In the refining industry, corrosion control has traditionally been a constant challenge, however, in recent years, digital technologies have evolved to address this challenge. During the AMPP 2025 event, Josep Marca, Global Marketing Manager – Refining and Sustainability, made it clear that corrosion control has taken a key step forward with Pathfinder, the solution presented by Nalco Water, which integrates advanced chemistry with state-of-the-art automation and digitalization.
Pathfinder: A Comprehensive Approach to Corrosion Control
Pathfinder is an advanced platform that combines Nalco Water’s chemical expertise with the power of technology. This system is designed to mitigate corrosion in refinery overhead crude oil systems, but does so in a way that integrates automation and real-time digital analysis.
Pathfinder’s key strength is its ability to offer a comprehensive solution using specialized chemicals such as neutralizers and inhibitors, and its incorporation of digital tools that enable more efficient and accurate process monitoring and control.
24/7 technology that boosts efficiency
This software connects directly to the refinery’s DCS (Distributed Control System) system, allowing data to be collected and sent to the cloud for analysis. Once there, the software performs critical calculations regarding the crude oil saturation point and other essential aspects of the process, and then sends recommendations back to the system in real time.
This system is capable of simulating up to 300 data points per day, allowing refineries to receive accurate and constantly updated recommendations. Prior to this advancement, results were obtained only once a day, limiting the ability to respond to rapid changes in the refining process.
Digital twin: the future of corrosion control
Pathfinder also uses digital twin to create a digital replica of the refinery’s physical system, which is then fed with data from sensors and other devices in the field. From this virtual replication, real-time analyses can be performed and simulations generated to help predict corrosion behavior under different operating conditions.
Automated analysis of variables allows system parameters to be constantly adjusted to ensure optimal conditions, thereby improving operational efficiency and reducing the risk of costly failures. With this technology, engineers can anticipate problems before they occur.
Implementation and positive feedback
Pathfinder isn’t just a promise for the future; it’s already being implemented in several refineries, and feedback from early adopters has been extremely positive. Customers already using this technology report significant improvements in corrosion control and increased operational efficiency thanks to the system’s rapid and accurate recommendations.
This initial success demonstrates the technology’s enormous potential and its ability to transform the way refineries manage corrosion control, resource optimization, and the sustainability of their operations.
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Source: Inspenet.