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A refiner operating a 40,000 barrel per day crude Nickel 32.6 35.0
unit had a history of short bundle life while proc- Sulfur 21.7 27.3
essing an Arab crude oil blend. The design was
such that the problem area was the first con- Iron 4.9 10.3
denser prior to the hot drum on a double drum Chlorine 3.4 1.3
overhead system. This condenser is constructed
of copper nickel (70/30) and is a vapor belt design. Aluminum 3.4 0.6
The vapor inlet temperature to the condenser was Barium 2.5 -
290°F (143.3°C) and the outlet was 200°F (93.3°C).
A water wash was used to eliminate the ammo- Silicon 0.6 0.9
nium chloride salts that form prior to the water Calcium - <0.5
dewpoint as a result of ammonia neutralization of
HCl and other acids. A filming amine was also Table 2: Semi-Quantitative SEM-EDXA Analysis Of Shell-
being fed for corrosion control. Side Deposits On The Non-Failed Tube.
Results were poor. The tube bundle had a history Blue Gold Black
of being replaced after only eight months of Element
(weight %) (weight %) (weight %)
operation. During the twenty-one months
between August 1994 and May 1996, the tube Copper 55.9 14.8 14.2
bundle was replaced three times and bypassed Nickel 11.7 54.6 43.4
twice to repair leaking tubes. Severe pitting and
general corrosion were seen throughout the con- Sulfur 30.2 28.5 38.4
denser. Also, weld repairs had been required on Iron 1.9 1.4 3.7
the overhead vapor line where severe thinning
was experienced. Chlorides from this Arabian Silicon <0.5 <0.5 -
crude slate, after a single stage desalter, were in Aluminum <0.5 <0.5 -
the range of 200 to 300 ppm (mg/L) in the over-
head water obtained from the hot drum. It was Potassium - - <0.5
clear that the high chlorides in the overhead was 1. Caustic injection to the desalted crude for
leading to salt-related corrosion and subsequent chloride control. Chlorides were brought under
tube failures.
control, and are now maintained in the 10 to
The high cost of corrosion was determined with 20 ppm (mg/L) range.
input from several groups within the refinery. 2. A low base strength neutralizer replaced the
Costs associated with the problem came from ammonia feed to the atmospheric tower over-
crude throughput reductions, frequent tube bun- head.
dle replacements, increased maintenance and
inspection costs. 3. The neutralizer injection point on the atmos-
pheric tower was moved from the reflux line to
GE Water & Process Technologies started a corro- the overhead vapor line.
sion control treatment program in April 1996. Over
4. Elimination of the overhead water wash. Due
the next year, several aspects of the program
were upgraded to improve performance. Key to high velocity and insufficient water, high
elements of the program included: corrosion rates were observed with the water
wash. At times, 50% naphtha was being recir-
culated.
Page 4 TP1101en 0603
5. Corrosion monitoring was upgraded with cou-
pon and corrosometer probes in several loca-
tions. This provided a means of collecting
information on both the corrosion rate and the
mechanism as well.
References
1. J. R. Rue and D. P. Naeger, “Advances in Crude
Unit Corrosion Control,” CORROSION/87, paper
no. 199, (Houston, TX: NACE 1987)
2. Ara Bagdasarian, Jim Feather, Bob Hull, Ray
Stephensen and Russell Strong, “Crude Unit
Corrosion and Corrosion Control,” CORRO-
SION/96, paper no. 615, (Houston, TX: NACE
1996)
3. M. S. Binford, P. R. Hart, “The Impact of Desalt-
ing Opportunity Crudes on Corrosion Precur-
sors,” CORROSION/95, paper no. 343,
(Houston, TX: NACE 1995)
4. M. A. Dion, “Desalting “Opportunity Crudes,” “
1995 NPRA Annual Meeting, paper no. AM-95-
69, (Washington, D.C.)
5. R. D. Merrick and T. Auerbach, “Crude Unit
Overhead Corrosion Control,” Materials Per-
formance, September 1983
6. J. R. Rue and D. P. Naeger, “Cold Tower Aque-
ous Corrosion: Causes and Control, CORRO-
SION/87, paper no. 211 (Houston, TX: NACE
1987)
7. J. G. Edmondson and S. E. Lehrer, “Advances in
Neutralizing Amine Technology,” CORRO-
SION/94, paper 514, (Houston, TX: NACE 1994)
8. Danny Clarida, Jim Johnson, Marc McConnell,
and Rusty Strong, “Corrosion and Fouling Ex-
periences in Crude Units Using Low Base-
Strength Neutralizer,” Materials Performance,
July 1997