Amine System Corrosion Mitigation & Prevention

The amine system is an efficient chemical process for removing H₂S, CO₂, and mercaptans from a variety of hydrocarbon streams. During the regeneration of rich amine solutions, acid breakouts create a highly corrosive environment that demands specialized treatment and the use of high-alloy materials, such as titanium, stainless steels, and other corrosion-resistant alloys, to ensure safe operation.

HVTS® (High Velocity Thermal Spray) technology provides a proprietary Corrosion-Resistant Alloy (CRA) cladding solution applied on-site to mitigate H₂S corrosion and prevent metal wastage.

Operational Challenges

Corrosion in amine units is primarily driven by contaminants, thermal factors, and process upsets, rather than by the amine itself. The operating environment within amine systems often accelerates localized corrosion of metal components.

  • Acid Gas Breakout – Occurs when acid gases (CO₂ and H₂S) flash out of solution due to high temperatures, high velocities, or pressure drops, leading to subsequent acid attack.
  • Heat Stable Amine Salts (HSAS) – Formed from reactions with contaminant acids that build up in the system. HSASs dissolve protective films and lower pH.
  • Contaminants – Includes solids (causing erosion-corrosion), oxygen (accelerating corrosion and HSAS formation).
  • High Temperatures – Corrosion activity is significantly accelerated by heat. Temperatures above 220°F (104°C) in rich amine service can cause severe localized corrosion.
  • Wet H₂S – A low H₂S concentration is recommended to support passivation film formation; however, when H₂S levels become too high, HIC corrosion becomes highly aggressive.

 

HVTS Application Experience by Unit

Reboiler and Regenerator Bottom

This area is the most frequent location for corrosion incidents across all amine systems due to extreme temperatures.

Regenerator/Stripper Overheads

Prone to corrosion, cracking, and blistering. This area is affected by high concentrations of corrosive species like ammonia (NH₃), H₂S, and hydrogen cyanide (HCN).

Lean/Rich Heat Exchangers

Highly susceptible to corrosion and failure on both the rich and lean sides.

Absorber and Coolers

Sweet amine plants experience a higher frequency of corrosion in the absorber column and lean amine coolers.

 

Proven, Long-Lasting Protection in Amine Service

HVTS is a NiCrMo alloy cladding system engineered to resist corrosive agents found in amine systems, including H₂S, CO₂, chlorides, and acid gases.

Long-Term Reliability

HVTS cladding is designed to last entire inspection cycles, offering long-term protection.

No PWHT, No HAZ

HVTS is applied in-situ without generating a Heat-Affected Zone (HAZ) or requiring Post-Weld Heat Treatment (PWHT). This preserves the integrity of the base metal and significantly speeds up application.

Impermeable CRA Barrier

The proprietary HVTS alloys form a dense, impermeable surface that resists chemical attack.

Fast, Safe On-Site Application

Application is fast and safe, even in confined vessels, drastically reducing project execution time compared to traditional weld overlays.

Case Study: Amine Regenerator HT H₂S Corrosion

Solution: IGS applied HVTS cladding across the affected shell, tray rings, downcomers, nozzles, and internal components.

Execution: The entire project was completed in just 7 shifts, and crucial internals were protected without the need for removal and replacement associated with conventional welding.

Result: Six years later, inspections confirmed no degradation, and the HVTS cladding remained in excellent condition, ensuring full structural integrity and long-term protection.

Read case study

Case Study: A Decade of Amine Corrosion Protection at an NGL Plant

Long-term evaluation of HVTS in amine service (2014–2024)

This case study examines the long-term performance of HVTS® cladding applications at a gas plant in Saudi Arabia, specifically focusing on protection against corrosion in amine service. The study spans a 10-year period from 2014 to 2024, documenting multiple application phases and subsequent inspections of the amine stripper column.

Read case study

 

HVTS_Thermal_Spray_coating-provides-corrosion-resistance-in-heat-exchangers

Watch: How HVTS Prevents Process Vessel Corrosion