GEMACO - Jean-Marc Sluyters.pdf

NITROGEN + SYNGAS 2015 (23RD - 26TH FEBRUARY 2015, HILTON ISTANBUL BOMONTI ISTANBUL, TURKEY)


Corrosion resistant stainless steels in Urea & Nitric Acid Plants Receiving the right amount and right quality materials in time as

promised

Jean-Marc Sluyters

GEMACO S.A.

(Herstal, Belgium)


Agenda

Introduction: Urea & Nitric Acid Plants

MOC: Special stainless steels for Urea Plants

Specific quality requirements: 316 LUG as example

Cases of typical failure modes of 316 L

MOC: Special stainless steels for Nitric Acid Plants

Cases of typical failure modes of stainless steels

GEMACOs capabilities & solutions

Urgent needs Projects & packages Tailor made products Technical & Logistic support Contractor services

Conclusions


UREA

Cocktail corrosion + T + pressure

Special grades:

316L UG WNR. 1.4435/1.4406/1.4429

25.22.2 UNS S31050 310Mo LN WNR. 1.4466

Specifications from licensors

Materials Of Construction in Urea plants


SPECIFIC QUALITY REQUIREMENTS

Example: 316 LUG

316 L UG

Probably the oldest type of urea grade

Widely used in HP Synthesis up to 190C

Specified by most of the licensors

Signifiant differences with standard 316 L which could lead

to safety risks, unplanned shut down & consequently high costs

Table 1 Chemical composition

Huey test


Element AISI 316L SAIPEM 316L UG Stamicarbon 316L UG

C 0,03 max 0,020 max 0,030 max

P 0,045 max 0,015 max 0,045 max

S 0,03 max 0,010 max 0,030 max

Ni 10-14 13 min 13,0-15,0

N 0,10 max 0,22 max

Cr 16-18 1.4429 = 16,50-18,50

1.4435 = 17,00-18,50 17,0-18,5

Mo 2-3 2,50 -3,00 2,20-3,0

Si 1,00 max 1,00 max 1,00 max

Mn 2,00 max 2,00 max 2,00 max

SAIPEM: according to Spec. CR UR 510 3)

STAMICARBON: according to Spec. 18005 BC 014)

Chemical composition 316L types (wt%)


Huey test requirements

HUEY TEST

MM/YEAR

SELECTIVE ATTACK

SURFACE m SELECTIVE ATTACK

CROSS CUT END m

SAIPEM LESS 0,36 100 MAX 100 MAX

STAMICARBON LESS 0,6 70 MAX 200 MAX

SAIPEM: according to Spec. CR UR 529 STAMICARBON: according to Spec. 18005 BC 01


Some Typical Failures of 316L UG

Passive/Active corrosion

Crevice corrosion

Strain Induced Intergranular Cracking (SIIC)

Stress Corrosion Cracking (SCC)

Challenge: grain size


SIIC in 316L UG elbow of HP Scrubber gas pipeline between top dome and bottom


SIIC in 316L UG elbow of HP Scrubber gas pipeline between top dome and bottom

Intergranular

stress/strain induced

cracking; grain size 2/3

acc. to ASTM E112


Special stainless steels for Nitric applications

NITRIC

Concentration and temperature Special stainless steel :

304L WNR.1.4307, 1.4306 or better 1.4306 S 304 LN WNR.1.4361 - UNS S30600 - Uranus S1 * WNR.1.4335 - 310L - UNS S31002 Uranus 65 * WNR.1.4362 UNS S 32304 Uranus 35 N *

*Industeels trademarks

100

3

Corrosion rate

(mm/yr)

80 60 40 20 0 0.0

0.2

0.4

0.6

0.8

1.0

316L

UR S1

HNO (%)

304L

UR 65

CORROSION RATE vs HNO3 CONCENTRATION At boiling temperature

< 5 0 % 5 0 - 7 0 % >7 0 %

PURE NITRIC UR 16 / 3 0 4 L NAG / WNR. 1. 4 3 0 6 S

ACID 3 0 4 L / WNR. 1. 4 3 0 6 UR S 1 / WNR. 1. 4 3 6 1

T = 60C UR 6 5 / WNR. 1. 4 3 3 5

PURE NITRIC

ACID UR 16 / 3 0 4 L NAG / WNR. 1. 4 3 0 6 S UR 6 5 / WNR. 1. 4 3 3 5 UR S 1 / WNR. 1. 4 3 6 1

BOILING

NITRIC ACID

+ UR S 1 / WNR. 1. 4 3 6 1 UR 6 5 / WNR. 1. 4 3 3 5 UR S 1 / WNR. 1. 4 3 6 1

OXIDIZING

IMPURITIES

NITRIC ACID

+ UR 6 5 / WNR. 1. 4 3 3 5 UR 6 5 / WNR. 1. 4 3 3 5

FLUORIDES

NITRIC ACID UR B6 6 UR 6 5

+ UR 2 5 . 2 2 . 2 / WNR. 1. 4 4 6 6 UR 2 5 . 2 2 . 2 / WNR. 1. 4 4 6 6

CHLORIDES

( up t o 3 0 % Boi l i ng)

( de pe ndi ng on Re dox )

GUIDE TABLE FOR THE SELECTION OF STAINLESS STEELS FOR NITRIC ACID SERVICE


Typical Failure modes of stainless steels in

concentrated nitric acid

Evaporation of droplets

Severe corrosion due to poor insulation

Changes of process conditions

Condensation of Nox phases

Variations of grain sizes

Another challenge: grain size > 5


Condensation corrosion in 304L nozzle pipe for thermo-well gas outlet line NH3 Converter

Corrosion in 304L tube of lower tail gas heater E6602 above tubesheet area due to evaporation of droplets HNO3

Condensation corrosion at 304L tube out of upper tail gas heater


Intergranular attack of X1CrNi25-21 shell of cooler condenser nitric acid plant (6 years on-stream)


Corrosion morphology in X1CrNi25-21 shell of cooler condenser in nitric acid plant (6 years on-stream)


Microstructure of X1CrNi25-21 shell of cooler condenser SZF4 (6 years on-stream)

Inhomogeneous microstructure: grain size 2 - 8


5 Mio ( 6 Mio $) stock material:

Raw material

Bars

Pipes: thin or heavy wall

Tubes: heat exchangers, strippers or condensers

Fittings

Plates & sheets

GEMACOS Solutions Urgent needs


GEMACOS Solutions Projects & packages

Complete range of products

Mill advantages with stock flexibility

Single source of supply for:

Projects (new, revamping, debottlenecking)

Shutdown and maintenance

Repairs


Tailor made products

Bendings

Isometrics

Special fittings

Service Center: Cutting, Sawing


GEMACOS Solutions Technical support

European mills & approved suppliers

Right choice, right procedures

Quality requirements

End-users

Licensors

Engineers

Producers

Sub-contractors


One single place

One point of responsibility

Internal testing & controls

Contractor services


Follow up and networking with all (sub)suppliers

Documents as per your instructions

GEMACOS Solutions Logistic support


" Sch Dia Th Random LengthRun

Pipe

001 0001 E90L-SR12BW10S

UNS S31002 - W.-Nr.1.4335

maufactured acc to ASTM A403 ASME

B 16.9

Seamless stainless steel elbow - 90 -

LR - BE2 10S 60,30 2,77 122 P U71606 Proform 1070534/3 644-2014 France

002 0002 PC-SRRT0501BW40SW.-Nr.1.4335 - UNS S31002

ASTM A182- A479

Stainless steel Cap - BE-ASME B16.9

machined from bar3/4 40 36 P U71606 H. Van Triel 212 568 769-2014 Germany

5,100 M

(1 length)U44811 Breda report n 877-2014

48,130 M

(17 lenghts)U45689 Breda report n 891-2014

37,080 M

(7 lenghts)

U44811Breda report n 877-2014

11,490 M

(2 lengths)

U45689Breda report n 891-2014

160,050 m

(27 lengths)U71606 Breda report n 891-2014

17,955 M


107,730 M

(18 lenghts)U71606 Breda report n 891-2014

48,670 M


29,575 M


171,230 M


004 0004 P-SR12PE40SW.-Nr. 1.4335 - X1CRNI2521

manufactured acc to EN 10216-5 TC1Seamless stainless steel pipes in RL - PE 3/4 40 26,67 2,87 3900 - 4300 mm

3965 mm

4161 mm

4275 mm

55661 Sotep 112619 JOC001-12-07-27137-10 France

005 0005 CS-SRRT0501BW10S40SW.-Nr.1.4335 manufactured acc to

ASTM A182Forged stainless weldolet - BW 3/4 2 36 P U71606 H. Van Triel 212 568 769-2014 Germany

006 0006 FW-300SRRT0501RF10S

W.-Nr.1.4335 manufactured acc to

ASTM A182 ASME B16.5 / B16.47

serie A

Stainless steel WN flange 300# RF 2 10S 2 P U71606 H. Van Triel 212 568 769-2014 Germany

007 0007 FW-300SRRT0501RF40SW.-Nr.1.4335 manufactured acc to

ASTM A182 ASME B16.5Stainless steel WN flange 300# RF 3/4 40 2 P U71606 H. Van Triel 212 568 769-2014 Germany

482,283 M

(89 lengths)

535039

(Lot 29494)

734,547 M

(136 lengths)

539332

(Lot 29495)

5,067 M

(1 length)

539332

(Lot 30040)

003 0003 P-SR12PE10SASTM A312 TP 310 L

welded and tested acc to ASTM A358

Welded stainless steel pipe -100% X-ray -

PE made out of plate 3 mm thick2 3 mm 2000 - 6500 mm

Butting 30 000 055 584 / 00 Germany

Germany

Germany

GermanyButting 30 000 055 376 / 00

Butting

Butting 30 000 055 175 / 02

30 000 054 889 / 02

Country

of

Origin

Corrosion

Test Report

Customer

item lineManufacturerHeat N

Dimensions

Quantity 3.1 CertificatesGemaco

Item

Customer item

codeFull specification details

008 SwedenBreda report n 955-2014A/14-024141 Rev 00Sandvik2 10S 60,33 2,77 5000 - 7000 mmSeamless stainless steel pipes - PEASTM A312 UNS S31002 (2RE10) P-SR12PE10S0008

" Sch Dia Th Random Length Run pipe

001 0001 E90L-SR12BW10SUNS S31002 - W.-Nr.1.4335

maufactured acc to ASTM A403 ASME B 16.9Seamless stainless steel elbow - 90 - LR - BE 2 10S 60,30 2,77 P U71606 Proform 1070534/3 to follow France

002 0002 PC-SRRT0501BW40SW.-Nr.1.4335 - UNS S31002

ASTM A182- A479

Stainless steel Cap - BE-ASME B16.9

machined from bar3/4 40 P U71606 H. Van Triel 212 568 to follow Germany

004 0004 P-SR12PE40SW.-Nr. 1.4335 - X1CRNI2521

manufactured acc to EN 10216-5 TC1Seamless stainless steel pipes in RL - PE 3/4 40 26,67 2,87 3900 - 4300 mm mm 55661 Sotep 112619 JOC001-12-07-27137-10 France

005 0005 CS-SRRT0501BW10S40SW.-Nr.1.4335 manufactured acc to

ASTM A182Forged stainless weldolet - BW 3/4 2 P U71606 H. Van Triel 212 568 to follow Germany


ASTM A182 ASME B16.5 / B16.47 serie AStainless steel WN flange 300# RF 2 10S P U71606 H. Van Triel 212 568 to follow Germany


ASTM A182 ASME B16.5Stainless steel WN flange 300# RF 3/4 40 P U71606 H. Van Triel 212 568 to follow Germany

36

2

2

Gemaco

Item

Customer item

code

122

36

3965

4161

4275

Full specification detailsCountry of

OriginCorrosion Test Report

Customer

item lineManufacturerHeat number

DimensionsQuantity 3.1 Certificates

Material Certificates Summary (MCS)

YOUR PO N R1TP-5-0043-PF/R1TP101841 - OUR REF. 003849


Follow up and networking with all (sub)suppliers

Documents as per your instructions

Partial deliveries when required

Packaging fit to your needs

Different places of delivery

Shipping all over the world

GEMACOS Solutions Logistic support


Conclusions

EXPERTISE + EFFICIENCY + FLEXIBILITY + REACTIVITY

=> No stress + Financial advantage

PERFORMANCE: Higher quality for less maintenance

PRICE:

Professional

Reliable

Intelligent

Customized

Execution


References


Thank you for your attention

Special thanks to Giel Notten

Thanks to Industeel

Any questions?

See you @ our booth