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corrosion in hydrocrackers
Factors in the corrosion of effluent condensers in hydrocrackers are the
subject of this artiele, which ineludes a case study of the problems experienced
at Riyadh refinery, Saudi Arabia, and the corrective actions that were taken
Walid A Al-Naim
Saudi Arameo
NH 4 (HS) formation
Ainmonium bi-sulphide corros ion is con
sidered a main source of potential hazard
to hydrocrackers in all parts of the world.
T~e recipitation of the ammonium bi
sulphide on t e effluent con enser tu es
causes under-deposit corrosin and tube
pitting. Thereafter, condenser failure is
bouna to occur, with a potential disaster.
A AS a result, remedial mea sures and correc
. .ive actions at design stages and unit oper-
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Temperature, Deg.
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110
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Optimum parameters
~~
Optimum
value
Operational
parameters
1. Piehi Kp Factor
0.15
2. NH.(HS) wt % in wash water 4.8
3. Wash water rate, vol% leed
5.2
4. Oxygen (ppm) in wash water 0.05
5_Condenser tube velocity, Ips
15
and analysed b~
Effect of Kp factor
Table 1
45
PTQ WINTER 1999/2000
REFINING
other proces' p~rameters . Moreover,
th,e Kp factor dicta tes how much high
er is the effluent condenser outlet tem
perature than the temperature at
which ammonium bi-sulphide starts
crystallising, as shown in Figure 1 (on
previous page).
The higher the ammonjum ru-sul
QEidt concentratjon, tbe higher the
condenser outlet temperatme sbollld be,
to avoid NH,(HS) crystallisation. In
essence, it is a very important factor dur
ing the design stage of the effluent con
denser to be capable of controlling the
outlet temperature, taking into account
feed rate and quality (organic N:! and
sulphur cantent) oscillations.
f. .
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i 41
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46
PTQ WINTER 1999/ 2000
REFINING
eonncnsers:
2 Tube material: killed es
Parallel b:nks: 8
Header box: killed es
Tube passes:
3
Tube diameter: lin
Tubes per pass:62
Return bends: No
As anticipated, this revamp helped to
mitigate the HPNA plugging problems,
and also enhanced ammonium bi-sul
phide corrosion by upsetting the original
design parameters of the effluent con
denser. Figure 3 shows the new location
for the effluent condenser.
Revamp consequences
Case study
Riyad/l refinery experience with
NHlHS) coTTosion
Kp factor ncrease
The KJ2 factor in the effluent condenser
has increased by 42 ger cent as compared
with the pre-revamp value. Since NH J
and H2S rema in in the ~lL-liiii~~
-de crease 10 the molar flow rate ioto tlle
effluent condenser (compared with the
pre-revamp situation where the entire
reactor effluent was processed into the
condenser) has resulted in an increase of
Hydrocracker unit history
Excessive HPNA formation at the NH J and H2S concenriations in the con
~nser, thus creating a higher Kp factor .
effluent condenser
For many years, Saudi Arameo Riyadh Uncontrollable outlet temperature
refinery has suffered greatly from an In addition to the increase in the Kp fac
ammonium bi-sulphide corrosion prob
tor, the lower molar flow rate inside the
which was originally
lero taking place in the hydrocracker condenser,
reactors effluent condenser, causing 1055 designed with a higher surface area, has
of production, increased maintenance consequently reduced the fluid velocity
cost, unit upsets, and potential hazard.
to below 10--20ft/sec at which overcool
However, prior to the appearance of ing of the vapour to below 50C is evi
this problem, Riyadh refinery was suffer
dent. Additionally, this velocity is low
ing from HPNA buildup in the effluent enough for the ammonium bi-sulphide
condensers, which required unit shut
to settle down in the tubes, causing pit
down for about one week, four to five ting and under-deposit corros ion.
times during ea eh cycle for tube clean
The average seasonal temperature
ing. This problem was increasingly recorded at the outlet of the effluent con
reducing the availability of the hydroc
denser after the revamp is ranging
racker unit throughout the year, hence between 20--S0C, which is below the
reducing the refinery's ()verall gross mar
gin. Figure 2 shows the originallocation
coi.ps.~~rates/~~f -
47
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REFINING
crystallising temperature of the ammoni
Hydraulic un-symmetry
I-"
Inspection findings
In light of the aboye, Riyadh refinery
started its metaIlurgical analysis by tak
ing radiographic shots and applying
ultrasonic thickness measurements
which showed elevted metal loss rates
on the cond~ns~r tubesandpiRing cir
cuit ranging from 8-126 mils ;Ier y_e.ar
(refer Table 2) . In particular, the worst
corrosion rates occurred at the con
dser outIe"i noZzles. According to the
velocity calculations in Table 3, the 4in
outlet nozzles have the highest velocity
in the effluent condenser circuit. In
addition, the corrcsicn was founo
extremely localised~ t p()ints of high tur
bulence and high velocity.
Inspectionhistory
During an emergency shutdown in Jan
uary 1994, 13 four-inch outlet nozzles of
the hydrocracker effluent condenser
Banks
Train A
A
B
2.50
0.90
0.50
0.60
, .30
, .30
0.90
0.90
e
D
E
F
il
Table 4
Train B
0.60
3.0
0.50
0.30
. , .05
'040
0.30
, .90
Figwe
REFINING
each train. From the aboye, it was founct that the ban..l<s were not
deaned ali at the same time, which fP..sulted in an uneven flow dis
tributio'n among the condenser banks. The high velodty causes ero
~ sion to the deaned bundles and low velodty causes Eouling to the
undeaned bundles. 11s practice has aggravated the piping un-sym
metry problem discussed aboye.
lt was concluded that the severe metal loss occurring in the
effluent condenser outlet nozzles was due to arnmonium bi-sul
phide corrosion and high outlet velodty, which intum leads to
erosion attack.
Remedial actions
The refinery carried out several remedial measures which were
intended to mitigate the ammonium bi-sulphide currosion prob
lem, thus ensuring the safety and integrity of the hydrocracking
unit. A total engineering solution of the subject eftluent con
denser arnmonium bi-sulphide corrosion \'Vas initiated and imple
mented as follows:
1. Nozzles alIoy overIay
The effluent condenser outlet nouJes were replaced in-kind with
~.1his was done to improve the resis
tance of the outlet nouJes to the high erosion/corrosion rates because
they maintain velodties of about 27ft/sec. Moreover, the lnconel 625
alioy nouJes can withstand a liquid velodty up to 3Oft/sec.
2. New water tanks and pumps
, . , A capital project was initiated to replace the ex.i.sting four water injec
tion pumps with three higher capadty and better type pumps. This
was done to ensure a delivery of 8 LV% water injection rateo Also,
new dosed water tanks with ~ alIevi
ate the oxygel),content in the water injection.
3. Piping symmetry
The effluent condenser iolet and outlet piping was made sym
O=Zoftsec(Fg;:ue 6).
The FCCU
Process Engineer's
~h3~~~~~~
~(Figure6).
..Resultsand discussion
After the implementation oE the aboye actions, the current effluent
condenser operation signilicantly improved in terms of equal flow
distribution, even water wash distribution, and lower corrosion rates.
As shown in Table 4, the corrosion rates appredably decreased to
below the industrial norm of 3-5mpy after one year and a half oE
implementing the remedial measures. Also, no indications of high
fouling rate were discovered.
However, ammonium bi-sulphide corrosion is bound to occur
because of the unsolved <;ondenser temperature control problem.
Nevertheless, ali other ammonium bi-sulphide corrosion-influenc
ing factors are being optimised in order to compensate for the tem
perature control malfunction.
49
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IENQUIRY NO
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