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Ni-based corrosion resistant alloys UNS N06035 and UNS N10362 were designed with the goal of withstanding some of the most aggressive environments found in various sectors of the chemical processing industry (CPI). These alloys have successfully found a niche in process-specific environments that are uncommonly aggressive, pushing the envelope for higher chemical processing efficiency, performance and durability.
N06035 alloy was designed to resist “wet process” phosphoric acid, which is used in the production of fertilizers.
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Nickel-based corrosion-resistant alloys are vitally important materials in chemical processing, petrochemical, agrichemical and pharmaceutical industries. When aggressive process streams are involved, corrosion-resistant alloys are selected for applications such as heat exchangers, reactors, pressure vessels and/or other process equipment in various industry sectors.1 The Ni-Mo alloys provide excellent resistance to reducing hydrochloric and sulfuric acids over large ranges of concentration and temperature. They also resist pure hydrobromic acid, hydrofluoric acid and other non-oxidizing halide salt solutions.
Alloy N06044 was developed for applications in chemical process industry and coal fired boiler. In this paper, corrosion resistant properties of that alloy in acidic solutions are shown.
Austenitic-ferritic stainless steels, commonly known as duplex stainless steels (DSSs), are a group of materials typically consisting of equal amounts austenite and ferrite. DSSs are well-known materials in chemical industry and are often a cost-effective alternative as they combine high mechanical strength and fatigue resistance with good corrosion properties. Contributing to the cost-effectiveness is the low nickel content compared to austenitic stainless steels. Advantages with DSSs are high chloride stress corrosion cracking resistance (SCC), where austenitic steels with moderate nickel content are inherently more sensitive. In combinations with carbon steel it can be a benefit to use DSSs since carbon steel and DSSs have matching thermal expansion.
Two of the most common acid gases produced by the refining industry are chloride compounds such as hydrogen chloride (HCl) and chlorine (Cl2). These compounds can react with water to form solutions of hypochlorous and hydrochloric acid. Droplets that condense are often highly concentrated, and acid concentrations in excess of 10% can be expected.1 A common source of these gaseous compounds is the overhead exhaust/vent of regeneration tower within a Continuous Catalytic Reforming (CCR) unit. Chloride compounds in the regenerator vent gas are absorbed in 1 wt.% caustic (NaOH) by subsequent contact in a venturi scrubber (ejector), before venting chloride free gas to atmosphere through a wash tower.
Equipment can have an important impact on the production at a refinery, petrochemical, or chemical plant. Change of equipment will often have a negative impact since it can disrupt the production with shutdowns, which will lead to production losses. In the long term, these short lifetimes for the equipment will cause many shutdowns, which will give a higher production cost. One example of equipment is the shell-and-tube heat exchanger.
Coiled tubing is defined as a continuous tubular product that is used for oil and gas well interventions. Its popularity continues to grow due to its versatility and speed of operation. Though superior grades of metal alloys exist in terms of corrosion resistance, coiled tubing operations primarily employ high-strength low-alloy steels because of their availability, lower cost and weldability. The low-alloy steel can also be thermo-mechanically controlled to elicit specific material properties, such as yield strength and ductility. These coiled tubing steels are often introduced into potentially corrosive downhole conditions, therefore proper testing must be completed to ensure adequate corrosion protection prior to job execution. Downhole corrosive conditions often encountered include; oxygen saturated fluids, elevated temperatures, exposure to oxidizing agents, hydrochloric acid and highly concentrated brines. Often these fluids will be recirculated in a closed loop system, consistently re-exposing equipment to potentially damaging conditions. Frequently, these challenging conditions faced are tested individually with pressurized mass loss coupon testing at bottom hole conditions. However, due to a recent coiled tubing incident in which the coiled tubing pipe had completely parted downhole, the post-job incident investigation involving SEM and metallographic analysis revealed pitting corrosion throughout the tubing, despite the pre-job testing performed indicating adequate acid corrosion protection for the entirety of the job. A literature review indicated very little research was available involving the possible interaction of brine solutions and diluted acid on coiled tubing carbon steels. This paper aims to investigate the possible corrosive interactions between salt brines and inhibited acid blends at elevated temperatures on high grade coiled tubing coupon samples through metallographic examinations and mass loss tests in pressurized heated cells. Coiled tubing coupons will be exposed to a variety of acid blends diluted with a 10% brine (8% wt NaCl and 2% wt CaCl2) or fresh water to investigate the possibility of corrosion enhancement between saline fluids in a diluted acid system.
Acid stimulation is a growing practice in the deep water subsea environment. Two acids were tested, one of hydrofluoric and acetic acids and another of hydrofluoric, hydrochloric, and acetic acids. Results and outlines recommendations for different alloys are presented.
In the present study, corrosion tests were performed using both weight loss and electrochemical techniques for Ni-Cr-Mo (W) alloys in hydrochloric (HCl), sulfuric (H2SO4), nitric (HNO3) acids and their various combinations.
The alloys used as clad material for this study are members of the so-called “C-family”. It consists of Ni-Cr-Mo alloys, which are known for combining the corrosion resistance of Ni-Cr alloys in oxidizing media with corrosion resistance of Ni-Mo alloys in reducing media. As a result, these materials have proven to be extremely durable in a wide range of highly aggressive media. The development of these materials started in the 1930s with Alloy C. This alloy showed remarkable corrosion resistance in a wide spread of media, low sensitivity for pitting or crevice corrosion and virtual immunity to chloride induced stress corrosion cracking.