How Pyrogel XTE Solves The Corrosion Under Insulation Problem?

Introduction

Industries that are exposed to harsh and extreme conditions such as the LNG facilities are prone to face significant challenges due to corrosion under insulation (CUI). Driers, which are essential components in such setups, are particularly susceptible to CUI as a result of their cyclic temperature operation.
The repercussions of severe corrosion causes financial as well as operational loss. This leads to increased maintenance costs and downtime.
In this blog post, we delve into the intricacies of CUI in driers and unveil effective strategies for corrosion prevention, championed by KLAY EnerSol with our product Pyrogel XTE.

Understanding the Challenge

Driers or large-scale Adsorbent Molecular Sieves (MolSiv) dehydration systems play a pivotal role in LNG facilities. Afterall, they are responsible for the removal of moisture from gas streams.

However, their operation at cyclic temperatures (below ambient to 200 deg C+) creates an ideal breeding ground for corrosion, especially when coupled with mineral wool insulation that absorbs and retains water. This leads to two major problems to the owner:

Corrosion Under Insulation (CUI) This corrosion, hidden beneath layers of insulation, often remains unnoticed until it escalates into a significant issue when discovered during Turnarounds (TA). The traditional approach involves the removal & replacement of existing insulation, blasting and painting during TAs which can be very time consuming and very often unplanned prior to the TA.
High Energy Losses Due to wet insulation, a significant amount of energy is leached in drying the insulation wrapped around the drier making it counterintuitive to insulate the equipment. In tropical climates with frequent rains, these losses are significantly higher and are compensated for by ramping up the heating capacity of the driers. These problems not only incurs high costs but also disrupts operations as the drying cycles are longer than the adsorbent life span. For a project at a leading LNG facility in Southeast Asia, the management, maintenance and civil engineers were eagerly looking for a solution to improve their TA schedule in order to avoid frequent blasting, painting and insulation replacement. They were also concerned about their asset integrity as every blasting activity would reduce wall thickness. Long term impact would be that the vessel is not fit for use and would require a replacement.

KLAY EnerSol's Innovative Solution

Recognizing the urgent need for a proactive solution, KLAY EnerSol proposed a robust approach to combat CUI in driers, which was to replace conventional mineral wool insulation with Pyrogel XTE insulation. Pyrogel XTE stands out for its:

Superior thermal performance
Moisture resistance
Breathability
Corrosion mitigation properties

Pyrogel XTE mitigates corrosive environments as they improve heat conservation and reduce moisture ingress. With its use, prolonging asset lifespan while reducing maintenance costs becomes possible.

Real-world Success Stories

In 2021, a customer grappling with severe CUI issues in their LNG facility embraced KLAY EnerSol’s proposal and implemented Pyrogel XTE insulation on four driers at one module during the TA.
The results were promising, with significant reductions in corrosion as well as eliminating the need to blast, paint and re-insulate the drier in the subsequent TA. It also made inspection easy, reduced energy losses and improved asset integrity.
Encouraged by these outcomes, the management has integrated the replacement of CUI-prone equipment and piping with Pyrogel XTE into their long-term maintenance plan.

Conclusion

Corrosion under insulation presents a formidable challenge for industries, often resulting in substantial financial and operational burdens. However, with innovative and advanced solutions like Pyrogel XTE insulation from KLAY EnerSol, the tide is turning in favor of corrosion prevention especially for Cyclic Thermal Regeneration adsorbent systems in the range of – 20 deg C to 350 deg C.
By addressing the root causes of CUI and implementing proactive measures, industries can safeguard their assets, minimize downtime, and optimize operational efficiency. As we continue to unravel the mysteries of CUI, KLAY EnerSol remains committed to pioneering solutions that redefine industry standards and empower businesses to thrive in challenging environments.