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Optimization
Dr. Russell D. Kane – iCorrosion LLC
Houston, Texas
Organization
Background
Conventional corrosion control approaches
What new approaches does electrochemical (echem)
corrosion monitoring bring for controlling corrosion and
process improvement?
Proven Applications
Amine gas processing
Cooling water
Black & white liquor
Developing Areas
Issues and Potential Problem Areas
Summary
Background
What the Chemical Industry Wants
to Know About Corrosion…
Process
Design: Optimization:
Which is the most How can I better
efficient metal for operate my process
my application?
to maximize
production but
control corrosion?
Troubleshooting:
Why did is Asset
material fail by Management:
pitting corrosion? What will be the
remaining asset life
at run rate X ?
Bottom Line:
How do I know my
What solutions should I recommendations are
recommend to keep the plant working?
operating?
“Corrosion Control 101”
Methods of Corrosion Control
Selection of materials
Chemical treatment
Cathodic/Anodic protection
Coatings
Corrosion Rate
Corrosion Rate
M etal Loss
Timing
Update Automate
inspection & Instructions,
maintenance follow-up
Planning Reports & KPIs
New Capabilities of Advanced
Electrochemical Monitoring
Corrosion Rate
Technique: Linear Polarization Resistance Wireless Antenna
Corrosion
rate
LEAN AMINE
C
O
ACID
N
FILTERS GASES
T
A
ACCU
C
M.
T
O S
R
T
A
Lean To R
Rich
B I
Amine
S P
Heat Exch.
O
R
P
B E Amine
SOUR GAS E R Reboiler
FEED R
RICH AMINE
* Highlighted areas can
be monitored by
Amine
Make-up electrochemical
techniques.
Amine Process Upset vs.
Real-Time Corrosion Rate
Spike in
differential Real-time corrosion rate
pressure across (black line) during an upset
the regenerator
event.
Upset was related to specific
events: ΔP and rapid change
in stream rates to reboiler.
Corrosion rate changed from
0.15 mm/yr to 1.25 mm/yr
Corrosion rate remained high
even after regenerator
regained some stability.
Loss of protective corrosion
Corrosion rate films from period of local
turbulence.
Lesson: Corrosion was not an
“always on” process, but
correlated with process
conditions and could be
controlled.
Pulp & Paper White Water:
Pitting vs. Neutralizer Control
Pitting Factor from
electrochemical monitoring
indicated episodes of pitting
in plant white water system.
Further examinations showed
the key role of white water
neutralizer selection in
determining its potential for
localized corrosion.
Monitoring usage of different
neutralizers clearly shows
importance of properly
pH & Neutralizer
selected dosage rate and
type of neutralizer.
Switch to new neutralizer
(marked as B) resulted in a
significant reduction in pitting
tendency.
Successful and Developing Applications
Critical catalyst feed rate
Impact of water upset in HC
process environment (Rohm &
Haas and BASF)
Corrosion in multiphase
(oil/gas/brine) environment
(USDOT field pipeline study).
New relationship Refinery ADU, VDU & FCCU
with neutralizer feed rate systems (West Pacific Refinery)
Amine gas processing (Shell
Canada)
Pulp & paper plant white water
(SCA Ortvikens)
Relationship with
Biodegradation of VOCs using
Inorganic feed rates trickle-bed bioreactor (Plant
Demonstration Project)
H2S-containing environments
(Extensive Lab Trials / Canadian
Pipeline)
Present Experience-based Limits
for Echem Monitoring
Need an electrically conductive environment; electrodes must be wetted
> 100 µS - Use of standard finger-electrode or flush-mounting probes
10-100 µS - Requires larger, more closely spaced electrodes
<10 µS – Requires use of a special low conductivity probe