a-190 projects talk€¦ · accelerated corrosion of 2205 duplex ss pipe carrying heavy black...
TRANSCRIPT
1
Flow Induced Corrosion in Pulping
Liquor Environments
School of Materials Science and Engineering
& Reusable Bioproducts Institute (RBI)
Georgia Institute Technology,
Atlanta, GA, USA
Preet M. Singh
Content
• Introduction
– Examples of Erosion Corrosion in Pulp Mills
• Laboratory Tests
– Rotating Cylinder Tests
• Results Under Different Pulping Liquor Conditions
– Different Alloys
– Effect of Test Temperature
– Effect of Liquor Type
• Conclusions and Mitigation Steps
2
Influence of Flow on Corrosion Reactions?
• By Transporting Reactants or Products
– Higher Flow Rate – Better Transportation – Higher Reaction Rate
• By Disruption of Passive Film at the Surface
– Film Breakdown Above Critical Velocity, Vc (Breakaway Velocity)
• Flow-Assisted Corrosion Regime
• Vc depends on alloy/environment systems
•B. Chexal, J. Horowitz, B. Dooley, P. Millett, C. Wood, R. Jones, Flow-Accelerated Corrosion in Power Plants-Revision-1,” EPRI TR-106611-R1, 1998.
Suspended Solids and Erosion Corrosion
• Flow-accelerated corrosion depends on the repassivation
kinetics and erosion rate.
– Alloy
– Environmental Parameters (pH, Temperature, Chemical Composition etc.)
– Flow Parameters
3
Flow Induced Corrosion of Cast Iron Valve
Valve in Weak Black Liquor Line
Erosion Corrosion
Hole
Erosion Corrosion in Sand Separator 2205 DSS
Courtesy – Dr. Angela Wensley
4
Flow-Induced Corrosion 2205 DSS Sand-Separator
Cone Exposed to Weak Black Liquor
Flash Tank - SS Overlaid Inlet Nozzle
Courtesy – Dr. Angela Wensley
5
Accelerated Corrosion of 2205 Duplex SS Pipe
Carrying Heavy Black Liquor
Failed DSS 2205 Pipe to Liquor Gun
8
Erosion Corrosion of 304L Evaporator Tubes
Upper Tube
Lower TubeJoint Between Upper and
Lower Tube
Sample used for SEM
Samples used for SEM
Erosion Corrosion Regimes for Active-Passive Alloys
Cu
rre
nt
Den
sit
y
A/c
m^
2
Potential (V)
Passive
Region
Active
CorrosionCathodic
Region
9
Effect of Particle Size – Chromium Steel in
1M NaOH (Deaerated)
Alumina Particle Size (m)
Weight Loss Rate (mg/cm2*hr)
M. M Stack et al. Wear, 256, pp 557-564, 2004
Corrosion of 304 Stainless Steel in Softwood Black
Liquors Taken From Mill-B @ 170oC
Corrosion Rate for Tensile Samples and Coupons - Mill-B
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0% 80.0%
% Solids in Softwood Black Liquor
Co
rro
sio
n R
ate
(m
py
)
304 Tensile Samples
304 Coupons
10
Flow Induced Corrosion or “Erosion Corrosion”
Testing in Laboratory
0.00
2.00
4.00
6.00
8.00
10.00
12.00
0 2,500 5,000 7,500 10,000
Lin
ear
Vel
oci
ty o
n E
lect
rod
e
Su
rface
(ft
/sec
RPM
Linear Velocity at the Electrode Surface vs RPM
Cylindrical Electrode and Flow in Pipe
- Erosion Corrosion Testing
Where • Ucyl (cm s–1), Target surface velocity at rotating cylinder
• Upipe (cm s–1) is flow rate in pipe
• dpipe (cm) is the diameter of the pipe,
• Sc is the Schmidt number,
• is absolute viscosity of solution in g/cm/s and
• is solution density in g/cm3.
• F is RPM of electrode
4/50857.0
28/5
7/325.0
,1185.0
pipe
pipe
cyl
electrodeCylUSc
d
dU
Using this equation:
• If water is flowing through a smooth 10-inch Schedule 40 pipe at 1.0 ft/sec,
• A Rotating Electrode with 1.2 cm diameter (and 3.0 cm2 area) rotating at 149 RPM
will match the flow conditions in that pipe
60
*,
FdU
cyl
electrodeCyl
11
Corrosion Rate as a Function of Velocity - 65% solids BL
Carbon steel (516-Gr70)
Cast Iron
0.000
0.100
0.200
0.300
0.400
0.500
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Corr
osi
on
Rate
(m
m/y
ear)
Velocity (rpm)
516Gr. 70 in 65% ISC Black Liquor
23 C
60 C
90 C
0.0
1.0
2.0
3.0
4.0
5.0
6.0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Corr
osi
on
Rate
(m
m/y
ear)
Velocity (rpm)
Cast Iron in 65% ISC Black Liquor
23 C
60 C
90 C
Corrosion Rate as a Function of Velocity in 65% solids BL
304L
316L
0.000
0.100
0.200
0.300
0.400
0.500
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Corro
sion
Rate
(m
m/y
ear)
Velocity (rpm)
316L in 65% ISC Black Liquor
23 C
60 C
90 C
0.000
0.100
0.200
0.300
0.400
0.500
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Corro
sion
Rate
(m
m/y
ear)
Velocity (rpm)
304L in 65% ISC Black Liquor
23 C
60 C
90 C
12
0.000
0.100
0.200
0.300
0.400
0.500
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Corro
sion
Ra
te (
mm
/yea
r)
Velocity (rpm)
2205 in 65% ISC Black Liquor
23 C
60 C
90 C
Corrosion Rate as a Function of Velocity in 65% solids BL
LDX 2101
DSS 2205
0.000
0.100
0.200
0.300
0.400
0.500
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Co
rro
sio
n R
ate
(m
m/y
ea
r)
Velocity (rpm)
2101 in 65% ISC Black Liquor
23 C
60 C
90 C
Critical Velocity in Different Pulping Liquors at
60oC
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
Crit
ica
l V
elo
cit
y (
RP
M)
Tested at 60oC 516-Gr70CF8M Cast Steel31621012205
13
Critical Velocity in Different Pulping Liquors at
90oC
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000C
rit
ica
l V
elo
cit
y (
RP
M)
Tested at 90oC 516-Gr70
CF8M Cast Steel
316
2101
2205
Conclusions - Lab Results
• Below the flow velocity of ~5 meters/sec, effect of flow on the corrosion
rate for tested materials in tested pulping liquors was negligible
• Alloys that form a stable passive film on the surface in pulping liquors
showed a critical flow rate
– Above a critical velocity range the corrosion rates for tested stainless steels
approached same order of magnitude as carbon steel
– Below critical velocity stainless steels had significantly lower corrosion rates in
tested pulping liquors, as is expected
• Cast iron had very high corrosion rate in tested pulping liquors so no
significant acceleration was seen due to flow velocity
• For carbon steel, the effect of flow on corrosion rate was gradual
compared to that for the stainless steels tested in pulping liquors
– Critical flow rate value was not clear for the C-Steel in white and green liquors
14
Strategies to Mitigation Erosion Corrosion
• Modify the fluid flow (locally or globally) to minimize turbulent flow
– by either modifying the fluid flow rates or by minimizing the flow
disruptions, especially at the joints and pipe entry points
• Keep flow rates below critical flow rate
– However, data of flow conditions is not always available to make a
good decision.
– In such case, generation of data under given environment and under
realistic flow conditions should be considered, whenever possible
• Use a more corrosion resistant alloy with stable passive film in a given
environment
• If possible, other changes to environment to stabilize passive film
– Temperature, pH, Concentration, Presence of Solids
Acknowledgements
• Margaret Gorog, Subhash Pati, Phil Hardin, Jorge
Mudri, Angela Wensley and many others in the related
pulp mills for their support
• Member Companies - RBI (IPST) at Georgia Tech
28