ALLOY ACID
PIPING
Galiakotwala Engineering has supplied Alloy Piping Systems to more than 63+ Acid Plants, many of which are operating satisfactorily even after 15 years.
Over the past decade, acid piping has evolved to utilize metallic alloys as the preferred material. This shift is attributed to the inherent advantages of using alloy acid piping over traditional materials.
Comparison Between Conventional and Alloy Piping
Conventional Piping
High corrosion rate (upto 2.5 mm/yr)*.
Large number of flanges, therefore higher risk of acid leaks.
Iron sulphate sludge can cause plugging of Mist Eliminators and tower packing.
Constant requirement of maintenance and inventory of spares in case of acid leaks. No possibility of welding.
Difficult to handle due to heavy weight and bulky size.
Low ductility and higher risk of brittle failure leads to reduction in safety levels.
Designed and operated at lower velocities due to risk of erosion and corrosion.
Alloy Piping
Low corrosion rate (0.025 mm/yr – 0.05 mm/yr)*.
Welded construction reduces the number of flanges, minimizing the risk of acid leaks.
No iron sulphate formation due to negligible corrosion, resulting in reduced plugging/ maintenance of tower internals.
Practically zero maintenance and no requirement for any spares. Full possibility to weld and repair on-site using conventional welding techniques.
Easy to erect. It is flexible due to lightweight and compact size.
Higher ductility and minimized risk of brittle failure, resulting in higher safety level.
Designed and operated at higher velocities without risk of erosion and corrosion.
*Depends on materials used
The life cycle cost of Galiakotwala Alloy Piping is lower due to significantly reduced maintenance requirements. Once installed, Alloy Acid Piping typically lasts the full life of the plant with minimal maintenance. Alloy Acid Piping has proven its reliability with numerous installations worldwide, with over 40,000 meters installed globally.
Alloy Nozzles, Sleeves and Dip Pipes
High-corrosion and leakage-prone areas in acid plants can be upgraded with alloy components, reducing or eliminating frequent maintenance.
Galiakotwala Engineering manufactures nozzles, sleeves, dip pipes, and other parts in alloy materials, designed to prevent damage to original equipment, which is often complex to replace.
Alloy Strainers
We supply both inline strainers and strainers for side and bottom outlet nozzles, available in mesh or perforated plate designs.
Alloy Strainers offer longer life, resist plugging, and are easy to clean. Vortex breakers can be integrated with strainers and nozzles and delivered as a single unit.
*Illustrations are for representation purposes only.
Typical Sulphuric Acid Plant Process Flow
What Our Customers Say
“I am pleased to report that since installing the GEC BMW Type Candle Filter in our Interpass Absorption Tower (IPAT) at our Sulphuric Acid Plant in 2019, it has performed exceptionally well. We have not observed any acid condensate at the outlet of the IPAT, indicating the filter is effectively removing any impurities.”
Manager SAP Plant
Birla Copper
“We were facing mist carryover problems in the Drying Tower for a long time. We discussed the problem with the Galiakotwala Technical Services (GTS) Technical team.They studied the issue and gave the solution of an advanced Demister Pad of SX Wire Mesh for Drying Tower and solved this prolonged problem permanently.”
General Manager (Auxiliary),
Century Rayon
“Galiakotwala Engineering Company has provided us with the best solution in form of Alloy Piping to get rid of continued issues of leakage in conventional Sulphuric Acid Piping. After installation of the Alloy Piping, we observed zero leakage and significant cost savings due to reduced downtime. Since then we have changed most of our Acid Piping in both Sulphuric Acid Plants at Haldia with their low corrosion alloy.”
General Manager (Engineering),
Tata Chemicals Limited, Haldia
“We wanted to replace our old Brick-Lined Acid Towers with a newer technology due to difficulty in location and repair of leaks in these Acid Towers. GEC gave a solution of an complete Alloy Tower 7500 mm in diameter including all internals such as Distributor, Mist Eliminators, Packing and Support, etc. We are happy to note we have observed no corrosion in last 7 years and achieved 99.99% absorption efficiency.”
JSC Apatit,
Russia
“We were continuously facing excess mist generation and moisture carryover problems in FAT and DT with the conventional distributors. Galiakotwala Engineering Company (GEC) replaced conventional distributors with Alloy Distributors in 2004. Since then, there is no change in the thickness and deformation of hole sizes of the branch pipes of the distributor. We appreciate the quality of work and and the materials used by GEC even after 18 years of operation.”
Deputy General Manager (Mechanical),
Paradeep Phosphates Limited
“We are using your Vane Separators for the last 15 years and have never faced any issues in the performance or life of the equipment. We are thankful to the Galiakotwala team for designing the special type Vane Separators according to our requirement that continues to ensure our process operates.”
Sr. Manager (Mechanical),
TATA Steel
“In 1987, Galiakotwala Engineering Company (GEC) provided our first Shell and Tube Type Heat Etxchanger with the assurance of an advanced, efficient design and manufactured with a low-corrosion alloy that would extend its lifespan. Even after 30+ years of trouble-free operation, the Heat Exchangers are still functioning effectively. We are pleased to report that GEC adhered to their commitments.”
Vice President Technology
Dharamsi Morarji, Roha
