Oxygen Contamination of Hydrocarbon Feedstocks
Oxygen Contamination of Hydrocarbon Feedstocks
Oxygen contamination of
hydrocarbon feedstocks
An examination of the detrimental effects caused by dissolved O2, and practical
solutions to control fouling, corrosion and expensive unplanned shutdowns
when processing feedstocks vulnerable to air or oxygen ingress
M Vadekar
Chem Tech Consulting
O
xygen is present in chemically nate the oxygen contamination from information has been exacerbated over
combined form as oxides of met- process feeds are well understood, the the past decade as older experienced
als and nonmetals, as minerals preventive and/or corrective steps can personnel who used to serve as mentors
in the earth’s crust and on the surface, as be expensive and in some cases difficult and a resource to a younger generation
a wide variety of oxygenates in bio- to implement. The problem frequently of engineers have been systematically
chemicals and as a gaseous component appears to be minor or is masked by “downsized out”, leaving a void. Within
in the atmosphere in its diatomic molec- other factors, and can be easily over- this context, the most important areas
ular form, constituting almost one fifth looked or set aside. However, it silently to address in pursuing cost effective
of the air surrounding the globe. In its takes its economic toll in the industry. solutions include:
form of hydrogen oxide, or water, and as Furthermore, comprehensive infor- — Sources of oxygen contamination
gas in the atmosphere, oxygen is essen- mation on the topic to address the prob- — Damage caused by oxygen contami-
tial to sustain all plant and animal life. lem is not easily available to most young nation
However, when it comes to processing engineers entering the technical work — Mechanisms of the role of oxygen in
hydrocarbons for fuels and chemicals in force on an ongoing basis. This is espe- causing fouling, corrosion etc
the petroleum and process industry, cially true since a unified database or — Influence of the chemical nature of
oxygen plays a subtle and insidious role compendium of resources is not readily the process feedstock
as a minute contaminant. available on the subject. This lack of — Reliable measurements of minute
The harmful role of elemental oxygen
when dissolved in petroleum fractions
Process units most affected by dissolved oxygen in feed
and related feedstocks has been well
established. Numerous papers and pre-
sentations in the industry as well as Operations mentioned below represent critical units in typical petroleum refineries and/or
almost yearly discussions at petroleum chemical plants. The adverse effects on operations referred to are caused by oxygen
refining and chemical processing dissolved in liquid feed to the units. Oxygen concentrations may be 0.5 to maximum
forums testify to the deleterious effects possible at solubility limits under storage or handling conditions.
of minute amounts of oxygen present in
hydrocarbon and other non-aqueous Operation/unit Nature of problems Consequences/penalties
feedstocks. type caused incurred
The problem affects a wide variety of Refinery hydrotreaters Preheat exchanger plugging, Heat transfer efficiency loss,
HDS/HDN/hydrocrackers, gums/coke depositions, crusting off-spec products,
process operations. Serious fouling, cok-
reformers and similar in reactors/high pressure drops, unplanned shutdowns,
ing and subsequent plugging as well as
cat deactivation high
severe corrosion occurs in some of the
maintenance costs
most important refining and process
operations including hydrotreaters Solvent extraction, amine/ Polymers/tar formation, lay- Capacity loss, solvent
(HDS/HDN units), reformers, solvent caustic treaters and down on surfaces, foaming, loss, corrosion, entrain-
extractors, amine/caustic treaters, frac- others carryover, acidic pH ment, shutdowns
tionators and several others. The impor-
tance and economic impact of this Fractionators Acidic pH, rusting and rust Potential for ruptures in
problem cannot be overemphasised due lay-down on trays, down spouts tower shells, reboilers,
the fact that fouling, plugging, corro- corrosion in overhead systems safety compromises
sion and other previously mentioned
problems lead to unplanned shutdowns, Vacuum towers, Air aspiration, oxygen buildup All above problems
service factor deterioration, loss of pro- regenerators, pump seals leading to all above
duction and significantly higher main-
tenance/repair costs to the plant Summary
operators. Oxygen in feed or system itself often unsuspected but the real cause of problems.
Deliberate, positive and proactive Penalties severe: loss of service factor and production.
steps must be taken to minimise or elim- High maintenance and repair costs, premature catalyst regenerations, perhaps change.
inate oxygen contamination to forestall Compromising personnel and public safety.
such eventualities.
Although the problem is well recog-
nised and the steps to control or elimi- Table 1
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120
also promotes formation of heavy poly- large marine life alive and
Toluene
mers and tars (from olefinic species in thriving. In comparison, 100 Iso octane
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Oxidation stability of
Table 3 hydrocarbons
promoted. The extent to which they are cess piping, heat exchangers and inert
promoted is determined by several fac- balls on top of catalyst beds and on the Oxygen stability factor, °C
tors such as exposure to radiation, tem- catalyst particles themselves, as well as Reported Experi-
perature, residence time (or length of deep into the pore structure of the cat- Hydrocarbon valuel mental data
type 1 2
contact), presence or absence of alyst particles. Eventually, polymer
Paraffins
inhibitors, chemical nature of the sol- films pyrolyse at the reaction tempera-
n-Hexane 68 70
vent molecules etc. tures over prolonged time to produce
Cyclohexane 55 –
coke.
n-Octane 125 125
Peroxides and free radicals The scenario is now complete to n-Dodecane 151 –
Free radicals and peroxides undergo exhibit increasing pressure drops, plug-
complex chain reactions in the liquid ging, restrictions to material flow and Mono-olefins
phase to ultimately produce polymers, heat transfer in the operating units as 1- Hexane – 60
aldehydes, carboxylic acids and other well as loss of catalyst activity by deny- 1-Octene 110 –
oxygenated compounds. The reactions ing contact of the reactive species with
are highly complex and their exact the active sites in the catalyst pores. It Diolefins (3)
sequences are difficult to predict. How- is important to note that the above Cyclopentadiene – 50
ever, a generally accepted scheme can reactions occur in the absence or pres- Hexadiene – 50
be written as shown in Table 3. As pre- ence of hydrogen in the systems.
viously mentioned, initiation and the Aromatics
subsequent reactions of free radicals are Oxidation stability Benzene 140-150 –
greatly influenced by storage tempera- It is well known that a wide range of para-Xylene 95 –
ture, long residence times, access to hydrocarbons processed in the industry Mixed Xylenes 95 –
and availability of oxygen, and the cat- exhibit widely varying stabilities
alytic influence of solids such as rust towards oxygen. Saturated aliphatic 1. Data reportedly obtained in simulated
closed circuit test apparatus with oxygen-
particles. (and cyclic) hydrocarbons in virgin
saturated feeds. Stability temperature was
petroleum oils are generally more stable
the lowest value at which minimum 10%
Polymer and coke formation towards, or resistant to, oxygen attack in
oxygen was consumed.
At elevated processing temperatures the previously mentioned scenario. Aro-
2. Experimental data from private
and in liquid or vapour phase, oxygen- matics such as benzene, toluene and communications from fellow workers in
induced polymerisation proceeds rapid- xylenes (in streams such as reformates) several laboratories.
ly to ultimately form much higher are even more resistant to oxygen 3. Rapid gum formation was evident and
molecular weight species, called “gums attack. the test unit plugged at 50°C
and/or “tar”. In all or partially vapour However, unsaturated or olefinic
phase operations, polymers drop out of hydrocarbons (in cracked stocks) react
vapour onto solid surfaces in hot pro- with oxygen much more readily. Fur- Table 4
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ination, compared to the same opera- etc). The presence of even minute oxy-
Measurement of dissolved tion with feed completely free of oxy- gen contamination in unit feed is harm-
oxygen gen. The extent of fouling increases ful to equipment. Since it is virtually
rapidly with progressively higher levels impossible to practically or economical-
of oxygen contamination. ly preclude oxygen from refinery or
Oxygen measurement routinely made
Despite such experience, quantitative chemical plant feed materials, it is desir-
in industry
In gaseous phase for combustion or predictable correlations or evalua- able to remove dissolved oxygen from
control, breathing apparatus etc tions, even in the same unit, have been unit feeds where possible.
Industrial oxidative processes and elusive. This is because actual rates of Oxygen ingress can be prevented by:
many other applications. polymer deposition, fouling, plugging, Blanketing the headspace in storage
Numerous instruments and know- coking or corrosion may depend on tanks (fixed or cone roof) scrupulously
how on market. many other factors in addition to the with inert gas while using an oxygen
Measurement ranges from ppm to presence of oxygen in the feed. analyser to ensure inert blanketing
high percentage possible Nonetheless, contribution of oxygen works reliably.
contamination cannot be ignored. It has Routing feed streams directly between
Measurements in aqueous liquid phase also been firmly established that units when possible without intermedi-
also routinely made removal of oxygen contamination by ate storage tanks.
Environmental control major expedient, deliberate means can virtual- “Floating” the feed line on the storage
objectives but need in many other ly eliminate the problems. tanks using bypasses around feed tanks
areas. whenever the need for surge capacity
Measurement ranges generally low Measuring dissolved O2 (intermediate tankage) is unavoidable.
(10-20+) ppm. Measurement of oxygen dissolved in liq- One such example is shown in Figure 2.
uid aqueous phase and particularly in Floating roofs can prevent oxygen
Measurements in non-aqueous, hydro-
non-aqueous hydrocarbons is tricky and ingress into tanks as well as prevent
carbon phase another important need.
was highly unreliable in the past. How- vapour loss to the atmosphere. It should
Dissolved oxygen levels relatively low
ever, with modern technology and be noted that in large volume storage
but higher than in water phase.
Need recognised in process newer instruments, very rapid reliable tanks, oxygen in the head space above
operations for many reasons. and reproducible measurements are now the liquid level will slowly diffuse into
Problems identified in this article possible. A brief account of the available the liquid and, depending on turbu-
another need. tools appears in Table 5. lence in the tank, dissolved oxygen may
Apparently, the most important step well be layered towards the bottom of
Instruments used for water phase in such measurements is preserving the tanks.
applications useful the integrity of batch samples for Another factor that should also be
Minor modification of sensor probe repeated measurements. In such cases, considered is that rainwater leaking into
needed online continuous measuring instru- tanks will introduce oxygen. Rainwater
Modern technology allows reliable, ments are now available. Several is usually saturated with oxygen, which
reproducible measurements instrument vendors market and ser- then will partition itself preferentially
possible by batch testing or on-line vice equipment for batch or continu- into the hydrocarbon phase. Often, seals
tools. ous online oxygen measurements around floating roofs leak to allow rain-
Measurement ranges cover <0.001 to today, at competitive prices. water leaks.
hundreds of ppm levels If contamination is unavoidable and
Major problem for batch measurements, Forestalling O2 problems the fouling problem is feared, strip dis-
“how to preserve integrity of
It is obvious from the previous discus- solved oxygen in a simple stripper
test samples from test to test”
sion that it is difficult to avoid oxy- tower. This can be readily achieved in a
Most reliable measurements by
gen/air ingress in feedstocks during simple tower with few theoretical trays
online techniques.
storage and transport in air breathing and minimum energy usage. Oxygen
tanks, marine or surface vessels (ships, can be completely removed and vented
tankers, barges, rail tank cars, trucks, overhead. Peroxides are also eliminated
Table 5
Nitrogen
How much oxygen? blanketing
Determination of the point at which system
there is excess oxygen is an important
N2
consideration within the context of
minimisation of the impact of oxygen- Tank floating
induced problems in processing units. on feed line
Anecdotally, it is apparent that even
the maximum amount of dissolved
oxygen (at solubility limit) in a hydro-
carbon feed may appear to be minis- Feed from Surge tank
cule. However, repeated experience upstream Typical
shows that concentration of dissolved unit hydrotreating
unit
oxygen in a unit feed, even as low as
0.5–5ppm oxygen content can cause Feed
serious fouling and other problems pre- pump
viously mentioned.
Generalised observations indicate
that a step change in the fouling pattern
occurs in a given unit with low contam- Figure 2 Typical piping scheme for floating tank on feed line
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boiler feedwater. This chemical is expen- Pertinent data for oxygen stability or
sive, highly toxic, and more important- the lowest temperatures at which
ly, extremely unstable for normal hydrocarbons start to react with dis-
handling and plant use. Hydrazine has solved oxygen were previously dis-
been known to explode upon exposure cussed. It was shown in literature that
to air. In practice, no scavengers of these temperatures are much lower
practical use to the petroleum/process than typical process operating levels. It
industry are on the market for use in was shown that lower aromatics exhib-
this application. it relatively high stability followed by
Several antioxidants are on the mar- saturated or virgin cuts from crude oils.
ket and are in fact used extensively to Unsaturated species such as the
prevent peroxides and gum formation mono-olefins are much less stable
in storage tanks and in many product towards oxygen while the conjugated
formulations such as gasoline, FCC diolefins and polyolefins generally
middle distillate fuels, cracked naphtha possess the lowest stabilities. Thus,
etc. Antioxidants do not chemically one can surmise that the lower the sta-
consume oxygen but disrupt the chain bility of a given feed mix, the more
reactions by combining with peroxides rapid will such a unit suffer from oxy-
and free radicals in the liquids, thus gen problem.
neutralising their potential to initiate Chemical mechanisms of the com-
the chain reactions mentioned earlier. plex reactions involved in the hydro-
In fact, they are found to coexist in the carbons and oxygen were briefly
hydrocarbon phase along with dis- discussed. It has been proven conclu-
solved oxygen. sively that free radical chain reactions
Nonetheless, additive package ven- between hydrocarbon molecules and
dors often claim that the discrete spe- elemental oxygen lead to polymers and
cialty products they promote will tars, which eventually pyrolyse to coke
scavenge dissolved oxygen and elimi- at elevated operating temperatures in
nate the fouling problems. But there HDS/HDN and/or other process reac-
appears to be scant reproducible data tors, preheat exchanger etc. Deposition
from years of plant testing to prove of heavy polymers and/or coke can in
these claims unequivocally. the long run severely restrict operations
leading to unplanned shutdowns and
Recommendations the subsequent process interruptions,
Oxygen also produces organic acids in lost production and maintenance costs.
fractionating towers, solvent extraction Corrosive acids are also produced by
systems etc, which lower pH in water such reactions.
phase and lead to corrosion of carbon Methods for avoiding oxygen inclu-
steel and other metal surfaces. Corro- sion or ingress in the feed streams were
sion can lead to catastrophic failure of suggested.
equipment. The oxygen problem, if However, if oxygen ingress is
unchecked, can force frequent unavoidable or feeds are received with
unplanned shut downs in order to dissolved oxygen, simple stripping can
eliminate the plugging, coking etc, and be considered. Stripping was shown to
will necessitate repairs at enormous completely remove oxygen and destroy
cost and service factor deterioration. peroxides. This can be a low-cost
The routes by which oxygen can option in specific situations, especially
enter the feedstocks include air breath- when costs of fixing fouled reactor sys-
ing storage tanks and marine or surface tems, corroded towers, etc, are pro-
transport vessels, aspiration of air via hibitive.
leaks in the equipment pieces into Strippers can often be retrofitted in
units operating at sub-atmospheric existing equipment lineups, at reason-
pressures and/or faulty pump seals. ably low costs. Several successful case
Experienced operating personnel can histories are known. In addition, the
most likely cite many other opportuni- use of antioxidants to prevent gum for-
ties in which air (and the concomitant mation in stored feeds is imperative,
oxygen) can ingress into process sys- especially with cracked feeds. Antioxi-
tems. dants can benefit virgin feeds as well.
Solubility of molecular oxygen in
hydrocarbons or other non-aqueous
industrial process feeds were shown to
be far higher than that in fresh and sea M Vadekar works with Chem Tech
water systems. However, it was indicat- Consulting at Sarnia, Ontario, Canada,
ed that presence of dissolved oxygen, and has been engaged with USAID and
even in concentration far lower than its Canadian equivalent, CIDA, on
the maximum solubility limits under technical aid projects in Estonia, Poland,
normal operating conditions, was Kazakhstan, Uzbekistan and China. He
enough to cause severe fouling and holds a PhD in physical chemistry from the
other problems in process units. University of Alberta in Edmonton.
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