Six Sigma review of root causes of corrosion incidents in hot potassium carbonate acid gas removal plant

This paper is a summary of a desktop review, using the Six Sigma methodology, of root causes for corrosion incidents in Hot Potassium Carbonate acid gas removal plant. These corrosion incidents involve rapid localised corrosion of carbon steel vessel walls by the CO2 containing process solution. The possible root causes are identified as (1) inadequate concentration of anodic inhibitor, (2) the presence of hydrocarbons, (3) process conditions of high gas loading and/or frothing/foaming, (4) formation of a sulfide layer and (5) galvanic interaction. An overview of the Six Sigma methodology is included. A methodology such as Six Sigma can be used to assist in overcoming the corrosion problem.