Case Study – Corrosive Gases

At Fluenta, we pride ourselves on our flexible approach to problem-solving, delivering innovative solutions that exceed client expectations, no matter how challenging the problem. When a client approached us with a significant issue—corrosive gases severely affecting the lifespan of their transducers—we didn’t just provide a standard solution. We went the extra mile to create something custom-built for their unique needs.

Challenge: Corrosive Gases Reducing Transducer Lifespan

In some installations, gases being vented through the flare system can be highly corrosive, posing a serious threat to transducer longevity. Standard transducers, even those made from typically durable materials like Titanium or Stainless Steel, are not always enough to withstand this constant exposure. For our client, this corrosion problem was causing frequent transducer failure, resulting in downtime, increased costs, and data loss—potentially leading to regulatory penalties due to gaps in emissions monitoring.

These challenges were particularly acute for this client, whose plant is located near a small town. Given the proximity to a populated area, regulatory scrutiny is higher, and accurate flare gas measurement is not just a matter of efficiency but also public safety and compliance.

Solution: A Custom-Built Transducer for Corrosive Gases

When this client came to us, they needed a solution that was both robust and customized. We understood that simply offering off-the-shelf transducers wouldn’t be sufficient. Our teams in Design & Development (D&D) and Production worked closely together to develop a special transducer that could withstand the highly corrosive gases. We began by evaluating different material options, moving beyond traditional choices like stainless steel and titanium, which were inadequate for the specific mix of gases involved.

Through several iterations and rigorous testing, our team decided on Hastelloy alloy as the optimal material. Hastelloy is known for its superior corrosion resistance, even in the most chemically aggressive environments. By utilizing this material, we ensured that the custom-built transducer could not only endure the harsh conditions but also maintain measurement accuracy over the long term.

The development process was meticulous, with multiple prototypes tested to ensure the transducer’s durability and performance. Our R&D efforts, coupled with comprehensive preventative maintenance plans, ensured that the system would continue to provide consistent, reliable readings, even under extreme conditions.

Results: Performance and Reliability in a Critical Setting

The custom-built Hastelloy transducers have proven highly effective. They have stood up well against the corrosive gases that were previously damaging standard equipment, ensuring no interruptions in flare gas measurement. As a result, the client has been able to maintain continuous data collection, avoiding the costly downtime that had been a frequent problem in the past.

More importantly, the accurate and reliable readings provided by these transducers have helped the plant meet strict environmental regulations, ensuring that their operations remain compliant and safe. This has been especially significant given the plant’s location near a small town, where the consequences of regulatory penalties would be particularly severe.

The successful implementation of these custom transducers has given our client the confidence to continue operating their plant in an environmentally responsible manner. They now have peace of mind knowing that their flare gas monitoring system is robust enough to handle the most challenging conditions, while ensuring the safety of the surrounding community.

Going the Extra Mile for Our Customers

At Fluenta, we believe that going the extra mile is part of our DNA. We are committed to finding solutions that fit the unique challenges faced by each client. When standard materials or configurations won’t work, we innovate. We involve all relevant departments, from R&D to production, to ensure that the solution we deliver is tailored and effective.

Our custom-built Hastelloy transducers are just one example of how we can adapt and innovate to solve problems, no matter how complex. By offering this level of service, we don’t just meet the expectations of our clients—we exceed them. With our flexible approach and dedication to creating cutting-edge solutions, we ensure that our customers remain compliant, efficient, and confident in their flare gas measurement systems.

This case highlights our philosophy of being customer-centric, developing solutions that specifically address the most pressing issues, and helping clients protect their operations while saving on costs, downtime, and regulatory penalties.