Corrosion in Systems for Storage and Transportation of Petroleum Products and Biofuels

Alec Groysman

Corrosion in Systems for Storage and Transportation of Petroleum Products and BiofuelsIdentification, Monitoring and Solutions

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ISBN 978-94-007-7883-2 ISBN 978-94-007-7884-9 (eBook)DOI 10.1007/978-94-007-7884-9Springer Dordrecht Heidelberg New York London

Library of Congress Control Number: 2013958378

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Alec GroysmanAssociation of Engineers and Architects in IsraelIsraeli Society of Chemical Engineers & Chemists,Tel Aviv, Israel

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Fuels occupy one of the main places in the history of modern mankind. More than ever today it is impossible to imagine our life without fuels. You drive your car, fly by airplane, travel by ship, and warm your house using different fuels. In this book, we will talk only about liquid fuels producing from petroleum products (called also distillates or refined products), such as liquefied petroleum gas (LPG), naphtha, gasoline, kerosene ( jet fuel), gas oil (diesel fuel), and fuel oil and corrosion in them. All these petroleum products are obtained from crude oil. We will also discuss cor-rosion in liquid biofuels which began occupy essential place in supply of energy and heat in many countries.

Metallic constructions for transportation and storage of crude oil, petroleum products and biofuels are made mainly from carbon steel. In spite of removing most corrosive species from fuels the paradox is that metallic constructions contacting with them are being damaged. Different polymeric and composite materials contact fuels. On the one hand, materials can deteriorate fuels. On the other hand, fuels can worsen important functional properties of materials. Therefore we will discuss metallic, polymeric and composite materials including organic coatings which also can contact fuels. Resistance of all these materials to fuels is very important in pre-serving both environment and fuels from deterioration. These problems can be sum up as following questions:

Why are crude oils, petroleum products, fuels and biofuels aggressive to metals, alloys and polymeric materials? Which corrosion control and monitoring methods are used in order to prevent corrosion failures in systems for transportation and stor-age petroleum products?

In this book, I summarized experience based on my long practical and research work, as well numerous literature data which are collected and analysed.

Thus I invite you to the marvelous world of liquid fuels, their aggressiveness, corrosion control and monitoring methods.

Preface

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To my great, wise, intelligent and smart wife Olga for constant support, endurance, understanding and assisting in creating, discussing and writing this book, and also to my lovely children Sasha, Anat, Tal and beautiful grandchildren Jonatan and Ido

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“I believe that getting to know more and more,a man acquires infinite power.”Émile François Zola (1840–1902), a French writer

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Contents

1 Physico-Chemical Properties and Corrosiveness of Crude Oils and Petroleum Products .................................................................... 11.1 Crude Oil Characteristics .................................................................... 2

1.1.1 Chemical Compounds in Crude Oils ....................................... 21.1.2 Corrosive Characteristics of Crude Oils .................................. 3

1.2 Physico-Chemical Characteristics of Petroleum Products .................. 81.2.1 Corrosiveness of Petroleum Products ...................................... 11

References .................................................................................................... 19

2 Fuel Additives ............................................................................................. 232.1 Action of Fuel Additives and Their Application ................................. 242.2 Additives to Fuel Oils.......................................................................... 372.3 Additives for Prevention Oil-ash and Cold-end

Corrosion in Boilers ............................................................................ 382.3.1 Combustion Improvers ............................................................ 39

2.4 Risks and Benefits in the Use of Fuel Additives: The Environmental Balance ................................................................ 40

Recommended Literature ............................................................................. 40

3 Fuel Oxygenates ......................................................................................... 433.1 Alcohols as Fuel Oxygenates .............................................................. 443.2 Ethers as Fuel Oxygenates .................................................................. 45References .................................................................................................... 47

4 Biofuels ........................................................................................................ 494.1 Additives to Biofuels ........................................................................... 54

4.1.1 Additives to Biodiesel .............................................................. 54Recommended Literature ............................................................................. 55

5 Corrosion of Metallic Constructions and Equipment in Petroleum Products ............................................................................... 575.1 General Theory of Corrosion .............................................................. 58

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5.2 Corrosion Phenomena ....................................................................... 605.3 Corrosion in Petroleum Products ...................................................... 65

5.3.1 Electrical Conductivity of Petroleum Products and Their Corrosiveness ........................................................ 69

5.4 Microbial Contamination of Fuels .................................................... 735.4.1 Microbial Contamination of Bioidesel .................................. 795.4.2 Participation of Microorganisms in Corrosion of

Metals in Fuels ...................................................................... 815.5 Corrosion in Biofuels ........................................................................ 90

5.5.1 Physico-Chemical Properties of Biofuels. ............................. 905.5.2 Corrosion of Metals in Alcohols ............................................ 925.5.3 Corrosion of Metals in Biodiesel ........................................... 101

5.6 Corrosion in the Atmosphere ............................................................ 1075.7 Corrosion in Soil ............................................................................... 1095.8 Corrosion of Tanks Containing Petroleum Products ......................... 1145.9 Corrosion of Tanks and Pipelines Under Thermal Insulation ........... 130

5.9.1 Prevention of Corrosion Under Thermal Insulation .............. 134References .................................................................................................. 134

6 Polymeric Materials in Systems for Transportation and Storage of Fuels................................................................................. 1456.1 Polymers and Their Properties .......................................................... 146

6.1.1 Permeability of Polymers ...................................................... 1506.2 Resistance of Polymers to Fuel Oxygenates and Aromatics ............. 1506.3 Aggressiveness of Biofuels to Polymers ........................................... 151

6.3.1 Aggressiveness of Alcohols to Polymers ............................... 1526.3.2 Aggressiveness of Biodiesel to Polymers .............................. 152

References .................................................................................................. 156

7 Corrosion Prevention and Control in Systems Containing Fuels ........ 1597.1 Choice of Materials ........................................................................... 1607.2 Coatings............................................................................................. 164

7.2.1 Antistatic Coatings for Anti-corrosion Protection of Inner Surface of AST Containing Gasoline and Naphtha ...... 166

7.2.2 Coating Systems for Protection of Outer Surface of AST Containing Crude Oil and Fuels .................................... 166

7.2.3 Coating Systems for Protection of Outer Surface of Underground and Submerged Pipelines ................................ 167

7.2.4 Metallic Coatings ................................................................... 1677.2.5 Recommendations for the Selection Coating System ........... 1697.2.6 Testing of Coating Compatibility Under the Condi-

tions of Fuel Storage Tanks ................................................... 1697.2.7 Experience of Anti-corrosion Protection of AST .................. 171

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7.3 Cathodic Protection ........................................................................... 1727.3.1 Internal Cathodic Protection .................................................. 1737.3.2 Cathodic Protection of the External Surface of AST

Bottoms, UST, Underground and Submerged Pipelines ....... 1737.4 Corrosion Inhibitors .......................................................................... 174

7.4.1 Liquid Phase .......................................................................... 1747.4.2 Vapor Phase ........................................................................... 175

7.5 Anti-Bacterial Treatment ................................................................... 1787.6 Technological Measures .................................................................... 1787.7 Combined Methods of Corrosion Control ......................................... 1797.8 Secondary Containment and Double Bottom .................................... 1797.9 Underground Storage Tanks .............................................................. 180References .................................................................................................. 181

8 Corrosion Monitoring and Nondestructive Testing in Systems Containing Fuels ................................................................... 1878.1 Control of Physical Properties of a Metal ......................................... 188

8.1.1 Ultrasonic Technique (UT) .................................................... 1898.1.2 Acoustic Emission (AE) ........................................................ 1918.1.3 Magnetic and Electromagnetic Methods ............................... 1928.1.4 Eddy Current Technique ........................................................ 1938.1.5 Other Physical NDT Methods ............................................... 1948.1.6 Weight Loss and Electrical Resistance (ER) Methods .......... 196

8.2 Examination and Control of the Environment .................................. 1978.3 Control the Interphase Metal–Environment ...................................... 1988.4 On-Line, Real-Time CM ................................................................... 1988.5 Monitoring of Cathodic Protection ................................................... 2018.6 Inspection of Tanks ........................................................................... 202

8.6.1 Conclusion ............................................................................. 203References .................................................................................................. 204

9 Cases of Typical and Unusual Corrosion of Tanks ............................... 2119.1 Corrosion of Outer Surface of Tanks’ Shell Under Bricks ................ 211

9.1.1 Case 1 .................................................................................... 2119.1.2 Case 2 .................................................................................... 2129.1.3 Case 3 .................................................................................... 2129.1.4 Case 4. Outside and Inside Corrosion of the AST

Containing Gas Oil ................................................................ 2139.1.5 Case 5. Corrosion Under Thermal Insulation of the

AST Containing Asphalt ........................................................ 2159.1.6 Case 6. General Corrosion and Coating Failure in

Gasoline AST ......................................................................... 2169.1.7 Case 7. General Corrosion and Coating Failure in

the AST (separator) ................................................................ 216

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9.1.8 Case 8. Inner Corrosion of AST Containing Kerosene ......... 2179.1.9 Case 9. Corrosion of Inner Surface of the Bottom

of AST Containing Gas Oil ................................................... 2199.1.10 Case 10. Underground Storage

Tank (UST) containing LPG.................................................. 219 Recommended Literature ......................................................................... 220

10 History of Crude Oil and Petroleum Products .................................... 221 10.1 History of Anti-knock Additives to Gasoline, Kerosene,

Diesel fuel, Fuel oil and Asphalt ................................................... 223 Recommended Literature ......................................................................... 226

Appendix ......................................................................................................... 227

Glossary .......................................................................................................... 281

Index ................................................................................................................ 291

Contents

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List of Abbreviations

AE Acoustic Emission.ANSI American National Standards Institute.API American Petroleum Institute.API RP American Petroleum Institute Recommended Practice.AR-AFFF Alcohol-Resistant Aqueous Film-Forming Foam.AR-FFFP Alcohol-Resistant Film-Forming Fluoroprotein Foam.ASA-3 Anti-static additive of Shell Oil Company.ASNT American Society for Nondestructive Testing.ASTM American Society for Testing and Materials (ASTM International).Avgas Aviation gasoline.B20 Fuel blend containing 20 vol% biodiesel and 80 vol% conven-

tional diesel fuel.B100 Neat biodiesel.BTX Benzene, Toluene, Xylene.BTEX Benzene, Toluene, Ethyl benzene, Xylene.CFU/ml Colony Forming Units per milliliter of liquid; an estimate of

viable bacterial or fungal numbers.CI Compression Ignition, i.e. a diesel engine.CIPS Close Interval Potential Survey.CU Conductivity Unit.DCVG Direct Current Voltage Gradient.DI Direct Injection.Di-EGME Diethylene glycol monomethyl ether.DIN Deutsches Institut Fur Normung E.V. (German National Standard).DS Data Series.EC Eddy Current.EDS Energy Dispersive Spectroscopy.EEMUA The Engineering Equipment and Materials Users’ Association.EGME Ethylene glycol monomethyl ether.EI Energy Institute (formerly IP—Institute of Petroleum), England.E10 Fuel blend containing 10 vol% ethanol and 90 vol% gasoline.E85 Fuel blend containing 85 vol% ethanol and 15 vol% gasoline.

xvi List of Abbreviations

EN European Norm, European Standard.EPS Extracellular polymeric substances.ETP Type of Viton.Euro 5 European emission standard.FAME Fatty Acid Methyl Ester.FAEE Fatty Acid Ethyl Ester.FBE Fusion Bonded Epoxy.FGA Fuel Grade Alcohol.FRP (GFRP,

GRP) Fiberglass Reinforced Plastic.FSII Fuel System Icing Inhibitor.FSM Field Signature Method.GFRP (see

GRP, FRP) Glass-fiber reinforced plastic.GRP (see

GFRP, FRP) Glass-reinforced plastic.GTBA Gasoline grade t-butanol; named also Tertiary-Butyl Alcohol

(TBA).HC Hydrocarbons.HDPE High Density Polyethylene.HDS Hydrodesulfurizer.HE Hydrogen Embrittlement.HUM bugs Hydrocarbon Utilizing Microorganisms.ICP Inductively Coupled Plazma.IDI Indirect Injection.ILI In-line inspection.IMPCA International Methanol Producers & Consumers Association.IOB Iron-oxidizing bacteria.IP (see EI).IPA Isopropanol.IPC Ion Plazma Couple.IR Infrared.ISO International Organization for Standardization.IUPAC International Union of Pure and Applied Chemistry.kPa Kilo Pascal.KWA Ken Wilcox Associates Inc.LL Low lead.LPG Liquefied petroleum gas.M15 Fuel blend containing 15 vol% methanol and 85 vol% gasoline.M85 Fuel blend containing 85 vol% methanol and 15 vol% gasoline.M100 Fuel containing 100 vol% methanol.MFL Magnetic Flux Leakage.MTBE Methyl Tertiary-Butyl Ether.NA Naphthenic acids.

xviiList of Abbreviations

NACE International National Association of Corrosion Engineers International.

NBR Nitrile Butadiene Rubber (Buna-N).NDA Nitrite Dicyclohexylamine.NDT Non-Destructive Technique.NFPA National Fire Protection Association.NLPA National Leak Prevention Association.NR Natural Rubber.PA Polyamide (Nylon 6), polymer.PE Polyethylene.PEC Pulsed Eddy Current.PEI Petroleum Equipment Institute.PP Polypropylene.PVC Polyvinyl Chloride.ppb Parts per billion; weight concentration; 1 mg of substance (solute)

in 1,000,000,000 mg (1,000 kg) of solution.ppm Parts per million; weight concentration; 1 mg of substance (sol-

ute) in 1,000,000 mg (1 kg) of solution.psi Pounds per square inch.pS/m Pico Siemens per meter.RCM Resistance Corrosion Monitoring.SEM Scanning Electron Microscope.S/m Siemens per meter.SFGA Synthetic Fuel Grade Alcohol.SP Standard Practice.SRB Sulphate Reducing Bacteria.SCC Stress Corrosion Cracking.SSPC Steel Structures Painting Council.STI Steel Tank Institute (USA).TAME Tetra amyl methyl ether.TAN Total Acid Number.TBA Tertiary-Butyl Alcohol; named also Gasoline grade t-butanol

(GTBA).TBC Total Bacteria Count.TEL Tetra-Ethyl Lead.TM Test Methods.TPC Total Plate Count.UL Underwriters Laboratory Inc.UV Ultra Violet.ULSD Ultra Low Sulphur Diesel Fuel (less than 10 ppm sulphur).UNS Unified Numbering System.UT Ultrasonic testing.US Ultrasound.UST Underground Storage Tank.VCI (VPI, VpCI) Vapor (Volatile) Corrosion Inhibitors.

xviii List of Abbreviations

VOC Volatile Organic Compounds.Vol% Volume percent.VpCI see VCI.VPI see VCI.Wt% Weight percent.

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About the Author

Dr. Alec Groysman graduated in 1973 from the Chem-ico-Technological University named after Mendeleev in Moscow. He received his Ph.D. in physical chemistry and corrosion in 1983 in Moscow. He has experience in cor-rosion and protection from corrosion from 1976 in the oil refining industry.

He deals with kinetics and thermodynamics of corrosion processes, on-line corrosion monitoring, choice and use of corrosion inhibitors, coating systems, selection of appro-priate alloys for corrosive conditions, and failure analysis.

He has special interests in corrosion education and in the searching of relationships between corrosion, art, history and philosophy.

His first book “Corrosion for Everybody” published by Springer in 2010 received the innovation award winner of Materials Performance Readers’ choice in 2012 year in the USA.

He is a lecturer of the courses “Corrosion and Corrosion Control”, “Physical Chem-istry”, and “Materials and Standards in Oil and Gas Engineering” in the Technion (Haifa) and in the ORT BRAUDE college of engineering in Karmiel in Israel.