Mature equipment presents new challenges.  Many time, the decision to replace is taken as the only choice.  However, it is also possible to retrofit modern sensors and wireless technology to increase oversight.  The sensors can detect issues and allow safe shutdown prior to an extreme failure.  The graph above shows a leak initiating in a reactor iniated a few hours before the reactor had to be shut down.

A known area for heat exchanger failure is at the tube to tube sheet junction as indicated by dye penetrant indications in the picture above.  Revising , upgrading or adding additional requirments to the standard specifications can alleviate future issues.

Tolerances and precision can be improved but the largest benefit  of 3D printing is perhaps  elimination of scrap and weight savings.  Both of these reduce energy costs and the carbon footprint.  Lighter parts made of modern materials can further maximize your profits. and increase your visibility as an environmentally conscious company.