We have a black sludge formation at the interphase of naphtha and water in OVHD accumulator. But all the OVHD paramters like pH, Iron and Chloride are normal. The crude unit has a partail condensation ovhd system and the black sludge is observed in the second boot (Cold reflux boot). There is a CI dosing in the accumulator upstream. What could be the reason for this sludge?Sep-2023
Marcio Wagner da Silva, Petrobras, email@example.com
This is a relatively common condition in overhead systems of crude oil distillation units. The black sludge observed in the overhead vessel is probably pickering emulsion stabilized by iron particles which is accumulated in the interface between sour water and naphtha, despite the information that the pH, Iron and Chloride content is controlled in the overhead system it's possible that this system and the atmospheric tower can operate under corrosion situation in the past. When the emulsion is formed in the vessel, this residue cant be removed without the shutdown of the processing unit or through draining the overhead vessel totally which requires a special procedure aiming to minimize the safety risks as well as the damage to the pumps of the overhead drum.
Regarding the corrosion control in the overhead systems it's important to analyze that the corrosion control parameters is under an adequate range, especially the operating temperature of the overhead system. There are some correlations in the literature which relates the ammonia and chloride concentration in the sour water to determine salt deposition temperature in the top of the tower and this needs to be considered to define the operating temperature of the system.