Post on 08-Dec-2021
GEA Crude Oil Treatment Systems
Modular centrifugal process lines for the efficient dehydration and desalting of crude oil
GEA CRUDE OIL TREATMENT SYSTEMS · 3
CENTERPIECE OF PEFORMANCEEvery GEA Crude Oil Treatment System consists of a
centrifuge for dehydrating or desalting the crude oil.
Introduction Tackling your challenges, keeping your 04
business running profitably
Our solutions for your challenges Ready to use, wherever needed 06 Process setups 08
GEA Separation Technology Customized solutions for the highest demands 12
GEA crude oil Dehydrators 14
GEA crude oil Desalters 16
Modular systems 18 In-house process engineering solutions 20
GEA – your service partner Trouble-free operation in demanding environments 22
Contents
2 · GEA CRUDE OIL TREATMENT SYSTEMS
4 · GEA CRUDE OIL TREATMENT SYSTEMS
According to Statista, global oil production has increased steadi-
ly over the past 50 years – to a peak of around 94.72 million bar-
rels a day in 2018. This means that daily production has roughly
tripled over the same period. Increasing global consumption,
particularly in the emerging markets of China, India, Brazil, the
Russian Federation and Mexico, requires more efficient technol-
ogies and new ways to also handle heavy-to-extract oil wells. The
role of unconventional crude oil production and the difficult to
recover oil reserves is becoming more important.
More and more oil companies are turning to unconventional
sources such as deep-sea oil, oil sand, and heavy crude oil (HCO).
Even resources that have already been developed still offer
considerable untapped potential. The conventional deposits
exploited by primary methods are – depending on the properties
of the deposit and the crude oil – only depleted on average by
around 35 %. There, the yields can be increased by up to 60 %
using a new “Enhanced Oil Recovery” (EOR) production method.
This method has also proven effective in the extraction of heavy
crude oil.
Centrifugal separators from GEA are the efficient, state-of-the-art
solution for the continuous treatment of crude oil. With the
new Crude Oil Treatment Systems, GEA has most flexibly im-
plemented 125 years of separation technology know-how and
designed a modular but easy-to-integrate solution for various
process setups, as side or full stream installation or as a pre-de-
hydrating option – both stationery and mobile.
The heart of the Crude Oil Treatment Systems is a unit with a
high-performance GEA centrifuge, which can be optionally
supplemented with additional units with transfer pump, heater
and mixer, providing a tailor-made solution for each customer
and process requirement. The innovative GEA solution can
process crude oils with high densities and high water/salt con-
tent efficiently while minimizing the consumption of chemicals,
which leads to considerable savings in operating costs.
The result: a more economical process, which is in addition safer
and more stable and thus easier to control. As an experienced
supplier to the oil & gas industry, our systems comply with all
relevant safety and production standards such as IEC, ATEX,
NEC, NACE, ANSI/ASME.
Tackling your challenges, keeping your business running profitably
Thanks to technological progress and the development of new oil reserves, crude oil will remain the most important source of energy and raw material for the global economy in the coming decades.
CONTINUOUS FLOWNew technologies and strategies enable operators to
give new life to mature fields and old platforms and
handle a wide range of process conditions.
GEA CRUDE OIL TREATMENT SYSTEMS · 5
Ready to use, wherever needed
The GEA solution separates crude oil of almost any quality and
composition into both a compliant crude oil stream and water
stream and a concentrated solids stream.
When produced from the reservoir, crude oil contains contam-
inants such as water, suspended solids and water-soluble salts
in changing compositions. Since these contaminants impact
the lifetime of downstream equipment, they must be removed
before the crude oil can be further processed.
Static and electrostatic systems are still state of the art in many
cases to remove contaminants from oil. However, they may
reach their limits to produce sufficient results with challenging
oils to be processed.
With the GEA Crude Oil Treatment System, it is no longer a challenge to meet industry standards, since contaminants are not only reduced to the required specifications, but our system enables oil qualities that even exceed these standards.
Increasing water cuts have a
negative impact on overall
performance and can affect
the operation of the electro-
static system.
Installation of the GEA Crude
Oil Treatment System as a pre-
dehydration stage upstream of
the electrostatic gravity settler.
Reduction of the amount of
water to < 5% to increase
overall performance and
ensure stable operation of
the electrostatic system.
Here, our ready-to-use yet flexible treatment systems provide an effective and reliable option to tackle the following challenges:
The treatment capacity of
the existing system must be
increased or the crude oil quality
degrades, resulting in decreasing
production rates.
Installation of the GEA Crude Oil
Treatment System as a parallel
side stream to the existing setup.
Increased or recovered
performance.
With oil qualities lower than
API 16, conventional equipment
can reach its economical limit.
Full stream installation of the
GEA Crude Oil Treatment System
Converting opportunity crude oil
into a full-value product.
Treatment of opportunity crude
oil in refineries, which requires
more rigorous desalting.
Full stream tank-to-tank
desalting with the GEA Crude
Oil Treatment System.
Treatment of extra heavy and / or
salt-charged oils is thus possible.
1
2
3
4
6 · GEA CRUDE OIL TREATMENT SYSTEMS GEA CRUDE OIL TREATMENT SYSTEMS · 7
1
2
3
1 Crude oil 2 Wellhead choke 3 Wellhead desander 4 Sand 5 Compressor* 6 Knockout drum 7 Gas treatment / dehydration 8 Gas export 9 High pressure separator (FWKO) 10 Low pressure separator11 Electrostratic dehydrator12 Crude oil export13 Desander cyclone14 Deoiler cyclone15 Oil recycler16 Water recycler17 Corrugated plate interceptor18 Induced gas flotation 19 Produced water pump20 Filtration21 Produced water for re-injection22 Produced water for disposal23 Centrifugal separator24 “In-spec”tank25 “Off-spec”tank
5*
6 78
1
2 3
9 10 11 12
13 14
16
15
17 18
19
20
21
22
4
23
23
23
23
24
25
11
11
114
*Available from GEA
5*
Optional GEA disk-stack centrifuges
14
19
8 · GEA CRUDE OIL TREATMENT SYSTEMS GEA CRUDE OIL TREATMENT SYSTEMS · 9
GAS PROCESS
WATER PROCESS
CONVENTIONAL SETUP
GEA SETUP
GEA SETUP
GEA SETUP
4GEA SETUP
CHALLENGE:INCREASE OF THE WATER CUT
GEA SOLUTION:UPSTREAM INSTALLATION
CHALLENGE: DECREASING API
GEA SOLUTION:PARALLEL INSTALLATION
CHALLENGE:(EXTRA) HEAVY / SALT-CHARGED OIL
GEA SOLUTION:STAND-ALONE INSTALLATION (SUBSTITUTION)
CHALLENGE: OFF-SPEC (OPPORTUNITY) CRUDE OIL IN REFINERIES
GEA SOLUTION:TANK-TO-TANK TREATMENT
Increasing water cuts that exceeds the treatment capacity of
the specified static separation equipment may limit the total
oil treatment capacity of an existing plant. At levels above
50 % WC, electrostatic systems may be subject to short
circuit and lack of residence time to achieve the required oil
quality.
Treatment systems with GEA crude oil Dehydrators can be
installed upstream of the electrostatic desalting system to
reduce the water cut from up to 90 % down to 5 %, so that
the capacity of the existing plant is recovered or exceeded.
The exploitation of heavy oil fields is a challenge to the
process due to lower density differences. At certain levels, the
flow through the electrostatic systems must be reduced to
maintain the desired oil quality.
Treatment systems with GEA crude oil Dehydrators and
Desalters installed in parallel with the existing static sepa-
rator avoid investment in a larger or additional electrostatic
system. As a result, parallel installations can also increase
overall system capacity.
Heavy crude oils have higher viscosity, higher density, can
have higher naphtenic acid content, and are more difficult
to dehydrate and desalt. By using earth gravitational settling
force for the separation process and relying on the principle
that an electrostatic field is evenly built up in their system,
electrostatic treatment systems may not reach the desired
performance.
Treatment systems with GEA crude oil Desalters operate at
high g-force (4,000 - 6,000 x g) and are not sensitive to oil
conductivity and higher water cuts. They can handle oils
down to API 12 as a substitute solution in 1- or 2-stage setups.
Opportunity crude oils are becoming a more attractive
option for refiners looking to improve flexibility, maximize
operating margins, increase distillate yields or convert high
sulfur fuel into diesel and gasoline, but they are not without
their difficulties. Whether it be oil sands, higher total acid
number (TAN) or increased level of elemental impurities and
contaminants, such as waxes, solids, all of these character-
istics can lead to processing issues. The efficient removal of
these impurities along with salts, sediments and water from
crude oil feedstock is imperative to maintain reliable opera-
tions, prevent unplanned shutdowns and outages, and reduce
corrosion and fouling.
Treatment systems with GEA centrifugal Desalters are the
ideal solution for tank-to-tank treatment. Fed from off-spec
storage tanks, the GEA systems may reduce the contaminants
to an acceptable level so that the oil can be returned to the
in-spec tank for further processing.
A blending of opportunity crude oil with “good” feedstock,
possibly resulting in challenges such as incompatibilities,
asphaltene destabilization and deposition, is therefore no
longer necessary. Refineries may even consider buying
off-specification crude oil to improve profit margins.
1GEA SETUP
2GEA SETUP
3GEA SETUP
4GEA SETUP
CHALLENGE:INCREASE OF THE WATER CUT
GEA SOLUTION:UPSTREAM INSTALLATION
CHALLENGE:DECREASING API
GEA SOLUTION:PARALLEL INSTALLATION
CHALLENGE:(EXTRA) HEAVY / SALT-CHARGED OIL
GEA SOLUTION:STAND-ALONE INSTALLATION
CHALLENGE:OFF-SPEC CRUDE OIL IN REFINERIES GEA SOLUTION:TANK-TO-TANK INSTALLATION
10 · GEA CRUDE OIL TREATMENT SYSTEMS GEA CRUDE OIL TREATMENT SYSTEMS · 11
Customized solutions for the highest demands
This is why GEA centrifuges worldwide ensure smoothly
functioning and cost-optimized, resource-saving production
processes.
Our centrifuges are designed to always focus on reliability,
safety, cost-effectiveness and environmental friendliness –
objectives that are also fulfilled by our dehydrating and
desalination systems.
EFFICIENT AND RESOURCE-SAVING TECHNOLOGIESWith the supply of plug and play processing systems which comply with even
the most stringent environmental requirements, GEA’s mechanical separation
solutions play a decisive role in making new resources available to the world
market efficiently and in an environmentally friendly manner.
Being successful for more than 125 years in the field of centrifugal separation technology means constantly dealing with increasing and diverse challanges and tasks by the industry and setting new standards through continuous developments and innovations.
Their main features that you can continuously benefit from are:
High g-forces
of 5,000
to 7,500
• Drastically decreased
separation time
• Mechanical emulsion
breaking capability
• Allowing lower separation
temperatures
• Reduced use of chemicals
• In-situ impurities and solids
removal
365 / 24
availability
• Back-up capacity with
multiple separation units
in operation
Continuous
reliability
• Installed base of 1000s
of machines running
• Average operating time
of 20 years
Feed conditions
and operation
flexibility
• Flexible turndown capacity
(20 to 100 %)
• Automatic response on
changing feed conditions
• No dependency on low or
stable oil conductivity
GEA CRUDE OIL TREATMENT SYSTEMS · 1312 · GEA CRUDE OIL TREATMENT SYSTEMS
Treatment systems with GEA crude oil Dehydrators
If the main task is to reduce the water content of the crude oil and if the solids content varies, GEA centrifuge units equipped with a nozzle-type disk-stack centrifuge are the right choice.
In a nozzle centrifuge, the solids and water are continuously
removed through open nozzles placed on the outer diameter
of the bowl. At the same time, oil and water are continuously
separated by the high g-forces and removed from the top of
the bowl under pressure. By using a large number of densely
packed disks, the clarification space is significantly increased
compared to static separators, thus further improving the
oil-water separation.
Depending on the required capacity, GEA supplies
two options for this application:
• GEA crude oil Dehydrator 130
• GEA crude oil Dehydrator 260
Operational features
• Single unit capacity up to 37,500 BPD (250 m3/h);
can easily be extended by combining several units
• Oil gravity > 12° API
• Direct drive or flat belt drive
• Reliable erosion protection
• High-grade material against corrosion
GEA NOZZLE CENTRIFUGESNozzle centrifuges are continuously operating machines that
clarify liquids while concentrating solids. The concentrated solids
are discharged continuously through nozzles. The clarified liquid
is discharged by a built-in centripetal pump.
10
100
1000
10 15 20 25 30
FLO
W R
ATE
, m³/
h
API GRADE OF CRUDE OIL
CRUDE OIL FLOW RATES OF GEA CENTRIFUGES
GEA crude oil Dehydrator 130
GEA crude oil Dehydrator 260
1 Emergency water / make-up water
2 Product feed
3 Inert gas discharge
4 Oil discharge
5 Oily water discharge
6 Solids discharge
7 Inert gas supply
14 · GEA CRUDE OIL TREATMENT SYSTEMS GEA CRUDE OIL TREATMENT SYSTEMS · 15
Treatment systems with GEA crude oil Desalters
If the main purpose is to reduce the salt content of the crude oil and if the solids content is limited, centrifuge units with a self-ejecting disk-stack bowl are the right choice to separate oil, water and solids.
In the rotating bowl, the salt-charged water and
fine particles are separated from the crude oil.
The desalting efficiency can be improved by
adding fresh water upstream of the centrifuge
to extract water-soluble salts from the crude oil.
Water and crude oil are discharged continu-
ously under pressure, with the solids collected
in the holding space and being automatically
ejected at regular intervals.
Depending on the required capacity, GEA
supplies three options for this application:
• GEA crude oil Desalter 80
• GEA crude oil Desalter 120
• GEA crude oil Desalter 200
Operational features
• Single unit capacity up to 12,500 BPD
(85 m3/h); can easily be extended by
combining several units
• Oil gravity > 12° API
• Direct drive (for GEA crude oil Desalter 200)
or flat belt drive (for GEA Crude oil Desalter
80 and 120)
• Reliable erosion protection
• High-grade material against corrosion
• Brings BS&W and water-soluble salt to pipe-
line / refinery quality
GEA SELF-EJECTION CENTRIFUGESIn self-ejecting centrifuges two liquids of
different densities are separated from each
other. Solids may also be separated at the
same time.
10
100
10 15 20 25 30
FLO
W R
ATE
, m³/
h
API GRADE OF CRUDE OIL
GEA crude oil Desalter 80
GEA crude oil Desalter 120
GEA crude oil Desalter 200
CRUDE OIL FLOW RATES OF GEA CENTRIFUGES
1 Product feed
2 Oil discharge
4 Solids discharge
3 Oily water discharge
16 · GEA CRUDE OIL TREATMENT SYSTEMS GEA CRUDE OIL TREATMENT SYSTEMS · 17
Modular systems
More than merely a sum of its parts
Only someone who can see the system as a whole can design it
from the start to achieve the highest efficiency. GEA develops
package units and process lines whose intelligent technology
and integrated concepts immediately create added value. This
secures investments – and thus an economic future solution.
Depending on the task and production environment, the GEA
Crude Oil Treatment System can be combined:
• First stage: nozzle-type disk-stack centrifuges for dehydration
• Second stage: self-ejecting disk-stack centrifuges for
dehydration and desalting
In addition, the system can be extended with:
• Feed pump unit
• Multi-stage mixer unit
• Heat exchanger unit
• Heat recovery unit
• Chemical dosing unit
Enclosures / containerized sulutions
For applications where mobility of the treatment system is
important, GEA offers corresponding solutions in standard
containers and enclosures.
The speed of implementation of new process and system
developments in line with market requirements is a significant
feature of GEA solutions. This is made possible by comprehen-
sive experience and process knowledge.
Complete solutions from one supplier eliminate time delays and
expensive coordination processes right from the start. Instead,
they ensure constant high performance in terms of flow rate and
separation performance – with minimal effort. This excellent
process economy secures your investment decisions in the long
term.
Highly productive process lines
from a single source
• Competence and clear responsibility
• Reliable communication and planning
• Optimum plant and process configuration without barriers
• High level of functionality and investment reliability
• Process safety
Feed pump unitMulti-stage mixer unit
Centrifuge unit
Comprehensive know-how from a single supplier
18 · GEA CRUDE OIL TREATMENT SYSTEMS GEA CRUDE OIL TREATMENT SYSTEMS · 19
In-house process engineering solutions
Centrifuge systems are specifically selected and designed for the user’s process. This is supported by our GEA Process Test Center (PTC).
Product investigations
The product investigations specify the crude oil properties to
be separated. For this purpose, the GEA PTC offers a range
of analysis methods, ranging from the test tube centrifuge to
rheology, corrosion pattern analysis, particle size measurement,
stability characterization and more. Product research provides
a good picture of the fluids to be treated. This also enables GEA
to make a realistic initial estimate of the required investment
costs and of the most efficient solution.
Basic parameters for the analysis of feedstock products are:
• Spin test with a heated laboratory centrifuge
• Determination of viscosity and specific gravity of all phases
• Salt (chloride) measurement
• pH value of the water phase
• Efficiency of chemical emulsion breakers and de-emulsifiers
• Flash point and ash content measurement
Trials in the GEA PTC
A technical trial provides all the important data for the final
process engineering design of the production plant in which the
centrifuges and peripheral equipment are operated. From this,
the specification of the machine type and size together with the
investment costs are determined under close involvement of the
customer. In the GEA PTC facility, tests can be carried out on an
industrial scale with real products from the site. In this way,
neither assumptions nor the use of model fluids are required.
Trials on the customer site
Alternatively, Field Test Units (FTUs) can be provided to the
customer on site. In this case, the trials are monitored and sup-
ported by experienced GEA PTC technicians. GEA has a wide
range of FTUs that can be used at the customer site to prove the
efficiency of the proposed solution in the field.
Process developments
Upon specific customer request or based on proprietary market
analysis, the GEA PTC is continuously improving its equipment
and developing new processes. The innovative solutions that we
have developed are constantly being tested and reviewed, from
laboratory tests through internal pilot tests to machine or prototype
tests on customer site.
Sampling of product
Product investigation /
site test
Process definition / machine sizing
Customer demand / inquiry
Investment estimation
PRODUCT INVESTIGATIONSThe PTC laboratory conducts an extensive and
conclusive analysis of the product sample.
20 · GEA CRUDE OIL TREATMENT SYSTEMS GEA CRUDE OIL TREATMENT SYSTEMS · 21
GEA – your service partner
Excellent equipment is one thing, the right service is another. With our global network of certified service engineers, Service Hubs in strategic locations and a network of Authorized Repair Workshops, our customers are optimally being supported. Our focus is to build, maintain, and improve customer performance throughout the entire life cycle of the plant and its equipment.
Trouble-free operation in demanding environments, with GEA Service
FULFILLING YOUR PERFORMANCE TARGETSYOUR PARTNER
FROM THE START PREVENTIVE SUPPORT PREDICTIVE SUPPORTSERVICE LEVEL AGREEMENTS DIGITAL SOUTIONS
Engineering
expertise for
installation,
commissioning
and training to
achieve high
performance
right from the
start.
Ensure that the
equipment is
always in a good
condition and
ready for
production.
Established
solutions and
tools that ensure
a reliable
production
environment
and continuous
uptime.
Optimize
production pro-
cesses in a long
term partnership
to enhance
uptime and
to minimize
losses.
Be always one
step ahead in
line with the
latest market
inventions and
regulations
to stay
competitive.
Transparency Availability Productivity Efficiency Sustainability
Worldwide repair network
and remote support
Mapping operating data
for future process
optimization
Uptime GrowthProfit
Getting you started with seamless support for
instant productivity and performance
• Partnering with you from the start, we will help you
to design your plant for maximum efficiency, install
and deliver it to you, safely, professionally and on
time.
• Our certified and experienced service engineers
train your employees – on site or in one of our
modern training centers.
Keeping it running with the cost-efficient way
of ensuring safety and reliability
• We provide fast support, professional maintenance
and top-quality spare parts, whenever and wherever
needed.
• Our maintenance and repair services stand for
precision work and utmost manufacturer’s
responsibility.
• With GEA’s preventive maintenance programs, our
global specialists are always on hand with up-to-date
equipment and process knowhow to ensure the
continued operation of your plant.
Constantly improving by sharing our knowledge
to safeguard your investment
• When market conditions or new regulatory
standards require you to upgrade or modernize we
are here to support you in the change to reduce
energy, cut costs, adapt output or enhance safety.
• Our predictive maintenance program ensures
availability with service level options that extend
way beyond routine preventive maintenance.
Together with you by enduring commitment
to you and your business
• Service Level Agreements offer support services to
maintain, monitor, analyze and optimize your
installation in a structured, yet flexible way, focus-
ing on availability and cost control across the entire
plant life cycle.
Further optimization potential through digital
service solutions
• We offer a variety of solutions – from virtual
support and monitoring tools to cloud-based
solutions including e-commerce and maintenance
planning – which create an enhanced level of
customer connectivity even in the most remote
locations.
Cloud-based service portal
Product investi-gations, process
develoments and trials
In-situ disk cleaning for centrifuges
GEA SERVICE – FOR YOUR CONTINUED SUCCESS
Save maintenance time, increase your uptime
Enhance your connectivity any time and everywhere
Monitor, analyze and
optimize your equipment
We are at your side, even
when not at your site
Specific optimization potential for your setup
22 · GEA CRUDE OIL TREATMENT SYSTEMS GEA CRUDE OIL TREATMENT SYSTEMS · 23
“Engineering for a better world” is the driving and energizing principle connecting GEA’s workforce. As one of the largest
systems suppliers, GEA makes an important contribution to a sustainable future with its solutions and services, particularly
in the food, beverage and pharmaceutical sectors. Across the globe, GEA’s plants, processes and components contribute
significantly to the reduction of CO2 emissions, plastic use as well as food waste in production.
GEA is listed on the German MDAX and the STOXX® Europe 600 Index and also included in the DAX 50 ESG and MSCI
Global Sustainability indexes.
We live our values.Excellence • Passion • Integrity • Responsibility • GEA-versity
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GEA Germany
GEA Westfalia Separator Group GmbH
Werner-Habig-Str. 1
59302 Oelde, Germany
Tel +49 2522 77-0
Fax +49 2522 77-1778
gea.com/contact
gea.com/crudeoil