Eliminated transient bulk calcium phosphate deposition in ethylene compressor intercoolers

What this case study covers

A Gulf / US petrochemical complex faced repeated cleanings and threat of plant shutdown from sudden bulk deposition that neither the incumbent supplier nor the operating team could resolve — for years. An independent root-cause review converted those recurring losses into $16.1M/yr in firm savings and cost avoidance.

Inside this case study

• Firm-savings breakdown: lost production, cleaning, and thermal losses
• Root cause: phosphate inhibitor vs dispersant imbalance mechanism
• Aligning disparate data sources into a single unified model
• Time-series competing-ion saturation modeling approach
• Corrected control bands and online monitoring plan
• How to detect this failure mode before it triggers