Crude Proquest

Download as pdf or txt
Download as pdf or txt
You are on page 1of 11

_______________________________________________________________

_______________________________________________________________

Report Information from ProQuest


06 December 2014 12:52
_______________________________________________________________

06 December 2014

ProQuest

Tabla de contenido
1. Mitigate fouling in crude unit overhead--Part 1............................................................................................. 1
Bibliografa........................................................................................................................................................ 9

06 December 2014

ii

ProQuest

Documento 1 de 1

Mitigate fouling in crude unit overhead--Part 1


Enlace de documentos de ProQuest
Resumen: In a refinery crude distillation column, up to 40% of the total heat removal may be found in the tower
overhead condenser. The quantity of duty available makes heat integration (HI) between the column overhead
and unit feed an interesting project. Approximately 70% of the present crude units recover some portion of this
duty. However, many of these units suffer from persistent and serious corrosion problems in the overhead
system. In extreme cases, the viability of the entire refinery site may be compromised due to fouling and
corrosion conditions. Up to 50% of the refinery's entire corrosion expense may occur in the crude unit. The root
cause of the fouling and corrosion issues can often be linked to the basic unit configuration choices. Once the
unit configuration is set, anti-fouling chemical addition and unit operating conditions limit but never completely
solve, the fouling and corrosion issues. An overview of major corrosion factors and a case study are presented.
Texto completo: In a refinery crude distillation column, up to 40% of the total heat removal may be found in the
tower overhead condenser. The quantity of duty available makes heat integration (HI) between the column
overhead and unit feed an interesting project. Approximately 70% of the present crude units recover some
portion of this duty. However, many of these units suffer from persistent and serious corrosion problems in the
overhead system. In extreme cases, the viability of the entire refinery site may be compromised due to fouling
and corrosion conditions.
Up to 50% of the refinery's entire corrosion expense may occur in the crude unit. The root cause of the fouling
and corrosion issues can often be linked to the basic unit configuration choices. Once the unit configuration is
set, anti-fouling chemical addition and unit operating conditions limit but never completely solve, the fouling and
corrosion issues. An overview of major corrosion factors and a case study are presented.
CORROSION SYSTEMS-BACKGROUND
The major corrosion problem in crude unit overhead systems comes from chloride-induced corrosion. The
"chloride-induced" corrosion includes two major mechanisms: 1) hydrochloric acid corrosion, and 2) underdeposit corrosion (UDC). Fig. 1 illustrates the areas where the crude unit suffers from chloride-induced
corrosion. Complexity results from the interaction of operating conditions, mitigation strategies and materials
selection. Chlorides are not new problems; they are a continuation of old problems, but under more severe
conditions. 1
Fig. 1. Areas of chlorine-induced corrosion on a crude distillation unit.
Chlorine source
Chlorides enter the crude unit as a component of dissolved salts in water mixed with the crude oil. The
dissolved salts include sodium chloride (NaCl), magnesium chloride (MgCl 2 ) and calcium chloride (CaCl 2 ). In
special cases, organic chlorides may be present. At one time, carbon tetra-chloride was used as a well-treating
chemical. Although this is no longer done, crudes may become contaminated with synthetic organic chlorides.
2,3 To a lesser extent, chlorides can also enter the unit as entrained solids protected by an oil film.
Upstream of the desalter, the temperature is low enough that salt corrosion is not a major issue. The crude unit
desalter uses electrostatic precipitation to extract most of the water and reduce the chloride content. However,
the desalter does not remove all the chlorides, resulting in some chloride contamination in the atmospheric
heater.
The native chlorides themselves are not the cause of corrosion. Instead, at 350 [degrees]F to 400 [degrees]F
(175 [degrees]C to 205 [degrees]C), the CaCl 2 and MgCl 2 thermally decompose (disassociate). The chlorine
rapidly reacts with hydrocarbons, producing HCl. At normal crude atmospheric heater operating conditions,
nearly all of the MgCl 2 and much of the CalCl 2 will hydrolyze. While NaCl may start to hydrolyze at
06 December 2014

Page 1 of 9

ProQuest

temperatures as low as 450 [degrees]F (232 [degrees]C), temperatures above 800 [degrees]F (425 [degrees]C)
are often required for significant cracking. NaCl decomposition is not a substantial chloride source for most
crude atmospheric tower overhead systems.
Chlorine consequences
HCl, in the absence of water, does not significantly corrode carbon steel (CS). The overhead system of the
crude tower condenses water. The water absorbs the HCl, creating hydrochloric acid. At this point, many
outcomes are possible, depending on the location of where the first drop of water forms. The first drop of water
will occur at the point where film temperatures reach the dewpoint. Bulk temperatures are often reviewed, but
this will miss many problems, as surface temperatures are what count. The initial drop of water may have very
high HCl concentrations, making it extremely corrosive.
The water also absorbs ammonia (NH 3 ). HCl combines with NH 4 and forms ammonium chloride (NH 4 Cl). In
situations where the water revaporizes, solid deposits of NH 4 Cl form, thus creating the potential for UDC.
Temperature predictions for dewpoints are often based on partial pressures from steam table values. This
method will underpredict the dewpoint temperature. Ionic interactions between multiple species--water,
hydrogen sulfide (H 2 S), NH 3, HCl, cyanide and others--increase the dewpoint temperature. In some reported
cases, dewpoint temperatures exceeded 25 [degrees]F (14 [degrees]C) or more above steam table based
predictions.
Processing configuration will also affect chloride corrosion: Preflash columns or drums often receive feed hot
enough to contain HCl. Preflash configurations may also reduce the amount of naphtha in the atmospheric
column overhead. This increases the partial pressure of water in the atmospheric column, increasing the water
dewpoint temperature. Columns with heavy naphtha (HN) draws have more problems. The HN draw makes the
column overhead composition lighter, reducing its temperature, making corrosion situations more likely.
Common overhead systems may include either one or two overhead drums. However, some crude units have
included up to five overhead drums. The cooling levels between each of the drums become significant in
determining the initial point for corrosion. The purpose of multiple overhead drums is for heat recovery from the
overhead vapor. Heat recovery implies corrosion locations where water condenses. Other situations may lead
to localized water condensation. This includes cold reflux and cold pumparound (PA) returns, creating shock
condensation inside the atmospheric columns. Shock condensation can also occur due to sub-cooled feed to
the crude column when connecting the atmospheric column and preflash column. Higher stripping steam rates
improve distillate recovery. They also increase steam partial pressure and make water condensation more
likely. High NH 3 concentrations can lead to a NH 4 Cl deposition directly from the vapor phase to a solid phase.
4, 5 This can occur inside the atmospheric column (most common), overhead lines or in overhead exchangers.
The NH 4 Cl then absorbs moisture, starting the process of UDC.
Common methods of alleviating chloride corrosion include additives, modification of unit design, selection of
operating conditions, corrosion inhibitors and materials selection. Other strategies include using a water wash to
ensure that the initial water condensation location is controlled, and the corrosive species are quickly diluted.
Combining all of these factors creates tremendous complexity. 6
Previous articles have discussed the options for materials selection and have focused on water wash and the
results of water wash on unit HI. 7 The potential for reduced heat recovery poses the major question for water
wash.
UNIT CONFIGURATION
Crude overhead-to-feed HI is a relic of a bygone era. With low-density crude, making high yields of naphtha,
without preflash drums or towers, and short-run durations (often 12-18 months) between shutdowns, these
heat-recovery systems can work. In refineries processing difficult-to-desalt crudes, with preflash expansions,
lower naphtha yields, and runs of four years to five years, the crude-overhead-to-preheat is a major and
continual problem. Nevertheless, about 70% of operating crude units have HI between the overhead and the
06 December 2014

Page 2 of 9

ProQuest

crude preheat. Fig. 2 shows a typical older crude unit with the HI between the tower overhead with the crude
feed highlighted. A well-heat integrated unit can recover all the necessary preheat without the overhead HI
service. Crude overhead-to-feed preheat should only be used on new units in exceptional cases.
Fig. 2. Over head-to-crude heat integration and corrosion example.
Configuration analysis criteria
To evaluate a crude unit, identifying these locations are important: Areas where water condensation starts
Areas where water may revaporize Areas susceptible to solid salt deposition How water can move from one
part of the unit to another.
Analysis of crude unit corrosion potential should examine all of these elements to determine the mitigation
strategy required.
Where does water condensation start?
The critical point in corrosion from chlorides is the initial point of water condensation, which is driven by surface
temperatures rather than bulk temperatures. It is very difficult to measure surface temperatures, so bulk
temperatures are typically measured. Common practice often adds temperature controls to the overhead of
crude columns and preflash columns to prevent water condensation. Typical practice sets a tower overhead
temperature 30 [degrees]F to 50 [degrees]F (17 [degrees]C to 28 [degrees]C) hotter than the calculated
dewpoint.
Shock condensation occurs when cold reflux enters the tower and creates localized water condensation. This is
a common mechanism for corrosion inside the tower. Operating at maximum reflux rates allows an increased
reflux return temperature for the same heat removal. Within the constraints of tower and external equipment,
reflux and PA rates should be maximized.
Where does water revaporize?
Once formed, water flows with the bulk hydrocarbon stream. As the water flows down the column, the water
enters a hotter zone. Eventually, the water will vaporize, increasing the concentration of corrosive solutes.
Finally, the water will completely vaporize, leaving a solid deposit, which creates the potential for UDC.
Where can solid salts form directly from the vapor?
Solid salts, especially of NH 4 Cl, can directly condense from the vapor. The condensation can be analyzed
similar to a solubility product with liquid solutes. If the product of the ammonia concentration, (NH 4 + ), times
the concentration of the chlorine, (Cl - ), exceeds a specific value, NH 4 Cl deposits. This can also be expressed
as an NH 4 Cl partial pressure. The higher the NH 3 and chloride concentrations, the higher the temperature at
which solid salts form.
Solid salts may form above the water dewpoint temperature. This creates solid salts even if the system remains
dry. If the solid salt deposition temperature is below the water dewpoint, the NH 3 and chloride are absorbed by
the water instead. Many additive systems have been proposed, and used, to lower the solid salt formation
temperature below the water dewpoint temperature.
The solid salts can form in two major locations. The first is the crude column and may be as far down as the
kerosine draw tray. The second is in high-temperature overhead systems. If the crude column takes kerosine
(or heavier) overhead, then the salts can form in the overhead exchangers.
How does water move around?
Extreme corrosion can result from overhead drum water returning to the crude tower. The water includes
chlorides, other salts and treating chemicals. These create deposits in the tower that lead to UDC. Levels
should always be carefully monitored to prevent water carryover to the crude column and preflash column.
CORROSION AND DEPOSIT CONSEQUENCES
The major consequences to the crude unit include direct corrosion and pressure drop due to fouling deposits.
Direct corrosion from the aqueous phase reduces unit life and increases maintenance costs. It can also lead to
unit shutdowns. UDC has the same direct consequences. When they occur, unplanned shutdowns incur the
06 December 2014

Page 3 of 9

ProQuest

highest expense, and may cost $2 million or more per day for a large refinery. In extreme cases, units have had
to shut down due to corrosion causing a leak. Leaks in the upper part of the crude unit are likely to contain
some mix of H 2 S, light gases and naphtha. H 2 S would be a direct hazard. Naphtha and light gases are a
significant fire hazard. With a flash point of -70 [degrees]F (-57 [degrees]C) or lower, naphtha will ignite easily.
Solid deposits have a second consequence, given their ability to cause fouling and block flow. Fouling in the
atmospheric column may block draw nozzles, and it often plugs trays. Fouling in the overhead exchangers
increases pressure drop in the system. Increased pressure drop raises the tower operating pressure. Many
atmospheric crude units run at a feed temperature limit. Higher operating pressure at a fixed operating
temperature drops liquid yield in the unit. Lower liquid yield forces more material downstream, creating
constraints in downstream vacuum processing. Fouling in overhead exchangers also reduces heat removal
capability of the overhead system. Reduced heat transfer may limit production rate or yield as well.
Exact consequences will vary from unit to unit. However, they are all bad. Maintenance costs increase, reliability
drops, capacity is reduced, and yields decrease.
MITIGATION STRATEGIES
Such actions include corrosion inhibitors, operating condition limits, feed quality, materials upgrades and unit
configuration choices. Unit configuration will be reviewed from two directions: What configurations reduce
corrosion and fouling? What configurations, imposed by conventional refinery economics, force the plant to use
configurations that increase the possibility of fouling and corrosion?
The basic configuration choices will focus on the crude tower overhead system and on the possible split
between overhead products on the crude unit. The overhead system configuration choices include three major
parameters: Number and type of overhead drums Inclusion of water wash Integration of overhead duty into
crude preheat.
The product split factors include: Full-range naphtha (FRN) product Split between light naphtha (LN) and HN
products Heavy product overhead (naphtha plus kerosine).
In addition, some units have switched the sequence of exchangers to initially warm up the cold crude before it
reaches the overhead-to-crude exchangers. This increases the minimum oil-film temperature in the overhead
exchanger. Higher film temperatures reduce the risk of localized water condensation. All of the mitigation
strategies that use a specific configuration (water wash, different preheat configurations) sacrifice recoverable
heat from the crude tower overhead to reduce corrosion rates.
Introducing overhead systems
Several possible options are available with different numbers of overhead drums used:
One-drum overhead system with reflux. As shown in Fig. 3, this atmospheric crude unit uses a one-drum
overhead system. It is a similar concept to the crude unit, as shown in Fig. 1. Overhead vapors from the crude
tower are condensed and collected in an overhead drum, and the reflux is sent back to the crude tower. It is a
common configuration. The system illustrated uses an air-fin exchanger followed by a cooling water exchanger.
Vapor loading in the overhead system is high. The overhead must generate all the product naphtha plus reflux.
Fig. 3. One-drum overhead system with reflux.
One-drum overhead system without reflux. Pressure drop in the overhead system reduces unit liquid yield. One
step to increase yield shifts some overhead heat removal from the overhead condensers into a PA-heat removal
loop. Fig. 4 shows a naphtha PA added to the top of the crude column. This shifts heat removal from a
condensing service to a subcooling service. The naphtha PA usually provides heat for feed heating. Corrosion
and fouling problems in the naphtha PA exchangers are usually minor. However, the PA heat removal lowers
the tower overhead temperature. Some reflux from the overhead drum may be added to the naphtha PA return
to control naphtha product composition. With colder overhead temperatures, little heat is available in the
overhead system for heat recovery. Fig. 4 shows the remaining overhead condenser duty going to air and
cooling water.
06 December 2014

Page 4 of 9

ProQuest

Fig. 4. One-drum overhead system without reflux.


Two-drum overhead system with dry reflux. The first condenser nominally operates at temperatures to support
heat integration. The second condenser uses heat rejection. Fig. 5 shows a two-drum system. At average
conditions in the first drum, it is too hot to allow water accumulation.
The intended benefit of this configuration is to allow heat recovery while minimizing water formation and
corrosion problems. Fig. 5 shows a nominal heat recovery service as the first exchanger in the system. This
system has a higher total pressure drop than the one-drum system without reflux, but it avoids investment in the
naphtha PA pumps.
Fig. 5. Two-drum overhead system with dry reflux.
Two-drum overhead system with wet reflux. Flexibility to handle different crude compositions may make
consistent dry-drum operation difficult. Having the capability to allow for water accumulation in the first drum
allows the unit to operate across a wider range of operating modes. Fig. 6 illustrates a system with water
condensation in both drums. Additionally, if correctly managed, the wet-drum system allows for higher energy
recovery. The disadvantage of the wet-drum system is that corrosion and fouling benefits are less clear.
Fig. 6. Two-drum overhead system with wet reflux.
Three-drum (plus) overhead system. Adding more drums allows for more complicated heat removal systems.
Conceptually, this improves heat recovery. Fig. 7 illustrates a three-drum system. While systems with more than
two drums are unusual, some units have been built that have five drums in the overhead.
Fig. 7. Three-drum overhead system.
Units that send a mixed naphtha-kerosine stream to a common hydrotreater shift the benefits of selection
criteria toward the multiple-drum configurations. The equilibrium conditions in the first drum of three-drum
systems reliably lie above the water dewpoint. However, localized water condensation still presents challenges.
Multiple-drum systems also impose pressure drops in series. This increases unit operating pressure, decreasing
liquid yields.
Product splits matter--no water wash
The previous illustrations stayed deliberately vague on product splits in each configuration. Specific product
splits do matter. This set of examples uses a basis of no water wash to examine the possible consequences.
Specifics in a given plant may vary greatly. Nevertheless, the analysis shows the important points to consider.
One-drum overhead system with reflux. The different operating modes for a one-drum system with reflux are
illustrated in Figs. 8 and 9. In Fig. 8, a FRN is produced as the overhead product. Fig. 9 shows the changes with
a light-naphtha product overhead.
Fig. 8. One-drum overhead system
for FRN overhead: typical operation.
Fig. 9. One-drum overhead system
for LN overhead: typical operation.
FRN product. A typical operation with FRN product will operate at approximately 300 [degrees]F (149
[degrees]C) overhead. This provides ample driving force for heat integration with crude feed. Normal practice
has the overhead condenser as the first crude preheat exchange, as shown in Fig. 2. Crude feed temperature
may vary from 65 [degrees]F (18 [degrees]C) to 100 [degrees]F (38 [degrees]C). Downstream of the preheat,
overhead temperatures will drop to 200 [degrees]F-240 [degrees]F (93 [degrees]C-116 [degrees]C). Some
combination of air and water cooling will drop the overhead drum temperature to 100 [degrees]F (38
[degrees]C). Fig. 8 shows kerosine as the upper side-draw from the crude column.
Under these conditions, the bulk of the water condensation may occur in the overhead exchangers, and surface
condensation on the tubes is certain. Tube metal temperatures may drop as low as 135 [degrees]F (57
[degrees]C). Localized presence of hydrochloric acid in the overhead exchangers is nearly certain. Standard CS
tubes will likely suffer from HCl attack. Fouling and UDC may occur in the exchangers as well. The exchangers
06 December 2014

Page 5 of 9

ProQuest

are cold enough that, once condensation starts, the water is unlikely to completely revaporize. However, local
flow regimes may create areas where deposits form.
The cold reflux returns to the crude tower at 100 [degrees]F (38 [degrees]C). Localized water condensation
occurs on the top tray, making fouling and corrosion attack in the tower top highly likely. Corrosion is initiated by
water formation on the top tray. Water vaporizes as it descends, causing deposits that can lead to UDC. The
overhead drum rarely suffers from severe corrosion. Enough water is present to dilute the HCl. Revaporization
does not occur, so solids deposits do not present major problems.
Product split between LN and HN
A typical operation with a light straight-run naphtha (LSRN) product will operate at approximately 200
[degrees]F-240 [degrees]F (149 [degrees]C-116 [degrees]C) overhead. Driving force remains sufficient for heat
integration with crude feed as long as the crude exchanger is the first in the preheat sequence. As previously,
crude feed temperature may vary from 65 [degrees]F (18 [degrees]C) to 100 [degrees]F (38 [degrees]C). After
preheat, overhead temperatures will drop to as low as 140 [degrees]F (60 [degrees]C). Some combination of air
and water cooling will drop the overhead drum temperature to 100 [degrees]F (38 [degrees]C). Fig. 9 shows HN
as the upper side-draw from the crude column. Under these conditions, bulk condensation of water will occur in
the overhead exchangers. Tube metal temperatures may drop as low as 100 [degrees]F (38 [degrees]C).
Standard CS tubes are nearly certain to suffer from HCl attack.
Fouling and UDC, if present, will concentrate at the exchanger inlet area. The exchangers are cold enough that
once condensation starts, water is unlikely to completely revaporize. However, local flow regimes may create
areas where deposits form.
The cold reflux returns to the crude tower at 100 [degrees]F (38 [degrees]C). Localized water condensation
occurs on the top tray. Fouling and corrosion attack in the tower top are highly likely. As the water descends
and vaporizes, deposits are left and UDC occurs. The corrosion area may reach down to as low as the kerosine
draw. The overhead drum rarely suffers from severe corrosion. Enough water is present to dilute the HCl.
Revaporization does not occur, so solids deposits do not present major problems.
Plant economics and product specifications drive the necessity for splitting the naphtha into LSRN and HN. This
split aids control of downstream isomerization and reformer unit operations. It also eases meeting gasoline
benzene specifications in many plants. The economics behind the LSRN-HN split are usually so large, that, if
this split is attractive, some method will be found to deal with the consequences.
One-drum overhead system without reflux. While slightly different, the performance of one-drum systems
without reflux closely resembles two-drum systems with dry reflux.
Two-drum overhead system with dry reflux. The different operating modes for a two-drum system with dry reflux
are represented in Figs. 10 and 11. In Fig. 10, FRN is the overhead product. Fig. 11 shows the changes with an
LN-product overhead and an HN side-draw.
FRN product. A typical operation with an FRN product will operate at approximately 340 [degrees]F (171
[degrees]C) overhead. This provides ample driving force for heat integration with crude feed. In this case, the
first overhead exchanger may not be the first exchanger in the crude preheat train. Crude feed temperature may
vary from 65 [degrees]F (18 [degrees]C) to 150 [degrees]F (66 [degrees]C). Fig. 10 shows operation with cold
crude.
Downstream of the preheat, overhead temperatures will be 276 [degrees]F (136 [degrees]C). Some
combination of air and water cooling will drop the overhead drum temperature to 100 [degrees]F (38
[degrees]C). Fig. 10 shows kerosine as the upper side-draw from the crude column.
Fig. 10. Two-drum overhead system with
dry reflux for FRN overhead: typical operation.
Under these conditions, bulk condensation is unlikely in the overhead exchangers. Surface condensation on the
tubes is possible. The main determinant of localized water condensation is the crude inlet temperature. If the
06 December 2014

Page 6 of 9

ProQuest

crude inlet temperature is low, 65 [degrees]F (18 [degrees]C), localized condensation is highly likely. If the
crude inlet temperature is high, 150 [degrees]F (66 [degrees]C), tube metal temperatures may reach 220
[degrees]F (104 [degrees]C). In units with little steam and efficient desalting, water condensation may not occur
with the hotter crude. However, operating upsets could lead to deposit formation and UDC. The first drum
overhead temperature at about 276 [degrees]F (136 [degrees]C) remains high enough to add heat integration
between the two drums. Consequences here closely resemble those in the one-drum system with the FRN
product overhead.
Hot reflux returns to the crude tower at 276 [degrees]F (136 [degrees]C). Corrosion in the crude tower is
unlikely. One complicating factor comes from the naphtha endpoint control. The hot reflux and FRN product
systems inter-connect to allow for FRN endpoint control. Large amounts of FRN added to the reflux may cool
the reflux to start localized water condensation in the crude column.
More split options for naphtha
Splitting the LSRN and HN cools the tower overhead. The LSRN-HN split can be done by having an HN draw
from the main column or by having segregated naphtha products from the two overhead drums. Fig. 11 shows
segregated products from the overhead drums. The tower overhead temperature drops to about 316 [degrees]F
(158 [degrees]C) overhead. This still provides ample driving force for HI with crude feed.
Downstream of the preheat, overhead temperatures go lower, to about 200 [degrees]F (93 [degrees]C). This
temperature is set by the need to get a specific composition for the LSRN-HN split. Some combination of air and
water cooling will drop the overhead drum temperature to 100 [degrees]F (38 [degrees]C). Fig. 11 shows
kerosine as the upper side-draw from the crude column. Under these conditions, bulk condensation is highly
likely in the overhead exchangers. To get the 200 [degrees]F (93 [degrees]C) drum temperature, cold crude is
required. Localized water condensation is nearly guaranteed. Reflux returns to the crude tower at 200
[degrees]F (93 [degrees]C). Corrosion in the crude tower is likely to be minor. If it occurs at all, localized water
condensation is slight and will be concentrated on the top tray.
Fig. 11. Two-drum overhead system with dry reflux-two naphtha overhead: typical operation.
Two-drum overhead with wet reflux and LSRN-HN split. Two-drum systems with wet reflux require a low first
drum temperature. This configuration is unlikely unless the intent is to draw an HN product from the atmospheric
column. Fig. 12 shows this configuration. The upper draw from the main column is HN. A typical operation will
operate at approximately 226 [degrees]F (108 [degrees]C) overhead. Driving force remains sufficient for HI with
crude feed as long as the crude exchanger is the first in the preheat sequence. As previously, crude feed
temperature may vary from 65 [degrees]F (18 [degrees]C) to 100 [degrees]F (38 [degrees]C). After preheat,
overhead temperatures will drop to as low as 170 [degrees]F (77 [degrees]C). If the overhead temperature is
much lower, then the system should really be considered a one-drum system with a booster drum. Some
combination of air and water cooling will drop the overhead drum temperature to 100 [degrees]F (38
[degrees]C).
Fig. 12. Two-drum overhead system with wet reflux-two naphtha overhead: typical operation.
Under these conditions, bulk condensation of water will occur in the overhead exchangers. Tube metal
temperatures may drop as low as 120 [degrees]F (49 [degrees]C). Standard CS tubes are nearly certain to
suffer from HCl attack. Fouling and UDC, if present, will concentrate at the exchanger inlet area. The
exchangers are cold enough that once condensation starts, water is unlikely to completely revaporize. However,
local flow regimes may create areas where deposits form.
The reflux returns to the crude tower at 170 [degrees]F (77 [degrees]C). Modest localized water condensation
occurs on the top tray, making fouling and corrosion attack in the tower top highly likely. The corrosion area may
reach down to as low as the kerosine draw. The overhead drum rarely suffers from severe corrosion. Enough
06 December 2014

Page 7 of 9

ProQuest

water is present to dilute the HCl. Revaporization does not occur, so solids deposits do not present major
problems.
Next month
In Part 2, the author discusses the benefits of water-wash systems in crude units. HP
LITERATURE CITED
1 Kronenberger, D. L., "Corrosion problems associated with the desalting difficulties of Maya and other heavy
crudes," Corrosion 1984, New Orleans, April 2-6, 1984.
2 NACE, "Effect of Nonextractable Chlorides on Refinery Corrosion and Fouling, "NACE, Houston, 2005.
3 Gutzeit, J., "Effect of organic chloride contamination of crude oil on refinery corrosion," NACE 00694,
Corrosion 2000. Orlando, 2000.
4 Carlton, R. H., "Refinery condenser and exchanger corrosion by ammonium chloride," Materials Protection,
January 1963, pp. 15-20.
5 Wu, Y.-M "Calculations estimate process stream depositions," Oil &Gas Journal, Jan. 3, 1994, pp. 38-41.
6 NACE, "Crude Distillation Unit-Distillation Tower Overhead System Corrosion," Houston, Texas, 2009.
7 Sloley, A. W., "Heavy oils processing requirements-Crude processing," Rio Oil &Gas 2012, Rio de Janeiro,
Brazil, Sept. 17-20, 2012.
Materia: Petroleum refining; Corrosion; Crude oil; Process engineering;
Ttulo: Mitigate fouling in crude unit overhead--Part 1
Autor: Sloley; A. W.
Ttulo de publicacin: Hydrocarbon Processing
Pginas: n/a
Ao de publicacin: 2013
Fecha de publicacin: Sep 2013
Ao: 2013
Editorial: Euromoney Trading Limited
Lugar de publicacin: Houston
Pas de publicacin: United Kingdom
Materia de publicacin: Chemistry, Engineering, Technology: Comprehensive Works, Petroleum And Gas
ISSN: 00188190
Tipo de fuente: Trade Journals
Idioma de la publicacin: English
Tipo de documento: Feature
Caractersticas del documento: References
ID del documento de ProQuest: 1439278811
URL del documento: http://search.proquest.com/docview/1439278811?accountid=150554
Copyright: ( (c) Euromoney Institutional Investor PLC Sept 2013)
ltima actualizacin: 2013-10-15
Base de datos: ProQuest Science Journals

06 December 2014

Page 8 of 9

ProQuest

Bibliografa
Citation style: APA 6th - American Psychological Association, 6th Edition
Sloley, & W., A. (2013). Mitigate fouling in crude unit overhead--part 1. Hydrocarbon Processing, Retrieved from
http://search.proquest.com/docview/1439278811?accountid=150554

_______________________________________________________________
Contactar con ProQuest

Copyright 2014 ProQuest LLC. Reservados todos los derechos. - Trminos y condiciones

06 December 2014

Page 9 of 9

ProQuest

You might also like