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Amine Regeneration
Column Repair with
High Velocity Thermal Spray
TA impact - 65 hours
Life cycle saving – $65.3M
Process Overview
Amine plants employ a regenerative process to remove acid gas
components (H2S or CO2) from a gas or light hydrocarbon stream. A Shell, tray supports
counter current reactive absorption process is utilized with an aqueous and downcomer brackets
amine solution in a multistage absorber column. The amine process protected with HVTS metal
permits regeneration of the solution by counter current steam stripping cladding
at higher temperature in a multistage regeneration column.
Severe pitting to a shell in a regeneration column was identified in a 400 000 bpd refinery. In some locations, pitting
had penetrated through the shell wall. Temporary clamps and plugs had been installed, but loss of containment posed
a major safety and environmental risk. Multiple sections of the column were cut out and replaced by a mechanical
contractor. IGS was contracted to employ a newly qualified technology to apply a corrosion resistant metal coating to
the internal surface to stop further corrosive attack. 407sqft of column shell was protected, including horizontal and
vertical tray supports. The operation was completed with 3 technicians in 65hours. The column was handed back to
the client for scaffold removal and tray installation.
Value Proposition
IGS’s ability to provide advanced protection to the vessel shell in 65 hours and limit production losses was a key cost
factor for the client. The use of a high velocity thermal spray process was deemed more economical when compared
to weld overlay and column replacement strategies due to this time sensitivity. Total savings of $17,400,000 were
realized with HVTS application as compared to weld overlay, factoring in opportunity cost savings for the first year.
Costs saving of $64,500,000 were realized over a 3 year period versus mechanical section replacement, which was the
incumbent repair approach. The duration of the repair solution and further maintenance due to recurring corrosion
were taken into the calculation. Non-metallic coatings were not considered due to their inability to reliably achieve a
3 year run cycle in this corrosive environment.
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