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Oilsand bitumen crudes, characterized as corrosive by the classical naphthenic model, are producing negligible naphthenic acid corrosion in crude and vacuum units after more than 50 years of operation. A new theory proposes that the corrosivity of naphthenic acids in Athabasca oilsand bitumen crudes is a function of its molecular characteristics.
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There has been recent interest in the use of hydrogen flux monitoring at high temperatures to evaluate ‘naphthenic acid’ and sulfidic corrosion in high temperature process streams associated with crude distillation units. In this report, we present flux and corrosion data obtained from samples drawn from a refinery process stream.
Evaluation of the proprietary prediction model and validation studies conducted in IOCL’s refinery crude units. Case studies comparing predictions with the refinery inspection / measured corrosion rate data are provided.
Sulfur and acidic impurities in crude oils pose serious hot oil corrosion problems in crude distillation units (CDU) and associated vacuum distillation units (VDU), especially with the increase in processing of lowquality, opportunity crudes.1-4 In the range of 200-400˚C, reactive sulfur compounds cause sulfidation corrosion of ferritic carbon and chrome steels in CDU, VDU, and front ends of downstream units operating at hot oil temperatures.5-7 Over the same temperature range, naturally occurring carboxylic acids in crudes can be so aggressive that higher alloy, austenitic stainless steels containing >2.5% Mo are required for processing high acid oils.8-11 Although sulfidation and acid corrosion occur over the same temperature range, they differ in two significant ways. Sulfidation forms an iron sulfide solid that is semiresistant to further corrosion and relatively insensitive to flow velocity. Acids form oil soluble organic salts that can be washed away especially in areas of high turbulence.12-14
Sulfur and acidic impurities in crude oils pose serious hot oil corrosion problems in crude distillation units (CDU) and associated vacuum distillation units (VDU), especially with the increase in processing of lowquality, opportunity crudes. In the range of 200-400˚C, reactive sulfur compounds cause sulfidation corrosion of ferritic carbon and chrome steels in CDU, VDU, and front ends of downstream units operating at hot oil temperatures. Over the same temperature range, naturally occurring carboxylic acids in crudes can be so aggressive that higher alloy, austenitic stainless steels containing >2.5% Mo are required for processing high acid oils.
In Corrosion/2021, the authors introduced a molecular mechanistic model that quantifies and predicts SNAPS corrosion rates. During Corrosion/2022, we presented the mechanistic corrosion prediction framework describing the molecular basis of the model’s reactions, kinetics, and mass transport of ROSC to vessel walls. In this molecular model, sulfidation corrosion is calculated for direct heterolytic reaction of ROSC with solid surfaces.