Careers Mitigating Metal Dusting Corrosion in Autothermal Reforming (ATR) Equipment
In a project in the Middle East, IGS successfully applied its proprietary High Velocity Thermal Spray (HVTS) cladding to critical components of an autothermal reforming (ATR) system experiencing advanced metal dusting corrosion.
The Problem of Metal Dusting Corrosion in Reformers
Metal dusting corrosion is a common challenge in gas-to-liquids (GTL) plants as well as ammonia and methanol reforming facilities. It particularly affects secondary reformer nozzles, heat exchangers, and ATR units. It occurs when carburizing environments at elevated temperatures degrade metal surfaces, leading to catastrophic pitting, thinning, and mechanical failure. In this case, significant degradation was observed in the internal shield pipes and discharge regions of the ATR burner unit.
Inspection revealed:
- Uniform pitting corrosion caused by metal dusting,
- Maximum pit depths of 3.0 mm in critical areas,
- Wall thickness reduction.
Such damage compromises equipment integrity, increases the risk of downtime, and presents potential safety hazards in continuous processing environments.
On-Site Alloy Upgrade Solution
To mitigate these issues, IGS deployed its proprietary cladding technology to protect against further metal dusting.
Key Elements of the Solution
- Application of corrosion-erosion-resistant cladding
- Full surface profiling, abrasive blasting, and contaminant removal prior to cladding
- Cladding applied to internal and external burner surfaces, including vulnerable nozzle tips and extended piping assemblies.
The project was completed at a local workshop under strict quality, safety, and environmental protocols. All cladding activities followed pre-approved quality control plans and environmental safeguards.
Scope of Work
The original scope, focused on damaged areas identified in prior repair reports, was expanded to include:
- Internal burner zones (multiple numbered areas),
- Nozzle tip externals,
- ERG lances and piping from flange to tip.
IGS collaborated with local inspection personnel and technical support teams to ensure accurate mapping of surface conditions and tracking of repairs throughout the project
“This plant operates under demanding conditions, andreliability is non-negotiable. When we identified metal dustingin the ATR burner, it was clear that action was needed toavoid future disruption. Our solution addressed the issue atits source, giving the unit the protection it needs to performsafely and consistently.”
– Dennis Snijders,Senior Director – Middle East, IGS
Results and Impact
The HVTS cladding restored the structural resilience of the affected equipment and created a dense, impermeable barrier that:
- Prevents further metal dusting corrosion
- Extends equipment life under harsh thermal and chemical conditions
- Reduces future maintenance cycles and associated costs
Conclusion
This project reinforces the value of proactive corrosion protection for ATR systems in reforming plants. By leveraging alloy upgrades, facilities can prevent critical failures and maintain safety and performance. With a global reach and localized execution, IGS remains a trusted partner for mitigating the complex challenges posed by metal dusting corrosion in reforming environments.
Productivity, safety, and asset life preserved.
That’s Asset Vitality.
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