Intensification of ultrasonic-assisted crude oil demulsification based on acoustic field distribution data

Water removal is an essential step during crude oil production due to several problems such as increased transportation costs and high corrosion rate due to dissolved salts. Indirect low frequency ultrasonic energy (US), using baths, has been recently proposed as an effective alternative for crude oil demulsification. However, the reactor position during sonication and its influence on the demulsification efficiency for crude oil has not been evaluated. In this sense, the aim of this study was to develop an automated system based on an open source hardware for mapping the acoustic field distribution in an US bath operating at 35 kHz using a hydrophone. Data acquired with this system provided information to evaluate the demulsification efficiency in the different positions of the US bath and correlate it with the acoustic intensity distribution. The automated 3D-mapping system revealed a higher acoustic intensity in the regions immediately above the transducers (ca. 0.6 W cm−2), while the other regions presented a relatively lower intensity (ca. 0.1 W cm−2). Experimental data demonstrated that reactors positioned in the most intense acoustic regions provided a much higher efficiency of demulsification in comparison with the ones positioned in the less intense acoustic field regions. Demulsification efficiency up to 93% was obtained with 15 min of sonication (100% amplitude) using few amount of chemical demulsifier. Hence, this work demonstrated that the information acquired with the developed mapping system could be used for inducing a higher efficiency of demulsification only by finding the more suitable position of reactor in the US bath, which certainly will help development of appropriate reactors design when looking for such approach.