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This presentation summarizes the development and expansion of a comprehensive information system for corrosion of metals and alloys in high temperature gases. New insights in analysis of thermochemical data for the Fe-Ni-Cr-Co-C-O-S-N system are being compiled. Corrosion mechanisms emphasized are oxidation, sulfidation, sulfidation/oxidation, and carburization.
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A new wrought alloy has been developed for use as furnace tubes in ethylene pyrolysis plants. This alloy has an excellent carburization resistance due to uniform formation of protective Al2O3 oxide scale on the metal surface. Laboratory corrosion tests have been carried out to evaluate carburization resistance of the developed alloy.
A standard carburization test method has been developed that will allow investigators to generate carburization data under uniform, repeatable test parameters and procedures. Test results are discussed with particular reference to test parameters and procedures, as well as the methods of sample evaluation.
A laboratory study was performed by exposing seven candidate heat exchanger alloys to simulated 2 (sCO2) Brayton power cycles. The alloys, consisting of fineirtriaitilcly s 3te.6e%ls ,O austenitic stainless steels, and nickel-base alloys, were exposed to impure CO2 containing 2 and 5.3% H2O at a constant pressure of 200 bar.
Selected Fe- and Ni-based alloys and superalloys have been exposed in 99.995% supercritical carbon dioxide for 500 hours at 750°C and 200 bar. Post exposure examination provided information on corrosion rates, microstructural evolution and the carbon concentration in the exposed materials.
In the framework of studies on the control rods lifetime for Sodium Fast Reactor, three commercial steels were exposed to B4C powder in liquid sodium at 600°C for durations up to 3000 h.
This paper explains the most common damage mechanisms of high temperature alloys in radiant section such as creep/carburization, thermal fatigue/carburization, and thermal shock.
Fired heaters in coking service are susceptible to carburization damage, which needs to be predicted and managed to prevent unexpected downtime and expedited replacement costs. Carburization damage occurs when carbonaceous material, i.e., coke, is deposited on a steel surface and exposed to high metal temperatures; such are the internal conditions present in fired heater tubes in coking services. At these high temperatures, the carbon diffuses into the steel microstructure and increases the hardness while reducing ductility. At an advanced state, this reduction in ductility may lead to tube failure if a mechanical or thermal shock is applied. The diffusion of carbon can also cause the formation of deleterious chromium carbides in the steel microstructure, reducing the high temperature corrosion resistance in those areas.
Common materials employed in catalytic reforming unit tubes are typically resistant to carburization due to protective chromium oxide films, but under low excess oxygen conditions can become compromised and allow carbon penetration and carbide formation at the exposed surface. Embrittlement and material wastage as a result of these mechanisms causes premature failures, with production loss, in addition to shutdown maintenance and replacement costs. Carburization in this environment is simulated in this paper through a pack carburizing method designed to create an environment optimal for diffusing carbon in an ASTM 335 9Cr-1Mo tube material.
This AMPP standard establishes a standard test procedure for pack bed carburization of alloys used for ethylene manufacture. The pack bed carburization procedure is specified in this standard because it is simple to perform. The test specimen geometry chosen reflects the intent of the procedure to be used for evaluation of carburization of furnace tube alloys intended for ethylene manufacture.
In Jan 2023, during reformer shutdown; one of the reformer inspections revealed cracks at hot collector and pigtail. Most of the cracks were on the surface and some of the cracks were through. Pigtail sample was removed, and it was taken for failure investigation to confirm the failure root cause.