Pictured: Paul Hallam, Operations Director of Spiro-Gills Thermal Products Ltd

A local company specialising in manufacturing bespoke heat exchange systems for the oil and gas sector is pioneering an innovative technology that offers outstanding protection against corrosion at a fraction of the cost of similar industry solutions.

Stafford-based Spiro-Gills Thermal Products Ltd, which produces a diverse range of heat exchangers, process cooling systems, and finned tubing for heavy industries including oil and gas, petrochemicals, and power generation, has partnered with globally-renowned heat exchanger restoration specialists CTI Industries to develop an exciting new air cooler unit for a major UK oil refinery.

The unit, which will operate in the notoriously harsh temperatures associated with oil processing, has been produced from carbon steel, but the tubing inside will be protected by CTI Industries' patented Full Length Tube Liners ™. The liners, consisting in this case of nickel-based C-276 Hastelloy, ensure the tubes maintain compressive strength and are protected against corrosion, pitting, and wall-thinning. It is anticipated the technique will extend the lifespan of the unit for anything up to 30 years, and will also dramatically reduce maintenance work, repair and replacement of tubes, and operational downtime.

"Producing an entire unit like this from C-276 Hastelloy isn't feasible, as the cost would run to millions of pounds," Paul Hallam, Operations Director of Spiro-Gills, revealed. "However, using a more cost-effective material initially - such as carbon steel in this example - and then employing Hastelloy as a protective lining ensures the unit is given a long-lasting protection against corrosion, at literally a fraction of the price.

"Whilst the technology utilised in this project has focused on providing a very specific solution to a client's particular problem, there is undoubtedly huge potential for wider-spread use throughout the entire oil and gas sector, due to the winning combination of cost-effectiveness and long-lasting protection."

Kelvin Cox, Europe and Asia Manager of CTI Industries, commented: "It is great to work with a company such as Spiro-Gills that is keen to embrace innovative technologies to ensure its customers receive the most appropriate and cost-effective solutions. By using our Full Length Tube Liners ™, the lifespan of the new unit will be greatly extended due to the increased protection against pitting, thinning and general corrosion."

Spiro-Gills Thermal Products Ltd has been designing and manufacturing bespoke industrial heat exchangers, process and engine coolers, and finned tubing since 1946. Based in Staffordshire, the company has more than 60 years knowledge and expertise gained from working with clients in sectors as diverse as petrochemicals, power generation, and oil and gas, and is renowned throughout the industry for its outstanding customer service, rapid turnaround, and comprehensive archive of products and spare parts.