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35 views

Powerpoint Presentation NACE 19

1

Uploaded by

shyam0087
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Corrosion Prevention in

Acid Gas Treating Units

Dr Nasar Miskin
Technical Manager
Corrosion in Acid Gas Scrubbing Cycle

B (in solution, Fe and Cr ions • Consider an absorber / regenerator cycle


J used in amine based gas purification
catalyse amine breakdown –
• ‘Problem’ areas are highlighted as shown
increased OpEX cost…)
I • Specialised coating can help with
nearly all areas

C H
G A IMPURE GAS G MAIN HEAT
B PURIFIED GAS EXCHANGER
L H REGENERATOR
C ABSORBER COLUMN
COLUMN I REFLUX
A F D RICH AMINE ACCUMULATOR
K PUMP J ACID GAS(ES)
E L E ‘FLASH’ DRUM K REBOILER
D D F ‘FLASH’ GAS L LEAN AMINE
PUMP
(corrosion-resistant alloys (CRAs) are required for moving
parts and/or close dimensional tolerances)
Acid Gas Removal Process

• ABSORBER: Lean amine falls through rising acid gas


and chemically absorbs H2S and CO2. Typical
temperature is around 60 Celsius or lower.

• REGENERATOR: Amine-acid gas (rich amine) is heated


within regenerator by reboiler to over 120 Celsius to
remove acid gases. Hot lean amine recirculates and
cooled before re-entering top of absorber.

• Cycle is repeated continuously.


Creating Corrosive Processes

• Hot lean amine gradually reacts with:


(a) Fe ions from carbon steel
(b) Cr ions from high chromium stainless steel
(c) Cr ions in Hastelloy metal spray.
Fe ions react with hot lean amine more quickly than Cr ions.
RESULT: Formation of amine metal ion complex

• Amine+Cr ion complex is more efficient at catalysing breakdown


of amine than Amine+Fe ion complex.
RESULT: Amine is broken down into organic acids and ineffective
amines.
Result of Corrosive Processes

• Amine breakdown leads to loss in efficiency of amine with


reduced ability to remove acid gas.

• Reaction of amine and organic acids (acetic, oxalic and formic


acids) create heat stable salts (HSS). Very corrosive.

• Galvanic corrosion from acid gas and HSS lead to deep pitting.

• Amine reaction to Fe and Cr ions leads to general wall thinning of


process vessels especially under fast flow conditions.
Corrosion Issues
• Wet acid Gas = Deep pitting corrosion
• Rich Amine = Pitting Corrosion
• Hot Lean Amine = Wall Thinning
• Heat Stable Salts (HSS) = Pitting Corrosion
• H2S = Hydrogen Induced Cracking from

Use of stainless steel equipment, hastelloy metal spray and SS


cladding in parts of the amine plant will exacerbate corrosion
in carbon steel sections.

Uncoated carbon steel and high chromium steels will degrade


amines at faster rate.
Prevention of Undesirable Processes

• DuraPol UHT is an organic-inorganic hybrid coating resistant to


amines and acid gases up to at least 150 Celsius and elevated
pressures. Plus 10 year track record at Saudi Aramco and
ADNOC.

• DuraPol UHT used instead of silicone sealers to effectively seal


and isolate porous metal spray from amine process. Typical bond
strength of metal spray with DuraPol UHT coating as sealer/top
coat exceeds 40 MPa.
Note: silicone sealers are washed out immediately when
exposed to amine – sour gas process environment. Result is
porous metal spray leading to under film corrosion
DuraPol UHT Coating Technology

• Inorganic molecules polymerised onto multi functional organic


polymers – hybridisation

• Increased crosslink density after ambient cure – high


immersion chemical resistance without post cure

• Inorganic nano groups – high temperature capability

• Nano modified hybrid molecule – chemical resistance at


ambient to high immersion temperatures
3rd Party Testing

Autoclave test in accorandace with


NACE TM0174

H2S ResistanceTest
1. Liquid Phase: 5% NaCl and 95% distilled water by volume
at 150oC and 1000 psi
Gas Phase: 38.8% H2S, 6.8% CO2, 54.4% CH4.

Amine Resistance Test


2. Liquid Phase: 50% MDEA and 50% distilled water by volume at
150oC and 1000 psi
Gas Phase: 2% H2S, 9% CO2, 89% CH4.
3. Liquid Phase: 55% DGA and 45% distilled water by volume at 150oC
and 1000 psi
Gas Phase: 5% H2S, 10% CO2, 85% CH4.
Test Results

• No softening, cracking, blistering or


delamination in all tests Test 1: H2S
Pre Test EIS: 10.88
• EIS (Log Z, where Z is the Coating Post Test EIS: 8.98
Impedance measured in ohms.cm2)
indicates very good to excellent
resistance after all tests.

Test 2: MDEA Test 3: DGA


Average Post Test Adhesion: 2,512 psi Average Post Test Adhesion: 2,287 psi
(Cohesive / Glue Failure) (Cohesive / Glue Failure)
Average Post Test EIS: 10.28 (Excellent) Average Post Test EIS: 8.81
Water Resistance

Seawater
Cathodic disbondment
-1.5V, 150oC, 1 month

RESULTS
No disbondment, no blistering,
cracking or delamination
Cold wall immersion in demin water
Duration: 6 months
Temperature: 150oC

RESULTS
No change in coating except discoloration

Average EIS: Coating Impedance, Log Z (Z in ohms.cm2)


Before: 10.97 After: 8.38

Average Adhesion:
Before: 1825 psi (GF) After: 2233 psi (GF)
Application of DuraPol UHT
• Single component standard airless spray. Pump
size: 63:1 ratio or greater.
Application Method
• Internal pipe coating equipment.

• Brush

• 1 coat @ 800-1000 microns


Number of Coats
• Repair: sweep blast 1st coat and apply 2nd coat

Cure Temperature • Min > 20oC Max. < 80oC

Cure Duration • 24 hours @ +40oC (Can use hot air)

• 3 days @ +20oC
British Petroleum – Rumaila, Iraq
3 Phase Pressure Vessel: 4.5 metre Diameter x 30 m T/T
Case Study 1 Carbon Capture Pilot
316L SS Stripper Operating at 128oC in Rich MEA

Results after 1 year trial: Stainless steel has undergone pitting whereas coating
shows only slight discoloration.
Case Study 2 Clean Coal Power Plant
MDEA/Sulphinol Stripper Operating at 120oC

DuraPol UHT coating in excellent condition after 5 years service


Case Study 3 Glycol Surge Drums

• Operating conditions: 99% lean TEG glycol, 37% dissolved H2S, 86% water vapour
concentration at an operating temperature of 103oC and a maximum
operating pressure of 14.5 psig.
BEFORE

Vessel internal surface prior to coating. Severe metal loss and deep pitting in roof
section due to deep penetrating H2S corrosion
Case Study 4 Glycol Surge Drums

AFTER

Vessels were corroded beyond corrosion allowance but were critical for operation until
new vessels could be manufactured. DuraPol UHT coating stopped corrosion and allowed
continued operation. Coated vessels in service since June 2014.
Case Study 5 AGR Stripper Reboilers 2 No. DuraPol UHT applied on roof section.
Operating conditions of 128oC in LP Steam, MDEA amine and sour
gas service.

RESULTS: Coating in excellent condition during inspection after 1 year


Conclusions & Recommendation
Tests and real life service experiences show that Specialised Coating provides
excellent resistance to corrosion in amine and sour service. In fact test
conditions are much more severe than those found in typical Amine Treating
Units.

Specialised Coating offers following benefits:


• Full protection to equipment built from carbon steel. Alternative is to use
specialist alloys or stainless-steels making projects economically unviable.

• Specialised coating is inert to amines and acid gases. Prevents metal ions
going into solution reducing formation of HSS. Maintain efficiency of amine
for continuous optimal use.

• Complete corrosion prevention in all areas of sour gas treating plant


including absorbers, strippers, reboilers, pumps, flash drums, storage tanks,
reflux drums and accumulator vessels.
Contact Details

DuraPol Limited
Thornton Road Industrial Estate,
Hockney Road,
Bradford, West Yorkshire
BD8 9HQ
United Kingdom

Tel: +44 (0)1274 484810


E-mail: [email protected]
Web: www.durapol.co.uk

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