Global Journal of Researches in Engineering, G: Industrial Engineering, Volume 23 Issue 2

Modeling and Optimization of Corrosion Penetration Rate in Crude Oil Pipeline using Response Surface Methodology based on Aspen HYSYS Simulation Software Sulayman H. Ameitiq α & Omar M. Aldenali σ Abstract- This study aims to investigate the influence of a number of related parameters namely temperature, pressure, flow rate and pH on the corrosion penetration rate (CPR) of crude oil transportation process by pipelines. It intends the mathematical model of these parameters as independent variables with corrosion penetration rate as a dependent variable. The model was used to establish the best values of these parameters using the response surface methodology . Aspen HYSYS software was utilized to simulate the experiments and to calculate the corrosion penetration rate for each experiment. The experiments designed based on the central composite experimental design (CCD) using Minitab 17 software. The mean absolute percentage error was used to determine the conformance of the developed mathematical model. Its value was 0.02%, this indicates that the developed mathematical model was consistent. The Nash Sutcliffe efficiency (NSE) was also calculated. Its value was 0.999 which confirms the high-efficiency of the model. The optimal corrosion penetration rate conditions were determined, temperature (100°F), pressure (360 psig), flow rate (150,000 bbl/day), and pH (5.65). Accordingly, the minimum corrosion penetration rate is (3.98 mm/year). I. I ntroduction orrosion has a very important economy impact in the oil and gas industry. Oilfield production environments can range from practically zero corrosion to extremely high rates corrosion. The most predominant form of corrosion encountered in oil and gas production is the one caused by CO2. Dissolved carbon dioxide in the produced brines is very corrosive to carbon and low alloy steel tubular and to process equipment used in this industry. The costs of corrosion control are significant and are mainly related to materials replacement and corrosion control programs. Approximately 60% of oilfield failures are related to CO2 corrosion mainly due to inadequate knowledge/predictive capability and the poor resistance of carbon and low alloy steels to this type of corrosive attack. CO2 can cause not only general corrosion but also localized corrosion, which is a much more serious problem [1, 3]. Pipelines whether buried in the ground, exposed to the atmosphere, or submerged in water, are liable to corrosion. Without proper maintenance, every pipeline system will eventually deteriorate, and a corroded pipe is unsafe as a means of transportation because of the associated failure risks. These failures in pipelines and flow lines lead to shutdown of facilities and platforms. Corrosion results in the deterioration of a metal and weakens its structural integrity as a result of chemical reactions between it and the surrounding environment [2]. Corrosion in pipelines occurs where there is loss of metal from an exposed surface in a corrosive environment. The majority of pipeline failures are caused by localized corrosion, and its mechanism can be induced by flow, metallurgy, deposits, internal stresses, and microbiologically influenced corrosion (MIC) among others. The internal corrosion of carbon steel is a noteworthy problem for the oil and gas industry because of its frequency of occurrence. Although high cost corrosion resistant alloys (CRAs) are often developed to resist internal corrosion, carbon steel is still the most cost effective material used for oil and gas production. Issues of possible corrosive species encountered in the oil and gas industry have been documented in so many literatures. The reports on the significance of CO2 in corrosion of metal have also been reported; and, there seems to be a consensus on the significance of CO2 in corrosion of flow lines [2]. Corrosion control is an ongoing dynamic process; therefore, an effective model for predicting pipeline corrosion is essential. Corrosion models give early caution signs of impending failures; they are developed correlations that relate processes and their corrosive effects on systems which help to diagnose a specific problem and in turn evaluate the effectiveness of any corrosion control measure/prevention technique applied to improve the service life of the target metal [2]. C Author α : Faculty of Engineering University of Benghazi/ Libya . sulayman.ameitiq@uob.edu.ly Author σ : Faculty of Engineering Libyan International Medical University. e-mail: omar.aldenali@limu.edu.ly e-mail: © 2023 Global Journals Global Journal of Researches in Engineering Volume XxXIII Issue II Version I 29 Year 2023 ( ) G Keywords: corrosion penetration rate (CPR), aspen hysys, response surface methodology (RSM), modeling, optimization.