The global crude oil supply is shifting toward lower quality resources, with high-sulfur crude oil (sulfur content exceeding 2%) now making up nearly half of total production. The Middle East, which holds the largest share of global oil production capacity, is heavily reliant on this type of crude. As oil prices have risen, the price gap between high-sulfur and low-sulfur crude has widened significantly. In 2004, the price difference was $4.60 per barrel, increasing to $5.10 in the first half of 2005. For a mid-sized refinery processing 2 million tons annually, this spread could translate into cost savings of approximately 560 million yuan. Despite higher processing costs—such as increased energy use, material consumption, and operational expenses—refineries still find it economically advantageous to process high-sulfur crude, especially in a high-price environment.
However, processing high-sulfur crude is not without challenges. The sulfur content in fuels like gasoline and diesel can lead to engine corrosion and equipment damage, requiring extensive desulfurization during refining. Although advanced technologies such as catalytic feedstock pretreatment, hydrodesulfurization, and hydrocracking have been developed and implemented, the issue of sulfur-related corrosion remains a critical concern. Even with these technologies, the risk of equipment failure, leakage, and production downtime persists, discouraging many refineries from adopting high-sulfur crude processing.
Despite these challenges, China is moving forward with new refinery projects designed to handle high-sulfur crude, and existing facilities are undergoing upgrades. This shift has introduced new demands for refinery equipment that can withstand sulfur corrosion. Previously, China’s refining industry did not require high standards for corrosion resistance, but now, updated guidelines have been established. The "Guidelines for the Selection of Major Equipment for the Design of Key Equipment for the Processing of High-Sulfur Crude Oil," issued by Sinopec and approved by the former State Economic and Trade Commission, sets strict requirements for materials like carbon steel, aluminized carbon steel, and duplex steel. Specific criteria are outlined for their manufacturing, welding, and inspection processes.
Moreover, components such as pressure vessels and heat exchangers must meet mechanical property standards, and materials must be tested for hydrogen-induced cracking. Design modifications—like increasing wall thickness, adding baffles, or adjusting flow areas—are often necessary to prevent localized corrosion. Corrosion protection in high-sulfur crude processing has become a top priority for design engineers, manufacturers, and refiners alike. All relevant parties must review and update their material standards to align with current industry regulations, assess the risks of existing equipment, implement monitoring systems, and develop plans for upgrading refinery infrastructure. This proactive approach is essential to ensure safe, efficient, and sustainable operations in the evolving refining landscape.
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