Material Selection Strategies for Petrochemical Processing Equipment in the Nigerian Refining Industry

This study examines material selection strategies for process equipment in Nigerian petroleum refining operations, focusing on the four operating refineries at Port Harcourt, Warri, and Kaduna. Material selection decisions critically affect the service life, maintenance frequency, and operational safety of refinery equipment exposed to corrosive hydrocarbons, hydrogen sulphide, high temperatures, and elevated pressures, yet a systematic evaluation of material selection practice in Nigerian refineries has not been published in recent literature. The study adopts a qualitative case study approach, incorporating semi-structured interviews with twelve senior process and materials engineers currently or recently employed in the target refineries, supplemented by review of equipment inspection records and material requisition documents with institutional approval. The investigation examines the decision criteria applied in selecting materials for heat exchangers, distillation column internals, reactor vessels, and piping. Findings reveal a dominant practice of direct substitution from imported equipment data books, with limited adaptation to the specific crude oil compositions and impurity profiles (particularly high sulphur content) of Nigerian feedstocks. Several documented corrosion failure cases in heat exchanger tubing and column trays are attributable to inadequate sulphidation resistance of the specified alloy. The study recommends developing a Nigeria-specific materials selection guide for refinery equipment based on local crude oil properties. Keywords: material selection, petrochemical equipment, refinery, corrosion, Nigeria.