Energy Risk Engineering Insights

Let’s discuss a sulfadation study at a refinery.

Sulfadation is a common issue in refineries and refers to the corrosion caused by the presence of sulfur compounds in various process streams. Sulfur compounds can be present in crude oil, fuel gases, and other hydrocarbon streams, and their presence can lead to the formation of corrosive species such as hydrogen sulfide (H2S) and sulfuric acid (H2SO4).

A sulfadation study in a refinery typically involves evaluating the extent of sulfadation corrosion in various equipment and determining the factors that contribute to its occurrence. The study aims to understand the corrosion mechanisms involved, identify vulnerable equipment, and develop strategies to mitigate sulfadation-related issues.

Here are some key aspects that may be considered in a sulfadation study:

1. Corrosion monitoring: The study may involve monitoring the corrosion rates in different equipment and locations within the refinery. This can be done through techniques like weight loss measurements, corrosion coupons, electrical resistance probes, or non-destructive testing methods.
2. Process stream analysis: Analyzing the composition of various process streams is crucial to understand the sulfur content and its different forms, such as elemental sulfur, sulfur compounds, or hydrogen sulfide. This analysis helps identify the sources of sulfur and how they interact with the equipment.
3. Material selection and evaluation: Different materials used in refinery equipment may exhibit varying resistance to sulfadation corrosion. The study may involve evaluating the performance of different materials under operating conditions, such as carbon steel, stainless steel, nickel alloys, or specialized coatings.
4. Operating conditions: Factors such as temperature, pressure, flow rates, and the presence of other contaminants can influence sulfadation corrosion. The study may investigate the impact of these operating conditions on the corrosion rates and identify critical areas where corrosion is likely to occur.
5. Mitigation strategies: Based on the study findings, recommendations can be made to mitigate sulfadation corrosion. These may include process modifications, the addition of corrosion inhibitors or scavengers, changes in material selection, or implementing monitoring and inspection programs.

It’s important to note that a sulfadation study is a specialized area of corrosion engineering, and refineries often employ experts in this field or work with external consultants to conduct such studies. The specific details and scope of a sulfadation study may vary depending on the refinery’s configuration, processes, and equipment.