Corrosion Analysis and Mitigation Strategies in NHT and CCR Refinery Units: A Data-Driven Approach

Corrosion in refinery units, particularly in Naphtha Hydrotreating (NHT) and Continuous Catalytic Reforming (CCR) units, represents a significant threat to operational reliability, safety, and economic efficiency. This study presents a comprehensive data-driven analysis of corrosion behavior in NHT and CCR units based on real-time plant data, historical maintenance logs, and process parameters. Using statistical and machine learning methods, we identify key operational factors contributing to corrosion rates, including temperature, pressure, hydrogen partial pressure, and contaminants such as chlorides and sulfur compounds. Furthermore, the study evaluates the effectiveness of different mitigation strategies such as corrosion inhibitors, metallurgy upgrades, process optimization, and vapor phase conditioning in various sections of the units, including reactors, heat exchangers, furnaces, and piping systems. It investigates how operating envelopes and process excursions influence the onset and progression of localized corrosion phenomena such as pitting, erosion-corrosion, and stress corrosion cracking. The findings aim to provide actionable insights for refining operators, integrity managers, and process engineers involved in asset management and corrosion control. The study further evaluates the effectiveness of various corrosion mitigation strategies including material upgrades, corrosion inhibitors, process control optimization, and predictive maintenance protocols. The findings aim to support refinery operators in making informed decisions to extend equipment life, reduce downtime, and enhance safety in high-temperature, hydrogen-rich environments.

کلیدواژه ها:

Corrosion Analysis ، Mitigation strategies ، NHT ، CCR ، Refinery Units