Corrosion Control in the Distillation Tower of Tobruk Refinery Using Chemical

Inhibitors: A Case Study

Abstract
This study investigates the effectiveness of chemical corrosion inhibitors in mitigating
corrosion within the distillation tower of the Tobruk Oil Refinery. Corrosion poses a
significant threat to operational efficiency and equipment integrity in petroleum
processing facilities. To address this, an oil-soluble film-forming corrosion inhibitor
(EC1020B) was applied to protect against corrosive agents such as hydrochloric acid,
hydrogen sulfide, and organic acids present in the hydrocarbon process stream. The
inhibitor was injected into the overhead system upstream of the initial water
condensation point at controlled dosages ranging from 5 to 20 ppm. Daily monitoring
included pH, chloride concentration, and iron levels, while corrosion rates were
measured using Linear Polarization Resistance (LPR) and Electrical Resistance (ER)
probes. The results demonstrated a noticeable reduction in corrosion rates, with values
typically ranging from 0.09 to 0.26 mm/year during the monitoring period. The study
confirms that the application of EC1020B significantly improves corrosion resistance
in the distillation unit, enhancing equipment longevity and reducing maintenance
downtime. These findings support the implementation of chemical treatment
programs as a reliable and cost-effective corrosion control strategy in refinery
.operations

(Keywords): Corrosion Inhibition, Distillation Tower, Chemical Inhibitors.

 1. Introduction

Corrosion is the destructive attack of a material by reaction with its environment. The
seriouequences of the corrosion process have become s cons a problem of worldwide
significance.
In addition to our everyday encounters with this form of corrosion causes plant
shutdowns, waste of valuable resources, loss or contamination of product, reduction in
efficiency, costly maintenance, and expensive over-design.
It also risks the safety and inhibits the technological progress. The multidisciplinary
aspect of corrosion problems combined with the distributed responsibilities
associated with such problems only increase the complexity of the subject. Major
corporations, industries, and government agencies have established groups and
committees to look after corrosion –related issues, but in many cases the
responsibilities are spread between the manufacturers or producers of systems and
their users. Such a situation can easily breed negligence and quite costly in terms and
human lives.
Mechanism of corrosion For corrosion to take place, the formation of a corrosion cell
is essential. A corrosion cell is essentially consisted of the following three
components:
■ Anode,
■ Cathode,
■ Electrolyte.
Anode: One of the two dissimilar metal electrodes in an electrolytic cell, represented
as the negative terminal of the cell. Oxidation takes place at anode causing the
electrons to be released and the anode is considered to be the more active metal.
Cathode: One of the two electrodes in an electrolytic cell represented as a positive
terminal of a cell. Reduction takes place at the cathode and electrons are consumed.
Electrolyte: It is the electrically conductive solution (e.g., salt solution) that must be
present for corrosion to occur

1.1 corrosion control methods

Corrosion control is achieved recognizing and understanding corrosion mechanisms;
and using corrosion-resistant material and designs; and by using protective systems;
and [Link] most cases; effective corrosion control is obtained by combining two
or more of these methods. Corrosion control should be considered at the design stage
of a given facility or system. The methods selected must be appropriate for the
material used, for the configurations, and for the types and forms of corrosion which
must be controlled.
There are four basic methods for corrosion control and corrosion protection:
1-Materials Selection (Materials resistant to Corrosion)
2-Protective coatings.
3-Cathodic protection.
4-Corrosion inhibitors (Modify the operating environment)
1.2 Corrosion Inhibitors

Corrosion is a major issue in distillation equipment even with proper designs.

Multiple factors can interact and create corrosive attack. With the current run length
of plants between maintenance outages approaching five years, corrosion control is a
must to maintain distillation efficiency and recovery.

Areas of corrosion in distillation include; crude distillation, vacuum distillation, and

solvent extraction. Proper metallurgy selection and then proper chemical treatment is
essential to prevent corrosion in the distillation equipment for hydrocarbon and
chemicals processing. Corrosion treatment chemicals include neutralizers, filmers,
and other corrosion inhibitors.

These chemical can prevent or mitigate damage from galvanic bi-metallic, aqueous
acidic, and under-deposit corrosion, as well as pitting.
, using corrosion inhibitors in power plant or in engine cooling systems, and
modifying structures to provide adequate drainage are all examples of theuse of this
method of corrosion control. Although best employed during the design stage, in
some cases, actions taken to correct corrosion problems through modifying the
environment can be taken after a system is built. Careful identification and
characterization of corrosion problems will often reveal opportunities for changing the
environment to control corrosion,

Distillation is the application and removal of heat to separate hydrocarbons by their

relative volatility or boiling points . This necessary addition of heat normally in the
feed stream or at the tower bottoms via a reboiler can also lead to unwanted
consequences such as polymerization, corrosion and reverse solubility. The removal
of heat can lead to sedimentation, solubility effects, corrosion and precipitation. The
concentration of certain constituents by the distillation process can cause corrosion,
polymerization,
sediment fouling and flow phenomena effects.

A properly designed distillation column can reduce the effects of these consequences,
but in certain applications the polymerization, corrosion and other effects are very
prominent leading to reduced separation efficiency in the column. This reduced
separation efficiency increases the need for column maintenance and unit down time.
Distillation is the most widely utilized separation technique and there are basically
two main types of chemical treatments in distillation columns; one is for corrosion
control and the second is fouling control.
● Location of Study

his research was carried out at the Tobruk Oil Refinery, a facility operated by the
National Petroleum Institution to fulfill the demand for various petroleum derivatives
in the region. The refinery functions primarily through atmospheric distillation to
separate crude oil into different fractions.

● Problem Statement

Corrosion remains one of the most critical challenges in petroleum refineries,

particularly in distillation towers, where high temperatures, acidic vapors, and saline
contaminants combine to create a highly corrosive environment. At the Tobruk
Refinery, routine operations revealed fluctuating corrosion rates and elevated iron
concentrations in process streams, indicating ongoing degradation of internal tower
.components

This corrosion not only threatens the structural integrity of equipment but also leads
to reduced distillation efficiency, increased maintenance costs, unexpected
shutdowns, and potential safety risks. Despite standard operational controls, existing
protection measures were insufficient to maintain corrosion rates within acceptable
.limits over prolonged operational cycles

Therefore, there was a pressing need to implement a more effective and responsive
corrosion mitigation strategy that could be monitored and adjusted in real time. This
study was conducted to investigate the application of chemical corrosion inhibitors as
a practical and cost-effective solution to this persistent problem.

● Objective of the Study

The primary objective of this study is to evaluate the effectiveness of chemical

corrosion inhibitors—specifically the film-forming inhibitor EC1020B—in reducing
.corrosion rates within the distillation tower of the Tobruk Oil Refinery

: The research aims to

Identify the dominant corrosion mechanisms affecting the distillation unit under real -
.operating conditions

Monitor and analyze key corrosion indicators such as pH, chloride concentration, -
.and total iron content before and after inhibitor application
Assess the performance of the inhibitor in mitigating corrosion using quantitative -
.data from LPR and ER probe measurements

Determine the optimal dosage and injection strategy for maintaining corrosion rates -
.within acceptable operational limits

Provide recommendations for the implementation of a comprehensive corrosion -

.control program in refinery environments

This investigation is expected to contribute to improved equipment reliability,

reduced maintenance costs, and safer, more efficient refinery operations.

2. Materials and Methods

This study was conducted on-site at the Tobruk Oil Refinery, focusing on mitigating
corrosion in the distillation tower (unit V105). The corrosion control program
involved the use of a chemical inhibitor (EC1020B), an oil-soluble, film-forming
compound specifically designed to combat acidic and saline corrosion in hydrocarbon
processing environments.

The inhibitor was injected upstream of the initial condensation zone using a calibrated
chemical injection pump. Dosage levels ranged from 5 to 20 ppm, depending on
observed corrosive conditions. Adjustments to the dosage were made in real time
based on laboratory results.

Daily monitoring was performed across three operational shifts (morning, noon, and
night). Samples were collected from storage tank V105 and analyzed for pH, chloride
concentration (max allowable: 20 ppm), and total iron content (target: <1 ppm). These
values served as indicators for evaluating corrosion severity and the effectiveness of
treatment.

.
 We have to take readings for patrol to work in the refinery which are taken every day
three times the first in the period of the morning and the second in the period of the
noon and third in period of the evening and then we take these samples to the lab to
malse disclosures results for (PH) chloride as well as the amount for iron and we
continued in this process for a two weeks as shown in the table follows

Table ( 1 ) shown result of storage tank V105

Date Morning shift After non shift Night shift

1 PH Chloride as T. iron as PH Chloride T. iron PH Chloride T. iron

6.5-7.0 ppm max20 ppm 6.5-7.0 as ppm as ppm 6.5-7.0 as ppm as
Max1 max20 Max1 max20 ppm
Max1
2 7.5 14 0.58 7.3 11 0.5 6.9 10 0.8
3 7.2 12 0.64 7.1 11 0.35 6.9 10 0.8
4 7.1 14 0.65 6.7 12 0.7 7.2 10 0.8
5 6.8 16 1.8 7.0 12 1.5 7.0 10 1.0
6 7.0 17 1.4 7.1 14 1.5 6.8 13 1.0
7 6.9 16 1.3 7.1 15 1.4 7.0 12 1.0
8 7.3 10 0.8 7.1 10 0.8 6.9 13 1.2
9 7.4 10 0.6 7.3 14 0.3 7.2 12 1.0
10 7.5 10 0.6 7.3 12 0.6 7.2 10 1.0
11 7.1 11 0.32 7.3 12 0.6 7.2 12 0.8
12 7.4 14 0.27 7.1 10 0.4 7.2 12 0.9
13 7.5 14 0.32 7.2 10 0.4 7.0 11 0.65
14 7.4 16 0.38 7.5 10 0.3 7.4 10 0.5
15 7.5 12 0.45 7.5 10 0.3 7.5 10 0.31
Samples shall be taken daily from the tank-called tank corrosion, which a capacity of
about 350L as shown in the following figure.

Figure ( 2 ) tank of corrosion .

Treatment process chemical you need to follow-up every day, accurate and start first
register rate daily consumption by reading the level of the tank and calculate the
consumption in liters, which is usually of 12 to 15 Liters per day

The second: Detection results of the laboratory which is a day three time

PH 6.5=7,0 ,, Chloride max 20 ,, Iron (Fe+++) >1

Any high in these results will be adjusted rate pumping a substance anti-corrosion
usually an increase of pumping.

Corrosion rates were measured using Linear Polarization Resistance (LPR) and
Electrical Resistance (ER) as shown below probes installed in the system.
Additionally, inhibitor consumption was monitored by recording the tank level daily,
with average usage ranging from 12 to 15 liters per day.
This combined approach of real-time monitoring and chemical adjustment ensured the
 effectiveness of EC1020B under actual operating conditions and allowed for
responsive corrosion control during the one-month study period

Fig ( 3 ) (LPR) liner polarization resistance Figure ( 4 ) Electrical Resistance

(ER)

TABELE ( 2 ) results taken from corrosion

Date PH Irion cont Nalco

1020

25/03 -- 0.26 18L Corr rate for v105=0.09

26/03 -- -- 20 Corr rate for v105=0.15

27/03 -- -- 11 Corr rate for v105=0.10

28/03 -- 1.26 9 Corr rate for v105=0.09

01/04 5.56 22.0 9 Corr rate for v105=0.10

02/04 -- 0.75 8 Corr rate for v105=0.10

05/04 -- 0.55 7 Corr rate for v105=0.16

09/04 -- 1.09 7 Corr rate for v105=0.11

10/04 -- -- 8 Corr rate for v105=0.12

12/04 -- 1.14 9 Corr rate for v105=0.11

16/04 -- 0.42 8 Corr rate for v105=012

17/04 -- -- 8 Corr rate for v105=0.15

Figure (5): Corrosion Rate over Time in Unit V105

Results and Discussion .3

Throughout the one-month monitoring period at the Tobruk Refinery’s distillation
tower (unit V105), corrosion data was collected daily across three shifts. Parameters
such as pH, chloride concentration, and total iron (Fe) content were measured and
.used to estimate the corrosion rate

The readings showed that the pH values were consistently within the acceptable
neutral range of 6.5–7.5, while chloride levels remained mostly below 20 ppm. Iron
concentration showed minor fluctuations, with higher values generally correlating
.with increased corrosion rates

Corrosion rates were calculated using both LPR (Linear Polarization Resistance) and
ER (Electrical Resistance) probes. The results demonstrated a significant reduction in
corrosion activity following the injection of EC1020B. During most of the
observation period, the corrosion rate remained within the range of 0.09 to 0.16
mm/year, with occasional peaks reaching 0.26 mm/year, likely due to fluctuations in
.pH or chloride levels

The consistent reduction in corrosion rate indicates the effectiveness of EC1020B as a

.corrosion inhibitor under actual refinery operating conditions

It was also observed that increasing the inhibitor dosage in response to elevated iron
or chloride levels resulted in rapid stabilization of the system, showcasing the
.product’s responsiveness and adaptability

These findings align with previous studies in similar distillation environments,

confirming that oil-soluble filming inhibitors are a practical solution for minimizing
.corrosion caused by acidic and saline contaminants in hydrocarbon processing units

Conclusion .4
This study has demonstrated the effectiveness of chemical corrosion inhibition using
EC1020B in the distillation tower of Tobruk Refinery. The consistent monitoring of
pH, chloride concentration, and total iron content, along with the use of corrosion
monitoring devices such as LPR and ER probes, allowed for accurate assessment of
.corrosion behavior under operational conditions

The use of EC1020B resulted in a noticeable reduction in corrosion rates, maintaining

values mostly within the acceptable range of 0.09 to 0.16 mm/year. The data also
showed that timely adjustments to inhibitor dosage based on laboratory results helped
.in maintaining system stability and preventing excessive corrosion

These results support the implementation of a comprehensive corrosion control

program that combines real-time monitoring with chemical treatment strategies.
EC1020B proved to be an effective and compatible inhibitor for refinery systems,
contributing to increased equipment lifespan, reduced downtime, and overall
.operational efficiency
Further studies could investigate long-term performance under varying operating
conditions, or explore combining EC1020B with other protective strategies such as
.neutralizers or coatings to enhance protection in more aggressive environments

Recommendations .5
:Based on the findings of this study, the following recommendations are suggested

Implement Routine Monitoring: Continue the regular use of corrosion monitoring .1

devices (LPR and ER probes) and laboratory testing for pH, chloride, and iron content
.to ensure early detection of corrosive conditions

Optimize Inhibitor Dosage: Maintain the EC1020B dosage within the effective .2
.range of 5–20 ppm, and adjust it dynamically based on field data

Conduct Long-Term Evaluation: Extend the monitoring period to include seasonal .3

.variations and assess long-term trends in corrosion behavior

Integrate Other Protective Measures: Combine chemical inhibitors with physical .4

.protection strategies such as coatings and material upgrades for critical equipment

Training and Awareness: Provide training to operational staff on corrosion control .5

.techniques and safety in handling inhibitors

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