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Naphthenic acids and sulfur species in crude oil cause severe corrosion of the steel equipment of crude distillation units in oil refineries.1–3 Because of rapidly changing oil economics, the refineries have inclined towards cheaper “opportunity crudes”, but the high levels of corrosive species, mainly naphthenic acids and organosulfur compounds, in these crudes would reduce the life of the equipment, and also increase the risk of catastrophic failure.3 So the opportunity crudes are often blended with the crudes containing lower levels of corrosive species; this decreases overall concentration of corrosive species and the corrosion rates.4,5 However, corrosion rates are not simply proportional to the concentrations of naphthenic acids and sulfur species that are present in the crude oil.4,5 Without accurate estimation of corrosion rates by crude oils or their “blends”, carbon steel equipment needs to be constructed with higher wall thickness for safety; if still insufficient, high alloy steels are required.
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