Electrocoalescence of water droplets in sunflower oil using a novel electrode geometry

Electrocoalescence is an energy-efficient and environmentally-friendly process for breaking water-in-oil emulsions. It has been used extensively in the oil and petroleum industries. However, the current technology requires long residence times, giving rise to bulky vessels for industrial scale operations and making it less attractive for offshore application. It is also highly desirable to develop compact devices for down-the-well use. In this study, the performance of a novel electrode geometry, a ladder-shaped set of electrodes through which the emulsion flows, is assessed for enhancing the electrocoalescence, hence providing the potential for a compact design. The electrodes are formed into a V shape, with the apex pointing towards the direction of flow. This configuration enables nesting a series of electrodes in a compact form. Furthermore, the water-in-oil emulsion flows through the electrodes rather than passing by them, thus maximizing the effect of the electric field for coalescence. The system under study uses dispersed water droplets in sunflower oil, flowing in a narrow rectangular duct through the electrodes, providing essentially a two-dimensional flowing stream. The performance of this design is investigated for different electrical parameters (i.e. electric field intensity, frequency and waveform), fluid physical properties (i.e. conductivity and water content) and residence time. Of the three types of electric field waveform (i.e. half-sinusoidal, square and sawtooth), sawtooth performs best at high conductivities. Experiments reveal the existence of optimal values of electric field intensity, electric field frequency, salt concentration and water concentration, where the coalescence efficiency is maximum for the current design. Numerical simulation of the electrocoalescence process is conducted to assess the influence of various geometric and process parameters on the coalescence mechanisms of the V-shape electrodes. The outcome of this work is potentially useful for optimizing the design of compact and efficient oil–water separators.