A major U.S. refiner set out to raise throughput in its HF Alkylation unit yet continued to face exchanger fouling and corrosion in critical piping. Standard indicators suggested stable conditions, but hidden corrosion disrupted operations and shortened run lengths. Working with OLI, the refinery deployed a Corrosion Digital Twin connected to plant historian data to reveal real-time corrosivity drivers and define clear operating limits. This cloud-based system delivered continuous analysis of dew point proximity, acidity distribution, and RHF solubility, giving operators the insight needed to act early and prevent damage. The program strengthened reliability across the unit and cut unplanned outages, which helped restore confidence in running at higher rates. It marked a meaningful step in the refinery’s digital modernization.
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