Refinery Applications: Inert Coatings Improve Reliability & Reduce Cost

  • Accurate H2S, sulfur, mercury, & ammonia sampling
  • Fast response assures compliance
  • Monitor process, stack and flare emissions
Subpart Ja
New refinery emissions
Tier 3
Mercury (MATS)
  • Consistent ppm and ppb measurement

SilcoTek® coatings improve efficiency and lower cost.

  • Eliminate surface adsorption and reactivity.
  • Low level detection protects catalyst from sulfur damage
  • Know what you're getting: accurate monitoring of feedstock and product
  • Fast response means better process control, fewer process upsets and regulatory compliance

Fast Response Means You're in Control

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SilcoNert 2000 treated electropolished tubing does not adsorb sulfurs like H2S, delivering a representative sample with no delay; assuring the highest level of process control. Untreated conventional and electropolished 316 stainless steel tubing adsorbs sulfur compounds for more than 75 minutes, the sulfur gas level did not stabilize until 130 minutes or longer.  The refinery is out of control with the potential for catalyst damage, substandard product, or regulatory compliance issues.

Flare and Stack Sampling

Stack and flare sampling is challenging enough without having to contend with seemingly random loss of sulfur, H2S, ammonia, or other air toxics.  Even one uncoated flow path component can adsorb reactive compounds; causing loss of sample, calibration failures, and endless system troubleshooting.

  • Detect costly process upsets
    in a fraction of the time
  • Prevent catalyst contamination
    by eliminating reactor wall effects
  • Assure regulatory compliance
    • Rule 1118, subpart Ja
    • Ultra-low sulfur diesel and gasoline

Accurate analysis of part-per-million and part-per-billion levels of sulfur containing compounds in stack and flare emissions are critical to meeting new regulations for low level sulfur. Many organo-sulfur compounds, like hydrogen sulfide (H2S) adsorb to metal surfaces.


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SilcoNert and Dursan virtually eliminate adsorption, improving system reliability, reducing calibration failures and troubleshooting. 

Sampling Steel Pipes: Flares and Stacks

How the sample is taken makes a big difference in overall test accuracy.  Samples taken in the laminar section (the middle) of the flow profile through a SilcoNert® coated sample pathway will give a real time representative sample of the stream.


Studies and presentations by Welker Engineering throughout the years demonstrate a good sample point is required

  • Away from the wall
  • Away from turbulent flow
  • From center of stream if possible
  • Away from any flow disruptions
  • Wall sample points are poor because of “zero velocity”

SilcoTek coated components are widely available from manufacturers like Swagelok, O'Brien Analytical, Concoa, Scott, and many others.

Purchase Coated Products Direct From the Manufacturer

SilcoNert® 2000 and Dursan® will conform to the most intricate surfaces while maintaining high dimensional tolerances. SilcoTek coatings will deform with tubing surfaces allowing for radius bends and will not interfere with threaded or compression joints; making our coatings ideal for process, refinery gas, stack, and flare sampling .

Coat the entire sample pathway:

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  • Tubing
  • Fittings
  • Regulators
  • Filters
  • Valves
  • Probes
  • Sample Cylinders

Value of an Inert Pathway

SilcoNert® 2000 treated sampling and transfer equipment results in more accurate sampling and faster cycle times. Shorter sampling cycles translate directly into more samples collected and analyzed in a given period of time. Process upsets can be detected faster while false readings can be eliminated. Typical savings can be calculated by looking at average per-hour cost of operating a process that relies on accurate quantification of sulfur compounds. A 1 hour delay in operations can cost an 800,000 tpy ethylene plant $50,000. A 250,000 tpy LDPE unit will cost operations $36,000 for a 1 hour upset while an EBSM styrene plant will cost $33,000 (See Figure 4).

SilcoNert® 2000 and Dursan treated sampling and transfer systems allow oil and gas, petrochemical, and refineries to obtain accurate sulfur, H2S, mercury and ammonia data the first time, every time with no delay, sample errors, or false readings. Analysts charged with monitoring mercury and sulfur levels in stack, flare and process streams can save thousands in improved yields, better test cycle times and improved system reliability. To learn more or to get a quotation for sending your parts to SilcoTek®  for coating services, visit our web site at or call us at 814-353-1778.

1. D. Smith, D. Shelow, G. Barone; “Instrument and Sampling Equipment Passivation Requirements to Meet Current Demands for Low-Level Sulfur Analysis”; Presented at Gulf Coast Conference, 2001; Restek Corporation, Bellefonte, PA 16823.

2. Application of TrueTube(tm) in Analytical Measurement Cardinal UHP, August 2004. The authors thank the staff at Shell Research and Technology Centre, Amsterdam, for data used in evaluating sulfur gas uptake and memory effects of tubing substrates.

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