Nickel Institute Corrosion by Process Waters R. W. Ross Consultant Nickel Institute.
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Transcript of Nickel Institute Corrosion by Process Waters R. W. Ross Consultant Nickel Institute.
Nickel InstituteNickel Institute
Corrosion by Process WatersCorrosion by Process Waters
R. W. RossR. W. RossConsultantConsultant
Nickel Institute Nickel Institute
SummarySummary
Scaling and CorrosionScaling and Corrosion
Effects of VelocityEffects of Velocity
Biological EffectsBiological Effects
ChloridesChlorides
Rouging of SSRouging of SS
Water Chemistry EffectsWater Chemistry Effects
CorrosionCorrosion
• Dissolved OxygenDissolved Oxygen
• ChloridesChlorides• pHpH
• HardnessHardness
• TemperatureTemperature
ScaleScale
• Dissolved SolidsDissolved Solids
• Calcium IonsCalcium Ions• pHpH
• TemperatureTemperature
Water Chemistry EffectsWater Chemistry Effects
Corrosion Of Carbon Steel Corrosion Of Carbon Steel In WaterIn Water
0
10
20
30
0 5 10 15
72 ºF (22 ºC)
104 ºF (40 ºC)
Co
rro
sio
n R
ate,
mp
yC
orr
osi
on
Rat
e, m
py
pH of WaterpH of Water
0.25
0.51
0.76
Co
rro
sio
n R
ate,
mm
/yC
orr
osi
on
Rat
e, m
m/y
Corrosion Of Carbon Steel Corrosion Of Carbon Steel In Low-velocity WaterIn Low-velocity Water
Corrosion Of Carbon Steel Corrosion Of Carbon Steel Effect Of Velocity In SeawaterEffect Of Velocity In Seawater
0
25
50
0 5 10 15 20 25
~ 72 ºF (22ºC )
ft/sec (m/s)
Co
rro
sio
n R
ate,
mp
yC
orr
osi
on
Rat
e, m
py
Co
rro
sio
n R
ate,
mm
/yC
orr
osi
on
Rat
e, m
m/y1.27
0.64
(1.5) (3.0) (4.7) (6.1) (7.6)
Erosion-corrosion - InletErosion-corrosion - Inlet
Erosion-corrosionErosion-corrosion
Flow
Erosion-corrosionErosion-corrosionTube BlockageTube Blockage
Flow
High-velocity SeawaterHigh-velocity Seawater >120 fps (36.6 m/s)>120 fps (36.6 m/s)
Corrosion Corrosion Rate,Rate,
Alloy Alloy mpympy mm/ymm/y
625/C-276625/C-276 <1 <1 < 0.03< 0.03
400/K-500400/K-500 <1 <1 < 0.03< 0.03
718/725/925718/725/925 <1 <1 < 0.03< 0.03
T-304/T-316T-304/T-316 <1 <1 < 0.03< 0.03
C SteelC Steel >300 >300 > 7.62> 7.62
Biological EffectsBiological EffectsMacrofoulingMacrofouling
• MusselsMussels
• ClamsClams
• BarnaclesBarnacles
• Plant LifePlant Life
Biological EffectsBiological EffectsMacrofoulingMacrofouling
Bacteria Effects - MICBacteria Effects - MIC(Microbiologically Induced Corrosion)(Microbiologically Induced Corrosion)
SpeciesSpecies OxygenOxygen MetalsMetals Corrosive Corrosive
DesulfovibrioDesulfovibrio No No Fe, Al, CuFe, Al, Cu Sulfide Sulfide
ThiobacillusThiobacillus Yes Yes Fe, CuFe, Cu Sulfuric AcidSulfuric Acid
GallionellaGallionella Yes Yes FeFe FeFe++++ to Fe to Fe++++++
MnMn++++ to Mn to Mn++++++
Type 304 SS Type 304 SS water tank water tank
8 months of 8 months of serviceservice
GuamGuam
Bacteria Effects - MICBacteria Effects - MIC
Bacteria Effects - MICBacteria Effects - MIC (Type 304 SS, Before Cleaning)(Type 304 SS, Before Cleaning)
Bacteria Effects - MICBacteria Effects - MIC (After Cleaning)(After Cleaning)
0.15 in. (3.8) mm)
Max. Attack
Bacteria Effects - MICBacteria Effects - MIC (After Cleaning - No Attack)(After Cleaning - No Attack)
Prevention Of MICPrevention Of MIC
• Keep The System CleanKeep The System Clean
• Keep Water Flow > 6 fps (2 m/s)Keep Water Flow > 6 fps (2 m/s)
• Use Bactericide:Use Bactericide:
– ChlorineChlorine
– Chlorine DioxideChlorine Dioxide
– HypochloriteHypochlorite
– OzoneOzone
– Non-oxidizingNon-oxidizing
Prevention Of MICPrevention Of MIC
• Use Continuous CleaningUse Continuous Cleaning
• Use High Pressure HydrolancingUse High Pressure Hydrolancing
• Use Stainless Steel ScrapersUse Stainless Steel Scrapers
(Hard to Remove or Heavy Deposits)(Hard to Remove or Heavy Deposits)
• Use Alloy Resistant to MICUse Alloy Resistant to MIC
Prevention Of MIC - 6% Mo ALLOYPrevention Of MIC - 6% Mo ALLOY
Effects of ChloridesEffects of Chlorides
Crevice Corrosion Type 303Crevice Corrosion Type 303
Stainless SteelsStainless SteelsLocalized Corrosion ResistanceLocalized Corrosion Resistance
AlloyAlloy PREPRE
304 18 304 18
316 25316 25
317 30317 30
2205 342205 34
2505 372505 37
2507/Alloy 100 412507/Alloy 100 41
6% Mo Alloys 40 - 456% Mo Alloys 40 - 45
Nickel AlloysNickel AlloysLocalized Corrosion ResistanceLocalized Corrosion Resistance
Alloy Alloy PRE PRE
316 25316 25
6% Mo 40 – 456% Mo 40 – 45
625625 52 52
22/622 6522/622 65
C-276C-276 69 69
20002000 76 76
686686 76 76
5959 76 76
Stainless Steels for Use in WatersStainless Steels for Use in Waters
Potable waterPotable water Type 304 < 200 ppm chloridesType 304 < 200 ppm chloridesType 316 < 1000 ppm chloridesType 316 < 1000 ppm chlorides
River waterRiver water Risk of MIC if water is not treatedRisk of MIC if water is not treatedUse type 316 or higher Mo grades:Use type 316 or higher Mo grades: 2205 904L2205 904L 2507 6Mo2507 6Mo
Well waterWell water Risk of MIC if water is not treatedRisk of MIC if water is not treatedUse type 316 or higher Mo gradesUse type 316 or higher Mo grades
Do not confuse Chloride ClDo not confuse Chloride Cl-- and Chlorine Cl and Chlorine Cl22
Maximum Concentration (ppm) in Maximum Concentration (ppm) in Water to Avoid Crevice CorrosionWater to Avoid Crevice Corrosion
Chloride ClChloride Cl-- Chlorine ClChlorine Cl22
304304 200200 22
316316 10001000 44
Shock dosing, such as 25 ppm chlorine for 24 hours, is common practice Shock dosing, such as 25 ppm chlorine for 24 hours, is common practice and has not been found to cause problems.and has not been found to cause problems.
Stress Corrosion Cracking (SCC)Stress Corrosion Cracking (SCC)
Steam Line
Chloride SCCChloride SCC Duplex vs T-316 Stainless Steel Duplex vs T-316 Stainless Steel
0
200
400
600
1 10 100 1000 10000
Chlorides, ppm
Tem
per
atu
re, F
(C
) (315)
(204)
(93)
Type 316
18 Cr Duplex
22 Cr Duplex
No cracking below lines
Effect of Nickel Content onEffect of Nickel Content onStress Corrosion CrackingStress Corrosion Cracking
Boiling 45% MgClBoiling 45% MgCl22
0
20
40
60
80
100
1 10 100 1000
Time to Failure, hrs
% N
icke
l No SCC
SCC 6% Mo SS6% Mo SSDuplex SSDuplex SS
Ni AlloysNi Alloys
HIGH CHLORIDE HIGH CHLORIDE WATERSWATERS
HIGH CHLORIDE HIGH CHLORIDE WATERSWATERS
How does external environment How does external environment affect process equipment?affect process equipment?
Marine Corrosion of C SteelMarine Corrosion of C SteelRelative Corrosion Rates* – Vary with Sea ConditionsRelative Corrosion Rates* – Vary with Sea Conditions
Atmospheric
Splash
Tidal
Submerged
Subsoil
5 mpy (0.13 mm/y)
25 mpy (0.64 mm/y)
*Protected Harbor
Uniform CorrosionUniform Corrosion
Effect of ChromiumEffect of Chromium
0
25
50
75
100
0 2 4 6 8 10 12 14 16 18
We
igh
t L
os
s, m
g. /
sq
. dm
.W
eig
ht
Lo
ss
, mg
. / s
q. d
m.
% Chromium% Chromium
250M Lot250M Lot44 Months44 Months
Alloy C in Marine AtmosphereAlloy C in Marine Atmosphere56 Years of Exposure56 Years of Exposure
Type 304 Fastener Type 304 Fastener InIn Marine Tide Marine Tide After 6 MonthsAfter 6 Months
Type 304 Fastener Type 304 Fastener AboveAbove Marine Tide Marine Tide After 6 Months After 6 Months
Crevice CorrosionCrevice Corrosion
Crevice Corrosion of Alloy 825Crevice Corrosion of Alloy 825Heat Exchanger Tubing – Shell Side Heat Exchanger Tubing – Shell Side
85 85° F° F, Aerated Seawater, Aerated Seawater
Crevice Corrosion of Alloy 625Crevice Corrosion of Alloy 625 Waterbox With Deaerated, Treated SeawaterWaterbox With Deaerated, Treated Seawater
165165°° F F 235235°° F F
165-235165-235°° F F
Crevice Corrosion of Alloy 825Crevice Corrosion of Alloy 825Heat Exchanger Tubesheet – Water Side Heat Exchanger Tubesheet – Water Side
225225°° F, Deaerated, Treated Seawater F, Deaerated, Treated Seawater
Tube to Tubesheet JointTube to Tubesheet Joint
Types Of Severe CrevicesTypes Of Severe Crevices
Stationary O Rings
Flange Face Under Gasket
Non-Metallic Connector
Tube to Tubesheet Joint
Corrosion of 90-10 Cu-NiCorrosion of 90-10 Cu-Niin Seawaterin Seawater
0
0.1
0.2
0.3
0.4
0.5
0.6
1 3 5 7 14
Time, Years
<1 fps
Tidal
3 fps
Co
rro
sio
n R
ate,
mp
y
Marine FoulingMarine Fouling18 Months in Quiet Seawater18 Months in Quiet Seawater
AluminumAluminumC SteelC Steel
Fouling of Titanium WaterboxFouling of Titanium Waterbox3 mo. Exposure3 mo. Exposure
Fouling of Titanium WaterboxFouling of Titanium Waterbox6 mo. Exposure6 mo. Exposure
Effect of ChlorinationEffect of Chlorination<1 fps Seawater Flow<1 fps Seawater Flow
0
10
20
30
0 1 4
Total Oxidant, ppm
Max
. Atta
ck, m
ils
90-10 Cu-Ni T-304
90-10 Cu-Ni Alloy90-10 Cu-Ni Alloy Fouling - Quiet SeawaterFouling - Quiet Seawater
3 Mo3 Mo 9 Mo9 Mo 18 Mo18 Mo
3 Yr3 Yr 4 Yr4 Yr 5 Yr5 Yr
90-10 Cu-Ni Intake Piping90-10 Cu-Ni Intake PipingDesalination PlantsDesalination Plants
90-10 Cu-Ni Alloy90-10 Cu-Ni AlloySeawater Piping SystemsSeawater Piping Systems
90-10 Cu-Ni Alloy90-10 Cu-Ni AlloySeawater Heat ExchangersSeawater Heat Exchangers
Pumps - ImpellersPumps - Impellers
Rouging of Stainless SteelsRouging of Stainless Steels
High Purity WaterHigh Purity Water
Water For Injection (WFI)Water For Injection (WFI)
Why Use Stainless Steels (316L) for Pharma & Biotech?
Good corrosion resistance and excellent batch Good corrosion resistance and excellent batch to batch cleanabilityto batch cleanability
Good structural properties for process Good structural properties for process equipmentequipment
Easily formed, fabricated and weldedEasily formed, fabricated and welded
What about Rouging?What about Rouging?What is Rouging?What is Rouging?
Rouging is a general term used to Rouging is a general term used to describe several species of describe several species of predominately iron oxide deposits on predominately iron oxide deposits on the wall of piping and vessels in high the wall of piping and vessels in high purity water systems.purity water systems.
Rouging is not New!Rouging is not New!
Rouging is not unique to the Rouging is not unique to the pharmaceutical and biotech pharmaceutical and biotech industries. Was recognized over 40 industries. Was recognized over 40 years ago with rouging of SS vessels years ago with rouging of SS vessels at Savannah River.at Savannah River.
Where is Rouge often FoundWhere is Rouge often Found
Water systems, usually high purity water and Water systems, usually high purity water and clean-steam systemsclean-steam systems
Distillation and clean-steam generating Distillation and clean-steam generating equipmentequipment
Rouge found on wall of vessels, piping and Rouge found on wall of vessels, piping and polymer gaskets (Teflonpolymer gaskets (Teflon®®) downstream of ) downstream of where originatedwhere originated
Is Rouge Harmful?Is Rouge Harmful?
No reports or evidence that rouging is No reports or evidence that rouging is precursor to a SS corrosion failure.precursor to a SS corrosion failure.
We are not in a position to comment on We are not in a position to comment on whether rouge is harmful to the product whether rouge is harmful to the product being produced. Common practice is to being produced. Common practice is to remove rouge.remove rouge.
Generally a loose powdery deposit, but can be Generally a loose powdery deposit, but can be tightly adherenttightly adherent
Hydrated or partially hydrated ferric oxide (FeHydrated or partially hydrated ferric oxide (Fe22OO33) )
or ferroso-ferric oxide (Feor ferroso-ferric oxide (Fe33OO44))
Usually occurs in high purity (0.5-1.0 µS/cm),Usually occurs in high purity (0.5-1.0 µS/cm),
high temperature water (60 – 100 high temperature water (60 – 100 C)C)
RougingRouging
Reddish brown rust color, but can range from Reddish brown rust color, but can range from orange to blue-black.orange to blue-black.
Origin is uncertain but generally thought to be Origin is uncertain but generally thought to be ions or colloids that are formed at one ions or colloids that are formed at one location and transported in the solution to location and transported in the solution to another where they are precipitated.another where they are precipitated.
Removed by acid cleaning in nitric, Removed by acid cleaning in nitric, phosphoric, citric, or oxalic acid.phosphoric, citric, or oxalic acid.
RougingRouging
Type 1 – Corrosion of Steel, Deposits DownstreamType 1 – Corrosion of Steel, Deposits Downstream
Pumps prime suspects – cavitation or erosion when velocity Pumps prime suspects – cavitation or erosion when velocity over ~ 100fps and higher temperaturesover ~ 100fps and higher temperatures
Delta ferrite in cast impellers may contribute by eroding easier Delta ferrite in cast impellers may contribute by eroding easier and higher iron contentand higher iron content
Type 2 – Corrosion Product of Stainless SteelType 2 – Corrosion Product of Stainless Steel
Type 3 – Corrosion Product of Stainless Steel in Steam Type 3 – Corrosion Product of Stainless Steel in Steam
Systems > 100 Systems > 100 CC
Rouging - TypesRouging - Types
Rouging of Stainless SteelsRouging of Stainless Steels
Rouging over 4 years inside electropolished Type 316L - column still used to produce ultra-pure water for pharmaceutical use
Rouging of Stainless SteelsRouging of Stainless Steels
De-rouging & PassivationDe-rouging & Passivation3 Steps3 Steps
Cleaning – detergent wash followed by Cleaning – detergent wash followed by thorough water rinsethorough water rinse
De-rouging chemical treatmentDe-rouging chemical treatment
Passivation followed by thorough water rinsePassivation followed by thorough water rinse
Electrochemical ColoringElectrochemical ColoringProprietary electrochemical processes – Proprietary electrochemical processes –
invented in 1972 by Inco, further developed invented in 1972 by Inco, further developed in Japanin Japan
• Interference between the Interference between the light beams refracted from light beams refracted from the substrate and the the substrate and the surface of the oxide film surface of the oxide film creates colorcreates color
• Appearance and colorAppearance and color vary vary with immersion time and with immersion time and surface finishsurface finish
IncidentIncidentlightlight ColorColor
OxideOxide
Experience Music ProjectExperience Music Project
SummarySummary
Discussed Scaling and CorrosionDiscussed Scaling and Corrosion
Described Effects of VelocityDescribed Effects of Velocity
Reviewed Biological EffectsReviewed Biological Effects
Discussed ChloridesDiscussed Chlorides
Summarized Rouging of SSSummarized Rouging of SS
Questions ?Questions ?