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Black tar-like fouling material was driving frequent shut-downs of a gas plant. Analysis indicated that the nitrogen containing corrosion inhibitor (CI) polymerized with sulfur compounds in a vulcanization process. Testing confirmed the role of the CI in creating this fouling.
Black tar-like fouling material was driving frequent shut-downs and increasing corrosion in the inlet area of a gas plant that processes lean gas with high acid gas content (68%CH4, 20%CO2 and 12%H2S). Analytical work indicated that the nitrogen containing corrosion inhibitor (CI) polymerized with sulfur compounds (polysulfides, elemental sulfur and/or H2S) in a type of a vulcanization process resulting in a hard-to-clean insoluble fouling product. Corrosion testing confirmed the role of the CI in creating this fouling. A customized autoclave testing was designed to include powdered elemental sulfur circulating in the bulk fluid. This allowed for a recreation of the condition in the plant where solid elemental sulfur comes out of solution and fouling occurs. The tests reproduced the tar-like fouling substance in the presence of the incumbent corrosion inhibitor. The data showed that a surfactant (wetting agent) used to keep elemental sulfur from depositing would also protect the steel from elemental sulfur corrosion. Other CIs were tested, but none provided protection at an acceptable dosage level without forming this foulant material.
Key words: sour corrosion, H2S, corrosion inhibitor, fouling, autoclave testing, elemental sulfur
This paper explains the most common damage mechanisms of high temperature alloys in radiant section such as creep/carburization, thermal fatigue/carburization, and thermal shock.
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A developed monitoring approach confirmed that the EN-based electrochemical surveillance can detect changes in a petrochemical plant that otherwise could lead to catastrophic failure.
There is an increasing need to define the operating envelope for materials typically used as oil country tubular goods. This paper reports results of sulfide stress cracking (SSC) tests that were performed in mild sour environment at temperatures below 107°C.