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Control DEA corrosion in a gas refinery | Hydrocarbon Processing | May 2012

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Control DEA corrosion in a gas refinery


05.01 .2 01 2 | At ash Jameh, A., Sarkhoon & Qeshm Gas Treating Com pany , Bandar Abbas, Iran; Gharaghoosh, A. Z., Sarkhoon and Qeshm Gas Treating Com pany , Bandar Abbas, Iran; Rashidfarokhi, A. R., Sarkhoon & Qeshm Gas Treating Co.,, Iran; Pakshir, M. , Shiraz Univ ersity , Iran; Pay dar, M. H., Shiraz Univ ersity , Iran

Corrosion inhibitor selection and protectiv e scales are key to prev ention Key words: [corrosion] [gas processing] [natural gas] The sweetening unit is a key component of the gas processing plant, and the amine regeneration tower is one of the major parts of this unit. The amine tower in the Sarkhoon gas plant in southern Iran has ex perienced sev ere corrosion [4050 mils per y ear (mpy )] ov er a 2.5-y ear period. The corrosion area is limited to the v apor and v apor/liquid interface spaces. The material in this area is carbon steel (A-51 6-GR-7 0) and is located on the inside of the tower shell. A recent study inv estigated the cause of this corrosion, along with the corrosions tendency to mov e from the top tray s of the tower to the bottom tray s. The performance of the chosen corrosion inhibitor was also scrutinized during the inv estigation. Results showed that an amine solution in the unit was degraded by dissolv ed ox y gen (O2 ), ex posing the inside of the tower shell to corrosiv e amine degradation products. The injection of an O2 scav enger inhibitor into the amine solution has not corrected the problem, and design issues with the injection point and its piping hav e been discov ered.

Corrosion sources in a gas plant


A portion of the Sarkhoon gas plants feed is sour gas. In the feed-sweetening process (Fig. 1 ), a solution of 7 0% water and 30% diethanolamine (DEA) is used to absorb H2 S in the contactor tower (C-1 01 ). Absorbed H2 S is released in the amine regeneration tower (C-1 03) in the presence of rising temperature and pressure drop. 1 In comparison with other amines [e.g., monoethanolamine (MEA), methy ldiethanolamine (MDEA), activ ated MDEA (aMDEA)], DEA is more susceptible to ox idation and degradation, and it produces organic acid bases that form heat-stable salts in an amine env ironment. 2

Fig. 1. Gas-sweetening unit at Sarkhoon gas plant.

One of the major sources of corrosion on carbon steel v essels in sweetening units is heat-stable materials, which are a product of amine degradation. 3 ,4 Ox y gen play s a major role in DEA degradation. The reaction of O2 and DEA produces organic acids, such as acetic acid, formic acid and so on. O2 solubility in a solution of amine (ex cept DEA) and water is similar to the solubility of O2 in water. 5 Foaming in the amine regeneration tower results in the increased contact of corrosiv e components of the amine solution with the tower internals, as

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well as in a loosening of the protectiv e iron sulfide (FeSX ) surface lay er that is formed by H2 S. Heat-stable salts play an important role in foaming and corrosion in the amine regeneration tower. 6 ,7 Organic acidssuch as formic acid, acetic acid and ox alic acidat a temperature of 200C contacting carbon steel would result in sev ere corrosion. Howev er, the corrosion activ ity of these acids is significantly reduced in an MDEA solution. 3 The corrosiv eness of a 20% amine solution on carbon steel in an env ironment containing either CO2 or H2 S gas at a temperature of 1 40F to 21 2F would increase dramatically . Howev er, env ironments containing either CO2 or H2 S gas in this temperature range tend to ex perience more aggressiv e corrosion compared with an env ironment containing a CO2 :H2 S mix ture of 1 :3 or 3:1 . 8 One method to prev ent corrosion in sweetening units is to use corrosion inhibitors. Corrosion inhibitors manufactured from heav y metals, such as arsenic and v anadium, hav e the ability to control corrosion in the aforementioned env ironments, although these heav y metals are incompatible with these env ironments. Furthermore, these ty pes of corrosion inhibitors are unable to protect splash zones and v apor spaces. Film corrosion inhibitors prev ent general corrosion, but are unable to control specific ty pes of corrosion. 8 To av oid certain corrosion ty pes (e.g., sulfide stress cracking, hy drogen-induced cracking, etc.), guidelines contained in NACE MR-01 -7 5 should be followed during the material selection of sweetening units. 9 Organic amines are traditionally used in the refinery crude column ov erhead to neutralize and reduce pH as a means of corrosion control. 1 0 Based on prev ious research on H2 S concentration increases in oil, two ty pes of scales form on contacting steel surfaces: Mackinawite and Py rrhotite. 1 1 Mackinawite scales hav e coarse grain in a loose and brittle form. Although Mackinawite scales reduce general corrosion, steel surfaces are still susceptible to aggressiv e, pitting corrosion. Py rrhotite scales hav e fine grains and ex ist in continuous form, and are resistant to both general and pitting corrosion. 1 2 There are three zones in the regeneration tower: the v apor space, the liquid/v apor interface and the liquid phase. In the v apor space, the formation of a protectiv e lay er of FeSX results in low corrosion rates for a rich solution containing H2 S, compared with a lean amine solution that does not contain H2 S. 1 2

Corrosion tests
A number of field and laboratory tests hav e been performed to measure corrosion rates and lev els at the Sarkhoon gas plant. Field tests included the following: Weight loss (coupon) test. This test was carried out based on standard test method ASTM-G-1 v ia coupon installation in 1 0 points of amine solution cy cle input. Test results are presented in Table 1 . 1 3

Iron count test. To ev aluate the corrosion rate of the unit, this test was performed according to the spectrophotometric method. Samples were taken from the circulating amine solution, and the amount of iron (which is generated by corrosion on v essels) was measured. The following iron counts were observ ed: 1 6.9 ppm (Test 1 ), 1 0.6 ppm (Test 2), 35.0 ppm (Test 3) and 38.0 ppm (Test 4). Based on these data, the presence of an amine solution containing concentrated heat-stable salts results in corrosion reactions. According to the unit design, the max imum allowable amount of iron in the amine solution is 1 0 mpy . Dissolv ed O2 in am ine solution. The amount of O2 present in the amine solution, which is a major factor in DEA degradation, was measured according to test methods outlined in ASTM D-888 and ASTM D-5543. Results are represented in Table 2. 1 4 ,1 5

Ultrasonic test. An ultrasonic thickness meter was used to measure tower wall thickness. The results of this test, which show a reduction in thickness, are represented in Tables 3 and 4.

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Laboratory corrosion tests included the following: Inlet gas analy sis. This test was carried out according to ASTM D-1 945 guidelines. A gas chromatography apparatus was used to pinpoint components of the feed gas entering the contactor tower. 1 6 Results are shown in Table 5.

Polarization test. To determine the corrosion rate of the lean amine solution containing 3.7 1 % heat-stable salts, three tests at temperatures of 25C, 50C and 7 0C were performed according to ASTM G-3 methods. Respectiv e corrosion rates of 2.0 mpy , 4.8 mpy and 8.8 mpy were observ ed at the v arious temperatures. These results are illustrated in Fig. 2. 1 7

Fig. 2. Lean amine polarization test at three different temperatures. Im m ersion weight loss. To simulate corrosion in the three tower regions, this test was conducted according to ASTM G-31 guidelines in static condition, with lean amine containing 3.7 1 % heat-stable salts at a temperature of 1 20C. The corrosion rates observ ed for the liquid phase, liquid/v apor interface, and v apor phase were 2.1 0 mpy , 5.02 mpy and 8.1 6 mpy , respectiv ely . 1 8 Scanning electron m icroscope. To ev aluate corrosion products on the carbon steel section of the tower shell, a sample from the bracket of the downcomer of the ninth tray was prepared and tested by microscope. Test results are shown in Fig. 3.

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Fig. 3. SEM test result on a specimen from the downcomer. Am ine solution analy sis. This test was performed to inv estigate lean amine solution components, and it is based on ion chromatography and National Iranian Gas Co.s test method for heat-stable salts. Results are presented in Table 6.

Corrosion inhibitor ev aluation. To ev aluate the O2 scav enging performance of a corrosion inhibitor injected into the amine cy cle, this test was conducted according to methods outlined in ASTM D-888 and ASTM D-5543 for two samples of freshwater and a solution of 30% amine and 7 0% water. Test results are shown in Table 7 . 1 4 ,1 5

Corrosion test in acid/DEA env ironm ent. This test was conducted to ev aluate the corrosion rate of carbon steel in a liquid phase contacting a lean amine solution. The solution contained organic acids at a temperature of 25C to 30C, which is the temperature of the circulated amine solution in the cy cle. Eighteen separate samples from the fresh amine solution containing an organic acid (i.e., acetic, ox alic, malonic, formic, buty ric, succinic or gly colic) were prepared, and corrosion coupons were installed. Test results showed a corrosion rate greater than or equal to 0.2 mpy for all of the abov e-named acids. X-ray diffraction. Samples from a non-corroded portion of the tower were used in this test, as it was not possible to prepare samples from the corroded area. The formation of iron disulfide (FeS2 ) was observ ed, as shown in Fig. 4.

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Fig. 4. XRD testFeS2 scale.

Corrosion in the gas-sweetening unit


DEA is used in the gas-sweetening unit. This unit was inspected one y ear after commissioning, at which time no corrosion or deterioration was detected. A second inspection was carried out 2.5 y ears after commissioning, and aggressiv e corrosion was detected in the v apor space of the tower shell, in the carbon steel section. This tower consists of 20 tray s. The tower shell is made up of 31 6L stainless steel from the top head through Tray 8, and the remaining 1 2 tray s are annealed SA51 6 Grade 7 0 carbon steel. The tower wall thickness is 1 2 mm, with 3 mm of corrosion allowance. The chemical composition of the aforementioned alloy is presented in Table 8. Due to the ex istence of chloride ions in the feed, the chloride ion content of the circulating amine was higher than the allowed limit during the first three months of operation. An anionic resin bed was used to absorb the negativ e ions. After feed quality improv ed and the ion chloride content was reduced, the bed was taken out of serv ice.

Corrosion was observ ed in sev eral forms. Local or island-shaped corrosion resembled sev eral concentric, closed curv es, with each curv e hav ing an almost equal center and differentiation in the borders between it and the nex t curv e (Fig. 5). The corrosion morphology was described as stepdown edges. The most corroded areas were found at the centers of the curv es. Here, the tower thickness was reduced by 3.5 mm to 4.0 mm.

Fig. 5. General corrosion at v apor phase area.

The v alley form of corrosion occurred in down-flowing liquid in the v apor/liquid interface of the shell. The depth of the v alley s was 5.5 mm to 6.0

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mm (Fig. 6). The corrosion shape was described as a smooth v alley and an escarpment.

Fig. 6. Tower corrosion (v alley ty pe).

Inv estigation of corroded areas for both forms showed: 1 . Corrosion on the regions of the shell contacting the amine solution (liquid phase) was negligible. This was v erified by coupon test results (Table 1 ). 2. Sev ere corrosion was observ ed on the tray v apor space and the liquid/v apor interface. 3. Corrosion sev erity in the aforementioned areas on tray s 8 to 20 (top to bottom) increased in correlation with area and depth. Inlet gas to the contactor contains a max imum of 40 ppm H2 S. Software was used to determine the H2 S concentration in each tray of the regenerator tower; this process was simulated based on rich amine content. Results are presented in Table 9.

In order to control corrosion, a corrosion inhibitor was injected into two lines with different pressures. These lines included a lean amine-tocontactor line with a pressure of 60 bar to 65 bar and a reflux stream line with a pressure of less than 2 bar. Ox y gen scav engers function as the duty of this inhibitor as well as a protectiv e lay er (along with a surface scale of FeSX ), based on the information prov ided by the inhibitor manufacturer.

Amine analysis results


The results of the circulating amine analy sis showed that the amine was degraded. Ox idation and degradation products are generally organic acids that cause sev ere corrosion on carbon steel at proportional concentrations (Fig. 7 ). The analy sis showed that the amine produced heat-stable salts after contacting organic acids, which can also cause corrosion on carbon steel (Fig. 8).

Fig. 7 . Carbon steel corrosion in v arious acids and salt.

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Fig. 8. Carbon steel corrosion in v arious acids.

V isual inspection and thickness monitoring detected no significant corrosion in the liquid phase of the amine stream on pipelines, towers or other v essels in the gas sweetening unit. An analy sis of corrosion-monitoring results (Table 1 ) observ ed during an aggressiv e period of corrosion (as well as subsequent corrosion periods) shows a corrosion rate of fewer than 2 mpy in the liquid phase. Field corrosion-monitoring results were v erified by immersion weight-loss tests in the laboratory . The corrosion rate of the lean amine in the liquid phase was found to be within an acceptable industrial margin, according to a polarization test of the lean amine solution (Fig. 2), which contained 3.7 1 % heat-stable salts. Organic acids were also present in the solution. Although the results of the polarization test showed rising temperature, the corrosion rate was less than 25% of the corrosion rate of the tower shell. Furthermore, the temperature increase was related to the rich amine stream in the unit. In a rich amine stream, the formation of an FeSX lay er protects the surface. No H2 S or FeSX lay er was observ ed in the lean amine solution in either the polarization test or the laboratory weight-loss test. Use of ox y gen scav enger inhibitor. To omit O2 , which is introduced into the solution by a demineralized water makeup, an O2 scav enger inhibitor was injected. Based on the characteristics of the inhibitor, the required temperature for starting a reaction with dissolv ed O2 is higher than 80C, while the amine temperature in the tank and onstream before entering the regenerator tower (1 03C) does not reach the specified temperature. Therefore, O2 cannot be entirely eliminated below 80C. Test results showed a partial decrease in the amount of dissolv ed ox y gen in the amine solution after the inhibitor was added, which raised the temperature to 98C for a period of 1 5 minutes. The O2 scav enging performance of this inhibitor at higher temperatures is in doubt, as it was found to be unsatisfactory during this test. Additionally , the results of the dissolv ed O2 field test are ev idence of the presence of O2 in the solution, which v erifies the unsatisfactory performance of the inhibitor. The poor performance was due to the amine coming into contact with O2 . In other words, the presence of ox y gen is a factor in the production of organic acids. The injection pump performs at a unique pressure, and it is not possible to inject the inhibitor into two points with different pressures, as setting the pressure on the reflux stream would result in lower-than-desired pressure in comparison with the contactor stream. If the pressure setting is based on contactor pressure (which is higher than reflux stream pressure), the high-pressure injection fluid would flow into the low-pressure stream (reflux ); therefore, it cannot be injected into the contactor stream. Causes of corrosion. As mentioned abov e, corrosion observ ed on the interior of the tower is located on the v apor space or on the v apor/liquid interface. According to an analy sis performed on degraded amine that was circulated during a period of sev ere corrosion, there are sev eral organic acid anions in amine that cause corrosion. Since tests cannot be v iably performed on liquids in the reflux drum or on outlet gases from the top of the tower, process simulation software was used to ev aluate the ex istence of acidic anions in gases flowing from the top of the tower. Simulation results (Table 9) confirmed the presence of these anions in the v apor space of the tower. V apor pressure research also indicated the presence of these anions in the towers v apor space. According to research and calculations, the corrosion rate is 40 mpy to 50 mpy . Taking into account the percentage of anion components found in field-sampled amine, the corrosion rate was applied to these test results, as shown in Figs. 7 and 8. The FeSX scale formation on carbon steel was found to hav e a smaller structure and to adhere better to metal in proportion to the increase in H2 S concentration. In lower H2 S concentrations, the FeSX scale has a larger structure and is less adhesiv e to metal. Organic acid anions ov ercome the sulfur element of FeSX and, in the process of destroy ing the scale, they form salts (e.g., iron acetate). An X-ray diffraction analy sis was performed on an FeSX scale on the v apor space of Tray 9, in an area that was not affected by corrosion. Test results (Fig. 4) show the scale ty pe to be Py rrhotite, which adheres suitably to metal and offers better surface protection than a Mackinawite scale. The process simulation results presented in Table 9 show the decreasing presence of H2 S in the carbon steel regions of Tray s 8 through 20. Consequently , these tray s hav e less adhesiv e FeSX scales. The results of the sour gas-sweetening unit analy sis show that the percentage of H2 S is suitably low and meets conditions outlined in NACE MR-01 7 5, ev en though the gas is sour. On the other hand, the low concentration of H2 S results in a loose and brittle FeSX scale, along with organic acid anions in the v apor phase, steam that allows for an electrochemical condition, and the inability to inject an inhibitor into the liquid phase. All of these factors create a tower env ironment that is susceptible to corrosion. Furthermore, internal temperatures approach 1 20C on the lower tray s of the tower and 1 00C on the upper tray s. The higher temperature and looseness of the FeSX scale on the lower tray s accelerate corrosion on the lower section of the tower. Corrosion formed in a v alley shape on the liquid/v apor interface due to FeS2 erosion from the use of an amine containing organic and inorganic contaminations. Low reforming potential and a high concentration of acidic components nex t to the liquid surface also contributed to the corrosion.

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Takeaway
According to the analy sis, the water used to prepare the amine solution contained an unacceptable concentration of ox y gen. Also, ex isting O2 in the reaction with DEA resulted in DEA ox idation in the circulating amine solution, producing organic acids that entered the v apor phase of the tower. In a corrosion-susceptible env ironment (i.e., the ex istence of water, high temperature, acids, and no amine in the v apor phase), the presence of these acids contributed to corrosion on the shell interior of the tower. The selection of a corrosion inhibitor was not correctly performed, as attention was not giv en to the required temperature for rationing with O2 . Furthermore, the design of the corrosion inhibitor injection sy stem was corrupt, and the injection of an inhibitor into two points is not practical. The lesson learned is that the selection of a corrosion inhibitor should be carefully performed. A rev amp of the injection processone that considers simultaneous injection into two points at different pressuresis necessary . Also, the ty pe of FeSX scale that forms on carbon steel must be considered, as this has a direct effect on the degree of surface protection achiev ed and the rate and ex tent of the corrosion that occurs. An anionic resin bed play ed an unex pected and important role in corrosion prev ention during the first y ear. In a situation where O2 cannot be eliminated, the dev elopment and use of this ty pe of bed is recommended. Also, the implementation of a suitable lining on the tower interior can prov ide temporary corrosion control. HP ACKNOWLEDGMENT Research for this surv ey was supported by Sarkhoon & Qeshm Gas Treating Co. LIERAT URE CIT ED
1 Robert, N. and J. Morgan, Gas Conditioning and Processing, V ol. 4, Campbell Petroleum Series, Oklahoma, 1 998. 2 Jenkins, H., Understanding gas treating fundamentals, Petroleum Technology Quarterly, Winter 2001 . 3 Dupart, M. S., T. R. Bacon and P. C. Rooney , Effect of heat-stable salts on MDEA solution corrosiv ity , Hydrocarbon Processing, March 1 996. 4 Rooney , C. P. and M. S. Dupart, Corrosion in Alkanolamine Plants: Causes and Minimization. NACE International, Corrosion 2000, Orlando, Fla.,

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Sequestration, Alex andria, V ir., 2003.


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T he authors Ahm ad Zam ani Gharaghoosh is the managing director of Sarkhoon & Qeshm Gas Treating Co. He joined National Iranian Gas Co. in 1 997 and has more than 1 5 y ears of ex perience in gas refineries as a senior corrosion and welding engineer, inspection department head and research committee member. He is an ex pert on static equipment inspection, risk-based inspection and corrosion inv estigation at gas refineries, and he has authored or co-authored fiv e papers for ISI journals and national and international conferences. Abolfazl Atash-Jam eh heads the process engineering group at Sarkhoon & Qeshm Gas Treating Co. He joined National Iranian Gas Co. in 1 999, and he has 1 0 y ears of ex perience in different aspects of process engineering for natural gas. He has published sev en papers for national and international conferences. Am ir Reza Rashidfarokhi is a mechanical engineer and heads the technical inspection group at Sarkhoon & Qeshm Gas Treating Co. He joined National Iranian Gas Co. in 2002, and he has eight y ears of ex perience in different aspects of the technical inspection industry . He has also participated in a number of industry studies and courses. Mahm oud Pakshir is a tenured professor at the Department of Material Science and Engineering at Shiraz Univ ersity in Iran. He has published more than 7 0 papers on corrosion control and prev ention. M. H. Pay dar is an associate professor at the Department of Material Science and Engineering at Shiraz Univ ersity in Iran. He has published more than 20 papers in international magazines.

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