Dew Point Corrosion in Incinerator Stack Shell

Abstract Asset integrity of pressure boundary components remains a primary concern in the oil and gas industry. However, certain areas in process plants are susceptible to insidious forms of corrosion that may not be immediately apparent but can significantly impact equipment over time, necessitating periodic inspection and maintenance. During a planned outage at one of Kuwait Oil Company facilities, the Tail Gas Incinerator stack was found to be affected by a corrosion mechanism known as Dew Point Corrosion. This phenomenon occurs when the fireside metal surface temperature falls below the dew point of the flue gases, creating a highly acidic environment between the refractory lining and the metal surface. The resulting conditions led to accelerated corrosion, compromising the integrity of the stack. This paper presents the authors’ recent experience and insights into the deleterious effects of dew point corrosion, shared on a broader knowledge-sharing platform. The findings underscore the importance of proactive monitoring and mitigation strategies, as the corrosion observed necessitated extensive repairs to ensure the continued safe operation of the equipment.