Ceresist was established in 1996 (New Jersey, USA) as a ceramic-lined pipe manufacturer. Since then, our product portfolio has grown to include a wide array of abrasion resistant process products, with many more in development. We have over fifteen years experience in the design and manufacture of ceramic piping, fittings, valves, orifice plates, and ancillary products.
Our products are designed with long-term service in mind. By utilizing only the finest materials to manufacture our products, we assure our customers the longest trouble-free and maintenance-free service life in the industry. For many years, sand erosion is one of the most significant major problems faced in oil & gas industries throughout the world. Many operators will find the easy way to overcome this problem will be scheduled replacement of the piping.
Knoop Hardness of 2800 kg/mm2, High density, low porosity and chemically inert Hot gases and liquids, oxidizing and corrosive atmospheres, Extremely high temperatures Erosive, corrosive and abrasive environments
Each ceramic material possesses its own benefits and weaknesses, and therefore the service in which a ceramic component is to be installed in must be reviewed thoroughly. Some of the factors that will affect ceramic performance (or may even cause disastrous failure) are:
Out of all the ceramic materials, Ceresist utilizes alumina and Hexoloy silicon carbide the most. We have found that high-alumina has superior resistance to corrosion and abrasion, and is a very cost-effective material when large or complex shapes are specified.
Sintered silicon carbide is our choice for the toughest applications when an extremely high level of erosion resistance is required, and/or the ceramic material is to be installed in a severely corrosive environment. In order to handle high mechanical impact we have Zirconia & Zirconia toughened alumina ceramics which can handle the mechanical impact caused by material or external sources which are usually concerns expressed by mechanical or maintenance engineers.
The growing demand for hydrocarbon resources has resulted in accelerated increase of oil production. Oil sands conveying requires erosion & corrosion resistant piping. This can be achieved by providing an extremely wear resistant material which can operate even at elevated temperatures. The presence of carbon dioxide (CO2), hydrogen sulfide (H2S) and free water can cause severe corrosion problems in oil and gas pipelines. Internal corrosion in wells and pipelines is influenced by temperature, CO2 and H2S content, water chemistry, flow velocity, oil or water wetting and composition and surface condition of the steel. A small change in one of these parameters can change the corrosion rate drastically due to changes in the properties of the thin layer of corrosion products that accumulates on the steel surface.
Ceramic liners provide the cost effective solution to achieve the production rate desired without loss in downtime or sudden maintenance. Our products are lined with silicon carbide liners which has the highest wear resistant compared to any other metal. SiC is also universally corrosion resistant even at elevated temperatures. Corrosion-resistant alloys such as 13% Cr steel and duplex stainless steel are often used downhole and, recently, also for short flowlines. For long-distance, large-diameter pipelines, carbon steel is the only economically feasible alternative and corrosion has to be controlled by chemical additives to the transported fluids. Using ceramics inside the pipe as the wetted components will provide considerably high cost savings over an extended period of time.
Ceramics have now taken the lead role in the oil & gas industry in solving erosion & corrosion problems. Ceramics like sintered silicon carbide offer the highest wear resistance as compared to any other liner or alloy in the materials family. Ceresist designs piping as per ASME codes and ensures that the wetted parts are always ceramic to ensure continuous operation and minimal downtime. Our piping is designed to last 36x times longer than carbon steel piping. Sand erosion is a major concern in the industry especially when conveyed at high velocities will wear out steel or alloy piping. Sand particles from oil and gas production may cause considerable erosion damage in critical parts of transport and processing equipment such as valves and chokes. Increased longevity of such components will lead to significant savings as offshore oil and gas production move subsea, and it can be achieved in two ways; through selection of erosion-resistant materials or through design optimization.
A total of 28 different materials including standard steel grades, solid tungsten carbide materials, coatings and ceramics have been tested under various impact angles and velocities of sand particles, and examined for erosion characteristics. Alpha sintered Silicon carbide & Reaction Bonded Silicon Carbide have shown the least wear resistance. This proves that with proper design these are the long term solutions for the oil & gas industry.