Corrosion Assessment Method Using CFD Modeling for Refinery Piping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for corrosion assessment in petroleum refineries are inadequate, as they fail to accurately identify corrosion levels in non-monitored areas and do not account for the varying corrosive tendencies of naphthenic acid precursors and sulfur compositions, leading to ineffective treatment responses.
Innovation Solution
A method and system that assess corrosion risk by identifying potentially corrosive species in crude oil samples, determining their boiling points, and evaluating them in the context of piping network information, using a predictive framework that combines corrosion modeling with fluid dynamics to optimize additive dosages and monitor device placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If corrosion monitoring devices are placed in specific locations, then corrosion levels in monitored areas can be detected, but the data cannot be extrapolated to represent non-monitored areas
Solution Approach 1:
The patent replaces physical corrosion monitoring devices with a computational fluid dynamics (CFD) model that uses mathematical equations to simulate corrosion behavior. The CFD model processes crude oil properties, flow conditions, and equipment geometry to predict corrosion rates without requiring physical sensors in every location, thereby eliminating the extrapolation problem while maintaining measurement precision through rigorous mathematical modeling.
Solution Approach 2:
The patent changes the approach from monitoring physical corrosion products to measuring upstream crude oil properties (naphthenic acid content, sulfur compositions, boiling points) and flow parameters. By predicting corrosion rates from these upstream parameters using CFD models, the system can assess corrosion state in non-monitored areas without physical intervention, resolving the information loss problem.
2Ease of operation
If all naphthenic acid components and sulfur compositions are treated equally, then treatment procedures are simplified, but treatment effectiveness is reduced due to varying corrosive tendencies
Solution Approach 1:
The patent applies local quality by differentiating treatment strategies based on the specific properties of corrosive species. Instead of uniform treatment, the system identifies and targets specific naphthenic acid components and sulfur compositions with different corrosive tendencies, molecular structures, and boiling points. This allows customized treatment approaches for different corrosive agents, improving reliability while maintaining operational simplicity through automated identification and classification.
Solution Approach 2:
The patent segments the corrosive species into distinct categories based on their properties (naphthenic acids, sulfur compositions, boiling point ranges, molecular structures). This segmentation enables differentiated treatment strategies for each segment, improving treatment effectiveness. The automated classification system maintains simplicity by handling the segmentation logic computationally rather than operationally.
3Reliability
If additive dosages are increased to control corrosion, then corrosion protection is improved, but treatment cost and complexity increase
Solution Approach 1:
The patent implements feedback through continuous monitoring of crude oil properties and corrosion rates, with the CFD model processing this data to optimize additive dosages. The system adjusts treatment parameters based on real-time or historical corrosion data, achieving effective corrosion protection with minimized chemical additions. This feedback mechanism reduces complexity by automating the optimization process rather than requiring manual trial-and-error adjustments.
Data Source
AI summary
A method includes assessing corrosion in a refinery operation having a piping network. Assessing can include identifying in a petroleum sample a presence and an amount of a species determined to be potentially corrosive to corrodible equipment in a refinery. A corrosion risk presented by the presence, the amount, and the boiling point of the species is determined. And, the corrosion risk is evaluated in view of piping network information. A system for implementing the method is provided, also.