Corrosion Management and Control Strategies for Modular Refineries in the Niger Delta Environment – A Case Study of Aradel Refineries

Abstract Corrosion remains one of the most pressing challenges facing the global oil and gas industry, with far-reaching implications for process safety, asset integrity, environmental protection, and operational reliability. According to the National Association of Corrosion Engineers (NACE), the cost of corrosion globally is estimated to exceed US $2.5 trillion annually, representing over 3-4% of global GDP, with the refining and petrochemical sectors accounting for a significant share due to their complex process environments, ageing infrastructure, and continuous exposure to aggressive chemical species. This study investigates corrosion mechanisms and control strategies within Aradel refinery which include an 11,000 bbl./day combined modular refining complex co-located with a flow station and a 100 MMSCF/day gas plant within PML 14 in the Niger Delta. Using field data, inspection records and chemical monitoring results, this paper identifies critical corrosion zones and several types of corrosion including uniform corrosion, localized pitting, corrosion under insulation, and microbiologically influenced corrosion (MIC) and evaluates the effectiveness of current preventive measures, including the use of corrosion inhibitors, coatings and cathodic protection systems. The study recommends an integrated corrosion management framework encompassing risk-based inspections (RBI), digital corrosion monitoring, material selection and workforce competence development. The results demonstrate that a systematic, data-driven corrosion management approach can significantly extend equipment service life, improve process reliability, reduce maintenance costs, and lower the likelihood of safety incidents. Importantly, while the study is grounded in a Niger Delta case, the insights and framework are transferable to other modular refineries, conventional refineries, flow stations, gas plants and petrochemical plants operating in tropical, coastal, or corrosive environments.