The evolution of a new gasket type for use in Hydrofluoric (HF) Alkylation Units from the standard HF alkylation spiral-wound type gasket, (Monel windings, PTFE filler, and outer carbon steel ring) to a more specialized and robust gasket type was driven by a need to minimize flange face corrosion, overcome handling limitations and improve sealing performance. Protecting the carbon steel flange face from aggressive HF acid corrosion and resulting iron fluoride scaling, while increasing both the reliability and sealability of an HF connection was achieved, preventing costly flange damage, potential leakage and associated unit shutdowns required for repairs. This paper highlights the journey taken by a major petrochemical company in determining the solution to improving gasket durability and leakage prevention, while significantly reducing flange face corrosion in their HF alkylation units.

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