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Steam Injection In Crude Oil Line
#1
Posted 20 September 2014 - 10:00 AM
#2
Posted 20 September 2014 - 11:51 AM
A quick and dirty calculation on the back of an envelope:
1) 800 m3/h mixture of 50 %oil/50%water to be heated from 20 to 42 oC requires a heating duty of 15000 kW.
2) Oil operating pressure is 60 psig, so steam pressure is to be, say, 100 psig (7 barg). Steam superheat of, say, 10 oC so steam operating temperature is ~ 180 oC.
3) Steam mechanical design temperature will therefor be 200 oC or more. Is the existing oil/water pipe able to handle that design temperature, both strengthwise and stresswise?
4) Injected steam of 180 oC will be converted into condensate of 42 oC, so enthalpy difference is 2600 kJ/kg.
Steam quantity required is 15000/2600 = 5.8 kg/s = ~ 21 t/h.
5) Steam injection volumetric flowrate at 60 psig is about 21000 kg/h flow divided by 2.4 kg/m3 density = 8750 m3/h.
That is 11 times the volume flow of oil/water.
6) Condensing steam will implode and can cause a similar effect as cavitation in a pump impeller: damage to the metal pipe wall.
7) 42 inch pipe for only 800 m3/h liquid flow is very oversized, so it may be able to handle the large volume of steam/oil/water. Residence time will depend very much on how quickly steam condenses into oil/water.
My first impression is that putting 11 times the volume of steam in a liquid via existing nozzles, and try to condense that within 100 meters, is going to be a problem. It all seems very ambitious.
In any case a proper steam/liquid mixing device from a qualified vendor should be used to introduce the steam into the liquid, not just some small PG or TG nozzles that happen to be present.
Edited by PingPong, 20 September 2014 - 12:14 PM.
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