In this episode, we're joined by Kevin Phillips, Director of Business Development for Integrated Global Services and a Thermal Spray expert. He discusses a Pulp and Paper CFB Boiler dealing with extreme erosion issues, worsened by the presence of plastics, resulting in corrosion problems. The boiler experienced forced outages due to tube leaks, leading to frequent mechanical repairs. Fast forward six years later, and there are no tube leaks or forced outages.
 
Items discussed in the episode:
 
Difference Between High Velocity Thermal Spray and Low Velocity
The True Cost of Metallurgy Cladding for Pulp and Paper CFB Boilers
The Dangers of Continued Forced Outages for CFB Boilers
What Is the Duration of the Agreement or Partnership Between IGS and Its Clients?

EPISODE 15 - How a Pulp and Paper CFB Boiler Mitigated Extreme Erosion and Saved Long-Term Costs

In this audio case study, we discuss a situation at a Gulf Coast chemical plant where an ethylene furnace encountered a hot spot challenge, requiring prompt action.

EPISODE 16 - Ethylene Cracking Furnace Hot Spot Repair Online

In this episode, Larry Emch, Furnace Efficiency Specialist from IGS, joins us again to discuss a project where his team audited furnaces and heaters at an oil and gas site, identifying inefficiencies and offering solutions for increased production, including a notable 13.5% improvement, and long-term efficiency.

EPISODE 17 - Catalytic Reformer Audits: 13.5% Furnace Efficiency Increase

A critical issue arose during the construction of a groundbreaking direct air capture facility in the US Gulf Coast, risking the project timeline and costing over $500k per day in delays, as a particular coating specification for a vessel proved inadequate for the required environment and temperature ranges, requiring urgent intervention to prevent further setbacks. The urgency was heightened by the need to address the problem during the New Year holidays.

EPISODE 18 - Solving Coating Issues in a Carbon Capture and Storage Project Amidst New Year Holidays

In this audio case study, we discuss the corrosion challenges within a sulfolane unit, showing why it's important for proactive maintenance strategies to safeguard operations and reinforce commitments to process safety, efficiency, and environmental responsibility.

EPISODE 19 - Sulfolane Corrosion Prevention with On-site Alloy Upgrade During Turnaround

A prominent player in the Japanese market, this energy company operates several refineries across the country, including Miyagi, Ibaraki, Chiba, Kanagawa, Okayama, Yamaguchi, and Oita, facing various corrosion and erosion challenges in critical refinery equipment, leading to premature deterioration and costly repairs or replacements during turnarounds.

EPISODE 20 - Corrosion Challenges in Japanese Refineries

A refinery faced a challenge during a turnaround project in 2022, aiming to enhance hydrotreater efficiency with a unique convection section configuration dedicated solely to boiler feed water heating, lacking process coils. This setup presented an opportunity to maximize processing efficiency in the radiant section, which required an innovative approach to optimize radiant heat transfer efficiency.

EPISODE 21 - Hydrotreater Efficiency Increase During Turnaround

This audio case study is about fouling challenges faced by a petrochemical company. There is a crucial need to restore heater efficiency and operational reliability, leveraging advanced robotic technology in alignment with the company's commitment to sustainability, this process generated minimal waste.

EPISODE 22 - Robotic Solutions: Enhancing Efficiency in Petrochemical Operations

In this episode of the Efficiency and Reliability Podcast, we discuss the significant challenges of erosion and corrosion in a plant's waste heat recovery system, leading to frequent repairs, extended downtime, and substantial production losses.

EPISODE 23 - Erosion and Corrosion in Waste Heat Recovery Systems

EPISODE 24 - Solving Fired Heater Radiant Tube Oxidation

Listen to our case studies that focus on challenges and innovative solutions for combating corrosion and erosion issues in industrial plants.

Efficiency & Reliability Audio Case Studies

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