Valve Durability
Figure 6 : Phenomenological model describing the corrosion fouling mechanism in relation to the residue upgrading processes .
Disruptive technology : a breakthrough in coating performance
By better understanding the fundamental mechanisms leading to fouling including the synergy between sulphidation and coke adhesion , we have designed coating structures that virtually eliminates sulphidation , hence preventing fouling . One prime example is a proprietary coating tested under resid upgrading conditions that does not react with sulphur . As confirmed by EDS mapping , sulphur was absent on the coated sample . Concurrently , no coke adhesion was detected ( see Figure 7 ). By blocking one failure mechanism , the other was effectively controlled .
Towards a new standard in coating performance
This research underscores the critical role of advanced coatings in mitigating fouling and extending component life in resid upgrading environments . While specific coating compositions remain proprietary , the methodologies and testing approaches developed in this study represent a significant step forward in enhancing valve and component performance . By combining innovative coating formulations with rigorous experimental validation , the industry can move toward more reliable and efficient heavy oil processing solutions . The continued development of highperformance coatings tailored for fouling and coking environments will play a pivotal role in improving refinery operations and reducing maintenance costs , ensuring that critical infrastructure remains resilient in the face of evolving industry challenges . All tests conducted so far have been in a laboratory environment . Velan is currently in discussions with licensors and end-users to scale-up the coating technology and conduct field tests .
About the Authors Fadila Khelfaoui is a Corporate Engineer at Velan with 27 years of experience in metallurgy and materials engineering , specialising in coatings and surface engineering . She has led high-profile projects that bridge R & D and engineering , driving innovative material solutions from concept to field application in demanding industrial environments . Fadila is a licensed Metallurgical Engineer in Quebec and holds a PhD in Material Science & Engineering .
Figure 7 : Velan proprietary coating after fouling test : optical images , SEM , and EDS analysis .
Luc Vernhes joined Velan in 2003 and has held multiple positions over the years . He is now Director , Business Development . He holds a PhD in Engineering Physics and is a Mechanical Engineer .
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