A mathematical model was developed to describe the hydrodynamics of a batch reactor for aluminum degassing utilizing the rotor-injector technique. The mathematical model uses the Eulerian algorithm to represent the two-phase system including the simulation of vortex formation at the free surface, and the use of the RNG k-ε model to account for the turbulence in the system. The model was employed to test the performances of three different impeller designs, two of which are available commercially, while the third one is a new design proposed in previous work. The model simulates the hydrodynamics and consequently helps to explain and connect the performances in terms of degassing kinetics and gas consumption found in physical modeling previously reported. Therefore, the model simulates a water physical model. The model reveals that the new impeller design distributes the bubbles more uniformly throughout the ladle, and exhibits a better-agitated bath, since the transfer of momentum to the fluids is better. Gas is evenly distributed with this design because both phases, gas and liquid, are dragged to the bottom of the ladle as a result of the higher pumping effect in comparison to the commercial designs.

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A systematic process analysis was conducted to study the effect of the main variables in an industrial electrostatic desalter, such as electric field intensity, wash water content, droplet size, and oil viscosity, on the efficiency of the separation of water from oil. The analysis was assessed through an already published and validated CFD multiphase numerical model that considers the expression of the frequency of collisions as a function of the mentioned process variables. Additionally, the study allowed the formal optimization exercise of the operation to maximize the separation efficiency. The most significant variables were the initial water content and the electric field intensity, while the temperature (oil viscosity) had an effect to a lower extent. An increase in the electric field and temperature and a decrease in the water content improved the water separation from oil. Optimum values suggested from the factorial experimental design and the optimization implemented in this work indicated the use of an electric field of 3 kV/cm, water content of 3%, and an oil viscosity of 0.017 kg/ms. At the same time, the droplet size showed no significant effect under the conditions explored in this work.

The desalting process of an electrostatic desalting unit was studied using the collision time of two droplets in a water-in-oil (W/O) emulsion based on force balance. Initially, the model was solved numerically to perform a process analysis and to indicate the effect of the main process parameters, such as electric field strength, water content, temperature (through oil viscosity) and droplet size on the collision time or frequency of collision between a pair of droplets. In decreasing order of importance on the reduction of collision time and consequently on the efficiency of desalting separation, the following variables can be classified such as moisture content, electrostatic field strength, oil viscosity and droplet size. After this analysis, a computational fluid dynamics (CFD) model of a biphasic water–oil flow was developed in steady state using a Eulerian multiphase framework, in which collision frequency and probability of coalescence of droplets were assumed. This study provides some insights into the heterogeneity of a desalination plant which highlights aspects of design performance. This study further emphasizes the importance of two variables as moisture content and intensity of electrostatic field for dehydrated desalination by comparing the simulation with the electrostatic field against the same simulation without its presence. The overall objective of this study is therefore to show the necessity of including complex phenomena such as the frequency of collisions and coalescence in a CFD model for better understanding and optimization of the desalting process from both process safety and improvement.