Numerical Simulation of the Mixing and Salt Washing Effects of a Static Mixer in an Electric Desalination Process

Abstract

Electric desalination units in the crude oil refining process are becoming increasingly important with the growing trend towards heavy and poor crude oils. The oil–water mixing effect of the static mixer plays a crucial role in the electric desalination process. The present study investigated the effect of various variables, such as mixer type, number of mixing elements, washing water consumption, and oil viscosity and density on the oil–water mixing efficiency of a static mixer. In addition, this study also analyzed the effect of these variables on the salt washing process that occurs during mixing using a kinetic equation for the dissolution of inorganic salts. The results showed that the number of mixing elements was the most significant variable, followed by the amount of washing water injected. The density of the crude oil had a negligible effect. Based on these results, the use of four mixing elements in the SMX static mixer was recommended. The injection of washing water should be controlled at about 8%, while ensuring that the interfacial tension between oil and water remains below 0.01 N/m. Under these conditions, the salt washing efficiency reached 46.3%. This study provides a theoretical basis for designing static mixers and optimizing their operation in electric desalination processes.