51312-01438-IDENTIFYING PROCESS CONDITIONS WHICH RESULTED IN THE FORMATION OF A NON-SULFUR BASED BLACK POWDER WI

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Product Number: 51312-01438-SG

ISBN: 01438 2012 CP

Author: Daniel E. Powell

Publication Date: 2012

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“Black powder” is a common term used in the gas industry to describe iron sulfide which may form within natural gas pipelines. Following startup of a new gas processing facility in North Central Colorado in 2009 dark to black powdery dust and flakes were found throughout the heat exchangers and piping in the inlet product and residue areas of the process stream clogging the filters and strainers including within the NGL liquids the plant produced. Samples of the powder were collected and analyzed using multiple analytical techniques and the composition was found to be a combination of graphite (carbon) cementite (Fe3C) and iron oxides (predominately Fe3O4 and Fe2O3). There was little to no indication of the presence of any sulfur or sulfur compounds in these black-colored powders. Investigations focused on (a) identifying the processes which could result in the formation of these powders as well as (b) methodologies which could be used for assessing the threats to the integrity of the process equipment and piping including those posed by a possible “metal dusting” mechanism. This paper summarizes the result of those investigations and integrity assessments including changes made to the processes which precluded further formation of the black-colored powdery material. KEY WORDS: Black Powder Internal Corrosion Natural Gas Gas Processing Heat Exchanger Integrity Assessment; Process Review Iron Sulfide Iron Oxide Fe3O4 Fe2O3 Fe3C Metal Dusting