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.
What was failing
A process reactor handles aggressive chemistry, and the lining that protects the shell is the only thing standing between that chemistry and the steel. Over time that lining breaks down, blisters, and disbonds, and once it loses contact the process media reaches the wall and attacks it. The steel starts to pit and thin, the contamination risk to the product rises, and the vessel is no longer safe to run. The owner needed the shell protected again and the reactor back in process service, without cutting the vessel up or sending it out for a long rebuild.
How AAS approaches it
We bring the reactor down and strip the failed lining back to the steel so we can see what the process has done to the wall. We grit-blast the interior to a clean, profiled surface, then rebuild the pitted and thinned areas cold with a Belzona 1000 Series composite so the substrate is sound and shaped to take a lining. Over the rebuilt steel we apply a Belzona 5000 Series chemical-resistant immersion lining keyed to the process media, covering the shell, the rebuilt areas, and the welds as one continuous barrier. We work the vessel so the crew stays on the turnaround clock and hand it back ready to run.
Assess and map
We inspect the interior to find where the old lining has failed and where the steel has been attacked, and confirm the process media so the new lining is keyed correctly.
Strip and grit-blast
We strip the broken-down lining off and grit-blast the shell back to clean, profiled steel so the rebuild and the lining bond to bare metal.
Rebuild the attacked steel
We rebuild the pitted and thinned areas cold with a Belzona 1000 Series composite, restoring the wall with no hot work.
Apply the immersion lining
We apply a Belzona 5000 Series chemical-resistant immersion lining over the shell, the rebuilt areas, and the welds as one continuous barrier.
Inspect and return to service
We check the finished lining and turn the reactor back over to the owner within the turnaround window.
The result
From the job
Repair and protection work of this kind, performed by AAS crews across Louisiana.
Capabilities used here
Where this work happens
Other projects
Storage Tank Floor Reclamation
Corroded aboveground tank floor rebuilt and lined back to immersion service without cutting out plate.
View project
Centrifugal Pump Rebuild & Efficiency Restoration
Cold-rebuilding an eroded pump casing and lining it to restore clearances, no new casting required.
View project
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.
View project
Wastewater Clarifier & Concrete Structure Relining
Spalled, rebar-exposed concrete clarifier rebuilt and relined for continued immersion service.
View project
Heat Exchanger Water Box Protection
Blasting, metal rebuild, and a barrier coating restore a corroded exchanger water box and tube sheet in cooling-water service.
View projectHave equipment that needs to stay in service?
Tell us what is failing. We respond quickly, and we offer 24-hour on-call service.