Pyrophoric Iron Control with FQE® Pyrophoric

FQE Pyrophoric is a water-based product designed to control the combustion of iron sulfide deposits. This is
accomplished in a unconventional way: by preventing oxidation.

As previously stated, pyrophoric iron combusts at high temperatures due to the heat of oxidation. In
many cases, the customer is not concerned about removing the iron sulfide deposits from the
equipment. The iron scale is actually a protective layer that inhibits further metal corrosion, but the
industry only knew two methods for controlling FeS before FQE Pyrophoric.

Our method involves using proprietary chemistry to prevent oxidation by blocking the sulfide reaction
sites. The inhibition is almost immediate on contact between the pyrophoric product and the iron sulfide
scale.

FQE Pyrophoric is chemically compatible with the other degassing chemical products offered by FQE
and is nonreactive in those chemistries. As a result, we can perform a steam-phase degassing job and
add in FQE Pyrophoric two hours before the end of the steaming process to completely eliminate any
iron oxidation concerns. The process of controlling FeS combustion is simultaneous with degassing,
degreasing, and hydrogen sulfide control.

The Benefits of Using FQE Pyrophoric:

1 No handling of hazardous chemicals like sulfuric acid or potassium permanganate

2 No solids management

3 No generation of large amounts of hydrogen sulfide

4 No excessive waste water volumes for disposal

5 No hold-ups in waste water disposal for pH adjustments

6 No extended down time for slow reactions or slow chemical addition rates

And most importantly, no more lost production time to manage iron sulfide. This is extra revenue for the
refinery; hundreds of thousands of dollars
Industry Practices for Controlling Pyrophoric Iron
• Acidification

One practice used in the oil industry to address pyrophoric iron is to destroy the iron deposits
by adding either hydrochloric or sulfuric acid to the cleaning process steps following degassing
and degreasing of the equipment. By adding the acid, large amounts of hydrogen sulfide are
produced that must be controlled for safety concerns. This is typically accomplished by the
addition of a product called Glyoxal.

The acidification practice is slow and is controlled time-wise to manage temperature and metal
corrosion rates. The waste fluids must be neutralized before the waste water can be disposed.
While the industry is well practised in the use of acids for this process, the acids are potentially
hazardous to human health and require careful to handling

Additionally, this process often results in solids that must be managed and disposed of.

Acidification equals:

• Handling hazardous chemicals with the acids

• Extended processing times to control heat and corrosion rates
• Generation of large amounts of hazardous hydrogen sulfide gas
• Requirement for control of generated H2S

• Permanganate Oxidation

One common way of dealing with pyrophoric iron is to intentionally oxidize the sulfide anion
into the sulfate by adding caustic permanganate. Potassium permanganate is a strong oxidizing
agent, and the oxidation is catalyzed with caustic soda. This is the same oxidation reaction of
oxygen with iron sulfide that already causes so much concern. The permanganate oxidation
process is very slow by design and is conducted like acidification: after the vessel is degassed
and degreased. Again, the heat of oxidation must be carefully controlled to avoid a potential
fire, as there is almost always some amount of organic material still in the vessel while this
process is taking place.

This step of decontamination for control of pyrophoric iron can take 1-3 days to complete. It
continues until the permanganate solution turns from purple to brown. The colour is typically
used as the point of completion, though the colour change in itself is not definitive, as no one
knows how much FeS is present. A colour change simply means that the permanganate is spent
and cannot oxidize more existing iron sulfide deposits. For this reason, the industry continues
to add more permanganate after the initial colour change to hopefully insure all of the FeS has
been oxidized.

In reaction with iron sulfide, permanganate creates an abundance of manganese dioxide solids.
Every project that uses permanganate must manage a lot of these brown solids. They typically
require a lot of water flushing to remove the solids from the vessel. The solids disposal is
another cost to the refiner.

Permanganate oxidation equals:

• Extended processing times; by extra days and not hours

• Hazardous chemical operations to control heat and rate of reactions
• An abundance of manganese dioxide solids for disposal
• Large volumes of water for disposal
• Big chemical cost as KMnO4 is expensive