REVERSE BREAKER DEVELOPED BY DORF KETAL ELIMINATES EMULSION ISSUE IN COKER UNIT

INTRODUCTION

One of the world’s largest refineries, located on the west coast of India, was facing a critical operational problem in its coker unit, specifically in the steam blowdown drum. During steam quenching operations, persistent stable emulsions were forming, directly compromising the performance of the downstream sour water stripper.

Initially, the treatment was carried out by a competing company that supplied a chloride-based demulsifier. Although the formulation showed apparent efficiency, it caused severe corrosion in the sour water stripper, generating operational risks and affecting equipment integrity.

THE CHALLENGE

Given the critical nature of the problem and the side effects associated with the current treatment, Dorf Ketal proposed a field test using a new solution: a chloride-free demulsifier specifically formulated to break reverse emulsions — a reverse breaker from the Maxfloc SR Series.

After technical analysis and formal proposal presentation, the refinery management approved the field test. Sampling points were defined to collect water from the blowdown drum before and after treatment application to quantify the new formulation’s efficiency in controlling the emulsion.

TREATMENT DEVELOPMENT

Dorf Ketal developed the reverse breaker in-house using proprietary technology designed for harsh environments and high compatibility with acid-base separation units.

During the test period, systematic samples were collected from the blowdown drum and analyzed for oil content in the aqueous phase. The methodology followed the standards required by the refinery, ensuring the reliability of the data obtained.

Table 1. Oil content before applying the Reverse breaker

 
Table 2. Oil content after applying Reverse Breaker

RESULTS & VALUE GENERATION

Applying the reverse breaker from the Maxfloc SR Series led to a significant reduction in oil content in the water from the blowdown drum, with values decreasing from 2–4% to an average below 100 ppm. In specific samples, levels reached as low as 32 ppm, demonstrating the product’s high efficiency.

In addition to the qualitative improvement of the effluent, the refinery observed a reduction in the volume of slops transferred from the sour water stripper, indicating a significant improvement in the overall system performance.

Dorf Ketal provided the refinery with a detailed technical report containing all performance data, allowing the technical team to visualize the new treatment’s operational gains. The reverse breaker product proved a safe, efficient, and economically viable alternative, eliminating corrosion issues and optimizing the liquid-liquid separation process.