Energy-Structure-Performance Coupling in Stirred Crude Oil Desalting: RSM Optimization and Identification of an...

This study introduces an innovative "energy-structure-performance" framework to quantify mixing intensity in stirred crude oil desalting, moving beyond traditional metrics such as stirring speed and duration. By analyzing droplet size distribution and estimating input energy via a Reynolds number-Power number approach, we identified a critical input-energy window centered around 50 J. Within this range, desalting efficiency exhibits a characteristic rise-fall trend that closely mirrors the evolution of the Sauter mean diameter (D₃₂) along the energy axis, emphasizing the pivotal role of droplet structure in translating energy input into performance. Mechanistically, operating within this optimal energy window promotes droplet coalescence while minimizing shear-induced overemulsification. These results provide a physically grounded methodology for refining engineering operations, allowing precise control of mixing valves and optimization of energy input to achieve enhanced salt removal and improved phase separation efficiency.