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00702 UNUSUAL ASPECTS OF CORROSION FAILURES IN REFINERY HYDROTREATER UNITS

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Product Number: 51300-00702-SG
ISBN: 00702 2000 CP
Author: Gerald W. Wilks
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During the past several years Whiting Refinery has experienced three unusual corrosion failures in hydrotreater units. The first failure occurred in a furnace-to-reactor line in an old distillate desulfurization unit. This failure was caused by localized high temperature sulfidic corrosion in an unexpected location. Another failure occurred in an air cooler outlet nozzle in a unit which desulfurizes feed to catalytic cracking units. This failure was an example of ammonium bisulfide corrosion that was enhanced by unusual operating conditions. The third failure occurred in a product stripper vessel on a unit that desulfurizes diesel. This failure was by deposit formation beneath the top tray of a tower. This paper reviews the circumstances which led to these failures and highlights the lessons learned from each failure.
During the past several years Whiting Refinery has experienced three unusual corrosion failures in hydrotreater units. The first failure occurred in a furnace-to-reactor line in an old distillate desulfurization unit. This failure was caused by localized high temperature sulfidic corrosion in an unexpected location. Another failure occurred in an air cooler outlet nozzle in a unit which desulfurizes feed to catalytic cracking units. This failure was an example of ammonium bisulfide corrosion that was enhanced by unusual operating conditions. The third failure occurred in a product stripper vessel on a unit that desulfurizes diesel. This failure was by deposit formation beneath the top tray of a tower. This paper reviews the circumstances which led to these failures and highlights the lessons learned from each failure.
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This paper helps answer some questions by surveying numerous units processing high naphthenic acid-containing feeds, e.g. feeds with high total acid number (TAN). The survey lists the unit temperatures, TAN’s, flow schemes, materials and corrosion history. 
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