Thermal spray applications in the chemical industry

The chemical industry has several applications of corrosion, cavitation and erosion, often at high temperatures and pressures.

Many of these are shared with the oil and gas industry (petrochemical) so it is worth reviewing the oil and gas applications too.

A common application is the occurrence of Corrosion Under Insulation (CUI) which is where accelerated corrosion can occur in cyclic temperature vessels and pipelines which are insulated. In the worst cases, CUI can cause corrosion rates up to 1mm/year.

A long proven method to protect against CUI is the use of Thermal Spray Aluminium (TSA). Protection in excess of 20 years has been shown in real life applications, leading to TSA being widely adopted by such companies as Shell and Exxon Mobil across their global refineries. The same conditions occur in downstream chemical processing plants.

In several areas, high temperature corrosion can occur with complex corrosion environments and pressures. At times, erosion from the products being stored and pumped adds further complexity. There are several thermal spray solutions available to combat high temperature corrosion from arc sprayed Hastelloy or Inconel CRA’s (corrosion resistant alloys) through to the same materials applied by HVOF or HVAF.

Please contact Metallisation for further advice on coating and process selection. You can also refer to independent standard EN ISO 17834:2003 for guidance on coatings for protection against corrosion and oxidation at elevated temperatures.


Application Data Sheets


Protection of Iron and steel at Elevated Temperatures

Reason for use: Protection of Iron and steel at Elevated Temperatures Download PDF Related Products Arcspray 145/S345-CL View Product Arcspray 340(16)-PLC View Product Arcspray 528E(16)-ICC View Product Unprotected iron and steel surfaces oxidise and corrode rapidly at elevated temperatures in the presence of industrial atmospheres, hot gases and condensation products. Experience within the Metallisation Group has shown that nickel-chromium alloys and/or aluminium coatings give protection and increase the life expectancy of steelwork up to temperatures as high as 1200°C. Because oxidation…

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Case Studies

Metallisation-MK73-flamespray-system TSA Process

Using TSA to Protect Pipelines from Corrosion Under Insulation (CUI)

Reason for use: Cost effective corrosion protection against aggressive corrosion under insulation (CUI) Related Products MK73-FS Wire Flame View Product Deflected Flame Spray Extension View Product In the petrochemical industry Corrosion Under Insulation (CUI) in pipeline systems consumes a significant percentage of the maintenance budget. A large portion of this money is spent on expensive items such as external piping inspection, insulation removal and re-installation, painting and pipe replacements. CUI prevention strategies provide long term and reliable prevention of CUI…

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