Some failure experiences with metallic components at the Synthane coal-gasification pilot plant are presented. In some cases, corrosion caused by a sulfur environment was a major factor in the failure initiation. Several instances of improper component manufacture or heat treatment led to failures. Chloride-assisted stress-corrosion cracking and an improper materials choice contributed to two cases of failure. In most cases, the recommended changes in materials, design or process conditions have resulted in an increase in component life.

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