Related Experiment Video
Updated: Jul 10, 2025
16:19
High Throughput Single-cell and Multiple-cell Micro-encapsulation
Published on: June 15, 2012
18.7K
Modelling droplet size distribution in inline electrostatic coalescers for improved crude oil processing
Ghazal Kooti1,2, Bahram Dabir3, Reza Taherdangkoo2
1Department of Petroleum Engineering, Amirkabir University of Technology, Tehran, Iran.
Scientific Reports
|November 19, 2023
Summary
A new mathematical model predicts water droplet size in inline electrostatic coalescers (IEC), enhancing water separation efficiency in oil processing. Optimized IEC operation improves performance and reduces energy use.
Area of Science:
- Petroleum Engineering
- Chemical Engineering
- Fluid Dynamics
Background:
- Water-in-oil emulsions present significant challenges in petroleum and chemical industries, requiring efficient water droplet coalescence for separation.
- Current oil processing systems often struggle with effective water removal from emulsified oils, impacting overall efficiency and product quality.
Purpose of the Study:
- To develop and validate a mathematical model for predicting water droplet size distribution in inline electrostatic coalescers (IEC).
- To enhance the understanding of droplet coalescence and breakage dynamics within IECs for improved water separation efficiency.
- To provide a tool for optimizing IEC operational parameters to increase performance and reduce operational costs.
Main Methods:
- Utilized population balance modeling (PBM) to simulate the dynamic processes of droplet coalescence and breakage.
- Employed the method of classes to solve the population balance equation (PBE).
- Validated the model's accuracy against experimental data from existing literature.
Main Results:
- The developed model accurately simulates droplet coalescence and breakage in emulsified oil, predicting droplet size distribution and water removal efficiency.
- Key operational parameters like electric field strength, residence time, and fluid flow rate were found to significantly influence droplet coalescence.
- Optimal conditions (4 kV, 5 m³/h, 4 s) resulted in a maximum mean droplet diameter (D50) of 432 µm and a separation efficiency of 94.3%.
Conclusions:
- The mathematical model provides a reliable method for predicting IEC performance and optimizing operational conditions.
- Optimized IEC operation leads to increased oil processing efficiency, reduced energy consumption, and decreased reliance on chemical demulsifiers.
- The findings are particularly advantageous for heavy oils and offshore applications, offering reduced equipment size and weight.
