Corrosion in crude distillation unit (CDU) overhead systems remains one of refining’s most costly and hazardous problems. Overhead lines and condensers are exposed to hydrogen chloride, ammonium chloride, and other corrosive compounds, with NACE estimating annual costs at $1.37 billion. Traditional tools like coupons or boot water pH are snapshots that often miss hidden risks such as acidic early condensation or salt deposition.
Our article explores how a corrosion-focused digital twin using Petro-SIM® software gives refiners a real-time radar. By continuously monitoring KPIs such as ionic dew point pH, salting temperature, aqueous phase acidity, and corrosion rate, the digital twin provides predictive insight that traditional spot checks can’t deliver. The result: safer operations, reduced downtime, and a framework for extending predictive monitoring across the refinery while Bringing Decarbonization to Life®.
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