WHITE PAPER-Best Practices in Syngas Plant Optimization.pdf

process design

1. Authors: Larry Emch, Sergei Merchev, John Bacon, Anton Korobeynikov
Increase Process Efficiency
and Service Life of Syngas
Process Equipment
Best Practice Guide

2. 2

3. Contents
Executive Summary
Introduction
Thermal Efficiency in Syngas Technologies
Best Practice 1: Improve Throughput by Restoring Convection Section Efficiency
Case Study 1: Tube Tech ROV Restores Efficiency at Fertilizer Plant
Best Practice 2: Increasing Radiant Section Efficiency and Reducing Emissions
Case Study 2: Achieving Radiant Efficiency with Cetek Coatings
Best Practice 3: Eliminate Fouling, Extend Asset Life and Prevent De-rates and Unplanned Shutdowns
Case Study 3: IGS SCR Technologies Deliver 90-Day Payback and $3M Cost Avoidance
Best Practice 4: Repair Hot Spots on the Primary Reformer External Shell While Continuing Safe Operation
Case Study 4: Hot-tek™ Solution Eliminates Hot Spots in Fertilizer Plant Ammonia Reformer
Best Practice 5: Corrosion Mitigation in Amine & Benfield Carbonate Vessels
Case Study 5: IGS HVTS® Applications Helps Minimize Downtime and Maximize Asset Integrity
Case Study 6: HVTS® Protection for UOP Benfield™ Process Equipment
Best Practice 6: Autothermal Reforming (ATR) Metal Dusting Mitigation
Case Study 7: 13 Years of Success: How IGS HVTS® Technology Standardized Corrosion Protection for a Leading GTL Producer
Conclusion
IGS Experience in the Syngas Industry
About IGS
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4. 4
Executive
Summary

5. 5
The syngas (synthesis gas) industry plays a crucial role in producing essential materials like
ammonia, methanol, hydrogen, and synthetic fuels. However, it faces significant operational
challenges that impact efficiency, safety, and profitability. These challenges arise from extreme
operating conditions – high temperatures, high pressures, and exposure to corrosive materials
– which accelerate wear and tear on critical equipment including, but not limited to, steam
methane reformers (SMRs), heat exchangers, and CO
2
absorption towers.
As global regulations push for decarbonization and stricter environmental compliance, syngas
producers must find new ways to enhance energy efficiency and reliability while minimizing
their environmental footprint.
By implementing the best practices in this paper, syngas producers can reduce their energy
consumption by 10-15%, significantly extend the life of their equipment, and avoid unplanned
shutdowns that can cost millions of dollars.

6. 6
An
Introduction

7. 7
This white paper presents field-proven best
practices that have delivered measurable
improvements in cost savings, reliability,
and environmental performance for syngas
producers worldwide. Drawing from decades
of experience in corrosion management
and energy efficiency optimization, these
solutions combine advanced alloy upgrade
techniques with the latest efficiency measures,
demonstrating success in autothermal
reforming (ATR) and steam methane reforming
(SMR) systems.
By leveraging these solutions, syngas plants
can reduce downtime, extend equipment life,
and significantly lower energy costs, positioning
themselves for sustained competitiveness in a
rapidly evolving industry.
Each best practice in this guide is based on the
collaboration between the client and Integrated
Global Services (IGS®), with key findings and
achieved results. Engineering recommendations
are based on technologies developed and
delivered by IGS as the sole applicator for these
technologies and services.
The syngas industry continues to experience
robust growth, with the global syngas market
projected to expand significantly due to
increasing demand for methanol, ammonia,
and other downstream products. According
to a report by Grand View Research, the global
syngas market demand was estimated at 230.05
million Nm3/hr in 2023 and is expected to grow at
a compound annual growth rate (CAGR) of 11.3%
from 2024 to 2030.
Rising demand for cleaner alternatives fuels is
expected to drive market growth, coupled with
growing government support for clean energy
initiatives, including tax credits and renewable
portfolio standards, incentivizes investments in
syngas technologies.
In addition, stringent environmental regulations,
such as the Clean Air Act and carbon emission
reduction targets are driving demand for cleaner
alternatives in various industries. Syngas
technology's ability to utilize diverse feedstocks
– including natural gas, biomass, and even
captured CO
2
– positions it as a key enabler of
both industrial sustainability and economic
growth.

8. 8
Thermal
Efficiency
in Syngas
Technologies

9. 9
Inefficiencies in heat recovery can significantly impact operational costs, increasing energy expenses by 10-15% – amounting to
millions of dollars annually for larger operations. Modern heat recovery solutions, including refractory encapsulation in radiant zones
and comprehensive cleaning of convective zones, can address these challenges while simultaneously reducing carbon emissions.
Through a detailed thermal efficiency audit, IGS evaluates fired equipment and delivers a comprehensive analysis including benefits,
pricing, payback periods, scope, timeline, and optional maintenance considerations. This analysis is provided before any commitment
from either the client or IGS. To ensure accountability and validate solution performance, IGS conducts thorough post-project analyses
as a fundamental part of its client relationships.
In addition to creating a select line of solutions, IGS has also assembled and trained employee-based crews capable of installing these
technologies anywhere in the world. IGS operations teams have completed over 5000 projects in more than 70 countries meeting both
the rigorous safety standards and timely execution required by turnaround-based project work. This suite of global references points to
decades of experience and validated technology.

10. 10
Best Practice 1
Convection Section
Efficiency

11. 11
Improve Throughput by Restoring
Convection Section Efficiency

The IGS Tube Tech Convection Section ROV is a proven
system for heavily fouled convection sections in Steam
Methane Reformers (SMRs). Unlike traditional methods
like water pressure lances or chemical cleaning, which
often fall short in fully removing heavy fouling, this
technology restores efficiency to near design levels
with unmatched precision, safety, and reliability.
The IGS business model includes a review of design
specifications, general arrangement drawings and
current process data as part of a site visit to inspect
the unit.
This comprehensive approach creates the opportunity to
consider the implications of utilizing multiple technologies
to regain optimal performance. In many cases, our
recommendation provides affordable options compared
to securing cap-ex funding for revamp options.
After a comprehensive review and detailed discussions
with the client, the IGS thermal efficiency team recommend
a scope and calculate a payback for the project. The
combination of a meaningful payback and short project
duration are typical for convection section applications. In
the following case study, the optimal scope of the project
was largely comprised of utilizing the Tube Tech ROV fouling
removal system.

12. 12
Prior to the project the outlet stack temperature was running
at 170 degrees Celsius, thirty (30) degrees above the original
design stack temperature. The client supplied post project
operational data confirmed that the stack temperature was
restored to 90% of design. CO
2
emissions were also reduced
as less fuel is consumed to produce the same results.
Other best practices for keeping the convection section
clean will be improving combustion air filtration and
protecting ceramic fiber refractory with refractory
encapsulation coatings.
Case Study 1
Tube Tech ROV Restores Efficiency
at Fertilizer Plant
A fertilizer production plant was suffering from heavy
fouling in the convection section of its primary reformer
furnace. The efficiency had dropped well below design,
negatively impacting operating parameters and
throughput. Restoring the asset to near design efficiency
during the upcoming turnaround was vital.
IGS implemented its Tube Tech ROV fouling removal
system to deep clean between each row and throughout
the bundles to dislodge excessive fouling. Even the fouling
material deeply embedded in the coils was readily
removed as confirmed by a Lancescope™ camera
inspection before and after the work.
The patented rover equipped with a power lance was pre-
programmed with the dimensional data of the tube bank
ensuring maximum access to the surface area. IGS crews
were able to access ~95% of the surface area, ensuring no
collateral damage to refractory fiber side walls. The crew
safely completed the scope within the quoted 48 hours.

13. 13

14. 14
Best Practice 2
Radiant Section
Efficiency

15. 15
Increasing Radiant Section Efficiency and Reducing Emissions
At most fertilizer and methanol plants, the steam methane reformer is positioned to feed the downstream units with syngas.
The SMR assets consume a significant amount of fuel resources due to the endothermic nature of the steam reforming reaction.
Therefore, maintaining the unit performance and energy efficiency is a key driver for site profitability and meeting local emissions
regulations. The client’s goal in the turnaround was to offset the emerging limitations of Bridgewall Temperature (BWT) and firing
duty.
BWT typically indicates how much heat is absorbed by the process and how much is absorbed by the export steam. Fortunately,
the coil outlet temperature (COT) can be readily adjusted to increase the conversion rate and decrease methane slip. However,
in some cases, an elevated COT will result in one or more bottleneck scenarios:
• Temperature of flue gas exiting the radiant section
• Radiant and/or convective tube metal temperature
• Uneven heat distribution in radiant section
• Burner firing, excess emissions and export steam utilization
All these limitations have the same origin derived from declining efficiency of the radiant section.
As previously stated, the IGS business model includes a detailed review of design specifications, general arrangement drawings
and current process data as part of a site visit to inspect the unit. This approach creates the opportunity to consider the
implications of utilizing multiple technologies to regain optimal performance and fit into turnaround critical path execution.

16. 16
Post-coating evaluation results based on client supplied
data clearly indicate the Cetek coating has improved the
radiant efficiency, resolving the limitations on firing duty
and BWT. The BWT decrease was reported as 33
0
C (600F)
alongside a relative fuel savings and C0
2
reduction of 3.2%.
Case Study 2
Achieving Radiant Efficiency with
Cetek
®
Coatings
In this application the steam reformer has a twin-cell
side-fired design with the common convection section on
the top of the radiant sections with an inclined flue gas
duct. The refractory was a typical combination of ceramic
fiber modules, insulating firebrick and castable burner
tiles.
The thermal efficiency team recommended a solution
and calculated a payback for the project.
To improve the radiant section efficiency the optimal
scope included applying Cetek high emissivity coating
to the refractory surfaces in the radiant sections. Cetek
coating is formulated and engineered for each type of
refractory material.
IGS crews safely executed the turnkey scope of cleaning
the refractory and applying multiple Cetek ceramic
coatings during the three (3) days project.

Parameter UOM
Before Cetek
®
Coating
After Cetek ®
Coating
Relative feed rate
Relative ammonia production
Radiant inlet temp
Radiant outlet temp
Bridgewall temp
Total fuel used
Relative fuel savings
Or production increase under
the same firing rate
%
%
O
C(
O
F)
O
C(
O
F)
O
C(
O
F)
Gcal/hr (MMBtu/hr)
%
%
100.00
100.00
529(984)
787(1449)
1062(1944)
228.33(906.54)
-
-
100.00
103.03
514(958)
792(1458)
1029(1884)
228.15(905.75)
3.2
3.3
This project met the initial predictions, providing an
immediate and long-term benefit for the plant by elevating
and maintaining the radiant efficiency. Site-based
economics indicates a payback of less than six months.

17. 17
Over 400,000 M
2

of Surface Area
Protected
Why High Emissivity?
In the radiant section of a fired heater, much of the radiant
energy from the flame/flue gas is transferred directly to the
process/catalyst tubes; however, a significant proportion
interacts with the refractory surfaces. The mechanism of this
interaction has an appreciable effect on the overall efficiency
of radiant heat transfer. A major factor in determining the
radiant efficiency is the emissivity of the refractory surface.
Traditional refractory materials, while designed primarily for
structural integrity and insulation, often fall short in radiation
efficiency. New ceramic fiber linings have emissivity values of
only around 0.4, while insulating fire brick (IFB) and castable
materials achieve values near 0.6. In contrast, Cetek®
engineered coatings have been specifically designed to
enhance the radiation characteristics of refractory surfaces,
achieving superior emissivity values above 0.9.
Cetek
®
Thermal Efficiency Technology
IGS applies Cetek coatings to process heaters, which have
been shown to successfully improve the efficiency of radiant
heat transfer to the feed.
In SMR applications, high and neutral emissivity coatings can
be applied on all types of refractory.
High Emissivity Coatings for
Refractory Surfaces
High emissivity ceramic coatings, pioneered by former Cetek
Ltd, have become a proven solution for enhancing radiant
heat transfer efficiency in fired heaters and tubular reformers.
Applied to refractory surfaces in radiant sections, these
coatings deliver significant energy savings while improving
environmental performance and operational reliability.
Over decades of development, various ceramic coating
formulations have been engineered to suit different substrate
materials, operating environments, and specific performance
requirements.
In fired heaters, the endothermic process is driven by thermal
energy generated from burning a fuel-air mixture, with heat
transfer occurring primarily through radiation.

18. 18
Understanding surface emissivity is crucial for evaluating
heat transfer efficiency, with two key factors to consider. First
is the spectral distribution of radiation absorbed and emitted
from a surface, and second is the surface's emissivity value.
The heat radiation (Q) from a surface can be calculated
using the Stefan-Boltzmann equation, where A represents
surface area, T represents temperature, and represents
emissivity:
Where is the Stephan Boltzmann constant.
Lobo & Evans and others extended the calculation with
reference to fired heaters and a simplified equation would
appear as:
Where F for tubes of area ,
surface temperature and emissivity are inside an
enclosure, area , with surface temperature and
emissivity . The effects of maximizing the emissivity of the
enclosure are clear; there is a significant increase in radiant
heat transfer to the tubes. As stated earlier, much of the
radiant heat to the tubes travels directly from the flame/flue
gas, but the emissive property of the refractory surface has a
profound effect.
Figure 2. Energy Spectra of Combustion Products of Methane
The chart in figure 2 shows the energy spectra for two major
components of the combustion products of methane: water
vapour and carbon dioxide. They are compared with the
spectrum of a perfect radiator, or black body, at the same
temperature.

19. 19
In the convection section, heat in the flue gas is used to
produce steam and preheat combustion air and often
process fluids. The heat transfer/absorbed duty balance
should be examined closely to ensure that the balance
is not adversely affected.
Environmental Benefits of
Cetek
® High Emissivity Coatings
The reduction in flue gas temperature leads to a significant
reduction in thermal NOx emissions. The typical reduction
in NOx emissions in steam methane reformers is 20% to
30%, irrespective of burner type. CO
2
emissions are reduced
proportionately with the productivity benefits.
Operational Benefits of
Cetek
® High Emissivity Coatings
In addition to the environmental benefits, Cetek coatings
(high emissivity or neutral emissivity) provide a robust
encapsulation of the ceramic fibre (blanket, modules, or
panel) insulation surfaces. This encapsulation prevents friable
fiber loss from refractory surfaces in the radiant section,
eliminating downstream fouling of catalyst tubes, convection
section tubes, and Selective Catalytic Reduction (SCR)
screens. It also prevents fiber release into the environment
through the stack. The coating not only extends refractory
life but also improves safety during shutdown maintenance,
as the minimal fiber contamination significantly reduces
hazards when accessing radiant sections.
The combustion products will radiate and absorb energy in
the narrow wave bands shown, whereas a black body will
radiate and absorb energy over a much wider wavelength
range.
High emissivity surfaces can radiate energy across a broad
wavelength band, lessening the interference of the CO
2
and
H
2
O in the flue gas.
When radiation from a flame strikes a perfect radiator, it
not only absorbs all energy but also transforms it into wide
waveband 'black body radiation.' This transformed radiation
can more effectively penetrate the furnace atmosphere of
combustion products, with minimal re-absorption by flue
gases before reaching the stack. As a result, more energy
becomes available for heating the furnace load, improving
overall thermal efficiency.
Surfaces with low emissivity act as poor radiators, reflecting
incoming energy without transforming it. When radiation
strikes these surfaces, it bounces off in its original state,
making it more susceptible to absorption by the furnace
atmosphere. This creates an inefficient cycle where the flue
gas becomes superheated, ultimately leading to wasted
energy escaping through the stack.
The improvement in radiant heat transfer efficiency
naturally leads to a reduction in flue gas temperature. This
has consequences for convective heat transfer in both the
radiant and convection sections of the fired heater.

20. 20
Best Practice 3
Prevent De-rates

21. 21
Eliminate Fouling, Extend Asset Life and Prevent De-rates
and Unplanned Shutdowns
Convection section and SCR fouling can be caused by a combination of devitrified refractory fiber, debris and dust from outside air that
would accumulate on the catalyst and, over time, block gas flow. The fouling sometimes accumulates so quickly that derate events
could be a semi-annual event.

22. 22
Case Study 3
IGS SCR Technologies Deliver 90-Day
Payback and $3M Cost Avoidance
A steam methane reformer suffered from severe SCR
fouling which resulted in a high pressure drop across
the catalyst bank, leading to production derates and
a potential unplanned shutdown. Lost production
for hydrogen supply led to a loss of ~$1M due to an
unplanned shutdown to clean the SCR and restore
production rates. This scenario also limited the SCR’s de-
NOx capabilities and caused poor ammonia distribution,
making it challenging to maintain environmental
emission compliance. Combined with the cost of
lost production, shortened catalyst life and elevated
ammonia usage, the cost of this event was estimated to
exceed $3M.
IGS offers multiple technologies to offset the headwinds
of fouling for both vertical and horizontal flow
configurations:

• Emergency relief from a patented online hot
vacuuming solution to remove the accumulated
debris. IGS crews perform this procedure while the unit
is in operation. This is a safe and effective option to
eliminate high pressure drops and return to full load
without an unplanned shutdown. This procedure does
not prevent future fouling.
SCR Fouling IGS Hot Vac cleaning SCR catalyst
• A proactive approach by installing patent-pending dual-stage
fine particle filtration upstream of the catalyst for continuous
cleaning to minimize dP. The supplemental air cannon system
is designed to sweep the captured material off the catalyst
and into a collection area out of the flue gas path. This
prevents the fibrous material from fouling the catalyst,
ensures proper flow distribution, minimized pressure drop,
and extended catalyst performance life.
Primary screen face and cleaning
system protecting the SCR catalyst

23. 23
Since the installation and startup in spring 2021, the plant has
maintained continuous operation without any SCR-related
production derates or forced shutdowns. The combination of
the fine particle screen system and refractory encapsulation
has eliminated the need for emergency online vacuuming,
though access ports remain available as a contingency for
system upsets.
Recent online inspections confirm the system's effectiveness,
showing minimal material accumulation on the SCR
catalyst face. The enhanced screens and mixing system
have improved RMS distribution by 15%, leading to increased
operational reliability and reduced ammonia slip. Most
notably, the elimination of derate episodes vs. the turnkey
cost of equipment installation enabled the project to achieve
full payback within just 90 days of installation.
• IGS can apply Cetek ceramic refractory coatings,
encapsulating refractory surfaces to prevent vitrification
of fibrous surfaces and prolong refractory life. The
proprietary technology includes surface preparation of
the refractory and multiple phase coatings designed to
stabilize and fully encapsulate the surface at operating
temperatures. The application of this coating will provide
years of protection and significantly reduce the rate of
accumulation on downstream equipment.
• During the design phase, the thermal efficiency team
identified opportunities to enhance ammonia mixing. IGS
incorporated a customized ammonia mixer into the fine
particle screen system. While the screen system helps
normalize flue gas distribution, the downstream mixing
system creates turbulent flow that improves ammonia
dispersion before the gas reaches the catalyst. This
resulted in a dramatic improvement in the Root Mean
Square (RMS) distribution uniformity at the catalyst face,
ensuring more effective NOx reduction.
The client chose to install the complete IGS suite of SCR
technologies including primary/secondary particle screens,
ammonia mixing system, refractory encapsulation with Cetek
ceramic coatings and access ports for hot vacuuming.

24. 24
Best Practice 4
Repair Hot Spots

25. 25
Repair Hot Spots on the Primary Reformer External Shell While
Continuing Safe Operation
Hot spots resulting from damaged refractory can affect the performance, reliability, operating capacity and in extreme cases the safe
operation of the asset. In many cases, the client’s planned turnaround is years away and maintenance managers are faced with the
dilemma of accumulating risks and inferior performance vs attempting temporary repairs during expensive unplanned events.
Online Hot-Tek Refractory Repair (HRR) is one of several unique services developed and performed by IGS to repair and maintain
furnaces and fired heaters between scheduled turnaround events. This approach safely and effectively replaces failed refractory
without cutting production or having unplanned shutdowns.

26. 26
Case Study 4
Hot-tek Solution Eliminates Hot Spot
in Fertilizer Plant Ammonia Reformer
Hot Spot on the Shell - view from the outside
Failed repair attempt: external steel box filled with castable refractory
This fertilizer plant’s products include anhydrous
ammonia, urea blends, ammonia nitrate solution,
phosphate, potash, ammonium polyphosphate, and
sulfur-based products.
The ammonia reformer was exhibiting a hot spot on
the external steel shell where a manway used to exist.
Previous attempts to repair this area with an external
steel box filled with castable refractory had failed
in short order.
Structural beam's proximity to the hot spot area
caused integrity and safety concerns.
Structural Beam Exposed to High Temperatures

27. 27
Seeking a more effective long-term solution, the plant
contacted IGS for its HRR (Hot Refractory Repair) solution.
Following the IGS model, the Hot-tek team conducted a
thorough review of the asset’s condition, drawings, and
operational data to engineer a solution that aligned with
the plant's safety requirements.
This collaborative approach resulted in the successful
completion of the HRR project within three days, with no
disruption to ongoing production. During the process,
additional, less critical hot spots were identified,
prompting the plant to expand the scope to include
repairs on three more areas, preventing potential future
failures.
Cutting access to the shell, installing internal supports,
utilizing pumpable refractory, replacing the shell and
monitoring skin temperatures culminated in safe and
efficient execution.
IGS Hot-tek Repair in Progress Reduces Shell Temperature
IGS Hot-tek Repair in Progress

28. 28
Best Practice 5
Corrosion
Mitigation

29. 29
Corrosion Mitigation in Amine & Benfield Carbonate Vessels
High-temperature and high-pressure conditions, along with corrosive media, affect the integrity of numerous critical assets.
Corrosion is a pervasive issue, often leading to unplanned downtime, costly repairs and reduced equipment lifespan. It
significantly affects reliability, safety and operational costs.
Beyond operational considerations, various mitigation and repair strategies have traditionally been used to address internal
shell metal loss. Mechanical solutions such as temporary clamps, plugs, vessel section replacements, and internal weld overlays
are common approaches. However, these methods often require significant time due to the need for Post Weld Heat Treatment
(PWHT) to address Heat Affected Zones (HAZ) and ensure structural integrity. As a result, they typically necessitate prolonged
turnarounds or shutdowns, leading to considerable production losses.
Amine process vessels are exposed to acidic gases (such as CO
2
and H
2
S) and temperature variations resulting in an accelerated
material degradation. Corrosion in these units can lead to costly downtime, reduced efficiency and safety risks, making effective
mitigation strategies a top priority for the efficiency of the operation.
Amine-induced corrosion (localized corrosion, stress corrosion cracking and general metal loss) can be successfully mitigated by
High Velocity Thermal Spray (HVTS®) claddings. IGS utilizes proprietary equipment and technology to apply a Corrosion Resistant
Alloy (CRA) Metalspray® cladding to stop amine system corrosion almost anywhere in the world. Such claddings are robust,
long-term, durable solutions for amine system corrosion, create no HAZ and require no pre or post application heat treatment.
With high mechanical toughness, abrasion resistance, and wide service temperature and pressure ranges, HVTS® claddings are
resistant to vessel steam out and cleaning processes.

30. 30
Types of Corrosion
in Syngas Plants
Syngas plants are susceptible to various forms of
corrosion due to the harsh operating conditions and
corrosive media present. Understanding these corrosion
mechanisms is crucial for implementing effective
prevention strategies:
1. General Corrosion
This type of corrosion occurs uniformly across the
surface of metal components, leading to overall thinning
of the material. In syngas plants, it's often caused by
the presence of acid gases like CO
2
and H
2
S in amine
solutions.
2. Localized Corrosion
a) Pitting Corrosion
Characterized by small, deep holes in the metal
surface, pitting corrosion is particularly dangerous as
it can lead to rapid failure of equipment. It's commonly
observed in amine vessels where protective films are
locally damaged.
b) Crevice Corrosion
This occurs in narrow gaps or crevices where corrosive
solutions can become trapped and concentrated.
In syngas plants, it's often found in flanged joints or
under deposits.
3. Flow-Enhanced Corrosion
Also known as erosion-corrosion, this type of damage occurs
when high-velocity fluid flow removes protective films or
directly erodes the metal surface. It's particularly problematic
in areas of turbulent flow, such as pipe bends or near
impingement points.
1. General Corrosion 2.(a) Local Corrosion (Pitting)
2.(b) Local Corrosion (Crevice) 3. Flow-Enhanced Corrosion

31. 31
6. Ammonia & Hydrogen Cyanide (HCN) Induced Corrosion
In refinery amine systems, the presence of ammonia and
HCN can lead to severe corrosion, particularly in the amine
regenerator overhead system. These compounds can form
highly corrosive solutions when combined with H
2
S and CO
2
.
Proper material selection, process control, and the
application of protective coatings or claddings can
significantly reduce the risk of corrosion-related failures and
extend the lifespan of critical equipment.
4. Stress Corrosion Cracking (SCC)
4. Stress Corrosion Cracking (SCC)
SCC is a form of environmentally assisted cracking that
occurs under the combined influence of tensile stress and
a corrosive environment. In amine systems, it's a significant
concern, especially in carbon steel equipment.
5. Wet CO
2
Corrosion
This type of corrosion is particularly relevant in hydrogen
plant amine absorbers and regenerators where CO2 is
the primary acid gas. When CO
2
dissolves in water, it forms
carbonic acid, which can rapidly attack carbon steel
surfaces.
5. Wet CO
2
Corrosion 6. Ammonia & Hydrogen Corrosion

32. 32
Case Study 5
IGS HVTS® Applications Helps
Minimize Downtime and Maximize
Asset Integrity
A notable example of these solutions was implemented
for an energy company in the APAC region, which
operates multiple facilities across the country, including
a chemical ammonia plant. The plant was facing pitting
corrosion in the unclad carbon steel section of its amine
regenerator column.
Despite numerous previous trials with organic coatings,
the corrosion persisted, prompting the need for a long-
term solution. Two primary solutions for addressing
amine column corrosion were considered: stainless
steel cladding and complete column replacement. Both
options were deemed expensive and time-consuming,
causing an additional two weeks of downtime, leading
them to search for a more efficient and cost-effective
alternative.
A detailed investigation was completed, assisted
by IGS, together with the client’s technical authority,
which oversees various plants globally. After numerous
technical evaluations and referrals, the company
selected IGS HVTS® as the preferred solution.
Pitting corrosion in the amine regenerator column
4.5 days (9 shifts) to success: The key benefit for the
chemical ammonia plant was the installation of an effective
long-term corrosion barrier system covering 76m² in only
4.5 days, minimizing equipment downtime and increasing
production. No heat treatment was required, and subsequent
inspections have proven successful in preventing further
corrosion. The same technology exercise has now been
replicated at other sister plants.
IGS HVTS® applied inside
a process vessel
Completed IGS HVTS ® application

33. 33
Case Study 6
HVTS® Protection for UOP Benfield™
Process Equipment
Another example of IGS asset integrity solutions is the
application to Benfield Process equipment. The hot
potassium carbonate process is licensed by Honeywell UOP
as the UOP Benfield™ Process. Carbonate wash towers are
essential for carbon dioxide removal in syngas, ethylene
production and other processes. However, caustic can attack
the vessel shell, leading to caustic stress corrosion cracking,
particularly under high applied or residual stress levels.
In a case study with a large company producing fuel and
lubricants, with world leading technology, great pressure has
been applied to the unit due to a combination of production
costs, product quality, and operational flexibility of the plant.
The plant had experienced metal loss in its carbonate wash
columns for many years, primarily driven by caustic corrosion
conditions. The carbonate wash columns had extensive
wall thickness loss in certain areas. The client selected IGS
as its partner of choice, considering effective maintenance
solutions for the columns to ensure safe and effective future
operations.
IGS initially applied Weld Metal Overlay (WMO) in 2007 and
subsequently upgraded it to HVTS® in the Benfield carbonate
wash columns.
The initial request from the client was to weld out the
complete column/s but over the years as time constraints
and costs became a significant issue, HVTS® was considered
and applied to reduce tight schedules and minimise cost
implications.
Caustic stress corrosion cracking and hydrogen-induced
corrosion on a total of four carbonate wash columns was
mitigated in only 7 days. With an experienced crew, this
turnkey solution ensured superior quality project execution.
The four-year inspection on all four columns in 2019, 2020,
2022 and 2023 deemed the cladding in good condition with
no repairs required.
The IGS project on Benfield carbonate wash towers stands as
a testament to the company’s innovative solutions, delivering
both commercial benefits and engineering excellence. This
case study exemplifies how IGS’s proactive approach, and
proven solutions can transform operational challenges
into opportunities for extended asset life and enhanced
productivity.
Pitting corrosion in the amine regenerator column

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Best Practice 6
Metal Dusting
Mitigation

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Autothermal Reforming (ATR) Metal Dusting Mitigation
One of the most significant challenges faced by ATR units is metal dusting, a severe form of corrosion that occurs under specific
high-temperature and carbon rich conditions.
Metal dusting is a degradation process where metallic surfaces disintegrate into fine metal particles, typically in environments
with high carbon activity: where CO and H2 interact with the metal at elevated temperatures (>400C). Autothermal reforming
(ATR) units are not exempt from this threat; the intense heat and reactive gases within these systems can accelerate the metal
dusting process, compromising the structural integrity of the equipment.
The use of alloy systems resistant to metal dusting can reduce the susceptibility of components. This can be achieved by the
application of an IGS HVTS® surface cladding that creates an effective barrier against carbon deposition and diffusion. This
approach involves the on-site application of high-performance alloy claddings, tailored to withstand the specific conditions
encountered in secondary reformers, heat exchangers, waste heat boilers and ATR units. These advanced claddings not only
protect against metal dusting but also enhance the overall performance and longevity of the equipment.

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Case Study 7
13 Years of Success: How IGS HVTS®
Technology Standardized Corrosion
Protection for a Leading GTL Producer
IGS have long term experience and references (since
2006) of extending the operational life of ATR units, with
both onsite brownfield interventions and at the new
construction phase, for various Gas to Liquid (GTL) plants
in the Middle East, Africa and Caspian regions.
IGS-installed HVTS® cladding significantly extends the life
of ATR burners, heat exchangers, waste heat boilers and
feed spargers.
IGS started repairing ATR burners for a prominent GTL
producer in 2011. As soon as the operator confirmed
a significant reduction of metal loss of the protected
equipment, the plant standardized IGS HVTS® application
for all new and repaired ATR burners, waste heat boiler
tube sheets and feed spargers. Between 2011 to 2024,
IGS protected and repaired 26 burners, 4 waste heat
boilers and several feed spargers on site.
Left side- IGS clad, right - not protected after
2 years in service

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Conclusion
The syngas industry is poised for significant growth and
transformation in the coming years, driven by increasing
demand and technological advancements. However,
whilst the future is promising for the industry it also faces
challenges, particularly in the areas of process efficiency and
environmental impact.
• As the industry evolves, focus areas for future
development include:
• Improving overall plant efficiency through
advanced process control and heat recovery systems.
• Developing more effective syngas cleanup technologies
to handle diverse feedstocks.
• Integrating carbon capture and utilization technologies
to further reduce the carbon footprint of syngas
production.
• Exploring new applications for syngas in the production
of sustainable fuels and chemicals. The best practices
outlined in this white paper demonstrate how modern
technological solutions can effectively address the key
operational challenges faced by syngas producers.
Through targeted applications of innovative technologies
like the Tube Tech convection section cleaning ROV,
Cetek coatings, Hot-tek repairs, and HVTS® cladding
systems, facilities can achieve significant improvements
in efficiency, reliability, and environmental
performance.
The case studies presented highlight measurable benefits
including:
• Restored thermal efficiency to
near-design levels
• Reduced emissions and fuel consumption
• Extended equipment life through effective
corrosion management
• Minimized downtime through online repair
capabilities
• Rapid return on investment,
often within months
Syngas plants continue to face increasing pressure for
decarbonization and operational efficiency, and these
field-proven solutions provide producers with practical
approaches to enhance their competitive position while
meeting environmental compliance requirements.
By implementing these best practices, operators can
optimize their assets' performance, reduce maintenance
costs, and ensure sustainable operations for years to
come.

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IGS Experience
in the Syngas
Industry

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With over 250 successful projects completed in the syngas sector, IGS has established itself as a leading solutions provider for
syngas production facilities worldwide. Our extensive experience spans critical equipment including waste heat boilers, process
vessels, amine columns/strippers, burners and nozzles, carbon capture units, fired heaters, heat exchangers, selective catalytic
reduction (SCR) systems, and various vessels, columns, and drums. In these applications, we've consistently delivered innovative
solutions for complex corrosion and thermal efficiency challenges.
IGS's specialized expertise in high-temperature applications and corrosive environments has enabled syngas producers to
significantly extend equipment life, reduce maintenance costs, and improve operational reliability. Through our proprietary HVTS®
technology and thermal efficiency solutions, we've helped clients achieve measurable improvements in plant performance while
meeting stringent environmental and safety standards. Our track record includes successful partnerships with major syngas
producers across diverse operating conditions and plant configurations, demonstrating our ability to adapt and
optimize solutions for each facility's unique requirements.
View Case Studies

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About IGS

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Integrated Global Services, Inc. (IGS) is an international provider of surface protection
solutions headquartered in Virginia, USA. We run operational hubs, subsidiaries, and sales
offices around the world to serve our global clients. We have over 40 years of experience
helping customers solve metal wastage and reliability problems in mission-critical
equipment and are an industry leader in the development and application of solutions to
corrosion and erosion problems in challenging operating environments.
IGS is a specialist in global on-site solutions with extensive shop production capabilities.
Our Technology Research Center helps the world’s leading energy, power, and industrial
companies solve their most critical surface engineering-related problems, improve
coating and welding techniques, and evaluate material performance.
Book a free technology
demo day at your facility
Contact Information
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Unique Solutions
600
Projects/Year
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TRIR (6-Year Avg)
28
Regional Offices
40+
Years Experience
41
Patents
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[email protected]
integratedglobal.com

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