W L Nelson's "Petroleum Refinery Engineering" (4th ed, McGraw-Hill, 1958), "Desalting of crude oil" (p. 265-268) briefly decribes settling and use of chemicals for coalescing. The latter seemed to be an alternative to electric desalters (20-30 kV electric field) in 1958, both having a crude salt removal efficiency of about 90%. Nowadays only electric desalters have been seen in local refineries.
Average salt content in USA crudes (ibid, table 4-6) varies from 1 to 261 ptb (pounds salt per 1000 bbl). Salt content of 29 ptb is understood upstream desalting, being in the median of figures presented in table 4-6 (not high).
According to Nelson, desalting usually reduces crude salt content to about one-tenth (efficiency 90%). Existing desalter can work well, but at low efficiency due to old age. You could check this by repeated mass balance based on measured quantities, <http://www.cheresour...r-mass-balance/>.
Ultrasound application was finally considered non feasible on industrial alumina crystallization <http://www.cheresour...mina#entry52003>. Large scale application had obstacles. But no knowledge / experience on breaking crude-water emulsions through ultrasounds.
Not having oil field experience, above is hopefully useful.
Edited by kkala, 10 March 2013 - 10:11 AM.