Assessing corrosion in oil refining and petrochemical processing (original) (raw)
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Critical factors in predicting CO{sub 2}/H{sub 2}S corrosion in multiphase systems
1998
One of the most fundamental issues in current day corrosion research is assessment of corrosion rates in steels and determination of corrosivity of typical operating environments in oil and gas production. Such an assessment requires an understanding of the role of primary environmental and metallurgical variables and underlying mechanisms of corrosion. A corrosion prediction computer model that assesses corrosivity of oil and gas systems in terms of pH, CO{sub 2}, H{sub 2}S temperature and flow has been developed. This paper describes further research undertaken by the authors in refining the corrosion prediction model and in assessing the role of H{sub 2}S scale formation and growth, role of hydrocarbons in promoting/inhibiting corrosion and the role of steel metallurgy in corrosion assessment.
Chemical Engineering Transactions, 2018
The current energy production processes go hand in hand with corrosive phenomena; which is the case of the combustion process in a refinery, where the presence of compounds such as CO2 and H2O, result in alloy catastrophic carburization and oxidation respectively. This research work was evaluated the corrosive effect that can be generated in a real combustion environment, for which, it was necessary to select a model mixture of refinery gases and simulate its theoretical combustions products. The main results showed the formation of a semi-protective duplex oxide layer; whose inner layer was composed mainly of chromium, while the outer layer was much richer in iron. On the other hand, the carburizing effect of CO2 was suppressed by the high oxygen potential in the combustion environment; leading to the conclusion that in real conditions, at 750 ºC and after 200 h of testing, steels such as ferritic alloy ASTM A335 P91, could not present appreciable damages during their operation in refinery boilers and furnaces.
15th Annual North American Waste-to-Energy Conference, 2007
High temperature corrosion is a major operating problem because it results in unscheduled shutdowns in Waste-to-Energy (WTE) plants and accounts for a significant fraction of the total operating cost of WTE plants. Due to the heterogeneous nature of municipal solid waste (MSW) fuel and the presence of aggressive elements such as sulfur and chlorine, WTE plants have higher corrosion rates than coal-fired power plants which operate at higher temperature. To reduce corrosion rates while maximizing the heat recovery efficiency has long been a critical task for WTE operators. Past researchers focused on high temperature corrosion mechanisms and have identified important factors which affect the corrosion rate [1–4]. Also, there have been many laboratory tests seeking to classify the effects of these corrosion factors. However, many tests were performed under isothermal conditions where temperatures of flue gas and metal surface were the same and did not incorporate the synergistic effect...
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.
Journal of Physics: Conf. Series, 2017
Corrosion studies are key elements that ensure the correct functioning of equipment in the industrial sector. The oxidation phenomena were evaluated, taking as a case study steel ASTM A335 P91 (P91), steel of typical use in equipment that works at high temperatures. Five (5) exposure times were selected for the experimental development: 1, 20, 50, 100, and 200h; as well as four (4) analysis temperatures: 450, 550, 650, and 750°C. Through the metallographic analysis was possible to evidence the presence of multiple carbide precipitates and a terrific structure, after all the temperatures tested. On the other hand, the analysis of hardness and microhardness showed an increase for all the evaluated temperatures. These increases were mainly related to the precipitation of carbides in the coupons of P91. Regarding the chemical analysis, it was possible to conclude that after 200h of experimentation at each temperature, a layer of duplex oxide, composed mainly of hematite, magnetite, and spinel iron-chromium, was formed in the O2/H2O atmosphere. Finally, the kinetic study demonstrated that the oxide layer formed on each coupon of P91 was of protective character.
Chemical Engineering Transactions, 2017
Prevention of corrosion damage is a key point to assure process safety in the refinery and petrochemical industry. Controlling and stopping corrosion is only possible through the detailed evaluation of all processes related to the corrosion damage. In this work was proposed a methodology to evaluate the corrosion damage during the combustion process in the refinery and petrochemical industry. As a study case, the evaluation of AISI 304 and ASTM A335 P5 steels was realized in an atmosphere generated during the combustion process. The corrosion products formed on each material were simulated at 750 °C in the software HSC Chemistry. As a model mixture for the simulation, it was used the historical chromatographic records from the gas mixture used in a typical furnace from Barrancabermeja (Colombia) refinery. These results were compared with experimental results, in which corrosion coupons of AISI 304 and ASTM A335 P5 steels were installed inside a furnace from Barrancabermeja refinery at 750 °C. The corrosion rate was calculated by gravimetric analysis, and the morphology and composition of the corrosion products were obtained by Scanning Electron Microscopy with X-Ray Microanalysis (SEM-EDS) and X-Ray Diffraction (XRD) analysis respectively; showing similarity between the corrosion products thrown in the simulation. The gravimetric analysis showed that the corrosion rate of ASTM P5 steel was higher than in AISI 304 steel; it was explained because the no formation of an internal protective chromium oxide layer in ASTM P5 steel. On the other hand, the SEM-EDS analysis showed that the corrosion products formed on AISI 304 steel corresponded mainly to iron oxides and spinels. Unlike the corrosion products obtained for ASTM P5 steel, for which only iron-rich layers were formed. Additionally, the EDS analysis revealed carburization and sulfidation in both sheets of steel, although these effects were more representative of AISI 304 steel. Finally, the kinetic study suggested the formation of non-protective oxide layers, which was confirmed through SEM analysis; where were revealed cracks and gaps in the morphology of the oxide layers formed in both sheets of steel. Finally, it is important to mention that the methodology applied in this work is applicable to other steels in typical corrosive environments from the refinery's equipment.
An Insight into Studies and Research on Corrosion in Petroleum Industries and Refineries
International Journal of Petroleum and Petrochemical Engineering, 2016
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.
CORROSION 2002, 2002
Metallic dissolution caused by molten vanadates has been classically considered the main corrosion procesS involved in the degradation of alloys exposed to the combustion products of heavy fuel oils. However, residual oils used today have higher sulfur contents, and field and laboratory studies have shown that alloys exposed at elevated temperatures to their combustion products experience a more complex corrosion process. High temperature oil ash corrosion involves, besides the occurrence of vanadium corrosion, accelerated oxidation, sulfidation and carburization, depending on temperature, local atmosphere and ash composition.
High Temperature Corrosion in Gas Turbines: Thermodynamic Modelling and Experimental Results
The introduction of new materials as well as the improvements in fuel quality have raised a need for re-evaluation of the hot corrosion risk in industrial gas turbines. In this study, the risk of hot corrosion was determined using thermodynamic modelling for different impuritycontents and combustion parameters. Based on these results, the parameters for the corrosion tests have been selected to investigate the response of the different materials under corrosive conditions.
Journal of Petroleum Science and Engineering, 2019
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