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High temperature sulfidation (or sulfidic) corrosion of steel by sulfur species in crude oil has long been known to damage refinery equipment. Corrosion engineers have been using prediction curves derived from field corrosion data to estimate rates of sulfidation corrosion. However, a significant inaccuracy is often encountered in these estimations because of the extensive diversity in molecular structures of sulfur compounds in crude oils.
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A constant challenge persists among corrosion engineers to estimate and predict field corrosion rates despite the huge advancements in corrosion science. This situation has compelled the corrosion engineers to opt for the machine learning (ML) algorithms for corrosion prediction. However, the “blackbox” ML algorithms are not appreciated in high stakes decisions because they use arbitrary fitting models rather than scientific principles.
Hydrogen Reformer or so-called Steam Methane Reformer (SMR) is an important equipment to produce hydrogen or synthesis gas for refineries, petrochemical and fertilizer plants. It is basically a fired heater component that consists of four main sections which are radiant section, convection section, transition duct and stack.1 The configuration and general arrangement of SMR varies from different designers.
Liquid H2S scavengers are sometimes injected into pipelines transporting wet gas to reduce the H2S concentration below allowable values before reaching certain points of the system. In these situations, the H2S scavenger injected into the pipeline should be able to reduce the H2S concentration in the gas to the target values within a given residence time.
The overall reaction kinetics when a liquid scavenger is directly injected into a wet gas pipeline can be separated in the following three steps, which have been described in previous publications:Step 1: Transport of the liquid scavenger into the aqueous phase.Step 2: Transport of H2S from the gas to the aqueous phases.Step 3: Chemical reaction between the scavenger and dissolved H2S
Stainless steel is one of the most resistant materials to chloride environments and is an important material for water applications. Selecting a suitable stainless steel grade for water applications requires information about the performance of the candidate stainless steel grades. The limiting conditions for the pitting resistance of stainless steel depend mainly on the alloying composition of the steel and the surrounding environment.
Fired heaters in coking service are susceptible to carburization damage, which needs to be predicted and managed to prevent unexpected downtime and expedited replacement costs. Carburization damage occurs when carbonaceous material, i.e., coke, is deposited on a steel surface and exposed to high metal temperatures; such are the internal conditions present in fired heater tubes in coking services. At these high temperatures, the carbon diffuses into the steel microstructure and increases the hardness while reducing ductility. At an advanced state, this reduction in ductility may lead to tube failure if a mechanical or thermal shock is applied. The diffusion of carbon can also cause the formation of deleterious chromium carbides in the steel microstructure, reducing the high temperature corrosion resistance in those areas.
The direct current electrical treatments are applied with the aim of improving corrosion resistance of steel embedded in concrete. It is the impressed current cathodic protection in both widely used modes – preventive or remedial, electrochemical chloride extraction, realkalization of carbonated concrete and electrochemical injection of protective agents. All the treatments are similar to each other in its principle and arrangement.
Stainless steels, e.g. 316 austenitic stainless steel, are commonly used in various hydrogen (H) delivery and storage applications, and the H embrittlement (HE) resistance of these steels is well-established. However, the alloying, particularly nickel (Ni), required to achieve the stable austenitic microstructure drives their relatively high cost and is a potential barrier to broad implementation of extensive infrastructure for the H economy. Figure 1 shows a plot of fracture toughness in H, KIH or KJH, versus yield strength for both austenitic stainless steels and lower alloy ferritic steels.
Stainless steel 316L (316SS) has been widely applied in relevant commercial fields (e.g. chemical, petrochemical, pharmaceutical, biomedical, and manufacturing industries) due to its excellent properties in corrosion and abrasion resistance, antioxidation, and service life. It is considered an austenitic material, non-magnetic, and thermally nonhardenable. The 316SS can be produced via powder by different methods such as: self-combustion, high-temperature synthesis (SHS), electron beam radiation, laser surface melting, plasma spray synthesis, mechanical alloying and casting methods among others.
Alloy UNS N07718 (hereafter abbreviated as 718) is one of the most versatile precipitation-hardened nickel-based corrosion-resistant alloys (CRAs) used for both surface and sub-sea components in oil and gas production service. API 6ACRA provides heat treatment windows and acceptance criteria for 718 in these oil and gas production environments, in which the heat treatment is intended to homogenize the microstructure and obtain the correct microstructure for targeting the desired mechanical properties. For fabricating high temperature materials via additive manufacturing (AM), alloy 718 is a primary focus due to its widespread applications in the past 60 years and excellent weldability in either age hardened or annealed condition.
Mildew growth on commodity storage tanks is not a new issue within the industry and has been seen for years. However, ethanol storage tanks pose an interesting dilemma as the mildew growth on these tanks are especially aggressive and can completely deface the tanks again within months after being cleaned off. Historical knowledge of this mildew growth can be found when looking at distilleries.
Production of highly sour oil and gas fields has increased recently, which introduces new challenges forcorrosion control. In recent years, some unexpected and unexplained pipeline failures have occurred,resulting in complex investigations and laboratory corrosion performance testing studies to assess theinhibitors that are applied in these environments. While some of these failures are due to cracking insour environments which are prevented by alternative material selection or different operation pipelinemaintenance, we were specifically looking at cases where chemical inhibitors could be used to mitigatecorrosion.