Probe for Corrosion Rate Measurement from Grand Prix INTARG®2022

The International Fair of Inventions and Innovations INTARG is a recurring event dedicated to presenting the potential and achievements of technological thought and science, i.e., inventions, technologies, and services directed towards thirteen industries, including manufacturing. Exhibitors at INTARG® have the opportunity to submit their inventions and innovations (technologies, products, and services) for the INTARG® competition, in which they are evaluated by an international jury. The main criteria for assessing presented solutions include: the level of innovation, market demand for the product, comparison with global equivalents, technology readiness level (TRL), implementation and commercialization possibilities, economic and social effects, and more.

The invention “Probe for measuring corrosion rate” was developed as part of the KORMON project acquired by Polski Koncern Naftowy ORLEN S.A. under the INNOCHEM program. The invention was filed by PKN ORLEN S.A. The probe was designed and constructed by a team of scientists from Gdańsk Tech under the guidance of prof. Kazimierz Darowicki, consisting of: PhD Eng. Juliusz Orlikowski, PhD Eng. Grzegorz Lentka, MSc Eng. Mateusz Cieślik, Eng. Andrzej Dul. The team was complemented by PKN ORLEN employees MSc Eng. Iwona Łuksa and MSc Eng. Radosław Gospoś.

More effective corrosion monitoring

The innovative integrated dual corrosion sensor system allows simultaneous real-time (on-line) monitoring of the rate of uniform corrosion and steel hydrogen embrittlement. The solution is based on resistometric technique, which is used to monitor the corrosion rate of metals/alloys in various environments including the oils & gas sector. In commercially available resistometric devices, a special sensor is placed in the analyzed process stream, e.g., in a pipeline or apparatus, where it corrodes over time. The corrosion rate, through the reduction of the probe’s cross-section, is proportional to the increase in its electrical resistance, which is continuously measured by a measurement module located outside of the pipeline/apparatus. The corrosion rate is calculated based on the change in electrical resistance in real time.

– Commercial devices based on resistometric technique do not allow distinction between uniform corrosion and hydrogen embrittlement – explains prof. Kazimierz Darowicki – Our invention consists of a dual sensor system: a main sensor and a reference sensor. The main sensor is susceptible to uniform corrosion and hydrogen embrittlement, while the reference sensor is susceptible only to hydrogen embrittlement and is simultaneously resistant to corrosion. Distinguishing between these phenomena is crucial due to completely different approaches and actions undertaken by refinery staff regarding threats related to various corrosion mechanisms.

The application of a dual corrosion system operating in real-time enables visualization of the current situation concerning uniform corrosion and hydrogen embrittlement. Installation operators can monitor and immediately respond to increased corrosion threats through appropriate remedial actions, such as adjusting process parameters or increasing doses of anticorrosion agents.

– Monitoring the corrosion and hydrogen embrittlement rates of steel in real time enables the prediction of the lifespan of structural materials and significantly reduces the likelihood of emergency situations causing unplanned industrial plant shutdowns due to corrosion or hydrogen embrittlement. The entire wireless corrosion monitoring system based on dual corrosion sensors has been implemented in the catalytic cracking installation FKK II of PKN ORLEN. Currently, preparations are underway for implementation of the corrosion monitoring system in two further installations.

The integrated dual corrosion sensor system has proven to be a very effective tool for assessing the current corrosion situation, monitoring the condition of structural materials, and adequate preparation during the processing of various feedstocks, including incompatible crude oil blends. The monitoring system has also proven to be an excellent tool for determining the relationship between corrosion and hydrogen embrittlement rates and process parameters and other factors, producing reports in the area of corrosion protection and serving as support in specialized corrosion analyses. The corrosion monitoring systems currently being built are part of a larger project, namely the creation of a corrosion management system within PKN ORLEN as part of RBI activities.

– It should be mentioned that cooperation between the Department of Electrochemistry, Corrosion and Materials Engineering and the PKN ORLEN group has a long-standing tradition and extremely fruitful history. Within this cooperation, over 40 research works and expert opinions have been completed. In 2022, PKN ORLEN decided to submit the invention “Probe for measuring corrosion rate” to the innovation fair. Thanks to its established high international reputation, the INTARG® fair has been supported by top-level institutions, led by the Ministry of Development and Technology and the World Intellectual Property Organization WIPO – one of the 16 UN agencies (INTARG® is the only fair in Poland, and one of few worldwide, held under WIPO's honorary patronage).

In total, 272 inventions from 13 industries were submitted for the competition. Awards were presented during the final gala of the Jubilant XV Edition of the International Fair of Inventions and Innovations INTARG® 2022, which took place on May 12.