At the end of September 2025, AGRU received an urgent request from Brazil: a Customer reported severe corrosion damage in a newly constructed sulfuric acid production plant—one of the largest WSA plants worldwide, commissioned only a few weeks earlier.
The cause was a combination of unfavorable process conditions and design weaknesses. Highly concentrated sulfuric acid (> 98%, approx. 200 °C) condensed in unintended areas, leading to severe corrosion within a very short time.
Following several video conferences and technical alignments—supported by experience from comparable OMV projects—the decision was made in mid-November:
The affected ducts must be lined with PFA films to ensure safe plant operation.
It quickly became clear that this challenge could only be handled by a highly experienced PFA processor. Therefore, the long-standing partner INWA AG, a specialist in highly critical PFA plant components, was involved from the outset.
A shutdown window of only two months was available for the refurbishment. Within this period, approximately 650 m² of steel duct surfaces had to be rehabilitated and lined using PFA fixed-point lining.
With this method, the PFA film is mechanically fixed to the steel surface via screw connections. Each fastening point is then sealed with a PFA cap produced by AGRU—more than 6,000 caps and around 165 kg of PFA welding rod in total.
Even in Europe, this project would have been challenging—in Brazil, it became even more demanding due to the lack of trained PFA welders and required equipment on site.
The solution was a rapidly established collaboration between INWA, the local partner Glastec, and AGRU.
All PFA components as well as the required welding equipment were transported to Brazil by air freight. INWA deployed 25–30 welders from Austria and Switzerland.
Installation work took place from December 10 to January 22. Despite intensive coordination and several critical discussions, the work was completed almost at the last minute and the plant was brought back into operation.
In retrospect, this was an extremely intense project that could only be realized thanks to the close cooperation of all parties involved.
The most critical areas of the plant have now been rehabilitated—further measures will follow. Petrobras is already planning an additional sulfuric acid plant, involving the preferred plant builder KVT from Austria. This opens up further opportunities for PFA film and PPS EL projects.
In the final stage of the project, it became apparent that too few PFA caps had been ordered. The distribution partner KVG quickly organized a courier who personally transported the missing caps to Brazil in hand luggage.
This ensured that the final welds could be completed on time.
