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distillate
Reducing atmospheric fractionator overhead temperatures to maximise middle
distillate production requires a full understanding of resulting corrosion mechanisms
Brandon Payne
GE Water & Process Technologies Reprinted from PTQ, 3rd Quarter issue, 2012, pp 75-81
S
ustained growth in the demand Overhead salt point and lower tower overhead system is selected based on
for jet fuel, diesel and other top temperatures three primary factors: neutralisation
middle distillate products is Crude unit overhead corrosion deals capacity (the strength of the neutral-
expected to have a continuing with corrosion affecting the upper iser), the water partition coefficient
impact on unit operations, product sections of the crude unit atmos- (the rate at which it will enter the
pricing, product selection and refin- pheric fractionation column, first water droplets formed in the
ing margins into the foreseeable including the top tower trays, over- overhead system) and the neutralis-
future. As more and more new head condenser system and top er’s salt point.
facilities come online to supply the pumparound circuits. Corrosion in The salt point is defined as the
demand for tighter product sulphur the crude unit overhead system is temperature at which the first
specifications, refiners will continue primarily due to acid attack at the neutralisation salts begin to precipi-
to maximise distillate production in tate from the vapour phase. These
their atmospheric distillation units salts can be very corrosive them-
to take advantage of favourable
Corrosion in the selves and can also give rise to
product pricing. However, maximis-
ing the production of these fuel
crude unit overhead under-deposit corrosion at certain
points in the system. In order to
streams requires a continual assess- system is primarily control the deposition and corrosiv-
ment of the entire processing system ity of these salts, a water wash is
beyond the mechanical capability of due to acid attack often used to provide a means of
pumps, piping and valves to ensure diluting and washing the corrosive
reliable operation of the unit in a at the initial water salts from the overhead system. In
market environment that favours these cases, the salts are scrubbed
distillate production. As refineries condensation point from the overhead vapour, washed
continue to lower tower top temper- from the overhead piping and
atures in an effort to increase initial water condensation point condenser system, and flow into the
product draws in the distillate (ICP), resulting in low pH conditions overhead receiver. However, as the
sections of the column, the condi- and the associated aggressive corro- overhead process temperature is
tions for introducing salt fouling sion of the system’s metal surfaces. lowered in an effort to force addi-
and corrosion mechanisms into Secondary corrosion mechanisms in tional material into the distillate
areas that previously were not the tower top and overhead are typi- draw section of the column, the loca-
affected come to the forefront. cally due to amine-chloride salt tion of the salt point temperature
Refiners must address the hazards deposition driving under-deposit moves further upstream into the
of unmonitored distillate maximisa- corrosion. overhead line, pumparound circuits
tion on corrosion in the crude Neutralisers are used to control the and tower top internals where there
distillation column top section and pH of condensing overhead waters is no water wash.
overhead system. In this article, within an optimal range to maximise Without the means of removing
overhead corrosion control strategies the reduction of corrosion rates while deposited salts in these areas, corro-
and guidelines are discussed to help minimising the tendency for salt sion can be severe and equipment
refiners maintain reliable unit opera- deposition caused by the neutralisa- failure rapid. Therefore, it is critical
tion while maximising distillate tion reaction with the acidic species. to continuously re-evaluate the
production. The type of neutraliser used in an neutraliser being used to determine
Neutraliser rate
Water dew point
15.7
Salt points
180 14.8 Top temperature
13.7
11.7 Operating point
11.5
130 9.7 GPD
8.3
7.7
80 5.7
5.0
1.7 3.7
30 1.7
10 30 50 70 90 110
Chlorides in boot, ppm
6
5
pH at 25ºC
0
0 10 20 30 40 50 60 70 80 90 100
Water condensed, %
Operating point at intersection of pH profile and red line
best performance is obtained from amine-chloride salt at a temperature allowed the refinery to decrease
the desalters. However, caustic usage that is at least 15°F (8°C) lower than average overhead corrosion rates by
must be carefully evaluated and the water dew point in the system. 80% to a corrosion rate of <5 mpy
monitored to determine accurately Calculating the ICP and salt point (verified by consecutive UT thickness
the downstream impacts and the are critical to controlling corrosion. readings).
critical threshold concentrations. It The use of modelling software, such Filming inhibitor chemistries are
should not be used as a replacement as GE Water & Process Technologies’ the mainstay of the overhead corro-
for optimising desalter operation. proprietary LoSalt Ionic Equilibrium sion inhibitor programme. Filmers
model (see Figures 2 and 3), allows work by coating the metal surface
Proper selection of filming corrosion for the rapid and efficient prediction with a hydrophobic barrier, which
inhibitors and neutralisers of the overhead system salt point. prevents corrosive species from reach-
In order to properly control corro- These modelling tools can be used to ing and reacting with the metal
sion in a crude unit overhead system, quickly determine the best neutralis- surface. While a neutraliser has a
a three-pronged strategy comprised ing amine and/or operating maximum theoretical limit to the
of an organic neutralising amine, a parameters by predicting salt points overall reduction of corrosion rates,
filming inhibitor and a water wash for various amines and the ICP for filmer chemistries are not constrained
should be implemented. Every corro- various operating conditions. by such a limit. The level of corrosion
sion control programme will utilise The LoSalt Ionic Equilibrium protection from a filming corrosion
these three elements to varying model has been effectively used to inhibitor can approach 100%, given
degrees, based upon the unit design, assist refiners in optimising tower adequate dosage and the proper
crude diet and operating envelope. top temperatures by establishing the conditions. However, the practical
Therefore, the selection of the proper operating limits they must not exceed aspects of the filmer application
treatment chemistry is critical to the in order to prevent salt formation generally do not allow such a degree
programme’s success and the unit’s and deposition in the system. In one of protection. It is, however, relatively
equipment reliability. case, the operational changes made, easy to realise 90-95% protection for
Under normal conditions, the ideal based on the information provided coated surfaces at reasonable dosages.
neutraliser utilised will form its by the ionic modelling analysis, Traditional filmers require a pH