water separation efficiency of current oil processing systems. The proposed model utilizes the population balance modelling approach to effectively simulate the dynamic and complex processes of coalescence and breakage of droplets in crude oil which directly influence the separation efficiency of the process. The method of classes as an effective mathematical technique is selected to solve the population balance equation (PBE). The accuracy of the model and considered assumptions agree well with experimental data collected from the literature. The results demonstrate the model's ability to accurately simulate droplet coalescence and breakage in emulsified oil while predicting droplet size distribution and water removal efficiency. The electric field strength, residence time, and fluid flow rate significantly influence the coalescence of droplets. At 4 kV and 5 m³/h after 4 s the mean diameter of droplets (D₅₀) and separation efficiency reach the maximum of 94.3% and 432 µm, respectively. The model enables the optimization of operational conditions, resulting in increased performance and reliability of oil-processing systems while reducing the energy consumption and use of chemical demulsifiers. Additionally, utilization of the device in optimized conditions significantly reduces the size and weight of downstream separation equipment, which is particularly advantageous for heavy oils and offshore fields.