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Combatting Corrosion
in Hydrocracker Units:
An Overview of
Damage Mechanisms
and Metallurgy
Selection
Orion Swanson
Corrosion and Materials Discipline Engineer | 39 articles Follow
Individual Contributor | Oil & Gas | Chemica…

January 17, 2023

Corrosion is a major concern in hydrocracker units, as it can

lead to equipment failure and downtime. There are several
mechanisms of corrosion that can occur in these units,
including:

1. High Temperature Corrosion: Hydrocracker units

operate at high temperatures, which can cause
corrosion of the equipment. High temperature
corrosion can be caused by the presence of sulfur,
chlorine, and other impurities in the feedstock.
 2. Hydrogen Attack: Hydrogen can react with the steel
equipment in the hydrocracker unit, causing hydrogen
embrittlement and cracking. This type of corrosion is
often caused by the presence of hydrogen sulfide
(H2S) and other sulfur compounds in the feedstock.

3. Stress Corrosion Cracking: This type of corrosion

occurs when the equipment is subject to both tensile
stress and a corrosive environment. It is often caused
by the presence of chloride ions in the feedstock.

To defend against these damage mechanisms, various

metallurgy selection options are available such as :

1. Stainless steels: Stainless steels are known for their

corrosion resistance and are often used in
hydrocracker units. Type 316L stainless steel is a
popular choice due to its resistance to high
temperature corrosion and hydrogen attack.

2. Nickel-based alloys: Nickel-based alloys such as

Inconel 625 and Incoloy 800 are also commonly used
in hydrocracker units due to their excellent resistance
to high temperature corrosion and hydrogen attack.

3. Duplex Stainless Steel: Duplex stainless steel, such as

2205 and 2507, provide a good combination of
corrosion resistance and mechanical properties. They
are often used in situations where chloride-induced
stress corrosion cracking is a concern.

4. Clad materials: Cladding is a method of providing

corrosion resistance to the surface of carbon steel. This
method allows for the use of a corrosion-resistant alloy
as a cladding on the surface of the carbon steel.

In conclusion, corrosion is a significant concern in

hydrocracker units, and various mechanisms of corrosion
can occur. To defend against these damage mechanisms,
various metallurgy selection options such as stainless steel,
nickel-based alloys, duplex stainless steel and clad materials
are available, each with its own set of advantages and
disadvantages. The selection of the appropriate metallurgy
will depend on the specific conditions and requirements of
the hydrocracker unit.

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