TRACK: Bioprocessing & Corrosion Mechanisms
Corrosion concerns in refineries are significant, often leading to extended turnarounds, unplanned shutdowns, and pressure boundary failures resulting in costly and complex shell and infrastructure replacement. High-Velocity Thermal Spray (HVTS) cladding technology, with alloys developed specifically for thermal spray application, have over twenty years of reliable service record in Amine processing units in upstream equipment. This technology has now been expanded into more chemically aggressive and elevated temperature environments in both caustic and sour conditions in refining and petrochemical facilities. With the repurposing of equipment for new feeds and biofuel processing, alloy upgrades are required to prevent enhanced corrosion rates associated with fatty acids. A combination of process technology, procedure and materials needed to be addressed to obtain the performance required for more challenging conditions. These modified superalloy systems are resistant to both basic and acidic conditions at elevated temperatures. They are effective in providing an impermeable metallurgical barrier, protecting the underlying substrate, and can be efficiently applied without metallurgical impact to the existing shell or the need for vessel post thermal processing (PWHT). Testing with crude and biofuel feed from facilities, and full field applications have been undertaken, validating recent advances in HVTS and materials technology for protection in reactors, separators, crude distillation units (CDUs), high concentration sulfuric acid drums, fractionators among others. These advancements with high protective layer density provide robustness for a longer, maintenance-free service life while reducing installation time associated with other mitigation methods. Complexities and costs associated with weld overlay are avoided, and organic coatings with limited performance can be replaced by HVTS Cladding systems for long term durability.
MTI Global Solutions Symposium 2024
February 26-29
Baton Rouge, LA
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