Anything that enters the plant has the potential to cause unintended side effects, resulting in problems such as fouling, corrosion, or product contamination. The impacts of feedstocks and their impurities have been well chronicled in past EPC papers. We will focus on the impacts of materials that are intentionally introduced into the process but have unintended side effects.

Plant operators routinely inject steam, nitrogen, sulfur, caustic, amine, alcohol, and acid compounds into the process. Complex chemical formulations are also introduced as additives to help control fouling and corrosion. In addition, contamination from waste treatment and flare system recycle streams, contact with gaskets, as well as from lubricants and seal fluids is addressed.

This paper will present an overview of the unexpected negative consequences resulting from these compounds and impurities.