Mission critical equipment, including process vessels, towers and columns play a major part in maintaining the success, profitability, and levels of production for the syngas industry. Corrosion, however, poses a persistent threat—leading to metal wastage and wall thickness loss. Once corrosion reduces thickness beyond the minimum allowance, options become limited to extensive repairs or equipment replacement, often resulting in costly unplanned shutdowns. Corrosion-resistant alloy (CRA) barriers are a proven solution, with the application method dictated by available shutdown time. Weld metal overlay has long been trusted but is slow, labor-intensive, and often requires high preheat and post-weld heat treatment (PWHT). In contrast, High Velocity Thermal Spray (HVTS) alloy cladding offers significantly faster application (~50 ft²/gun/shift), no heat-affected zone, and no need for PWHT. Decades of laboratory testing, successful field applications, and post-project inspections confirm that HVTS performs on par with weld overlays—offering a durable, cost-effective alternative. With a thoroughly validated quality control system, HVTS alloy cladding from IGS has become a reliable, field-proven solution for extending asset life and mitigating corrosion in critical equipment. This paper explores the advantages of HVTS and its growing adoption as a modern, efficient strategy for corrosion protection in the syngas industry.
