API PUBL 932-A-2002 A Study of Corrosion in Hydroprocess Reactor Effluent Air Cooler Systems《研究出水空冷器系统裂化反应器的腐蚀》.pdf

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1、 A Study of Corrosion in Hydroprocess Reactor EffluentAir Cooler SystemsAPI PUBLICATION 932-ASEPTEMBER 2002A Study of Corrosion inHydroprocess Reactor Effluent Air Cooler SystemsDownstream SegmentAPI PUBLICATION 932-ASEPTEMBER 2002SPECIAL NOTESAPI publications necessarily address problems of a gener

2、al nature. With respect to partic-ular circumstances, local, state, and federal laws and regulations should be reviewed.API is not undertaking to meet the duties of employers, manufacturers, or suppliers towarn and properly train and equip their employees, and others exposed, concerning healthand sa

3、fety risks and precautions, nor undertaking their obligations under local, state, or fed-eral laws.Information concerning safety and health risks and proper precautions with respect to par-ticular materials and conditions should be obtained from the employer, the manufacturer orsupplier of that mate

4、rial, or the material safety data sheet.Nothing contained in any API publication is to be construed as granting any right, byimplication or otherwise, for the manufacture, sale, or use of any method, apparatus, or prod-uct covered by letters patent. Neither should anything contained in the publicati

5、on be con-strued as insuring anyone against liability for infringement of letters patent.Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least everyfive years. Sometimes a one-time extension of up to two years will be added to this reviewcycle. This publication will no

6、 longer be in effect five years after its publication date as anoperative API standard or, where an extension has been granted, upon republication. Statusof the publication can be ascertained from the API Standards Department telephone (202)682-8000. A catalog of API publications and materials is pu

7、blished annually and updatedquarterly by API, 1220 L Street, N.W., Washington, D.C. 20005.This document was produced under API standardization procedures that ensure appropri-ate notification and participation in the developmental process and is designated as an APIstandard. Questions concerning the

8、 interpretation of the content of this standard or commentsand questions concerning the procedures under which this standard was developed should bedirected in writing to the standardization manager of the Standards Department, AmericanPetroleum Institute, 1220 L Street, N.W., Washington, D.C. 20005

9、, standardsapi.org.Requests for permission to reproduce or translate all or any part of the material publishedherein should also be addressed to the Publications Department at publicationsapi.org.API standards are published to facilitate the broad availability of proven, sound engineer-ing and opera

10、ting practices. These standards are not intended to obviate the need for apply-ing sound engineering judgment regarding when and where these standards should beutilized. The formulation and publication of API standards is not intended in any way toinhibit anyone from using any other practices.Any ma

11、nufacturer marking equipment or materials in conformance with the markingrequirements of an API standard is solely responsible for complying with all the applicablerequirements of that standard. API does not represent, warrant, or guarantee that such prod-ucts do in fact conform to the applicable AP

12、I standard.All rights reserved. No part of this work may be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220

13、L Street, N.W., Washington, D.C. 20005.Copyright 2002 American Petroleum InstituteFOREWORDAPI publications may be used by anyone desiring to do so. Every effort has been made bythe Institute to assure the accuracy and reliability of the data contained in them; however, theInstitute makes no represen

14、tation, warranty, or guarantee in connection with this publicationand hereby expressly disclaims any liability or responsibility for loss or damage resultingfrom its use or for the violation of any federal, state, or municipal regulation with which thispublication may conflict.Suggested revisions ar

15、e invited and should be submitted to the standardization manager ofthe Standards Department, American Petroleum Institute, 1220 L Street, N.W., Washington,D.C. 20005, standardsapi.org.iiiCONTENTSPage1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16、. . . . . . . . . . . 12 PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1975 NACE SURVEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 1996 UOP SURVEY . . . . . .

17、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1998 API SURVEY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.1 Preliminary SurveyBroad Overview . . . . . . . . . . . . . . . . . . . . . . .

18、 . . . . . . . . . . 75.2 Interview Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105.3 Reactor Effluent Air Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125.4 REAC Inlet and Outlet Piping . . . .

19、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135.5 Water Wash Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225.6 Water Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20、. . . . . 235.7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235.8 Corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255.9 Alloy Substitution to Prevent

21、Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255.10 Inhibition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 DISCUSSION AND ANALYSIS OF SURVEY RESPONSES . . . . . . . . . . . . . . . . . 276.1 General Equi

22、pment Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276.2 Nitrogen Content of the Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276.3 Salt Deposition and Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23、. . . . . . . . . 286.4 Management of Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286.5 Factors Influencing Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286.6 Corrosion Control . . . . . . . . . . . . . . .

24、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296.7 Water Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296.8 Corrosion Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25、 . . . 306.9 Flow Effects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 CONCLUSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 FUTURE RESEARCH . . . . . . . . . . . .

26、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31APPENDIX A PLOTS OF CORROSION SEVERITY VERSUS VARIOUS PARAMETERS FROM THE UOP SURVEY DATA FOR ALL COOLER TUBES (REFERENCE 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . 33APPENDIX B PLOTS OF CORROSION SEVERITY VERS

27、US VARIOUS PARAMETERS FROM THE UOP SURVEY DATA FORREAC PIPING (REFERENCE 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37APPENDIX C QUESTIONNAIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Figures1 Effect of Kpon REAC Tube Corrosion (from Ref

28、. 7) . . . . . . . . . . . . . . . . . . . . . . . 42 Effect of NH4HS Concentration in the Downstream Separator on REACTube Corrosion (from Ref. 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Effect of Velocity on REAC Tube Corrosion (from Ref. 7) . . . . .

29、 . . . . . . . . . . . . . . 6vPage4 Preliminary Survey of Subcommittee Participants for Levels of Experience . . . . . 8A-1 Corrosion of Air Cooler TubesThe Combined Effect of Calculated Ammonium Bisulfide Concentration in the Downstream Separator and Calculated Maximum Tube Velocity (ft/s) on Corr

30、osion Severity. . . . . . . . . . . . . 34A-2 Corrosion of Air Cooler TubesThe Combined Effect of Calculated Ammonium Bisulfide Concentration in the Downstream Separatorand Calculated Maximum Tube Velocity (ft/s) on Corrosion Severityfor Balanced and Unbalanced Headers. . . . . . . . . . . . . . . .

31、 . . . . . . . . . . . . . . . . . . 34A-3 Corrosion of Air Cooler TubesThe Combined Effect of Calculated Ammonium Bisulfide Concentration in the Downstream Separator andCalculated Maximum Tube Velocity (ft/s) on Corrosion Severity for Balanced Header Systems. . . . . . . . . . . . . . . . . . . . .

32、 . . . . . . . . . . . . . . . . . . . . . . . 35A-4 Corrosion of Air Cooler TubesThe Combined Effect of CalculatedAmmonium Bisulfide Concentration in the Downstream Separator and Calculated Maximum Tube Velocity (ft/s) on Corrosion Severity for Balanced Inlet and Unbalanced Outlet Header Systems .

33、. . . . . . . . . . . . . . . . . . . 35A-5 Corrosion of Air Cooler TubesThe Combined Effect of CalculatedAmmonium Bisulfide Concentration in the Downstream Separator andCalculated Maximum Tube Velocity (ft/s) on Corrosion Severity for Unbalanced Header Systems. . . . . . . . . . . . . . . . . . . .

34、 . . . . . . . . . . . . . . . . . . . . . . 36B-1 Corrosion of REAC Outlet HeaderThe Combined Effect of CalculatedAmmonium Bisulfide Concentration in the Downstream Separator andCalculated Maximum Outlet Header Velocity (ft/s)on Corrosion Severity . . . . . . 38B-2 Corrosion of REAC Outlet Header o

35、r PipingThe Combined Effect ofCalculated Ammonium Bisulfide Concentration in the Downstream Separator and Calculated Maximum Velocity (ft/s) in the Outlet Headeror Piping on Corrosion Severity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38B-3 Corrosion of REAC Outle

36、t PipingThe Combined Effect of Calculated Ammonium Bisulfide Concentration in the Downstream Separator andCalculated Maximum Outlet Piping Velocity (ft/s) on Corrosion Severity . . . . . . 39B-4 Corrosion of REAC Outlet HeaderThe Combined Effect of Calculated Ammonium Bisulfide Concentration in the

37、Downstream Separator andCalculated Maximum Outlet Header Velocity (ft/s) on Corrosion Severityfor Balanced and Unbalanced Header Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 39B-5 Corrosion of REAC Outlet HeaderThe Combined Effect of Calculated Ammonium Bisulfide Concentration in th

38、e Downstream Separator and Calculated Maximum Outlet Header Velocity (ft/s) on Corrosion Severityfor Balanced Header Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40B-6 Corrosion of REAC Outlet HeaderThe Combined Effect of Calculated Ammonium Bisulfide Con

39、centration in the Downstream Separator andCalculated Maximum Outlet Header Velocity (ft/s) on Corrosion Severity for Balanced Inlet and Unbalanced Outlet Header Systems . . . . . . . . . . . . . . . . . 40B-7 Corrosion of REAC Outlet HeaderThe Combined Effect of CalculatedAmmonium Bisulfide Concentr

40、ation in the Downstream Separator and Calculated Maximum Outlet Header Velocity (ft/s) on Corrosion Severity for Unbalanced Header Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Tables 1 Summary of REAC Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41、 . . . . . . . . 32 Preliminary Survey Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Summary of Preliminary Survey Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Preliminary Survey Results (Showing Only Units Selected f

42、or Site Visits) . . . . . 11viPage5 Summary of Preliminary Survey Results (Showing Only Units Selected for Site Visits) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Compilation of Information from Plant Interviews . . . . . . . . . . .

43、 . . . . . . . . . . . . . 147 Compilation of Information from Plant InterviewsAir Cooler Tubes . . . . . . . . 178 Air Cooler Tube Experience from Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Compilation of Information from Plant InterviewsPiping Information. . . . . . .

44、 1910 Piping Experience from Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2011 Wash Water Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2112 Inspection Summary . . . . . . . . . . . . . . . . . . . .

45、. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2413 Corrosion Experience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26vii1A Study of Corrosion in Hydroprocess Reactor Effluent Air Cooler SystemsThis study was sponsored by the American Petro

46、leumInstitute (API), Committee on Refinery Equipment, Subcom-mittee on Corrosion and Materials Research. The purpose ofthe study was to provide technical background, based onindustry experience and consensus practice, for controllingcorrosion in hydroprocess reactor effluent systems. The find-ings r

47、eported herein will be used as an interim resource by theindustry and as a basis for a future API recommended prac-tice document.1 IntroductionThe treatment of crude distillation products with hydrogento produce higher yields of gasoline and jet fuel became amajor part of refinery technology with th

48、e introduction ofhydrocracking in the 1950s. Later, other hydrofining pro-cesses for removal of impurities from products were intro-duced. These technologies all had similar corrosionexperiences that eventually were identified as being associ-ated with the presence of hydrogen sulfide (H2S) and ammo

49、-nia (NH3), and their reaction product ammonium bisulfide(NH4HS), in the reactor effluents. Minor contaminants suchas chlorides and oxygen were also believed to have an influ-ence on corrosion. But in general, corrosion was associatedwith salt deposition, concentrated solutions of ammoniumbisulfide and the flow velocity.In 1976, R. L. Piehl (Standard Oil of California) conducteda survey for the National Association of Corrosion Engineers(NACE) on corrosion in Reactor Effluent Air Cooler (REAC)systems. Industry-wide experience was gathered and ana-lyzed to establish guidel

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