Enhanced Safety and Availability with CSX™ Piping

One of the world’s largest fertilizer producers contracted Clark Solutions to solve a critical issue at one of its major plants: the sulfuric acid piping, made of cast iron, was causing frequent leaks and maintenance shutdowns, along with acid contamination from iron corrosion.

Clark provided the ideal solution: replacing the old cast iron (FoFo) lines with CSX™ — a specially engineered alloy designed to withstand sulfuric acid corrosion.

To fully meet the client’s needs, Clark also redesigned the acid distribution system in the Drying Tower, replacing connection lines between towers, tanks, and heat exchangers.

The project required meticulous planning. A comprehensive field survey was conducted, mapping all acid lines and prioritizing those most critical. The material change altered pipe stress and flexibility, and with the reduction in diameters, 3D modeling and flexibility calculations were performed for each line.

A full logistics study was also conducted to minimize field welding and the number of flanges. A total of 7 tons of CSX™ piping, ranging from 1” to 24”, were fabricated, assembled, and installed over three years of contract.

The results brought major benefits. Spare parts inventory dropped significantly — a common issue with cast iron systems. Leak risks were minimized, and maintenance became simpler and faster thanks to fewer flanges and lighter components.

Clark exceeded client expectations with a solution that enhanced reliability, safety, and performance.

Clark Solutions invests around 10% of its revenue in innovation, keeping us competitive in demanding markets. With over 30 years of experience, we deliver customized, high-performance solutions grounded in cutting-edge materials and engineering expertise.