Sep-2024

Enhancing refinery sustainability with EmulsionSENS in desalter operations (RI 2024)

In the continuous pursuit of optimising refinery efficiency and sustainability, the integration of advanced instrumentation plays a pivotal role.

David Williams
Berthold

Article Summary

Berthold’s EmulsionSENS technology, when applied to desalter units in refineries, represents a significant advancement in controlling the separation process of crude oil from its entrained salts, minerals, and metals.

In our presentation, we will explore the application of this technology in refining operations, focusing on its capability to enhance level control within desalters, thereby enabling better operational control.

Traditionally, achieving the necessary separation temperatures requires substantial energy consumption; however, with improved level control, the operational temperature can be significantly reduced.

Further, we will discuss how the improved level control provided by EmulsionSENS minimises the carryover of salts, minerals, and metals. This reduction is crucial as it decreases the fouling of critical heat exchange equipment and furnace tubes, a common challenge in refineries.

This leads to increased fuel consumption in downstream processing units due to higher normal firing temperatures to counteract the effects of fouling or loss of efficiency due to poor recovery of energy in heat exchangers. By addressing these challenges, EmulsionSENS not only contributes to immediate cost savings but also bolsters the overall sustainability of refinery operations by reducing energy requirements and enhancing the longevity of key refinery components.

We will also discuss other potential savings, such as the reduction of corrosion in piping and vessels due to acids formed from salts carried over from the desalter, as well as increased catalyst life due to the reduction of poisonous metals such as iron (Fe).
Attendees will gain an understanding of how strategic implementation of this technology can play a crucial role in enhancing refinery sustainability, aligning with global trends towards more energy-efficient and environmentally-friendly industrial practices.

Three Takeaways from the abstract
Enhanced efficiency through advanced instrumentation: The integration of Berthold’s EmulsionSENS technology in refinery desalter units represents a significant advancement in optimising crude oil separation processes. By focusing on improving level control within desalters, this technology enables better operational control, leading to reduced energy consumption and increased efficiency.

Prevention of fouling and corrosion: EmulsionSENS facilitates better level control, which minimises the carryover of salts, minerals, and metals, thereby reducing fouling in critical heat exchange equipment and furnace tubes. This not only decreases fuel consumption in downstream processing units but also extends the longevity of key refinery components by mitigating corrosion in piping and vessels caused by acids formed from salt carryover.

Long-term sustainability benefits: Strategic implementation of EmulsionSENS technology not only contributes to immediate cost savings but also aligns with global trends toward more energy-efficient and environmentally-friendly industrial practices. By reducing energy requirements, enhancing operational efficiency, and minimising environmental impact, this technology plays a crucial role in enhancing refinery sustainability and aligning with broader industry goals.

This short article originally appeared in the 2024 Refining India Newspaper, which you can VIEW HERE