Designing a Methodology for Optimisation of Heater Treater
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1 Designing a Methodology for Optimisation of Heater Treater Deepankar Chadha 1, Pulkit Chaudhary 2 pulkit.chaudhary03@gmail.com Abstract Emulsions refer to mixture of two or more immiscible liquids. For an emulsion to form the components should be immiscible with each other. Various equipments are available in the oil and gas industry. Heater treaters are predominantly used in the oil industry. Heater treater, as the name implies, heat the feed to break the emulsion. There are two types of heater treaters i.e. horizontal heater treaters and vertical heater treaters. Vertical heater treaters are used when the flow is coming from the single well. When the flow is coming from the number of wells, horizontal heater treater is used. In this paper, an attempt has been made to design horizontal heater treater for the crude oil coming from a loosely consolidated, water drive sandstone reservoir in offshore South Louisiana field. As the flow is coming from 10 wells, therefore horizontal heater treater is used. In designing of treater three equations are used i.e. settling equation, retention time equations for heat required. An adequate solution of the dimensions and the fire tube rating of the heater treater has been provided at the end of the paper. Keywords Emulsion, heater treater, horizontal heater treater, dimensions of heater treater, fire tube rating. Introduction Emulsions are normally encountered in the oil and gas industry and these are needed to be broken. Emulsion refers to the heterogeneous mixture of two or more immiscible liquids with one liquid dispersed as droplets into the other liquid. They can be liquid /liquid, liquid/gas etc. In liquid/liquid emulsion both the liquid forming emulsion should be immiscible with one another. In liquid/gas emulsion gas should be immiscible with liquid [1]. In oil and gas industry crude oil/water emulsions are normally encountered. This type of emulsion is called normal emulsion if water is dispersed phase and oil is dispersing phase. If reverse process takes place, then it is called reverse emulsion i.e. if water is dispersing phase and oil is dispersed phase [2]. Emulsions can be stable as well as unstable. Emulsions which can be separated easily by agitation are called unstable emulsion. The emulsion which cannot be separated easily is known as stable emulsions [3]. The type depends upon the density of the crude oil. Crude oils with low API gravity form more stable emulsion than crude oils having higher API gravity [4]. Different types of Deepankar Chadha, Pulkit Chaudhary Page 1
2 methods are employed to break different emulsions like heating, de-emulsification, agitation, electrostatic coalescence, water washing, filtering, gravity settling, centrifugation and distillation [5]. By heating the crude oil, it reduces the viscosity of crude oil which in turn reduces the viscosity of crude oil and thus water droplets coalesce faster and settle down [6]. De-emulsification refers to the use of chemical de-emulsifier which helps in destabilising the emulsion, increasing the coalescence of water droplets which in turn breaks the emulsion. Agitation increases the collision between the water droplets which in turn increases the coalescence between the water droplets and helps in resolving the emulsion. In electrostatic coalescence three phenomenon helps in separating out the emulsion i.e. polarization of water droplets in the line of the electric charge, attraction of water droplets by the electrode due to induced charge, weakening of the film of the emulsifier around the water droplets [7]. In water washing, emulsion is processed from the bottom of the vessel which travels upwards to the top of the vessel through water resulting in coalescence of water droplets which settles at the bottom of the vessel [8]. Filtering refers to the selection of proper pore size and wetting the filtering material with oil and keeping it submerged in oil and resulting in breaking of emulsion. Gravity settling refers to the separation of oil and water due to the density differences [9]. Various types of equipments used to break the emulsion are free water knock-out drum (FWKO), settling tanks, electrostatic coalesces, horizontal and vertical heater treater. In FWKO, three different types of layers are formed when agitated i.e. the top layer containing pure crude oil with small amount of water dispersed in it, the bottom layer containing clean water with oil dispersed in it and the layer of emulsion in between the top and bottom layer. As the coalescence takes place the layer of emulsion vanishes. Settling tank are also called gun barrels [10]. They treat the emulsion by heating. Nowadays gun barrels are replaced by vertical heater (fig1). In this type of treaters, flow is entered from the top of the vessel. The upper section is called gas separating section. This section consists of inlet diverter and mist extractor. When the flow enters, it first passes through the inlet diverter where most of the separation takes place and then it passes through the mist extractor where the residual gas is vented off through the gas vent line. Now the flow comes downwards around the coalescence where coalescence of water droplets takes place and then it settles down and is collected in the water outlet line. The middle portion consists of the treated oil [10]. It should be made sure that steam does not enter that steam does not enter the fire tube. In this paper major emphasis is given on the designing of horizontal heater treater. Horizontal heater treater is depicted in the fig 2. Fig. 1: Vertical heater treater Deepankar Chadha, Pulkit Chaudhary Page 2
3 Fig. 2: Horizontal heater treater Horizontal heater treater is divided into three sections i.e. heating section or degassing section, surge section and coalescing section. Oil is entered through the front section of the treater and then it is flashed where the gas is separated out through the inlet diverter and mist extractor. The oil settles down in oil water interface where the process of water washing takes place where the free water is separated. Free water refers to the water that does not contain any emulsified particles. Now the oil comes in contact with fire tubes and then goes to the surge section. In surge section only part of the emulsion is separated out. Then oil enters the coalescing section where rest of the separation takes place. This section should be sized most efficiently as this part of the treater defines the efficiency of the heater treater. The spreader is installed which distributes the flow evenly throughout the section. Treated oil is collected on the collection device located at the top whereas water droplets fall at the bottom through the rising oil and therefore water is collected at the bottom and oil is collected at the top of the horizontal heater treater [11, 12]. In this paper, an attempt has been made to design the horizontal heater treater for de-emulsification of crude oil from water. Main focus is given on the coalescing section as this section determines the cost of heater treater. These calculations are done if laboratory data is unavailable. At the end of the paper an economical solution is given with full validation. Methodology and Optimisation For designing a horizontal heater treater, the input parameters required are oil gravity ( 0 API), oil flow rate (bbl/day), gas gravity, number of wells, inlet oil temperature ( 0 F) and Inlet BS & W (percent). After obtaining these parameters, settling equation (at various temperatures) and retention time equation are solved. After this, heat required is estimated followed by selection of adequate d and L eff is done. For solving the settling equation, difference in specific gravity of oil and gas, viscosity of oil, diameter of water droplet in microns at different temperatures is required. The viscosity of oil (µ) is calculated from the following equations µ = 10 X [1] X = Y[T] [2] Y = 10 z [3] Z= *G where G = gas gravity [4] The drop diameter at 1% water cut (BS & W) is calculated by using equation 5 d m = 200 µ.25 [5] Deepankar Chadha, Pulkit Chaudhary Page 3
4 The settling equation is given by d*l eff = 438[Q 0 µ / (ΔS.G)*(d m ) 2 ] [6] Using equation 6, combination of d and L eff are drawn at different temperatures. The next step is to solve the retention time equation (eq. 7). In the absence of laboratory data, retention time can be taken between 20 to 30 minutes. d 2 L eff = [Q 0 [t r ] 0 / 1.05] [7] Combination of d and L eff at retention time is plotted on the same graph. Heat required to raise the temperature of the feed to the selected temperature substituting the initial temperature as feed in temperature is given by equation 8. q = 16 Q 0 ΔT [0.5(S.G) o +0.1] [8] Next step is followed by selection of adequate combination of d and L eff. Shade all the area below the line of retention time. A point can be chosen that comes out of the shaded area and requires minimum heat. Minimum heat required would be the fire tube rating of the heater treater. Calculations The input parameters are shown in table 1. s.no. Parameters Value 1. Specific gravity of oil 30 0 API 2. Specific gravity of gas Treating temperature 90 0 F 4. BS&W(water cut) 1% 5. Oil flow rate( per well) 500 bpd 6. Number of wells 10 Table 1: Input parameters. The parameters for the settling equation are given in table 2. s.no. Temperature Δ S.G.(specific gravity) µ(viscosity) d m (drop diameter) dl eff Table 2: Settling equation parameters Where, ΔS.G. = difference in the specific gravity of gas and oil µ = viscosity of oil, cp d m = diameter of the water droplet to be settled down, in microns d = diameter of the heater treater,inches L eff = length of the coalescing section, feet Deepankar Chadha, Pulkit Chaudhary Page 4
5 The value of µ is calculated with the help of equations [1,2,3,4] and the value of d m is calculated from the equation [5]. Now, calculation of retention time equation has been made. In this case, we have taken retention time i.e. t r = 20 minutes. Next is to solve the retention time equation d 2 L eff = [5000[20] / 1.05]= A combination of d and L eff has been made for both retention time equation as well as the settling equation. Combination for settling equation is given in table 3. S.No Treating temperature d L eff Heat required Combination of d and L eff is given in table Table 3: Combination for settling equation Retention D time L eff Table 4: Combination for retention time equation In the next step, heat required is calculated. q = 16 Q 0 ΔT [0.5(S.G) o +0.1] = 16*5000*ΔT[0.5*(.876)+0.1]=43040*ΔT Deepankar Chadha, Pulkit Chaudhary Page 5
6 Putting the values for initial temperature as 90 0 F and calculating for treating temperatures of 90 0 F,110 0 F and F q 1 =43040*[90-90]=0 q 2 =43040[110-90]= MMbtu/hour q 3 =43040[130-90]=1.10 MMbtu/hour where, q 1,q 2 and q 3 are the heat required for 90 0 F,110 0 Fand F respectively The graph has been plotted for the settling as well as the retention time equations. Figure 3: d and L eff at different temperatures Area for retention time less than 20 minutes has been marked, only one point comes outside that area i.e. for L eff = 5.78 feet and d=132.5 inch the treating temperature can go upto F if the field conditions changes. Results and Conclusion The above study reveals that the length of the coalescing section in a horizontal heater treater should be ideally equal to 5.78 feet and the diameter should be inches. The fire tube rating should be MMbtu/hour or MMbtu/day. References [1] Kokal, S. L. (2005, February 1). Crude Oil Emulsions: A State-Of-The-Art Review. Society of Petroleum Engineers. doi: /77497-pa [2] Minnie, J. (1933, January 1). TREATMENT OF CRUDE OIL EMULSIONS. World Petroleum Congress. [3] Smith, H. V., Arnold, K. E. (1987, January 1). Crude Oil Emulsions (1987 PEH Chapter 19). Society of Petroleum Engineers. [4] Augustina, O., Sylvester, O. (2015, August 4). Emulsion Treatment in the Oil Industry: A Case Study of Oredo Field Crude Oil Emulsion. Society of Petroleum Engineers. doi: / ms Deepankar Chadha, Pulkit Chaudhary Page 6
7 [5] Duerksen, J. H., Hsueh, L. (1983, April 1). Steam Distillation of Crude Oils. Society of Petroleum Engineers. doi: /10070-pa [6] Harr, J. D. (19, January 1). Field Approach To Crude Oil Demulsification. Society of Petroleum Engineers. [7] Boling, D. R. (16, January 1). The Use of Electrostatic Coalescence in the Dehydration of Gulf Coast Crudes. American Petroleum Institute. [8] Kale, H. B., Wyllie, H., Tainsh, H. R. (1951, January 1). Solvent Washing of Wells in the Digboi Oil Field, Assam. World Petroleum Congress. [9] Cartmill, J. C., Dickey, P. A. (19, January 1). Flow Of A Disperse Emulsion Of Crude Oil In Water In Porous Media. Society of Petroleum Engineers. doi: /2481-ms [10] Ferguson, K. R., Stechmann, R. H. (1980, June 1). Improving Heater Treater Fuel Efficiency. Society of Petroleum Engineers. doi: /8304-pa [11] Bartz, D., Gotterba, J. (2015, June 9). Performance Data of a Distributed Flux Burner in a Heavy Oil Heater Treater. Society of Petroleum Engineers. doi: / MS [12] Bartz, D., Gotterba, J. (2014, June 10). Results of Field Operation of a Distributed Flux Burner in a Heater Treater in a Northern Canada Heavy Oil Field; Thermal Performance and Firetube Life. Society of Petroleum Engineers. doi: /1701-ms This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution 4.0 International License ( by the Authors. Licensed by HCTL Open, India. Deepankar Chadha, Pulkit Chaudhary Page 7
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PRESSURE TRANSIENT BEHAVIOUR OF A HORIZONTAL STEAM INJECTION WELL IN A NATURALLY FRACTURED RESERVOIR Tan Tiek Yi and Azeb D. Habte Department of Petroleum Engineering, Universiti Teknologi PETRONAS, Malaysia
Below Ground Oil Water Separators
Below Ground Oil Water Separators Smaller units, higher flow rates Low maintenance cost Equipment can be serviced and maintained from outside; no confined spaces Easily cleaned through the removable vapor-tight
USING A DENSITOMETER FOR QUANTITATIVE DETERMINATIONS OF FLUID DENSITY AND FLUID VOLUME IN CORE FLOODING EXPERIMENTS AT RESERVOIR CONDITIONS
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Influence of Clay Content on Surfactant- Polymer Flooding For an Egyptian Oil Field. Prof. Atef Abdelhady, British University in Egypt
Influence of Clay Content on Surfactant- Polymer Flooding For an Egyptian Oil Field Prof. Atef Abdelhady, British University in Egypt Presentation Outline Background. Surfactant- Polymer Flooding Overview
Experimental Investigation on the Effect of Parameters Influencing the Performance of a Horizontal Styrene-Water Separator
Iranian Journal of Chemical Engineering Vol. 9, No. 3 (Summer), 2012, IAChE Resea rch note Experimental Investigation on the Effect of Parameters Influencing the Performance of a Horizontal Styrene-Water
SOLVENT EXTRACTION N 1
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Performance Evaluation of Cooling Tower in Thermal Power Plant - A Case Study of RTPS, Karnataka
Performance Evaluation of Cooling Tower in Thermal Power Plant - A Case Study of RTPS, Karnataka Pushpa B. S, Vasant Vaze, P. T. Nimbalkar Abstract: An evaporative cooling tower is a heat exchanger where
Zhejiang Fotech International Co. Ltd. PTFE Molding Powder. Tensile strength (Mpa) Elongation at break %
PTFE Molding Powder FT 4TM FT 4TN S Appearance White powder, no impurities Tensile strength (Mpa) 36 35.0 Elongation at break % 320 320 Bulk density (g/l) 300 450 300 550 Average particle size (μm) 30±5
FORMERLY SMITH PIPE - SAME PEOPLE, SAME SERVICE PETROSMITH.COM
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Modular Oil & Gas Equipment Onshore & Offshore
Modular Oil & Gas Equipment Onshore & Offshore Separators & Desalters AI Energy Solutions onshore and offshore oil process solutions offer innovative technologies packaged with global project management
Determination of Oil and Water Compositions of Oil/Water Emulsions Using Low Field NMR Relaxometry
PAPER -95 Determination of Oil and Water Compositions of Oil/Water Emulsions Using Low Field NMR Relaxometry K. Mirotchnik, K. Allsopp Tomographic Imaging and Porous Media Laboratory A. Kantzas University
Module 2: Solid Fossil Fuel (Coal) Lecture 12: Combustion of coal and coke making
1 P age Module 2: Solid Fossil Fuel (Coal) Lecture 12: Combustion of coal and coke making 2 P age Keywords: Coal tar, distillation, caustic washing, deoiling 2.4 Combustion of coal and coke making 2.4.3
Primary Recovery Mechanisms
Primary Recovery Mechanisms The recovery of oil by any of the natural drive mechanisms is called primary recovery. The term refers to the production of hydrocarbons from a reservoir without the use of
Oil Recovery Enhancement: Approaches, Methods, Project Design and Current Status, Application to Egyptian Oil Fields
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The Study of Salinity Effect on Flow Rate of Water in Piping System
International Journal of Engineering Research and Advanced Technology (IJERAT) E-ISSN : 2454-6135 DOI: http://dx.doi.org/10.7324/ijerat.2018.3137 Volume.4, Issue 1 January-2018 The Study of Salinity Effect
NORTHERN ARIZONA UNIVERSITY Separation of Oil from Water
NORTHERN ARIZONA UNIVERSITY Separation of Oil from Water 1 Separation of Oil from Water School Name: Northern Arizona University Team Name: H2Oleum Team Member Names: Ali Hasan Christina Holt Mahdi Mohammad
Research Article Simulation of Sugarcane Juice Evaporation in a Falling Film Evaporator by Variation of Air Flow
Research Journal of Applied Sciences, Engineering and Technology 10(3): 322-327, 2015 DOI: 10.19026/rjaset.10.2494 ISSN: 2040-7459; e-issn: 2040-7467 2015, Maxwell Scientific Publication Corp. Submitted:
CCSD & CCSE Series Oil/Water Separators
CCSD & CCSE Series Oil/Water Separators NEW Engineered to Save Oil/Water Separators Condensate generated by lubricated type air compressors is comprised of atmospheric borne water vapor and lubricant from
DEVELOPMENT OF NOVEL DROP DIAMETER MEASURING METHOD IN THE MANUFACTURING PROCESS OF FUNCTIONAL O/W MICROCAPSULES
14 th European Conference on Mixing Warszawa, 10-13 September 2012 DEVELOPMENT OF NOVEL DROP DIAMETER MEASURING METHOD IN THE MANUFACTURING PROCESS OF FUNCTIONAL O/W MICROCAPSULES K. Kanaya a, S. Akao
The Use of Finite Element Analysis in the Design of Oil-Water Separators
The Use of Finite Element Analysis in the Design of Oil-Water Separators Mohamed E. Wanas 1*, Yehia M. S. Elshazly 1, Dina A. ElGayar 1 1 Chemical Engineering Department, Faculty of Engineering, University
INTEGRATION OF EXTRACTION AND RESS FOR SOLVENT RECOVERY FROM ASPHALTENE
INTEGRATION OF EXTRACTION AND RESS FOR SOLVENT RECOVERY FROM ASPHALTENE Zhao Suoqi*, Wang Shuhui, Ma Jianwei, Wang Renan State Key Laboratory of Heavy Oil Processing University of Petroleum, Beijing, P.
Media Filtration of Produced Water in Polymer Flood Applications
Media Filtration of Produced Water in Polymer Flood Applications, P.E. and Shane Wiercinski Siemens Water Solutions www.siemens.com/water-solutions Global Oil Recovery It is likely that an oil well will
Presby Maze Design and Installation Manual
Presby Design and Installation Manual PRESBY ENVIRONMENTAL, INC. INNOVATIVE SEPTIC TECHNOLOGIES 143 Airport Rd., Whitefield, NH 03598 Tel: 1-800-473-5298 Fax: (603) 837-9864 www.presbyenvironmental.com
Glossary l. Btu British thermal unit; the amount of heat needed to raise the temperature of 1 pound of water 10 F at or near 39.
Glossary Glossary l Accelerated depreciation Any of a number of forms of depreciation which allow the writeoff of capital investments more rapidly than straight Iine depreciation. Straight Iine depreciation
How A Vertical Tube Falling Film Evaporator Can Be Used to Deliver the Lowest Total Life Cycle Cost for Alberta Produced Water Treatment
How A Vertical Tube Falling Film Evaporator Can Be Used to Deliver the Lowest Total Life Cycle Cost for Alberta Produced Water Treatment Overview Minimizing Installation Costs Evaporator Pilot Program
OIL WATER SEPARATORS. We thank you for your valued enquiry and have pleasure in submitting our quote/proposal as follows: PRICELIST FOR:
We thank you for your valued enquiry and have pleasure in submitting our quote/proposal as follows: PRICELIST FOR: OIL WATER SEPARATORS Oil water separators are typically considered very simple devices.
Estimation of Boil-off-Gas BOG from Refrigerated Vessels in Liquefied Natural Gas Plant
International Journal of Engineering and Technology Volume 3 No. 1, January, 2013 Estimation of Boil-off-Gas BOG from Refrigerated Vessels in Liquefied Natural Gas Plant Wordu, A. A, Peterside, B Department
ERT 318/4 UNIT OPERATIONS SEMESTER 1 (2013/2014)
ERT 318/4 UNIT OPERATIONS SEMESTER 1 (2013/2014) WATER COOLING TOWER School of Bioprocess Engineering University Malaysia Perlis EXPERIMENT Water Cooling Tower 1.0 OBJECTIVES 1.1 To determine energy and
A Comparison Study between the Newly Developed Vertical Wells Steam Assisted Gravity Drainage and the Conventional SAGD Process
Engineering, 217, 9, 575-59 http://www.scirp.org/journal/eng ISSN Online: 1947-394X ISSN Print: 1947-3931 A Comparison Study between the Newly Developed Vertical Wells Steam Assisted Gravity Drainage and
ESK TM. Oil/Water Separator with Automatic Shutoff Valve. Our waterways. Our future.
ESK TM Oil/Water Separator with Automatic Shutoff Valve Our waterways. Our future. ESK TM Industrial Site Solution The ESK is a passive high efficiency coalescing separator that removes free oil from contaminated
The Use of Walnut Shell Filtration with Enhanced Synthetic Media for the Reduction and/or Elimination of Upstream Produced Water Treatment Equipment
Siemens Water Solutions The Use of Walnut Shell Filtration with Enhanced Synthetic Media for the Reduction and/or Elimination of Upstream Produced Water Treatment Equipment White Paper January 2016 Researchers
Physical modelling of slag-metal dispersion
AKDOGAN, G. and ERIC, R.H. Physical modelling of slag-metal dispersion. VII International Conference on Molten Slags Fluxes and Salts, The South African Institute of Mining and Metallurgy, 2004. Physical
OriginClear Water Treatment with Innovative Desalination Techniques High TDS Water Treatment for Oil & Gas Markets in Oman
OriginClear Water Treatment with Innovative Desalination Techniques High TDS Water Treatment for Oil & Gas Markets in Oman A Technology & A Process Electro Water Separation (EWS) A first stage technology
A BASIC IMMERSION FIRETUBE FLOWNEX MODEL
A BASIC IMMERSION FIRETUBE FLOWNEX MODEL This case study demonstrates the implementation of a basic immersion firetube model in Flownex and presents natural draft and forced draft examples. OIL AND GAS
MODELING THE RELATIVE PERMEABILITY RELATIONSHIP IN A TAR SAND FORMATION
MODELING THE RELATIVE PERMEABILITY RELATIONSHIP IN A TAR SAND FORMATION Nmegbu, Chukwuma Godwin Jacob 1 1 Department of Petroleum Engineering, Rivers State University of Science and Technology, P.M.B 5080,
Effect of Corrugation Angle on Heat Transfer Studies of Viscous Fluids in Corrugated Plate Heat Exchangers
Effect of Corrugation Angle on Heat Transfer Studies of Viscous Fluids in Corrugated Plate Heat Exchangers B Sreedhara Rao 1, Surywanshi Gajanan D 2, Varun S 2, MVS Murali Krishna 3, R C Sastry 2,* 1 Department