Corrosion in Crude Distillation Unit Overhead Operations: A Comprehensive Review (original) (raw)
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Corrosion in Crude Oil Distillation Unit Overhead: A recent Case Study
ARO-THE SCIENTIFIC JOURNAL OF KOYA UNIVERSITY, 2021
Despite all the technological advances and the control mechanisms that exist today to achieve the control of corrosion in overhead systems in atmospheric crude oil distillation units, there is still a high level of difficulty in predicting the phenomenon due to the complexity of the chemical compounds involved in the entire process. The study of this practical case aims to determine what control mechanisms should be optimized in a refinery located in the Autonomous Region of Iraqi Kurdistan to prevent corrosion phenomena's in this specific system and how it should be done to achieve these improvements. It has been suggested that the corrosion mechanisms by hydrochloric acid and by ammonium chloride have been those that have acted in the operational context of the mentioned facility. To test this hypothesis, a study of the unit's operational conditions and analytical tests were carried out on the construction material of various components and the products (sediments) found inside the tower. The results show that a lack of control in the salts and sediments content of the feed crude have caused an increase in the hydrolysis process of certain components upstream of the tower and thus the generation of acids and salts was promoted. On this basis, it is necessary to optimize the primary treatment of crude oil and update the chemical treatments and washing water systems to adapt to the new conditions of the feed of the refinery.
Corrosion Monitoring and Control in Refinery Process Units
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This paper describes the experience gained in “corrosion monitoring” in the overhead systems of three crude dktillation units of a refinery in Haifa, Israel. The data of electrical resistance (ER) probes, connected to an on-line data acquisition system were compared with the mass loss method and chemical analysis of accumulated sour water tier condensation in the overhead system, SEM & EDS anrdysis of films and deposits formed on the coupons showed that iron sulfide with impurities of chlorides are responsible for the comosion extent. The corrosion was less than 5 MPY when a uniform tenacious iron sulfide tilms of 10-50 microns thickness were formed. The severe corrosion occurred when deposits and non-uniform films of more than 80100 microns thickness were formed. Special attention was given to ER probes which were connected on-line to the process units and enabled the operators to react immediately to any change in corrosion rates.
Open journal of Yangtze oil and gas, 2022
Atmospheric distillation is the first step in separating crude oil into by-products. It uses the different boiling temperatures of the components of crude oil to separate them. But crude oil contains a large quantity of acids and corrosive gases, including sulfur compounds, naphthenic acids, carbon dioxide, oxygen, etc. However, the temperature has an important influence on the aggressiveness of the corrosion factors in the atmospheric distillation column. This paper aims to investigate the role of temperature on corrosive products in the atmospheric distillation column. The results of the developed model show that the temperature increases the corrosion rate in the atmospheric distillation column but above a certain temperature value (about 600 K), it decreases. This illustrates the dual role played by temperature in the study of corrosion within the atmospheric distillation column.
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This paper summarizes the development of an information system used to manage corrosion of metals and alloys by high temperature gases found in many different oil refining, petrochemical, power generation, and chemical processes. The database currently represents about 7.9 million h of exposure time for about 5,500 tests with 89 commercial alloys for a temperature range of 200-1,200 °C. The system manages corrosion data from well-defined exposures and determines corrosion product stabilities. New models used in the analysis of thermochemical data for the Fe-Ni-Cr-Co-CO -S-N-H system are being compiled. All known phases based upon combinations of the elements have been analyzed to allow complete assessments of corrosion product stabilities. Use of these data allows prediction of stable corrosion products and hence identification of the possible dominant corrosion mechanisms. The system has the potential to be used in corrosion research, alloy development, failure analysis, lifetime prediction, and process operations evaluations. The corrosion mechanisms emphasized are oxidation, sulfidation, sulfidation/oxidation, and carburization.
Corrosion Problems in Petroleum Industry and their solution
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Corrosion costs the oil industry billions of dollars a year, a fact that makes the role of the corrosion engineer an increasingly important one. Corrosion affects every aspect of exploration and production, from offshore rigs to casing, and reviews the role of corrosion agents such as drilling and production fluids. Methods of control and techniques to monitor corrosion, along with an explanation of the chemical causes of corrosion are discussed.
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Chemical and petrochemical industries comprise of many equipments like storage tank, reactors, columns and jackets. These are often exposed to corrosive liquids and gases. Strong acids and gases such as carbon dioxide, sulphur oxides, organic vapours corrode the material and causes damage. It is desired to know the extent and mechanism of corrosion for proper and cost effective corrosion prevention method. Various investigators have carried out studies and research for corrosion, its measurement and prevention. Current review summarizes research on corrosion in petroleum, chemical and allied industries.
Metallurgical Factors Affecting Corrosion in Petroleum and Chemical Industries
Metallurgical Factors Affecting Corrosion in Petroleum and Chemical Industries Abstract: Humans have most likely been trying to understand and control corrosion for as long as they have been using metal objects. With a few exceptions, metals are unstable in ordinary aqueous environments. Certain environments offer opportunities for these metals to combine chemically with elements to form compounds and return to their lower energy levels. Corrosion is the primary means by which metals deteriorate. Most metals corrode on contact with water (and moisture in the air), acids, bases, salts, oils, aggressive metal polishes, and other solid and liquid chemicals. Metals will also corrode when exposed to gaseous materials like acid vapors, formaldehyde gas, ammonia gas, and sulfur containing gases. The production of oil and gas, its transportation and refining, and its subsequent use as fuel and raw materials for chemicals constitute a complex and demanding process. Various problems are encountered in this process, and corrosion is the major one. Since metals are the principal material suffering corrosive deterioration, it is important to develop a background in the principles of metallurgy to fully understand corrosion. The control of corrosion through the use of coatings, metallurgy, nonmetallic materials for constructions cathodic protection and other methods has evolved into a science in its own right and has created industries devoted solely to corrosion control. Metallurgical factors that affect corrosion are chemical composition, material structure, grain boundaries, alloying elements, mechanical properties, heat treatment, surface coating, welding and manufacturing conditions. Understanding these factors are of great importance to decrease and control corrosion problem in many industrial applications.
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