Wet Scrubber and Ductwork Lining
Corroding wet scrubber and ductwork blasted, rebuilt, and lined under one chemical-resistant film so the condensate runs over the lining instead of into the steel.
A job completed with Belzona. This describes what the Belzona system does and how it goes on, not a record of a specific project by this distributor.
The challenge
A wet scrubber and its inlet and outlet ductwork corrode where acidic condensate forms on the gas side and runs down the walls. The condensate collects at the seams and the floor, and that is where the attack concentrates, thinning the plate and starting pinholes at the welds. Once a pinhole opens, the scrubber leaks and the duct loses the wall it needs to carry the gas stream safely. Left untreated, the condensate keeps finding the lowest points, the pitting spreads across the plate, and the unit comes off line for repairs that the plant did not plan for.
The Belzona approach
Work starts by blasting the scrubber internals and the duct walls back to clean steel so the repair and the lining bond to bare metal. A cold-applied composite rebuilds the thinned seams and the pitted plate back to profile, and the floor is sealed where the condensate had been collecting. The scrubber and duct internals are then lined with a chemical-resistant barrier keyed to the gas and the condensate, so the walls, the seams, and the floor all sit under one continuous film. With the lining in place the condensate runs over the barrier and off the unit instead of soaking into the steel.
- Assess and mapThe scrubber and the inlet and outlet ductwork are inspected to map the pitting, the thinned seams, and the floor area where the condensate collects, and the gas and condensate are confirmed so the lining is keyed correctly.
- Blast to clean steelThe scrubber internals and the duct walls are grit-blasted to a clean, profiled surface so both the composite and the lining bond to bare steel.
- Rebuild seams and pittingA cold-applied composite rebuilds the thinned weld seams and the pitted plate, with no hot work, bringing the surface back to profile.
- Seal the floor and line internalsThe floor is sealed where the condensate had pooled, and a chemical-resistant lining goes across the scrubber and duct internals as one continuous barrier.
- Inspect and return to serviceThe lining is checked for continuity over the walls, seams, and floor, and the scrubber and ductwork go back ready for the gas stream.
The result
- Scrubber and ductwork returned to service without cutting out or replacing plate
- Thinned seams and pitted plate rebuilt in place with no hot work
- Walls, seams, and floor lined under one continuous chemical-resistant film keyed to the gas and condensate
- Repair delivered by factory-trained and factory-certified Belzona applicators
In the field
More Petrochemical & Chemical projects
Live Pipe Leak Seal & Composite Wrap
Live leak sealed and a degraded process line reinforced with an engineered composite wrap, no welding and often no shutdown.
Furnace Stack High-Temperature Coating
A corroding furnace stack prepared and coated in situ at operating heat, with no shutdown and no cool-down.
Reactor Vessel Chemical-Resistant Relining
Failed reactor lining stripped back, attacked steel rebuilt cold, and a chemical-resistant immersion lining applied to return the vessel to process service.
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Belzona Houston is the authorized Belzona distributor for South Texas and the Gulf, based in Alvin, Texas, we’ll survey your equipment and recommend the right cold-applied Belzona system, with 24-hour support.