This document provides guidelines for selecting materials for unsaturated gas plants. It discusses major corrosion considerations, including hydrogen sulfide and cyanides in plants handling FCC and coker streams. Carbon steel is commonly used but epoxy coating or corrosion inhibitors may be needed. Tables 1-3 recommend minimum construction materials for vessels, exchangers, piping and other equipment. Methods to control corrosion include water washing streams, adding inhibitors, and monitoring hydrogen buildup and cyanide levels. Special requirements apply to equipment exposed to wet hydrogen sulfide, such as limiting carbon steel impurities.
This document provides guidelines for selecting materials for unsaturated gas plants. It discusses major corrosion considerations, including hydrogen sulfide and cyanides in plants handling FCC and coker streams. Carbon steel is commonly used but epoxy coating or corrosion inhibitors may be needed. Tables 1-3 recommend minimum construction materials for vessels, exchangers, piping and other equipment. Methods to control corrosion include water washing streams, adding inhibitors, and monitoring hydrogen buildup and cyanide levels. Special requirements apply to equipment exposed to wet hydrogen sulfide, such as limiting carbon steel impurities.
This document provides guidelines for selecting materials for unsaturated gas plants. It discusses major corrosion considerations, including hydrogen sulfide and cyanides in plants handling FCC and coker streams. Carbon steel is commonly used but epoxy coating or corrosion inhibitors may be needed. Tables 1-3 recommend minimum construction materials for vessels, exchangers, piping and other equipment. Methods to control corrosion include water washing streams, adding inhibitors, and monitoring hydrogen buildup and cyanide levels. Special requirements apply to equipment exposed to wet hydrogen sulfide, such as limiting carbon steel impurities.
This document provides guidelines for selecting materials for unsaturated gas plants. It discusses major corrosion considerations, including hydrogen sulfide and cyanides in plants handling FCC and coker streams. Carbon steel is commonly used but epoxy coating or corrosion inhibitors may be needed. Tables 1-3 recommend minimum construction materials for vessels, exchangers, piping and other equipment. Methods to control corrosion include water washing streams, adding inhibitors, and monitoring hydrogen buildup and cyanide levels. Special requirements apply to equipment exposed to wet hydrogen sulfide, such as limiting carbon steel impurities.
2. References 6.1 Plants Handling TCC Streams, 3. General Delayed Coker Streams, or Both 4. Major Materials and Corrosion 6.2 Plants Handling FCC Gas Considerations Streams 5. Construction Materials 7. Materials Considerations During Fabrication
1. SCOPE
This Guide provides information for the selection and use of materials in unsaturate gas plants.
2. REFERENCES
The following Mobil Engineering Guides form a part of this Guide. In each case, use the latest edition.
Mobil Engineering Guides
EGE 00-B-20 Pressure Casting Inspection
EGE 00-B-21 Pressure-Containing Equipment — Welding and Inspection EGE 00-B-22 Pressure Equipment and Tanks — Impact Test Requirements EGE 11-B-1 Direct Fired Process Heaters — Design and Fabrication EGE 12-B-1 Pressure Vessels — Design and Fabrication EGE 12-B-2 Pressure Vessels for Special Service — Design and Fabrication EGE 12-B-21 Fractionating Tower Trays and Internals EGE 13-B-10 Shell-and-Tube Heat Exchangers — Design and Construction EGE 13-B-15 Air-Cooled Heat Exchangers — Design and Construction EGE 15-B-1 Centrifugal Pumps for General Refinery Services EGE 15-B-2 Positive Displacement Pumps — Rotary EGE 16-B-30 Piping — Selection and Application of Piping Components and Materials (With Classification Sheets and Appendix) EGE 16-B-40 Piping — Fabrication, Erection, Inspection, and Testing
3. GENERAL
3.1 This Guide shall be used for Mobil projects specifying construction materials for unsaturate gas plants.
3.2 The purpose of the unsaturate gas plant is to recover light hydrocarbons from cracked gases for subsequent processing. MOBIL ENGINEERING GUIDE
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3.3 One representative unsaturate gas plant is shown in Figure 1. Since each refinery charges different stocks and has specific product slate requirements, this general scheme usually is modified for the various refinery installations.
In catalytic cracking units, wet gas streams from overhead accumulators or fractionation receivers are compressed, amine treated to remove hydrogen sulfide, and charged to the fractionating absorber. In the absorption section, hydrocarbons are assimilated by the lean oil (debutanized gasoline) flowing countercurrent with the gas. In the fractionation section, the light boiling fractions of the liquid and the saturated lean oil are separated by heat supplied through a reboiling action. The fractionating absorber offgas is routed to a sponge absorber for recovery of low-molecular-weight lean oil carryover. Either a TCC syntower or an FCC main column sidestream may be used as the absorption medium in the sponge absorber.
The fractionating absorber bottoms are charged to the debutanizer, which also serves as a lean oil still. The hydrocarbon (C3/C4) overhead usually is used as alkylation unit feed. A portion of debutanized gasoline is returned to the top of the fractionating absorber. The net debutanizer bottoms are sent to the gasoline splitter for separation into light and heavy gasoline and further treating.
Another common variation of this process flow involves removal of hydrogen sulfide subsequent to the absorption step.
4. MAJOR MATERIALS AND CORROSION CONSIDERATIONS
4.1 In gas plants handling TCC or delay coker streams, corrosion problems are caused by hydrogen sulfide and underdeposit attack from ammonium compounds. Carbon steel equipment has performed satisfactorily in such plants; however, the use of filming amine inhibitors and water slugging has been necessary in some units.
4.2 In gas plants handling FCC streams, corrosion problems are caused by hydrogen sulfide and cyanides. Carbon steel exposed to moist hydrogen sulfide and cyanides may corrode, hydrogen blister or stress crack. In this service, killed carbon steel generally is used with a water wash and addition of corrosion inhibitors. Equipment in severe service usually is epoxy coated; for example, compressor receivers or compressor suction knockout drums.
4.3 Killed carbon steel normally is used for equipment exposed to moist hydrogen sulfide (greater than 100 ppm H2S). Refer to Paragraph 7.2 for special requirements.
4.4 Copper alloy tubes generally are used in water coolers and condensers if the ammonia content in the aqueous phases does not exceed 0.1 percent by weight. E-Brite 26-1, Type 430 stainless steel, or carbon steel tubes are used where ammonia content is higher. However, the carbon steel tubes may be subject to inherent fouling problems and may require frequent replacement. When tempered water is available for cooling, all-carbon-steel exchangers may be used. Air coolers with carbon steel tubes have performed satisfactorily. MOBIL ENGINEERING GUIDE
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4.5 The channel, tubesheets, and tubes in fractionating tower reboilers, which are heated with hot oil and operate above 288ºC (550ºF), are constructed from 5 Cr-1/2Mo steel. E-Brite 26-1 tubes may be used as an alternative.
5. CONSTRUCTION MATERIALS
Recommended construction materials are presented in Tables 1 through 3 for vessels, exchangers, piping, and other equipment such as heaters and pumps. The materials and corrosion allowances shown are minimum requirements selected to provide satisfactory service in units operating at standard design conditions. Where deviations from standard design conditions require changes in materials selection, consult Mobil Technology Company, Facilities Group.
For additional materials information such as design, fabrication, and inspection requirements, see EGE 00-B-20, 00-B-21, 00-B-22, 11-B-1, 12-B-1, 12-B-2, 12-B-21, 13-B-10, 13-B-15, 15-B-1, 15-B-2, 16-B-30, and 16-B-40.
6. CORROSION CONTROL METHODS
6.1 Plants Handling TCC Streams, Delayed Coker Streams, or Both
6.1.1 Fouling and underdeposit corrosion may occur if high levels of ammonium hydrosulfide and ammonium chloride are present in the gas streams. The principal problem area is the high-pressure section of the gas compressors, where water is evaporated.
6.1.2 The gas stream from the low-pressure section should be water washed to remove ammonium compounds and sulfides.
6.1.3 When necessary to mitigate fouling, antifoulants may be added in the high-pressure stages.
6.1.4 Filming amine corrosion inhibitors may be added to the gas stream feed or to overhead systems of fractionating towers if high corrosion rates are experienced in carbon steel equipment.
6.2 Plants Handling FCC Gas Streams
6.2.1 Corrosion is generally due to the presence of moist hydrogen sulfide and cyanides. Fouling is usually the result of ammonium compounds.
6.2.2 To remove cyanides, wash the gas stream with water (about 6.5 pH) or a combination of water and ammonium polysulfide (an alkaline solution of pH 8 and higher).
6.2.3 Corrosion rates in areas where water condenses are not expected to be more than 50 µm (2 mil) per year on carbon steel components. If extensive corrosion of carbon steel equipment is experienced, a film-forming corrosion inhibitor should be injected into the incoming gas stream.
6.2.4 Retractable corrosometer probes shall be installed between the high-pressure coolers and the high-pressure receiver and near the middle of the absorber tower.
6.2.5 Hydrogen activity shall be monitored to determine the effectiveness of controls. Hydrogen buildup in the probes should not exceed 69 kPa gage (10 psig) per week at the following locations:
(a) High-pressure and interstage receiver:
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(1) Top of vessel.
(2) Side just above liquid level.
(b) Main absorber:
(1) Second manway from bottom.
(2) Third manway from bottom at liquid level.
(3) Second manway from top.
(c) Above top tray in stripper tower.
(d) Debutanizer overhead receiver:
(1) Bottom boot.
(2) Top of vessel.
6.2.6 Daily spot tests for cyanide and thiocyanate shall be made in water drawn from the high-pressure receiver and debutanizer overhead accumulator.
7. MATERIALS CONSIDERATION DURING FABRICATION
7.1 In FCC unsaturate gas plants, the hardness of welds and heat-affected zones (HAZ) shall not exceed 225 HB (238 HV10).
7.2 Equipment exposed to wet hydrogen sulfide [aqueous phase with $100 ppm (weight) H2S] shall meet the following special materials and fabrication requirements.
(a) The carbon steel plate materials for vessels and exchangers, in order of preference, are ASTM A515 Grade 60, ASTM A515 Grade 70, ASTM A516 Grade 60, and ASTM A516 Grade 70. Sulfur and phosphorus shall be limited to 0.005 and 0.010 percent by weight, respectively. Oxygen and nitrogen shall be minimized by vacuum degassing. Elements such as tin, antimony, arsenic, oxygen, and nitrogen shall be included in the certified materials test report.
The carbon equivalent shall not exceed 0.40 for Grade 60 steels and 0.42 for Grade 70 steels. Tramp elements shall not exceed the following limits in percent by weight: chromium 0.40, copper 0.40, molybdenum 0.15, nickel 0.40, and vanadium 0.05. The total of all five elements shall not exceed 1.00 percent. All plate materials shall be manufactured utilizing inclusion shape control melting practice and shall be vacuum degassed. Any inclusions such as oxides and sulfides shall exhibit a rounded morphology. All steel plates shall be normalized regardless of thickness.
(b) All welds shall receive postweld heat treatment. All welding and heat treating shall meet EGE 00-B-21 requirements. Hardness of welds and HAZ shall not exceed 225 HB (238 HV10).
(c) All plate materials shall undergo ultrasonic testing (UT) by the supplier as specified in ASTM A578. Any discontinuity causing a total loss of back reflection that cannot be contained within a circle of 25.4 mm (1 in.) diameter shall be considered unacceptable. MOBIL ENGINEERING GUIDE
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(d) All completed pressure-containing welds shall be 100 percent examined by radiography or UT and wet fluorescent magnetic particle treatment (WFMT). All welds attaching nonpressure attachments to the pressure envelope shall be WFMT examined. The WFMT shall be performed after the final PWHT.
7.3 Inhibited admiralty tubes and all other copper alloy tubes shall be annealed. MOBIL ENGINEERING GUIDE
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TABLE 2 — Contd
NOTES:
1. See Paragraph 7.2 for special materials and fabrication requirements for equipment in wet H2S service.
2. May be part of the catalytic cracking unit.
3. Ferrous tube bundles may be required under conditions where ammonia concentrations may build up (over 1000 ppm) in stagnant areas.
4. Depending on the quality of available cooling water, seamless carbon steel tubes may be substituted for E-Brite 26-1.
5. Use killed carbon steel in plants handling FCC streams.
6. If metal temperatures of channels or tubes exceed 288ºC (550 ºF), replace carbon steel with 5 Cr-½ Mo steel. MOBIL ENGINEERING GUIDE
