How to Stop Caustic Vessel Corrosion





Controlling Caustic Corrosion in High pH Vessels

Caustic systems, including Merox and demercaptanization units, are subject to aggressive corrosion mechanisms -  caustic cracking, aggressive pitting corrosion, and caustic embrittlement. Even process vessels with generous corrosion allowance can suffer extensive metal wastage in localized areas.  

This webinar  features:

  • Caustic Corrosion in High PH Vessels
  • Causes of Caustic Corrosion in Demercaptanization Processes + Two Failure Examples
  • Caustic Corrosion: Material Selection
  • Solutions to Metal Wastage Caused by Caustic Corrosion - Pros and Cons
  • HVTS Alloy Cladding Suitability for Caustic Environment
  • Case Study 1: HVTS Prevents the Need for Vessel Replacement
  • Case Study 2: Upgrading a Weld Overlay Solution to a Faster Alternative, Reducing Critical Path
  • Live Q&A with the Speaker

How to Stop Caustic Vessel Corrosion | Sneak Peak | Short Video Preview

Caustic Corrosion in High PH Vessels

Caustic conditions, within MEROX and other demercaptanization processes can rapidly attack steel's protective magnetite layer and cause material wastage. Following destruction of the protective magnetite layer, NaOH can additionally react with exposed elemental iron to form atomic hydrogen, leading to hydrogen embrittlement, decreased wall thickness, and caustic stress corrosion cracking (CSCC) or caustic embrittlement. These phenomena have led to multiple plant failures under different caustic conditions.

About the Speaker | Colin Bateman

Colin has 20+ years experience in specifying protective solutions to mission critical assets. He currently supports asset owners in Europe and Middle East, mitigating their erosion and corrosion issues.

Corrosion Resistant Alloy (CRA)

To address these challenges, a robust, fit for purpose, field applied solution is required.  This webinar presents a technology that has been highly successful in delivering long-term internal surface protection over the last 20 years.  The webinar will explain how the technology was developed and functions, as well as presenting numerous documented case histories, from initial application to subsequent inspections.

Learn How to

  • Prevent forced outages and emergency shutdowns
  • Extend maintenance-free periods
  • Choose an appropriate corrosion solution, considering time, costs, and longevity

"To protect against caustic corrosion and cracking, the High Velocity Thermal Spray (HVTS) technology has been tested and successfully deployed as a solution. Traditional alloys that have previously been used in thermal spray and overlay options, such as Monel and Hastelloy, exhibit possible porosity and failures in aggressive caustic conditions. However, IGS modified NiCrMo-XX alloys provide effective protection of the carbon steel substrates in aggressive caustic environments. "


- Colin Bateman, IGS Mission-Critical Equipment Maintenance Subject Matter Expert