Scrubber Units

• Acid attack on internal walls and outlet ducts in wet FGD service.
• Erosion-corrosion at spray nozzles, distribution headers, and packing supports.
• Coating breakdown on linings rated below the actual acid and temperature service.
• Floor-and-sump pitting at the slurry collection point.
• Internal-pipework wall loss in scrubber recycle and bleed lines.
• External shell corrosion from condensate dripping at the cold-end.

Match the lining to the actual chemistry, not the design intent

Scrubber linings often fail because the as-built service drifts from the design service: acid concentration creeps up, fly-ash carryover increases, the operating temperature climbs as throughput increases. Specifying a lining against the actual operating envelope, not the original design, is the most important call on a scrubber rebuild.

Belzona product families used on scrubber units

Chemical-resistant primary lining

Belzona 4311 (Magma CR1) and Belzona 4341 (Magma CR4) are high-temperature, chemically resistant lining systems rated for acid and alkali service well above the temperature ceiling of standard epoxy. They are the typical primary lining on wet FGD vessels, scrubber sumps, and acid-side ductwork.

Erosion-corrosion at distribution internals

Spray headers, distributor plates, and packing-support grids that see two-phase erosion-corrosion are rebuilt with Belzona 1311 (Ceramic R-Metal) or 1591 / equivalent immersion-grade composites and topcoated with the relevant 4000-series chemical lining.

Floor-and-sump rebuild

Scrubber sumps and floor collection zones see the highest combined acid and solids loading. The rebuild scope typically combines metal-loss buildup with Belzona 1111 / 1311, then the chemical-resistant topcoat with 4311 or 4341 at specified dry film thickness.

Outage compatibility

Most scrubber rebuilds run inside a planned unit outage of three to seven days. Belzona systems are cold-cure and 100% solids, which keeps the application crew off hot work permits and out of confined-space heat-load issues. The repair file goes back to the integrity record so the next outage sees the same data.

Selecting product against the corrosion file

Belzona Baton Rouge verifies the actual acid concentration, peak operating temperature, and slurry solids loading from the plant's sample log before specifying. The 4000-series is sized against that file rather than against the original design basis.