Stability and Process Optimization of Heavy Crude Oil Desalting Systems: Operational and Simulation-based Analysis
DOI:
https://doi.org/10.15377/2409-787X.2026.13.5Keywords:
Demulsifier optimization, Heavy crude oil desalting, Emulsion stability analysis, Electrostatic desalting process, Process simulation and optimizationAbstract
Process integrity is paramount in the oil industry to ensure operational reliability, safety, efficiency, and profitability. This is particularly vital in the Orinoco Oil Belt, the world’s largest heavy and extra-heavy crude reserve, where the inherent properties of the resource impose strict requirements on its transportation, processing, and marketing. Consequently, this study performs an emulsion stability analysis to optimize the desalting process for these specific crudes. The methodology combines lab experiments, plant data analysis, and computer simulation of the process. The study results provide new insights to achieve this goal, such as: 1) Advanced modeling: Combining computer simulations and statistical analysis to map fluid thermodynamic and hydraulic behaviors. 2) Flow-mechanical insights: Correlating mixing valve pressure drops directly with emulsion stability. 3) Targeted parameter adjustments: Setting specific limits for heavy crude processing, including wash water pH, demulsifier concentration, and pressure thresholds to prevent gasification in electrostatic desalters. 4) Dynamic flow control: Upgrading mixing dynamics via optimized valves, control loops, and a new chemical injection system. 5) System stabilization: Resolving industry constraints through targeted mechanical and automation enhancements that ensure process integrity and predictable operations.
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Copyright (c) 2026 Miguel López-Patiño, Marinee Figueroa, Victoria Salazar-Palencia, José Rengel-Hernández, Shirley Marfisi-Valladares, Mario Lobo, Alix Guerrero, Carlos Carvajal
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