US20260035803A1

US20260035803A1 - Vapor-phase degreasing, cleaning, passivating, and/or descaling of processing equipment

Info

Publication number: US20260035803A1
Application number: US18/793,406
Authority: US
Inventors: Giselle Braganza; Aaron M. BEUTERBAUGH; Jason Adam Denny
Original assignee: Halliburton Energy Services Inc
Current assignee: Halliburton Energy Services Inc
Filing date: 2024-08-02
Publication date: 2026-02-05

Abstract

A method comprising: prior to commissioning of a processing equipment into service, cleaning and/or passivating a contact surface of the processing equipment with a vapor comprising a chemistry and a carrier, wherein cleaning comprises removing one or more contaminants from the contact surface and wherein passivating comprises creating a passive film on the contact surface. A method of vapor phase descaling is also provided.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

None.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

The present disclosure generally relates to cleaning and/or passivating contact surfaces of processing equipment via vapor phase delivery of a cleaning and/or passivating chemistry.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawing and detailed description, wherein like reference numerals represent like parts.

The Figure depicts an illustrative vapor phase cleaning and/or passivating system which may be used to carry out the present methods, according to embodiments of this disclosure.

DETAILED DESCRIPTION

It should be understood at the outset that although illustrative implementations of one or more embodiments are illustrated below, the disclosed systems and methods may be implemented using any number of techniques, whether currently known or not yet in existence. The disclosure should in no way be limited to the illustrative implementations, drawings, and techniques illustrated below, but may be modified within the scope of the appended claims along with their full scope of equivalents.
It should be noted that when “about” is used herein at the beginning of a numerical list, “about” modifies each number of the numerical list. Further, in some numerical listings of ranges, some lower limits listed may be greater than some upper limits listed. One skilled in the art will recognize that the selected subset will require the selection of an upper limit in excess of the selected lower limit. Unless otherwise indicated, all numbers expressing quantities of ingredients, particle sizes, reaction conditions, and so forth used in the present specification and associated claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the illustrative embodiments described herein. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claim, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. The term “about” as used herein can thus allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range.
The term “substantially” as used herein refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more.
The term “downhole” as used herein refers to under the surface of the earth, such as a location within or fluidly connected to a wellbore.
If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.
After initial construction and assembly of oil and gas and/or other chemical processing equipment, to prepare the equipment for commissioning (that is, during “pre-commissioning”), internal surfaces (e.g., contact surfaces) of the equipment can be cleaned for the removal of contaminants, including, but not limited to, mill-oil, grease, rust and/or corrosion products and provide a cleaned surface; and/or a passive film can be deposited on the surface to provide a passivated surface. Generally, the surface can be cleaned prior to passivating. The “dirty” surface is thus contaminated and the “cleaned” or “clean” surface exhibits a reduced amount of contaminants as compared to the surface (i.e., the “dirty” surface) prior to cleaning. The inner surface can be passivated (e.g., when clean) to protect it until it is put into operation (or “commissioned into service”) which can be days or even months later. Conventionally, such cleaning (and optional passivating) is carried out using circulation as a method. This circulation method typically involves filling up the system/equipment (e.g., the internal volume thereof) with water, circulating the water, heating the circulating water, and adding in chemistry to degrease, pickle and/or passivate the equipment. This process of filling, circulating, heating and draining and treating of waste can generate many (e.g., 2 to 3 or more) system volumes of waste, which can incur substantial additional costs. Furthermore, personnel required for a conventional circulation application can be based on the size of the equipment and the complexity of the rig-up, and, at minimum, can typically involve numerous (e.g., 6-8) personnel covering continuous (e.g., 24 hour) operations. Additionally, each of the phases of degreasing, pickling and passivation may be requested individually based on the type of asset that requires cleaning.
During ongoing maintenance stages after the processing equipment has been in operation for a while (i.e., has been “commissioned”), similar cleaning can be requested, with scale removal being an additional service that can often be performed, especially for cooling water and heat exchange systems.
With the move towards greener energy sources, such as and without limitation liquefied natural gas (LNG), carbon capture, utilization, and storage (CCUS) and hydrogen, the size of the processing equipment typically increases by at least two fold. For example, in some applications the size of the processing equipment utilized by such greener energy sources can be as large as 1500 to 5000 m³, as compared to 300 to 500 m³. This further complicates resource requirements and dramatically increases waste quantities for subsequent disposal produced via conventional circulation methods.
Herein disclosed is a method of cleaning (e.g., degreasing, pickling, and/or descaling as described further hereinbelow) and/or passivation that utilizes vapor phase as the method of delivery for the cleaning and/or passivation chemistry. Degreasing, pickling, passivation or scale removal chemicals (referred to herein also as “chemistry” or “treatment fluid”) can be delivered to the equipment using any suitable vapor phase carrier, such as and without limitation, steam, air, nitrogen, hydrocarbon, or any other similar phase that does not involve filling the processing equipment entirely with liquid (e.g., water). As detailed further hereinbelow, via this disclosure, the chemistry can be sprayed, nebulized, vaporized and/or atomized into the carrying phase (also referred to as a “carrier”), for example prior to introduction/injection into the processing equipment. The chemistry in the vapor phase then contacts the contaminants inside the processing equipment, cleans and removes the contaminants from the internal surfaces thereof, and leaves the equipment clean and ready for commissioning into service (e.g., production), optionally subsequent (e.g., vapor phase or conventional circulation method) passivating. Via this disclosure, the chemistries for the degreasing, pickling, descaling, and/or passivating can be deployed using a vapor medium.
The equipment, personnel, liquid (e.g., water), and chemistry utilization for the herein disclosed vapor phase cleaning and/or passivation can be significantly reduced relative to traditional cleaning using (e.g., liquid) circulation. The waste generated via the herein disclosed method can be reduced by at least ⅓ or more, relative to conventional liquid (e.g., water) circulation methods, with little or no impact on cleaning efficiency and efficacy.
As utilized herein, “cleaning” is intended to cover removing substantially all of one or more contaminants, as disparate from “decontamination”, which refers to the removal of components in order to make an equipment “human-entry” ready. Decontaminated process equipment is not “clean” in the sense of this disclosure, as the decontaminated equipment generally still contains contaminants not harmful to humans during human (e.g., personnel) entry. Decontamination is typically performed, for example, to remove hydrogen sulfide (H₂S), benzene (C₆H₆), and/or other components (e.g., hydrocarbons) and reduce the lower explosive limit (LEL), thus making the decontaminated processing equipment safe for human-entry. Once decontaminated, personnel can enter the processing equipment, for example to further clean the equipment, or for other maintenance. The decontaminated equipment is generally not pristine, with a very low (e.g., substantially zero) level of contaminants, and thus is not “clean” as per this disclosure. Decontamination processes thus refer to the removal of hydrocarbon to bring LEL, H₂S and/or benzene levels, or other substances harmful to personnel, to zero (or non-zero acceptable levels) prior to opening the system for maintenance work and/or hot works, while cleaning a per this disclosure refers to the removal of substantially all of one or more contaminants from the contact surface being cleaned.
A method of this disclosure can comprise: prior to commissioning of a processing equipment into service, cleaning and/or passivating a contact surface (e.g., an internal surface, a surface that contacts a process fluid during operation) of the processing equipment with a vapor comprising a chemistry and a carrier (also referred to as a carrier vapor or carrier phase). Cleaning comprises removing one or more contaminants from the contact surface and passivating comprises creating a passive film on the contact surface.
In embodiments, the method comprises degreasing cleaning alone to provide a cleaned processing equipment. In embodiments, the method comprises pickling cleaning alone to provide a cleaned processing equipment. In embodiments, the method comprises passivating (e.g., an already clean contact surface) alone to provide a (cleaned and) passivated processing equipment. In embodiments, the method comprises degreasing cleaning and pickling cleaning to provide a cleaned processing equipment. In embodiments, the method comprises degreasing cleaning and passivating to provide a cleaned and passivated processing equipment. In embodiments, the method comprises pickling cleaning and passivating to provide a cleaned and passivated processing equipment. In embodiments, the method comprises degreasing cleaning, pickling cleaning, and passivating to provide a cleaned and passivated processing equipment.
The pre-commissioning cleaning can thus comprise: (a) degreasing; (b) pickling; or (c) a combination thereof. Descaling cleaning, which can be performed as a maintenance cleaning, is also described hereinbelow.
In embodiments, the method comprises (a) degreasing. In such embodiments, the one or more contaminants can comprise milling oil, cutting oil, grease, lubricant, corrosion inhibitor, hydrocarbon film, rust preventative compound, or a combination of one or more thereof. Such contaminants can have been added to the contact surface during and/or after manufacturing of the processing equipment, for example to prevent pre-commissioning rust formation on the contact surface during transport and/or storage of the manufactured processing equipment prior to commissioning. As utilized herein, “degreasing” can refer to the removal of such one or more contaminants to a low level (e.g., a level of the one or more contaminants that is less than or equal to about 0 g/m³of cleaned surface area). For example, degreasing can refer to the removal of such one or more contaminants to a low level that can be non-detectable by standard analyses known to those of skill in the art.
For degreasing cleaning, the chemistry can be any suitable chemistry for removing the contaminants noted above (e.g., the milling oil, cutting oil, grease, hydrocarbon film, rust preventative compound, lubricant, corrosion inhibitor, or combination of one or more thereof). Examples of such chemistry can include surfactants, organic solvents, alkaline detergents, water, or a combination thereof.
The chemistry for degreasing can include a surfactant. A person of ordinary skill, with the benefit of this disclosure, will be able to identify the type of surfactant as well as the appropriate concentration of surfactant to be used. The surfactant can be ionic, nonionic, anionic, cationic, or amphoteric. Examples of surfactants that may be suitable include, but are not limited to, ethoxylated nonyl phenol phosphate esters, nonionic surfactants, cationic surfactants, anionic surfactants, amphoteric/zwitterionic surfactants, alkyl phosphonate surfactants, linear alcohols, nonylphenol compounds, alkyoxylated fatty acids, alkylphenol alkoxylates, ethoxylated amides, ethoxylated alkyl amines, amphoteric surfactants (such as betaines), methyl ester sulfonates (e.g., as described in U.S. Patent Application Nos. 2006/0180310, 2006/0180309, 2006/65 0183646 and U.S. Pat. No. 7,159,659, the relevant disclosures of which are incorporated herein by reference), hydrolyzed keratin (e.g., as described in U.S. Pat. No. 6,547,871, the relevant disclosure of which is incorporated herein by reference), sulfosuccinates, taurates, amine oxides, alkoxylated fatty acids, alkoxylated alcohols (e.g., lauryl alcohol ethoxylate, ethoxylated nonyl phenol), ethoxylated fatty amines, ethoxylated alkyl amines (e.g., cocoalkylamine ethoxylate), betaines, modified betaines, alkylamidobetaines (e.g., cocoamidopropyl betaine), quaternary ammonium compounds (e.g., trimethyltallowammonium chloride, trimethylcocoammonium chloride), derivatives thereof, and mixtures thereof. Examples of surfactants that may be suitable include non-emulsifiers commercially available from Halliburton Energy Services, Inc., of Duncan, OK, under the tradenames “LOSURF-300M™” nonionic surfactant, “LOSURF-357™” nonionic surfactant, “LOSURF-400™” surfactant, “LOSURF-2000S™” solid surfactant, “LOSURF-2000M™” solid surfactant, and “LOSURF-259™” nonionic non-emulsifier. Another example of a surfactant that may be suitable is a non-emulsifier commercially available from Halliburton Energy Services, Inc., of Duncan, OK, under the tradename “NEA-96M™” Surfactant. Other examples of surfactants that may be suitable that are commercially available from Halliburton Energy Services in Duncan, OK. are products “SGA-1,” “EFS-1,” “EFS-2,” “EFS-3,” 35 and “EFS-4.” Other surfactants that may be suitable may include betaines and quaternary ammonium compounds. Examples of betaines that are commercially available include MIRATAINE® and MIRATAINE® BET 0-30 both available for Rhodia and REWOTERIC® AM TEG available for Degussa. Examples of commercially available quaternary ammonium compounds include ARQUADR 22-80 and ETHOQUAD® 0/12 PG both available from Akzo Nobel and GENAMIN KDMP available from Clariant. Surfactants such as those comprising inner salt of alkyl amines, such as HY-CLEAN (HC-2)™ surface-active suspending agent (e.g., comprising alkyl amines and sodium chloride) or AQF-2™ additive, both commercially available from Halliburton Energy Services, Inc., of Duncan, OK, may be used.
The chemistry for degreasing can include an organic solvent. A person of ordinary skill, with the benefit of this disclosure, will be able to identify the type of organic solvent as well as the appropriate concentration of organic solvent to be used. In embodiments, the organic solvent comprises one or more hydrocarbons, alcohols, glycols, amines, esters, ethers, halogenated compounds, carboxylic acids, or a derivative or combination thereof.
The chemistry for degreasing can include an alkaline detergent. A person of ordinary skill, with the benefit of this disclosure, will be able to identify the type of alkaline detergent as well as the appropriate concentration of alkaline detergent to be used. In embodiments, the alkaline detergent comprises one or more selected from metal hydroxides, phosphates, carbonates, and/or sulfates, or a combination thereof.
In embodiments, the chemistry for degreasing comprises PARAGON™, PEN-5™, MUSOL™, MX™ 5-4225, RPA-880™, TRANSCEND(s)™, or a combination thereof, all available from Halliburton Energy Services of Duncan, OK.
In embodiments, the method comprises (b) pickling. In such embodiments, the one or more contaminants can comprise mill scale (e.g., particles of steel, aluminum, or cast iron or the like), welding slag, rust, sand, corrosion product(s), or a combination thereof. Such contaminants may remain in the interior volume/on the contact surface of the processing equipment as a result of the manufacturing process utilized to manufacture the processing equipment. As utilized herein, “pickling” can refer to the removal of such one or more contaminants to a low level (e.g., a level of the one or more contaminants that is less than or equal to about 0 g/m³of cleaned surface area). For example, pickling can refer to the removal of such one or more contaminants to a low level that can be non-detectable by standard analyses known to those of skill in the art.
For pickling cleaning, the chemistry can be any suitable chemistry for removing the contaminants noted above (e.g., the mill scale, welding slag, rust, sand, corrosion products, or combination thereof). Examples of such chemistry can include acids, chelants (also referred to herein as “chelant based chemistry”), or a combination thereof.
The chemistry for pickling can include an acid. A person of ordinary skill, with the benefit of this disclosure, will be able to identify the type of acid as well as the appropriate concentration of acid to be used. In embodiments, the acid comprises hydrochloric acid, acetic acid, formic acid, hydrofluoric acid, citric acid, ethylene diamine tetra acetic acid (“EDTA”), glycolic acid, sulfamic acid, N-phosphonomethyl iminodiacetic acid (“PMIDA”), phosphonic acid, p-toluenesulfonic acid, carbonic acids, citric acids, glycolic acids, lactic acids, ethylenediaminetetraacetic acid (“EDTA”), hydroxyethyl ethylenediamine triacetic acid (“HEDTA”), p-toluenesulfonic acid, methane sulfonic acid, or one or more derivatives or combinations thereof.
Suitable acids can include any acid suitable for removing the one or more contaminants (e.g., the mill scale, welding slag, rust, sand, or combination thereof). Examples include, without limitation, hydrochloric acid, hydrofluoric acid, acetic acid, formic acid, citric acid, ethylene diamine tetra acetic acid (“EDTA”), glycolic acid, sulfamic acid, N-phosphonomethyl iminodiacetic acid (“PMIDA”), phosphoric acid, sulfuric acid, methane sulfonic acid, nitric acid, or derivatives or combinations thereof. Hydrochloric acid, acetic acid, or formic acid can be utilized in certain applications. The term “derivative” is defined herein to include any compound that is made from one of the listed compounds, for example, by replacing one atom in the listed compound with another atom or group of atoms, rearranging two or more atoms in the listed compound, ionizing one of the listed compounds, or creating a salt of one of the listed compounds. The concentration and type of acid selected may be based upon the function of the acid (e.g., scale removal), compatibility with carrier and the interior (i.e., contact) surface, etc. One should be mindful that certain concentrations of acids, such as formic acid, may have a tendency to form precipitates upon spending. A precipitation control additive (e.g., aluminum chloride) may be desirable to include as well depending on the acid and the carrier.
In embodiments, the chemistry for pickling can include an acid, an acid generating compound, or a combination thereof. Any known acid may be suitable for use in the chemistry of the vapor phase of this disclosure. Examples of acids that may be suitable for use in this disclosure include, but are not limited to organic acids (e.g., formic acids, acetic acids, carbonic acids, citric acids, glycolic acids, lactic acids, ethylenediaminetetraacetic acid (“EDTA”), hydroxyethyl ethylenediamine triacetic acid (“HEDTA”), p-toluenesulfonic acid, methane sulfonic acid and the like), inorganic acids (e.g., hydrochloric acid, hydrofluoric acid, phosphonic acid, p-toluenesulfonic acid, and the like), and combinations thereof. Examples of acid generating compounds that may be suitable for use in this disclosure include, but are not limited to, esters, aliphatic polyesters, ortho esters, which may also be known as ortho ethers, poly(ortho esters), which may also be known as poly(ortho ethers), poly(lactides), poly (glycolides), poly(E-caprolactones), poly(hydroxybutyrates), poly(anhydrides), or copolymers thereof. Derivatives and combinations also may be suitable. Other suitable acid-generating compounds include: esters including, but not limited to, ethylene glycol monoformate, ethylene glycol diformate, diethylene glycol diformate, glyceryl monoformate, glyceryl diformate, glyceryl triformate, triethylene glycol diformate and formate esters of pentaerythritol. An example of a suitable acid generating compound is a citrate ester commercially available from Halliburton Energy Services, Inc., of Duncan, OK, under the tradename MATRIXFLO™ II Breaker. Other suitable materials may be disclosed in U.S. Pat. Nos. 6,877,563 and 7,021,383, the disclosures of which are incorporated by reference.
The chemistry for pickling can include a chelant. A person of ordinary skill, with the benefit of this disclosure, will be able to identify the type of chelant as well as the appropriate concentration of chelant to be used. Any suitable chelating agent that can be incorporated into the vapor phase and is compatible with the carrier and the contact surface can be used with this disclosure. Suitable chelants can include, but are not limited to, citric acid or sodium citrate, ethylene diamine tetra acetic acid (“EDTA”), hydroxyethyl ethylenediamine triacetic acid (“HEDTA”), dicarboxymethyl glutamic acid tetrasodium salt (“GLDA”), methyl glycine diaceticacid (“MGDA”) diethylenetriaminepentaacetic acid (“DTPA”), propylenediaminetetraacetic acid (“PDTA”), N-phosphonoalkyl diacetic acids (including but not limited to N-phosphonomethyl iminodiacetic acid (“PMIDA”), ethylenediaminedi (o-hydroxyphenylacetic) acid (“EDDHA”), glucoheptonic acid, gluconic acid, and the like, and nitrilotriacetic acid (“NTA”). Other chelating agents also may be suitable.
Examples of chelating agents that may be suitable include, but are not limited to, an anhydrous form of citric acid, commercially available under the tradename “FE-2™” Iron Sequestering Agent from Halliburton Energy Services, Inc., of Duncan, OK. Another example of a suitable chelating agent is a solution of citric acid dissolved in water, commercially available under the tradename “FE-2 ATM” buffering agent from Halliburton Energy Services, Inc., of Duncan, OK. Another example of a suitable chelating agent is sodium citrate from Halliburton Energy Services, Inc. of Duncan, OK. Other chelating agents that may be suitable for use with this disclosure include, inter alia, nitrilotriacetic acid and any form of ethylene diamine tetracetic acid (“EDTA”) or its salts, hydroxyethylethylenediaminetriacetic acid (“HEDTA”), dicarboxymethyl glutamic acid tetrasodium salt (“GLDA”), diethylenetriaminepentaacetic acid (“DTPA”), propylenediaminetetraacetic acid (“PDTA”), N-phosphonomethyliminodiacetic acid (“PMIDA”) ethylenediaminedi (o-hydroxyphenylacetic) acid (“EDDHA”), glucoheptonic acid, gluconic acid, sodium citrate, phosphonic acid, salts thereof, and the like. In embodiments, the chelating agent maybe a sodium or potassium salt form of the chelating agent. In embodiments, the chelating agent is present in the form of potassium carbonate commercially available from Halliburton Energy Services, Inc., of Duncan, OK, under the tradename “BA-40L™” buffering agent.
In embodiments, the chemistry for pickling comprises HALKLEEN™ C, G, B, S, or a combination thereof, all available from Halliburton Energy Services of Duncan, OK, a chemistry noted above, and/or another (e.g., acid based) pickling product.
In embodiments, the method comprises passivating, wherein passivating comprises creating the passive film on the contact surface of the processing equipment. The passivating can be effected, for example, to prevent flash rusting and/or otherwise preserve the processing equipment until commissioning thereof into service.
For passivating, the chemistry can be any suitable chemistry for providing the passive film on the contact/internal surface. Examples of such chemistry can include nitrite based chemistry, phosphate based chemistry, another chemistry that creates a steel grey passive film, a vapor phase corrosion inhibitor (VpCI), oxides, another chemistry that creates a polymer film (e.g., chemistry that creates a polymer coating), or a combination thereof. A steel grey passive film can comprise a thin layer of metal oxide (e.g., on the contact surface). As utilized herein, “passive” in relation to a film on the contact surface indicates that the film does not react with components of the fluids to contact the contact surface of the processing equipment when it is commissioned (e.g., when it is in service).
The chemistry for passivating can include a nitrite based chemistry. A person of ordinary skill, with the benefit of this disclosure, will be able to identify the type of nitrite based chemistry as well as the appropriate concentration of nitrite based chemistry to be used.
The chemistry for passivating can include a phosphate based chemistry. A person of ordinary skill, with the benefit of this disclosure, will be able to identify the type of phosphate based chemistry as well as the appropriate concentration of phosphate based chemistry to be used.
The chemistry for passivating can include another chemistry that creates a steel grey passive film on the contact surface. A person of ordinary skill, with the benefit of this disclosure, will be able to identify the type of chemistry that creates a steel grey passive film as well as the appropriate concentration thereof to be used.
The chemistry for passivating can include a VpCI. A person of ordinary skill, with the benefit of this disclosure, will be able to identify the type of VpCI as well as the appropriate concentration thereof to be used.
In embodiments, the chemistry for passivating includes a corrosion inhibitor. Examples of corrosion inhibitors that may be suitable for use include acetylenic alcohols, Mannich condensation products (such as those formed by reacting an aldehyde, a carbonyl containing compound and a nitrogen containing compound), unsaturated carbonyl compounds, unsaturated ether compounds, formamide, formic acid, formates, other sources of carbonyl, iodides, terpenes, and aromatic hydrocarbons, coffee, tobacco, gelatin, thio-compounds, cinnamaldehyde, cinnamaldehyde derivatives, fluorinated surfactants, quaternary derivatives of heterocyclic nitrogen bases, quaternary derivatives of halomethylated aromatic compounds, formamides, combinations of such compounds used in conjunction with iodine, quaternary ammonium compounds, cuprous iodide; cuprous chloride; an antimony compound; an antimony oxide; an antimony halide; antimony tartrate; antimony citrate; an alkali metal salt of an antimony tartrate and antimony citrate; an alkali metal salt of pyroantimonate and an antimony adduct of ethylene glycol; a bismuth compound; a bismuth oxide; a bismuth halide; a bismuth tartrate; a bismuth citrate; an alkali metal salts of bismuth tartrate and bismuth citrate; iodine and combinations thereof. Corrosion inhibitors that may be suitable are available from Halliburton Energy Services and include: “MSA-II™” corrosion inhibitor, “MSA-III” corrosion inhibitor, “HAI-25 E+” environmentally friendly low temp corrosion inhibitor, “HAI-404™” acid corrosion inhibitor, “HAI-50™” Inhibitor, “HAI-60™” Corrosion inhibitor, “HAI-62™” acid corrosion inhibitor, “HAI-65™” Corrosion inhibitor, “HAI-72E+™” Corrosion inhibitor, “HAI-75™” High temperature acid inhibitor, “HAI-8™” Acid corrosion inhibitor, “HAI-85™” Acid corrosion inhibitor, “HAI-85™” Acid corrosion inhibitor, “HAI-202 Environmental Corrosion Inhibitor,” “HAI-OS” Corrosion Inhibitor, “HAI-GE” Corrosion Inhibitor, “FDP-S692-03” Corrosion inhibitor for organic acids, “FDP-S656AM-02” and “FDPS656BW-02” Environmental Corrosion Inhibitor System, “HII-500” Corrosion inhibitor intensifier, “HII-500M” Corrosion inhibitor intensifier, “HII-124” Acid inhibitor intensifier, “HII-124B” Acid inhibitor intensifier, “HII-124C™” Inhibitor intensifier, and “HII-124F™” corrosion inhibitor intensifier.
In embodiments, a corrosion inhibitor activator may be included. Examples of corrosion inhibitor activators that may be used include, but are not limited to, cuprous iodide; cuprous chloride; antimony compounds such as antimony oxides, antimony halides, antimony tartrate, antimony citrate, alkali metal salts of antimony tartrate and antimony citrate, alkali metal salts of pyroantimonate and antimony adducts of ethylene glycol; bismuth compounds such as bismuth oxides, bismuth halides, bismuth tartrate, bismuth citrate, alkali metal salts of bismuth tartrate and bismuth citrate; iodine; iodide compounds; formic acid; and mixtures of the foregoing activators such as a mixture of formic acid and potassium iodide. Corrosion inhibitors intensifiers that may be suitable are available from Halliburton Energy Services and include: “HII-500™” Corrosion inhibitor intensifier, “HII-500M™ ” Corrosion inhibitor intensifier, “HII-124B” Acid inhibitor intensifier, “HII-124C™” Inhibitor intensifier, and “HII-124F™” corrosion inhibitor intensifier.
The chemistry can include a scale inhibitor. Any scale inhibitor that can be incorporated into the vapor phase and is compatible with the carrier and the contact surface may be suitable for use in this disclosure. This may include water soluble organic molecules with carboxylic acid, aspartic acid, maleic acids, sulphonic acids, N-phosphonoalkyl iminodiacetic acid, phosphonic acid and phosphate esters groups including copolymers, terpolymers, grafted copolymers, derivatives thereof, and combinations thereof. Examples of such compounds include aliphatic phosphonic acids such as diethylene triamine penta (methylene phosphonate) and polymeric species such as polyvinylsulphonate. The scale inhibitor may be in the form of the free acid, or may be in the form of mono- and polyvalent cation salts such as those comprising cations of sodium, potassium, aluminum, iron, calcium, magnesium, ammonia, etc. (e.g., Na⁺, K⁺, Al⁺³, Fe⁺³, Ca⁺², Mg⁺², NH⁴⁺ cations). An example of a suitable scale inhibitor is “SCALECHECK® LP-55 Scale Inhibitor” from Halliburton Energy Services in Duncan, OK. Another example of a suitable scale inhibitor is “LP-65™ Scale Inhibitor” available from Halliburton Energy Services in Duncan, OK. If used, a scale inhibitor can be included in an amount effective to inhibit scale formation.
The chemistry can include a bactericide. Any bactericides known in the art that can be incorporated into the vapor phase and is compatible with the selected carrier and the interior/contact surface of the processing equipment can be suitable. An artisan of ordinary skill with the benefit of this disclosure will be able to identify a suitable bactericide and the proper concentration of such bactericide for a given application. Examples of suitable bactericides include, but are not limited to, a 2,2-dibromo-3-nitrilopropionamide, commercially available under the tradename BE-3S™ biocide from Halliburton Energy Services, Inc., of Duncan, OK, and a 2-bromo-2-nitro-1,3-propanediol commercially available under the tradename BE-6™ biocide from Halliburton Energy Services, Inc., of Duncan, OK.
As described hereinabove, the one or more contaminants removed by the cleaning can comprise one or more components present on the contact surface of the processing equipment inherently as a result of manufacturing of the processing equipment or post-manufacturing (e.g., to prevent damage (e.g., rust) to the contact surface post-manufacturing and prior to commissioning). The cleaning (e.g., the degreasing, pickling, and/or descaling) can remove substantially all (e.g., greater than or equal to about 80, 85, 90, 95, 96, 97, 98, 99, or 100%) of the one or more targeted contaminants.
The processing equipment can be in human-entry condition (i.e., be safe for personnel to enter, as noted hereinabove) prior to (and after) the cleaning and/or passivating.
The vapor phase cleaning and/or passivating comprises contacting the contact surface of the processing equipment with the chemistry in the vapor phase such that the one or more contaminants are removed from the contact surface and/or the passive film is created on the contact surface, respectively.
The vapor carrier can comprise any suitable vapor for carrying the chemistry into contact with the contact surface of the processing equipment during the cleaning and/or passivating. For example, in embodiments, the carrier vapor can comprise steam, air, an inert gas (e.g., nitrogen), a hydrocarbon, or a combination thereof.
As discussed further hereinbelow with reference to The Figure, the method can further comprise introducing the chemistry into the carrier of the vapor phase via any suitable methods, such as by pumping, vaporizing, nebulizing, atomizing, spraying, or a combination thereof.
The processing equipment cleaned and/or passivated via the herein disclosed vapor phase method can have an interior volume of greater than or equal to about 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, 1600, 1700, 1800, 1900, 2000, 2500, 3000, 3500, 4500, 5000 cubic meters (m³). In embodiments, the processing equipment cleaned and/or passivated via the herein disclosed vapor phase method can have an interior volume in a range of from about 1500 to 10,000 m³, from about 1500 to about 5000 m³, or from about 2000 to about 5000 m³. Smaller or larger interior volumes can also be treated via the herein disclosed vapor phase method, in embodiments. Based on the size of the processing equipment being cleaned and/or passivated, one or multiple (e.g., a plurality of) injection points can be selected for optimum distribution of the cleaning and/or passivating chemistry.
The processing equipment can be a component of a refinery (e.g., a crude refinery, a liquid natural gas (LNG) refinery) or a component of a petrochemical plant. The processing equipment can be in the LNG, carbon capture, utilization, and storage (CCUS), or hydrogen market. The processing equipment can be any piece of industrial equipment comprising the noted contaminants (to be removed via degreasing, pickling, or, as detailed further hereinbelow, descaled) on a contact surface and/or to which a passivating layer is to be applied. The herein disclosed method of utilizing a vapor phase delivery of chemicals for cleaning and/or passivating can be utilized with a variety of process facility equipment, such as and without limitation boilers, condensers, exchangers, piping, towers, tanks (e.g. storage tanks), etc., during pre-commissioning and/or for scale removal during maintenance cleaning, as described further hereinbelow.
The vapor phase cleaning and/or passivating method of this disclosure can be utilized for surface equipment cleaning and/or passivating, although in embodiments, the vapor phase chemistries can be pumped downhole for downhole equipment cleaning and/or passivating. According to this disclosure, the chemistry can be dosed into a vapor as the carrying medium (e.g., the carrier), not dosing these chemistries into a liquid, such as liquid water.
In embodiments, the cleaning and/or passivating uses (⅓ of the) liquid (e.g., water or other liquid from which the carrier vapor is vaporized) relative to conventional circulation cleaning and/or passivating methods. For example, where a conventional circulation cleaning may employ 2 or 3 system volumes (e.g., a volume 2-3 times the interior volume of the processing equipment) or more, the herein disclosed vapor phase cleaning and/or passivating method can utilize less than or equal to about 3, 2, or 1 system volumes of liquid (e.g., water or other liquid vaporized to provide the vapor carrier). The vapor phase cleaning and/or passivating method of this disclosure can provide a smaller a (e.g., at least 10, 20, 30, 40, 50, 60, 70, 80, 90, or more smaller) carbon footprint than conventional circulation methods of cleaning and/or passivating. For example, one pallet of equipment vs. at least one flat bed trailer of equipment may be employed to treat a processing equipment of a same interior volume.
As detailed further hereinbelow with reference to The Figure, the contact surface can have a temperature equal to or greater than a boiling point temperature of the vapor phase (the vapor phase, the chemistry, the carrier). For example, in embodiments in which the carrier comprises steam, the contact surface can have a temperature equal to or greater than 100° C. during the cleaning and/or passivating. In embodiments, for steam-based chemistry, injection of the chemistry will only commence once the temperature of the unit (e.g., the processing equipment) has reached or exceeded 100° C. at a top of the unit. For example, steam can be pumped through the equipment. The steam can be greater than 100° C. (e.g., around 170° C.), and steam can be flowed until the equipment reaches or exceeds 100° C. at the top of the equipment. In this manner, the steam can continue on to the flare and get burned off rather than condensing in the equipment and having to be collected for waste disposal. The temperature can be increased by any methods known to those of skill in the art.
Testing can be performed during the cleaning and/or the passivating to determine when the cleaning and/or passivating is complete. For example, in embodiments, the method can further comprise assessing a degree: (i) of cleaning by: semi-continuously, continuously, or intermittently performing an analysis of a condensed vapor sample extracted from the processing equipment during the method and comparing a result of the analysis at a current sampling time with a result of one or more condensed vapor samples at one or more prior times; and/or (ii) of passivating by: visual observation. The analysis can be any suitable analysis for measuring an amount (e.g., a mass) of the one or more contaminants being extracted from the contact surface. For example, with a steam carrier and oil contaminant, the analysis can comprise an oil and water analysis of condensed vapor samples extracted from the processing equipment during the cleaning. The visual observation utilized to assess the degree of passivating can comprise the use of human vision, camera, borescope, or another visual observation method/apparatus.
The method can include determining that the cleaning is complete when no further change in the analysis result is seen in multiple (two, three, or more) consecutive condensed vapor samples. This can indicate that no further contaminant(s) is (are) being extracted via the cleaning, and that the cleaning is complete. The result of the analysis at which the cleaning is determined to be complete can show an amount of each of the one or more contaminants in the sample to be substantially zero and/or level(s) of contaminant(s) in the collected waste are no longer changing (e.g., increasing).
In embodiments, the analysis comprises an oil and water (O&W) analysis, a gas chromatography (GC) analysis, a nuclear magnetic resonance (NMR) analysis, visual inspection or a combination thereof. As noted above, the cleaning of this disclosure does not comprise decontamination to make ready for human-entry. Accordingly, the testing/analysis for completion of the cleaning may not generally include testing/analysis for substances (e.g., pyrophoric iron oxides, H₂S, benzene, etc.) that preclude human-entry of the processing equipment, as may be utilized when decontaminating a piece of processing equipment.
In embodiments, a method of this disclosure comprises: providing a processing equipment prior to commissioning (e.g., providing a “non-commissioned” processing equipment); utilizing vapor phase cleaning to remove one or more contaminants from a contact surface of the processing equipment (to provide a cleaned processing equipment), and/or utilizing vapor phase passivating to create a passive film on the contact surface of the processing equipment (to provide a passivated processing equipment); and commissioning the (e.g., cleaned and/or passivated) processing equipment (e.g., putting the processing equipment into service). The cleaning and/or passivating can be performed as detailed hereinabove. As mentioned previously, the processing equipment as provided and before (and after) the vapor phase cleaning and/or passivating can be suitable for human-entry.
Injection of chemistry can continue until the end point or acceptance criteria (e.g., multiple unchanging sample analysis readings, below a certain contaminant level per analysis sample, etc.) have been met. A post-flush or rinse can be utilized to help remove any residual contaminants in the processing equipment. For example, a post-flush can comprise a water rinse, for example from the top of the equipment and/or down the sides.
Also provided herein is a method comprising: performing maintenance cleaning of a processing equipment by removing scale from a contact surface of the processing equipment via vapor phase cleaning. In such embodiments, the processing equipment can comprise, for example, a component of a cooling water system, a heat exchange system, or a combination thereof. The processing equipment subjected to vapor phase descaling according to this disclosure can be a processing equipment that has been in service (e.g., a commissioned processing equipment) or a pre-commissioning processing equipment. In such embodiments, the processing equipment can be in human-entry condition prior to (and after) the removing of the scale (i.e., the “descaling”). As in the degreasing and pickling noted hereinabove, the vapor phase for descaling can comprise a vapor comprising a chemistry and a carrier.
As utilized herein, descaling indicates the removal of one or more scale from a contact surface of the processing equipment. For example, the descaling can be designed for the removal of water hardness scale, mill scale, rust, corrosion or oxidation scale, or a combination thereof. For descaling cleaning, the chemistry can be any suitable chemistry for removing the scale (e.g., the water hardness scale, the mill scale, the rust, the corrosion or oxidation scale, or combination thereof). Examples of such descaling chemistry can include acids, chelants (also referred to herein as “chelant based chemistry”), or a combination thereof.
The chemistry for descaling can include an acid. A person of ordinary skill, with the benefit of this disclosure, will be able to identify the type of acid as the appropriate concentration thereof to be used.
Suitable acids can include any acid suitable for removing the scale contaminant present. Examples include, without limitation, hydrochloric acid, hydrofluoric acid, acetic acid, formic acid, citric acid, ethylene diamine tetra acetic acid (“EDTA”), glycolic acid, sulfuric acid, sulfamic acid, phosphoric acid, N-phosphonomethyl iminodiacetic acid (“PMIDA”), and derivatives or a combination thereof. Hydrochloric acid, acetic acid, or formic acid can be utilized in certain applications. The term “derivative” is defined herein to include any compound that is made from one of the listed compounds, for example, by replacing one atom in the listed compound with another atom or group of atoms, rearranging two or more atoms in the listed compound, ionizing one of the listed compounds, or creating a salt of one of the listed compounds. The concentration and type of acid selected may be based upon the function of the acid (e.g., scale removal), compatibility with carrier and the interior/contact surface, etc. One should be mindful that certain concentrations of acids, such as formic acid, may have a tendency to form precipitates upon spending. A precipitation control additive (e.g., aluminum chloride) may be desirable to include as well depending on the acid and the carrier.
Examples of acids that may be suitable include, inter alia, hydrochloric acid, hydrofluoric acid, phosphonic acid, p-toluenesulfonic acid, acetic acid, formic acid, citric acid, sulfuric acid, derivatives thereof, and combinations thereof.
In embodiments, the chemistry for descaling can include an acid, an acid generating compound, or a combinations thereof. Any known acid, such as noted hereinabove, may be suitable for use in the chemistry of the vapor phase of this disclosure. Examples of acids that may be suitable for use in this disclosure include, but are not limited to organic acids (e.g., formic acids, acetic acids, carbonic acids, citric acids, glycolic acids, lactic acids, ethylenediaminetetraacetic acid (“EDTA”), hydroxyethyl ethylenediamine triacetic acid (“HEDTA”), p-toluenesulfonic acid, methane sulfonic acid and the like), inorganic acids (e.g., hydrochloric acid, hydrofluoric acid, phosphonic acid, p-toluenesulfonic acid, and the like), and combinations thereof. Examples of acid generating compounds that may be suitable for use in this disclosure include, but are not limited to, esters, aliphatic polyesters, ortho esters, which may also be known as ortho ethers, poly(ortho esters), which may also be known as poly(ortho ethers), poly(lactides), poly(glycolides), poly(E-caprolactones), poly(hydroxybutyrates), poly(anhydrides), or copolymers thereof. Derivatives and combinations also may be suitable. Other suitable acid-generating compounds include: esters including, but not limited to, ethylene glycol monoformate, ethylene glycol diformate, diethylene glycol diformate, glyceryl monoformate, glyceryl diformate, glyceryl triformate, triethylene glycol diformate and formate esters of pentaerythritol. An example of a suitable acid generating compound is a citrate ester commercially available from Halliburton Energy Services, Inc., of Duncan, OK, under the tradename MATRIXFLO™ II Breaker. Other suitable materials may be disclosed in U.S. Pat. Nos. 6,877,563 and 7,021,383, the disclosures of which are incorporated by reference.
The chemistry for descaling can include a chelant. A person of ordinary skill, with the benefit of this disclosure, will be able to identify the type of chelant as the appropriate concentration thereof to be used. In embodiments, the chelant for descaling comprises a chelant as noted hereinabove for the pickling chemistry, and/or anther chelant.
Various techniques may be used to achieve contact of the surface to be cleaned with the vapor phase during the vapor phase cleaning and/or passivating. Such embodiments comprise exposing the internal surface to a vapor phase comprising a carrier and the chemistry. The vapor can condense on the surface, and condensed vapor can be removed (e.g., allowed to leave the internal surface) to provide the cleaned surface. The condensed vapor can dissolve contaminants on the surface, if present during cleaning and/or form the passive film on the contact/interior surface(s) during passivating thereof. The condensed vapor can be removed from the contact surface(s), e.g., via gravity or a rinse. Various vapor phase systems may be used to carry out these steps. The vapor phase can be formed from a liquid carrier into which the chosen cleaning and/or passivating chemistry is injected.
A schematic of an illustrative such vapor phase cleaning and/or passivating system I is shown in The Figure. The system I includes a carrier 11, which can be provided in a carrier vessel 10. A line 15 can be configured to introduce carrier into processing equipment 40. A heater 28 can be utilized to vaporize the carrier 11 (and provide vaporized carrier in line 15A exiting heater), as needed. In embodiments, carrier 11 from carrier vessel 10 in line 15 is provided as a vapor and heater 28 is not utilized. Chemistry 21 from chemistry vessel 20 in line 25 can be injected (e.g., at chemistry injection point(s) 32) into the carrier 11 from line 15 and/or heater 28 to provide the vapor phase in vapor phase line 30 comprising the carrier and the chemistry. An injection apparatus 30, such as and without limitation, can be configured to introduce the chemistry 21 (e.g., from chemistry line 25) into the carrier 11 and thus provide the vapor phase 30 comprising the chemistry 21 and the carrier 11. Injection apparatus 30 can be configured to spray, vaporize, nebulize, atomize, or otherwise introduce the chemistry 21 into the carrier 11. Alternatively or additionally, a heater 28 can be positioned downstream of injection point(s) 32, wherein carrier 11 and chemistry 21 can be combined prior to heating in heater 28.
In embodiments as shown in The Figure, a one or more contaminants 44 can be disposed within processing equipment 40 (e.g., a crude oil tank). As used herein, “contaminated” refers to a surface (e.g., an interior or “contact surface) 43 contaminated with one or more contaminants 44 as described hereinabove. It is to be understood that “contaminated” does not exclude contamination with other types of contaminants in addition to those noted herein. Processing unit 40 can be any type of vessel (e.g., a tank, as depicted) that can be utilized in the oil and gas industry (e.g., a hydrocarbon tank, regardless of the phase of matter of the hydrocarbon contained therein when commissioned into service (e.g., after cleaning and/or passivating as described herein)). In an embodiment, processing unit 40 can comprise one or more selected from refining equipment, chemical processing equipment, tanks (e.g., storage tanks, crude oil tanks), reactors, heat exchangers, piping, or a combination thereof.
The vapor phase in vapor phase line 30 comprising the chemistry 21 in the carrier 11 can be introduced into the processing equipment 40 at one or a plurality of vapor phase injection points 31. Three vapor phase injection points 31A, 31B, and 31C are depicted in the embodiment of The Figure for introducing the vapor phase (via lines 30A, 30B, and 30C, respectively) into processing equipment 40. The multiple injection points 31 (31=31A+31B+31C) can be selected for optimum distribution of the cleaning and/or passivating chemistry 21. For large scale apparatus, a greater number (e.g., 5, 10, or more) of vapor phase injection points can be utilized to introduce the chemistry 21 into the processing equipment 40.
The temperature of the contact surface(s) 43 can be elevated above the boiling point of the carrier 11/vapor phase 30 prior to or during the cleaning and/or passivating. For example, in embodiments wherein carrier 11 comprises steam, water in carrier vessel 11 can be vaporized in heater 28 to form steam. At the start of the cleaning and/or passivation method, steam can be introduced into processing vessel 40 until a temperature at a top 41 thereof reaches the boiling point (i.e., 100° C.) before chemistry 21 is injected into the vapor phase 30.
The vapor phase 30 is introduced into processing equipment 40 to remove contaminants from and/or form the passivation layer on the internal surfaces 43 of processing unit 40 until the end point or acceptance criteria (such as described hereinabove) have been attained. A post flush can be effected to promote the removal of any residual contaminants from the processing equipment 40. For example, once the end point criteria have been met, injection of chemistry 21 into vapor phase 30 may be ceased, and the processing unit 40 flushed with carrier 11 alone (e.g., steam alone). A vent 46 and associated vent valve 47 positioned at or near the top 41 of the processing unit 40 can be utilized to vent processing equipment 40 (e.g., during heating and/or flushing of processing unit 40). A drain 45 can be positioned at or near a bottom 42 of the processing unit, for example to drain therefrom condensed materials and/or samples for testing the cleaning and/or passivating completeness. Samples 46 can be tested in testing apparatus 50 as described hereinabove to determine when the cleaning and/or passivating is complete (e.g., when no more contaminants are being removed and/or when the passive layer has been formed on the internal surface 43 of processing unit 40).
During operation, the relatively hot vapor 30 can condense on the relatively cold internal surfaces 43 of the processing equipment 40. The condensed vapor, including any contaminants dissolved herein, may drain to bottom 42 of processing equipment 40, and can be sampled and/or drained via drain 45. In embodiments, the vapor phase cleaning and/or passivating system I is a closed top system. In embodiments, the vapor phase cleaning and/or passivating and/or descaling system I comprises an open system. For example, in embodiments, a top of the equipment can connect to a flare system (e.g., via other piping and equipment) to burn off the vapor (e.g., water and light contaminants) to the atmosphere. Alternatively or additionally, the vapor (e.g., steam and remaining chemistry) can travel to a condenser to return the carrier and chemistry into a liquid phase.
The cleaning and/or passivating can be allowed to occur for a sufficient time to allow the contaminants to be removed from or the passivation layer to be formed on the internal surface*(s) 43. In embodiments, the reaction is allowed to occur from about one hour to about fifty hours, alternatively from about one hour to about twenty-five hours. In embodiments, the reaction time may be any individual time in the above times or any smaller time ranges that are included in the above ranges. Without limitation by theory, it is to be understood that, in embodiments, with a higher temperature, a reduced reaction time may provide the cleaning and/or passivating. In embodiments, the reaction is allowed to occur for a sufficient time, for cleaning, to substantially remove all of the one or more contaminants and/or, for passivating, to provide the passive film on contact/interior surface(s) 43.
It is to be understood that The Figure is merely illustrative and other vapor phase cleaning and/or passivating systems may be used which may have fewer, additional, and/or different components as shown in The Figure, e.g., a water separator, a sonicator, a vacuum pump, piping valves, etc. The type of vapor phase cleaning and/or passivating system is not particularly limiting. The present methods may be carried out using other techniques to achieve contact of the internal surface(s) 43 to be cleaned and/or passivated with the vapor phase 30, including spraying, atomizing, nebulizing, etc. These techniques may also be achieved with the vapor phase cleaning and/or passivating system I of The Figure. For example, the internal surface(s) 43 to be cleaned may be exposed to the vapor phase 30 comprising the chemistry 21 in the carrier 11 as the vapor rises in processing equipment 40. Spraying the internal surface(s) 43 with the vapor phase 30 comprising the chemistry 21 in the carrier 11 may also be used.
The (e.g., contact) interior surfaces 43 which may be cleaned by the present methods are not particularly limited. By way of illustration, the interior or contact surface 43 can be a metal surface, a polymeric surface, a glass surface, a semiconductor surface, a ceramic surface, and/or a composite thereof. Metal surfaces include, e.g., surfaces of aluminum, magnesium, titanium, zinc, brass, steel, and alloys or combinations thereof. The interior or contact surface 43 can also include plates, baffles, or other internal structures located inside the equipment.
As noted hereinabove, the present methods can be utilized to remove a variety of contaminants from the interior or contact surfaces 43 described herein. However, the methods can be particularly useful for degreasing, pickling, and/or passivating as described hereinabove. In embodiments, cleaning is effected to remove one or more contaminants such as milling oil, cutting oil, grease, mill scale, welding slag, rust, sand, oils, fats, waxes, resins, gums, rosins, (substituted or unsubstituted) hydrocarbon molecules (e.g., polybutenes, polyisobutenes) and/or fragments thereof, mold release agents, or a combination thereof. As noted above, the contaminant(s) removed via the cleaning can be derived from materials used (e.g., for lubricating) during manufacturing of the processing equipment 40, such as and without limitation, substrate (e.g., metal) cutting, bending, and forming.
As described hereinabove, confirmation that the present methods have successfully cleaned the internal surface 43, and/or quantification of an amount of contaminants removed from the surface or a thickness of a passive film deposited on the internal surface(s) 43 can be carried out during and/or subsequent the cleaning and/or passivating of the processing equipment 40. For example, the mass of a component in a sample (e.g., extracted via drain 45 or a dedicated sampling port) can be determined/measured before, during, and/or after carrying out the present methods. In embodiments, the cleaned surface exhibits a reduced amount of contaminants as compared to the surface prior to cleaning, e.g., as evidenced by a loss of mass. For example, Fourier-Transform Infrared Spectroscopy (FTIR) may be carried out to identify the contaminants removed. Another technique to confirm contamination removal involves exposing the desired surface to a solvent such as hexane, recovering the solvent, performing FTIR analysis on a portion of the recovered solvent to identify soluble contaminants, and evaporating a remaining portion of the recovered solvent to identify insoluble contaminants. This may be carried out on the desired surface before and after cleaning. Other analysis methods and techniques are within the scope of this disclosure, and will be apparent to those of skill in the art and with the help of this disclosure. As noted above, the degree of passivating can be determined by measuring (e.g., optically, visually) a thickness and/or presence of a passive film on interior or contact surface(s) 43.
It is to be understood that the embodiment of The Figure depicts a generalized schematic of a system for the cleaning and/or passivating of a processing equipment 40. One or more components may be added or removed as would be apparent to one of ordinary skill in the art. Further, other components may be substituted for suitable alternatives as would be apparent to one of ordinary skill in the art.
The herein disclosed vapor phase method of pre-(or post-) commissioning cleaning and./or passivating (e.g., degreasing, pickling, descaling, and/or passivation) can be utilized to remove contaminants from and/or apply a passive film to a contact surface of a processing equipment. Any chemistry that can be incorporated into the vapor phase and is compatible with the carrier and the contact surface can be utilized. The herein disclosed vapor phase method of cleaning and/or passivating significantly reduces the resources (e.g., liquid (e.g., water) and/or personnel) needed for the cleaning and/or passivating and the amount of waste that is produced and associated disposal. This can provide savings, along with an overall lower carbon footprint of the operation.
Conventional techniques require personnel and equipment to remain on site for extended durations, while the herein disclosed method enables a reduction in the overall operational schedule. The herein disclosed vapor phase cleaning and/or passivating method can provide significant savings, especially for LNG, CCUS, hydrogen, and other markets in which large scale processing equipment is utilized, although the method can also be utilized to benefit with traditional process facilities.
To facilitate a better understanding of the present embodiments, the following examples of certain aspects of some embodiments are given. In no way should the following examples be read to limit, or define, the entire scope of the embodiments.

EXAMPLE

Experiments were conducted to analyze the degreasing ability of a number of formulations, which involved combinations of one or more of the following components: an alcohol, ethylene glycol or derivative thereof, surfactant, water, and/or alkaline detergent. To test the cleaning ability of a formulation, 20 mL of a cleaning solution were added to 0.8 mL of a cutting oil. Each formulation was tested against numerous types and brands of cutting oils. The mixtures were examined for solid formation, multiple layers in the solution, and formation of a successful clear homogeneous mixture. Formulations that yielded clear homogeneous mixtures were further tested in a 1-liter piece of equipment. The equipment interior was coated with a cutting oil, then the formulation (chemistry) was injected into a steam line (the carrier) which carried the treatment into the equipment. After successful treatment, the interior of the equipment was washed, and the washings were analyzed by gas chromatography for any remaining cutting oil. The vapor phase cleaning of this disclosure successfully cleaned the interior of the equipment.

Additional Disclosure

The following are non-limiting, specific embodiments in accordance with the present disclosure:
In a first embodiment, a method comprises: prior to commissioning of a processing equipment into service, cleaning and/or passivating a contact surface of the processing equipment with a vapor comprising a chemistry and a carrier, wherein cleaning comprises removing one or more contaminants from the contact surface and wherein passivating comprises creating a passive film on the contact surface.
A second embodiment can include the method of the first embodiment, wherein cleaning comprises: (a) degreasing; (b) pickling; or (c) a combination thereof.
A third embodiment can include the method of the second embodiment comprising (a) degreasing, wherein the one or more contaminants comprise milling oil, cutting oil, grease, lubricant, corrosion inhibitor, hydrocarbon film, rust preventative compound, or a combination of one or more thereof.
A fourth embodiment can include the method of the third embodiment, wherein the chemistry is selected from surfactants, organic solvents, alkaline detergents, water, or a combination thereof.
A fifth embodiment can include the method of any one of the second to fourth embodiments comprising (b) pickling, wherein the one or more contaminants comprise mill scale, welding slag, rust, sand, corrosion products, or a combination thereof.
A sixth embodiment can include the method of the fifth embodiment, wherein the chemistry is selected from acids, chelants (chelant based chemistry), or a combination thereof.
A seventh embodiment can include the method of any one of the first to sixth embodiments, comprising passivating, wherein passivating comprises creating the passive film on the contact surface of the processing equipment to prevent flash rusting and/or otherwise preserve the processing equipment until commissioning thereof into service.
An eighth embodiment can include the method of the seventh embodiment, wherein the chemistry is selected from nitrite based chemistry, phosphate based chemistry, another chemistry that creates a steel grey passive film, a vapor phase corrosion inhibitor (VpCI), chemistry that creates a polymer coating, or a combination thereof.
A ninth embodiment can include the method of any one of the first to eighth embodiments, wherein the one or more contaminants comprise one or more components present on the contact surface inherently as a result of manufacturing of the processing equipment or post-manufacturing (e.g., to prevent damage (e.g., rust) to the contact surface post-manufacturing and prior to commissioning).
A tenth embodiment can include the method of the ninth embodiment, wherein the cleaning comprises removing substantially all (e.g., greater than or equal to about 80, 85, 90, 95, 96, 97, 98, 99, or 100%) of the one or more contaminants.
An eleventh embodiment can include the method of any one of the first to tenth embodiments, wherein the processing equipment is in human-entry condition prior to (and after) the cleaning and/or passivating.
A twelfth embodiment can include the method of any one of the first to eleventh embodiments, wherein vapor phase cleaning and/or passivating comprises contacting the contact surface of the processing equipment with the chemistry in the vapor phase such that the one or more contaminants are removed from the contact surface and/or the passive film is created on the contact surface, respectively.
A thirteenth embodiment can include the method of the twelfth embodiment, wherein the vapor carrier comprises steam, air, an inert gas (e.g., nitrogen), a hydrocarbon, or a combination thereof.
A fourteenth embodiment can include the method of any one of the first to thirteenth embodiments further comprising introducing the chemistry into the carrier of the vapor phase via vaporizing, nebulizing, atomization, spraying, pumping, or a combination thereof.
A fifteenth embodiment can include the method of any one of the first to fourteenth embodiments, wherein the processing equipment has a volume of greater than or equal to about 1500, 2000, 2500, 3000, 3500, 4500, 5000 cubic meters (m³).
A sixteenth embodiment can include the method of any one of the first to fifteenth embodiments, wherein the cleaning and/or passivating uses (e.g., at least 50, 60, 70, or 80%) less carrier (e.g., water, liquid; less than 3, 2, or 1 system volumes of carrier/water/liquid) and/or produces less waste than conventional circulation cleaning and/or passivating.
A seventeenth embodiment can include the method of any one of the first to sixteenth embodiments, wherein the vapor phase cleaning and/or passivating has smaller a carbon footprint than (e.g., is ⅓ the size of) conventional/traditional circulation cleaning and/or passivating.
An eighteenth embodiment can include the method of any one of the first to seventeenth embodiments, wherein the contact surface has a temperature equal to or greater than a boiling point temperature of the vapor phase (the chemistry and/or the carrier).
A nineteenth embodiment can include the method of the eighteenth embodiment, wherein the carrier comprises steam, and wherein the contact surface has a temperature equal to or greater than 100° C.
A twentieth embodiment can include the method of any one of the first to nineteenth embodiments, wherein the processing equipment is a chemical processing equipment, a refinery (e.g., crude refinery, LNG refinery) or petrochemical plant processing equipment, a power plant, or a floating production storage and offloading (FPSO) unit.
A twenty first embodiment can include the method of any one of the first to twentieth embodiments, wherein the processing equipment is in the LNG, carbon capture and utilization (CCUS), or hydrogen market.
A twenty second embodiment can include the method of any one of the first to twenty first embodiments further comprising assessing a degree: (i) of cleaning by: semi-continuously, continuously, or intermittently performing an (e.g., oil and water, NMR, GC, etc.) analysis of a condensed vapor sample and comparing a result of the analysis at a current sampling time with a result of one or more condensed vapor samples at one or more prior times; and/or (ii) of passivating by: visual observation.
A twenty third embodiment can include the method of the twenty second embodiment further comprising determining the cleaning is complete when no further change in the analysis result is seen in multiple (2, 3, or more) consecutive samples.
A twenty fourth embodiment can include the method of the twenty third embodiment, wherein the result of the analysis at which the cleaning is determined to be complete shows an amount of each of the one or more contaminants in the sample is substantially zero and/or shows no further change in contaminants.
A twenty fifth embodiment can include the method of any one of the twenty second to twenty fourth embodiments, wherein the analysis comprises an oil and water (O&W) analysis, gas chromatography (GC) analysis, nuclear magnetic resonance (NMR) analysis, and/or other analytical technique.
A twenty sixth embodiment can include the method of any one of the first to twenty fifth embodiments, wherein the cleaning does not comprise decontamination to make ready for human-entry.
In a twenty seventh embodiment a method comprises: providing a processing equipment prior to commissioning (e.g., a “non-commissioned” processing equipment); utilizing vapor phase cleaning to remove one or more contaminants from a contact surface of the processing equipment, and/or utilizing vapor phase passivating to create a passive film on the contact surface of the processing equipment; and commissioning the processing equipment into service.
A twenty eighth embodiment can include the method of the twenty seventh embodiment, wherein the processing equipment as provided and before the vapor phase cleaning and/or passivating is suitable for human-entry.
In a twenty ninth embodiment, a method comprises: performing maintenance cleaning of a processing equipment by removing scale from a contact surface of the processing equipment via vapor phase cleaning.
A thirtieth embodiment can include the method of the twenty ninth embodiment, wherein the processing equipment comprises a component of a cooling water system, a heat exchange system, or a combination thereof.
A thirty first embodiment can include the method of the twenty ninth or thirtieth embodiment, wherein the processing equipment is in human-entry condition prior to (and after) the removing of the scale.
A thirty second embodiment can include the method of any one of the twenty ninth to thirty first embodiments, wherein the vapor phase comprises a vapor comprising a chemistry and a carrier, wherein the chemistry is selected from acids, chelants, or a combination thereof.
In a thirty third embodiment, a method of commissioning process equipment having an interior surface (e.g., for contact with one or more chemical compounds) and an exterior surface (e.g., in contact with an above ground or below ground ambient environment), comprises: (i) degreasing, in a gas phase, at least a portion of the interior surface, wherein the degreasing removes mill oil, cutting oil, grease, or combinations thereof from the interior surface; (ii) pickling, in a gas phase, at least a portion of the interior surface, wherein pickling removes [e.g., fine] particulate material (e.g., cuttings, welding slag, mill scale, rust, or combinations thereof) from the interior surface; (iii) passivating, in a gas phase, at least a portion of the interior surface, wherein passivating provides a film coating on the at least a portion of the interior surface; or (iv) any combination of (i)-(iii).
A thirty fourth embodiment can include the method of the thirty third embodiment further comprising monitoring a composition of an outlet/purge stream (e.g., gas and/or liquid) from the process equipment to determine when the (i) degreasing, (ii) pickling, (iii) passivating, or (iv) any combination thereof is complete.
A thirty fifth embodiment can include the method of the thirty fourth embodiment further comprising starting up the process equipment to perform its intended function.
A thirty sixth embodiment can include the method of any one of the thirty third to thirty fifth embodiments, wherein the gas phase comprises steam [e.g., saturated steam, unsaturated steam).
While embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit and teachings of this disclosure. The embodiments described herein are exemplary only, and are not intended to be limiting. Many variations and modifications of the embodiments disclosed herein are possible and are within the scope of this disclosure. Where numerical ranges or limitations are expressly stated, such express ranges or limitations should be understood to include iterative ranges or limitations of like magnitude falling within the expressly stated ranges or limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example, whenever a numerical range with a lower limit, Rl, and an upper limit, Ru, is disclosed, any number falling within the range is specifically disclosed. In particular, the following numbers within the range are specifically disclosed: R=R1+k*(Ru−Rl), wherein k is a variable ranging from 1 percent to 100 percent with a 1 percent increment, i.e., k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . 50 percent, 51 percent, 52 percent, . . . 95 percent, 96 percent, 97 percent, 98 percent, 99 percent, or 100 percent. Moreover, any numerical range defined by two R numbers as defined in the above is also specifically disclosed. Use of broader terms such as comprises, includes, having, etc. should be understood to provide support for narrower terms such as consisting of, consisting essentially of, comprised substantially of, etc. When a feature is described as “optional,” both embodiments with this feature and embodiments without this feature are disclosed. Similarly, the present disclosure contemplates embodiments where this “optional” feature is required and embodiments where this feature is specifically excluded.
Accordingly, the scope of protection is not limited by the description set out above but is only limited by the claims which follow, that scope including all equivalents of the subject matter of the claims. Each and every claim is incorporated into the specification as embodiments of the present disclosure. Thus, the claims are a further description and are an addition to the embodiments of the present disclosure. The discussion of a reference herein is not an admission that it is prior art, especially any reference that can have a publication date after the priority date of this application. The disclosures of all patents, patent applications, and publications cited herein are hereby incorporated by reference, to the extent that they provide exemplary, procedural, or other details supplementary to those set forth herein.
While several embodiments have been provided in the present disclosure, it should be understood that the disclosed systems and methods may be embodied in many other specific forms without departing from the spirit or scope of the present disclosure. The present examples are to be considered as illustrative and not restrictive, and the intention is not to be limited to the details given herein. For example, the various elements or components may be combined or integrated in another system or certain features may be omitted or not implemented.
Also, techniques, systems, subsystems, and methods described and illustrated in the various embodiments as discrete or separate may be combined or integrated with other systems, modules, techniques, or methods without departing from the scope of the present disclosure. Other items shown or discussed as directly coupled or communicating with each other may be indirectly coupled or communicating through some interface, device, or intermediate component, whether electrically, mechanically, or otherwise. Other examples of changes, substitutions, and alterations are ascertainable by one skilled in the art and could be made without departing from the spirit and scope disclosed herein.

Claims

What is claimed is:

1. A method comprising:

prior to commissioning of a processing equipment into service, cleaning and/or passivating a contact surface of the processing equipment with a vapor comprising a chemistry and a carrier, wherein cleaning comprises removing one or more contaminants from the contact surface and wherein passivating comprises creating a passive film on the contact surface.

2. The method of claim 1, wherein cleaning comprises:

(a) degreasing;

(b) pickling; or

(c) a combination thereof.

3. The method of claim 2 comprising (a) degreasing, wherein the one or more contaminants comprise milling oil, cutting oil, grease, lubricant, corrosion inhibitor, hydrocarbon film, rust preventative compound, or a combination of one or more thereof.

4. The method of claim 3, wherein the chemistry is selected from surfactants, organic solvents, alkaline detergents, water, or a combination thereof.

5. The method of claim 2, comprising (b) pickling, wherein the one or more contaminants comprise mill scale, welding slag, rust, sand, corrosion products, or a combination thereof.

6. The method of claim 5, wherein the chemistry is selected from acids, chelants, or a combination thereof.

7. The method of claim 1 comprising passivating, wherein passivating comprises creating the passive film on the contact surface of the processing equipment to prevent flash rusting and/or otherwise preserve the processing equipment until commissioning thereof into service.

8. The method of claim 7, wherein the chemistry is selected from nitrite based chemistry, phosphate based chemistry, another chemistry that creates a steel grey passive film, a vapor phase corrosion inhibitor (VpCI), chemistry that creates a polymer coating, or a combination thereof.

9. The method of claim 1, wherein the one or more contaminants comprise one or more components present on the contact surface inherently as a result of manufacturing of the processing equipment or post-manufacturing.

10. The method of claim 9, wherein the cleaning comprises removing substantially all of the one or more contaminants.

11. The method of claim 1, wherein the processing equipment is in human-entry condition prior to and after the cleaning and/or passivating.

12. The method of claim 1, wherein vapor phase cleaning and/or passivating comprises contacting the contact surface of the processing equipment with the chemistry in the vapor phase such that the one or more contaminants are removed from the contact surface and/or the passive film is created on the contact surface, respectively.

13. The method of claim 1 further comprising assessing a degree:

(i) of cleaning by: semi-continuously, continuously, or intermittently performing an analysis of a condensed vapor sample and comparing a result of the analysis at a current sampling time with a result of one or more condensed vapor samples at one or more prior times; and/or

(ii) of passivating by: visual observation.

14. The method of claim 13 further comprising determining the cleaning is complete when no further change in the analysis result is seen in multiple consecutive samples and/or when an amount of each of the one or more contaminants in the sample is substantially zero.

15. The method of claim 1, wherein the cleaning does not comprise decontamination to make ready for human-entry.

16. A method comprising:

providing a processing equipment prior to commissioning;

utilizing vapor phase cleaning to remove one or more contaminants from a contact surface of the processing equipment, and/or utilizing vapor phase passivating to create a passive film on the contact surface of the processing equipment; and

commissioning the processing equipment into service.

17. The method of claim 16, wherein the processing equipment as provided and before the vapor phase cleaning and/or passivating is suitable for human-entry.

18. A method comprising:

performing maintenance cleaning of a processing equipment by removing scale from a contact surface of the processing equipment via vapor phase cleaning.

19. The method of claim 18, wherein the processing equipment is in human-entry condition prior to and after the removing of the scale.

20. The method of claim 18, wherein the vapor phase comprises a vapor comprising a chemistry and a carrier, wherein the chemistry is selected from acids, chelants, or a combination thereof.