Stainless Steel Welded Tube - steel- · PDF fileprocess steps compared to rolling solid steel...

The World Market

for Clad Plate

Stainless Steel – Nickel Alloy – Titanium

© SMI GmbH 2016 - This report may not be copied, published or disclosed to third parties without the permission of SMI GmbH.

July 2016

The World Market for Clad Plate

© SMI – Steel Market Intelligence GmbH 2016

TABLE OF CONTENTS

DISCLAIMER AND COPYRIGHT .............................................................................. 7

Disclaimer ............................................................................................................. 7

Copyright Protection ............................................................................................ 7

1 Introduction ....................................................................................................... 8

1.1 Clad Plates ...................................................................................................... 8

1.1.1 Rolled Clad Plates ...................................................................................... 9 1.1.2 Explosion Clad Plates ............................................................................... 16 1.1.3 Weld Overlay ............................................................................................ 22

1.1.4 Size Range Comparisons ......................................................................... 23

1.2 Clad Pipes ..................................................................................................... 25

1.2.1 Metallurgically Bonded Clad Pipes ............................................................ 26 1.2.2 Mechanically Bonded Clad Pipes .............................................................. 28

1.2.3 Co-Extruded Seamless Clad Pipes ........................................................... 29 1.2.4 Centrifugal Cast Pipe ................................................................................ 30

1.3 Cost Comparison Clad vs. Solid Plate ........................................................ 31

1.3.1 Grade 316 ................................................................................................. 31

1.3.2 Grade 825 ................................................................................................. 33 1.3.3 Grade 625 ................................................................................................. 35

2 Clad Plate Production ..................................................................................... 37

2.1 Long Term Trend .......................................................................................... 37

2.1.1 Correlation to Nickel and Oil Prices .......................................................... 37 2.1.2 Long Term Trend China vs. ROW ............................................................. 39 2.1.3 Long Term Trend Rolled vs. Explosion ..................................................... 43

2.2 Production By Region .................................................................................. 44

2.2.1 Production by Region (2010 – 2015) ........................................................ 44

2.2.2 Production by Region (2015) .................................................................... 47 2.2.3 Production by Country (2015) ................................................................... 52

2.3 Production by Producer (2015) ................................................................... 55

2.3.1 Roll Bonded Clad Plate ............................................................................. 55 2.3.2 Explosion Bonded Clad Plate ................................................................... 56



3 International Trade Flows .............................................................................. 57

4 Clad Plate Consumption ................................................................................ 59

4.1 Consumption By region 2004 – 2015 .......................................................... 59

4.2 Consumption by Country 2014 - 2015 ........................................................ 60

5 Market Structures 2015 .................................................................................. 61

5.1 Market by Size ............................................................................................... 61

5.1.1 Total Clad Plate ........................................................................................ 61

5.1.2 Rolled Bonded Clad Plate ......................................................................... 67 5.1.3 Explosion Bonded Clad Plate ................................................................... 69

5.2 Market by Grade ........................................................................................... 71

5.2.1 Total Clad Plate ........................................................................................ 71 5.2.2 Roll Bonded Clad Plate ............................................................................. 75 5.2.3 Explosion Bonded Clad Plate ................................................................... 76

5.3 Market by Application and Industry ............................................................ 77

5.3.1 Clad Plate Consumption by Major Application .......................................... 77

5.3.2 Clad Plate Consumption by Industry ......................................................... 79

6 Description of Applications ........................................................................... 81

6.1 Overview ....................................................................................................... 81

6.2 Oil & Gas ....................................................................................................... 85

6.2.1 Flowlines & Pipelines ................................................................................ 85 6.2.2 Steel Catenary Risers ............................................................................... 92 6.2.3 Subsea Jumpers ....................................................................................... 95

6.2.4 Subsea Manifold Piping Systems and Pigging Loops ............................... 97 6.2.5 Slug Catchers ........................................................................................... 98 6.2.6 Topside Pressure Vessels and Separators ............................................. 101

6.2.7 Topside Process Piping .......................................................................... 104 6.2.8 Splash Zone Sheathing ........................................................................... 106

6.3 Refineries, Petrochemical & Chemical Industry ...................................... 107

6.3.1 Towers & Columns .................................................................................. 108 6.3.2 Coke Drums ............................................................................................ 114

6.3.3 Reactors ................................................................................................. 117 6.3.4 High Pressure Vessels, Drums and Separators ...................................... 124

6.3.5 Storage Tanks......................................................................................... 127



6.4 Heat Exchangers ........................................................................................ 129

6.4.1 Shell & Tube Heat Exchangers ............................................................... 129 6.4.2 Plate Heat Exchangers ........................................................................... 132 6.4.3 Thin Film/Wiped Film Evaporators .......................................................... 134 6.4.4 Air/Gas Coolers ....................................................................................... 136

6.5 Fertilizer Industry ....................................................................................... 139

6.6 Power Generation ....................................................................................... 145

6.6.1 Condensers............................................................................................. 145

6.6.2 Geothermal ............................................................................................. 148 6.6.3 Coal Gasification/Liquefaction................................................................. 152 6.6.4 Hydroelectricity ....................................................................................... 154

6.7 Flue Gas Desulfurization ........................................................................... 155

6.8 Seawater Desalination ............................................................................... 159

6.9 Pulp & Paper ............................................................................................... 164

6.9.1 Steaming Vessels ................................................................................... 165

6.9.2 Digesters ................................................................................................. 166 6.9.3 Black Liquor Tanks ................................................................................. 167 6.9.4 Paper Machine (Former, Press) .............................................................. 167

6.9.5 Bleaching ................................................................................................ 168 6.9.6 Evaporators/Boilers ................................................................................. 168

6.10 Shipbuilding .............................................................................................. 170

6.10.1 Chemical Tankers ................................................................................. 170

6.10.2 Icebreaker Hulls .................................................................................... 172

6.11 Transition Joints ....................................................................................... 174

6.12 Hydrometallurgy ....................................................................................... 180

6.13 Polysilicon ................................................................................................. 181

6.14 Food and Beverage .................................................................................. 182

7 Forecast ......................................................................................................... 183

7.1 Project Activty by Region .......................................................................... 183

7.1.1 Summary ................................................................................................ 183

7.1.2 Africa ....................................................................................................... 184 7.1.3 Asia ......................................................................................................... 185

7.1.4 Australia .................................................................................................. 187 7.1.5 CIS .......................................................................................................... 188

7.1.6 Europe .................................................................................................... 189



7.1.7 Middle East ............................................................................................. 190

7.1.8 North America ......................................................................................... 192 7.1.9 South America ........................................................................................ 194

7.2 Clad Plate Demand Forecast by Region ................................................... 195

8 Clad Plate Producers .................................................................................... 197

8.1 Producers of Roll Bonded Clad Plate ....................................................... 197

8.1.1 voestalpine Grobbelch ............................................................................ 197 8.1.2 JSW ........................................................................................................ 200

8.1.3 JFE Steel Corporation ............................................................................. 202 8.1.4 Industeel ................................................................................................. 204 8.1.5 Nippon Steel & Sumitomo Metal Corp. ................................................... 206 8.1.6 Shandong Baode Metal Clad .................................................................. 207 8.1.7 Jiangsu Debei ......................................................................................... 211

8.1.8 AMETEK Specialty Metal Products ......................................................... 212

8.2 Producers of Explosion Bonded Clad Plate ............................................. 214

8.2.1 NobelClad™/DMC Corporation ............................................................... 214 8.2.2 BACLAD™/Asahi Kasei Corporation ...................................................... 219 8.2.3 TISCO ..................................................................................................... 221

8.2.4 Hanwha Corporation ............................................................................... 222 8.2.5 Shockwave Metalworking Technologies ................................................. 223

8.2.6 Energometall ........................................................................................... 224

8.2.7 ICEM Engineering Company................................................................... 225

8.2.8 Sichuan JInglei ........................................................................................ 226 8.2.9 Baoji Baotai ............................................................................................. 227 8.2.10 Dalian Shipbuilding ............................................................................... 228

8.2.11 Nanjing Baotai ....................................................................................... 229 8.2.12 Xian Tianli ............................................................................................. 230

8.2.13 Zhengzhou Yugunag ............................................................................. 231 8.2.14 Nanjing Runbang .................................................................................. 232

9 Users of Clad Plate ....................................................................................... 233

9.1 Clad Pipe Producers and Providers of Weld Overlay .............................. 233

9.1.1 List of Companies ................................................................................... 233 9.1.2 Butting ..................................................................................................... 234

9.1.3 Canadoil Group ....................................................................................... 237

9.1.4 Cladtek International ............................................................................... 240 9.1.5 EEW Erndtebrücker Eisenwerk ............................................................... 241 9.1.6 Eisenbau Krämer (EBK) .......................................................................... 243 9.1.7 Gieminox Tectubi Racordi ....................................................................... 244



9.1.8 Inox Tech ................................................................................................ 245

9.1.9 IODS Pipe Clad ....................................................................................... 246 9.1.10 Jiuli Hi-Tech Metals ............................................................................... 247 9.1.11 JSW ...................................................................................................... 248 9.1.12 MesoCoat ............................................................................................. 249 9.1.13 PCC Klad .............................................................................................. 250

9.1.14 Proclad Group ....................................................................................... 251 9.1.15 Protubo ................................................................................................. 252 9.1.16 Wellclad ................................................................................................ 253

9.2 Other End Users ......................................................................................... 254

10 Authors of this Report .................................................................................. 255

Wolfgang Lipp ................................................................................................... 255

Alina Racu ......................................................................................................... 255

Markus Moll ....................................................................................................... 255

11 How to Order this report? ............................................................................ 256


© SMI – Steel Market Intelligence GmbH 2016 Page 8

1 INTRODUCTION

1.1 CLAD PLATES

Extensively used in industrial applications, clad steel plates are composed of two or more different materials, called base metal and cladding metal (CRA incl. stainless steel, nickel alloy or Titanium). They combine the higher strength and better thermal conductivity of the base material with corrosion resistance of the cladding material. Due to lower material cost of the base material, clad plate are an economical option compared to solid CRA plates.

There are two different production process to produce clad plates: roll bonding and explosion bonding. Alternatively, weld overlay can be applied on finished equipment (e.g. vessel components, pipes) as a competing solution to clad plates.

The choice of the method depends primarily on the material and dimension requirements. While the roll bonded clad plates are considered to have superior quality over explosion bonding and are usually available in wider widths, the latter is preferred for larger thicknesses or for welding dissimilar metals. Weld overlay is used for large thicknesses but limited surfaces as the process is time consuming.

The tables below compare dimension and material ranges across the three types of metallurgical bonding processes.

This study will cover roll bonded and explosion bonded clad plates and also discuss metallurgical bonded clad pipes and mechanically lined pipes.

Clad Plate Type

Plate

Thickness

[in mm]

Cladding

Thickness

[in mm]

Width

[in mm]

Length

[in m]

Weight

[in t]

Roll Bonded Clad Plate 6.0 - 200.0 0.5 - 12.0 1,000 - 5,000 2.5 - 17.0 max. 17

Explosion Bonded Clad Plate 6.0 - 500.0 1.0 - 30.0 100 - 5,000 1.0 - 13.0 max. 50

Weld Overlay min. 5.0 min. 2.5

Clad Plate Type Thin Wall Heavy Wall Large WidthRefractory

Metals

Roll Bonded Clad Plate ++ + ++ +

Explosion Bonded Clad Plate - - ++ - ++

Weld Overlay - ++ - - -

Limited by access of equipment

Only available for subscribers.




1.1.1 Rolled Clad Plates

The process of roll bonding involves a clad assembly made of two plates vacuum sealed together in the sandwich method (i.e. backing steel, cladding, parting compound, cladding and backing steel again) which is then rolled to achieve metal-to-metal bonding, then heat treated and cut. The metallurgical bond is created under high pressure and high temperature conditions.

Japan Steel Works (JSW), a major producer of clad plates and clad pipes describes the process as follows: “Two pairs of plates, each with the backing steel outside and cladding metal inside are matched together to form a composite assembly and then sealed along the edges by welding. The welding is performed to protect the corrosion resistant alloy from possible contamination by exposure to atmosphere during heating before rolling. The composite assembly is heated to the proper temperature in a heating furnace and rolled to the given sizes in order to bond the cladding and backing materials metallurgically. After rolling, the assembly is heat-treated as required considering the mechanical properties of the backing steel and corrosion resistance of the cladding metal. The assembly is then separated into two clad plates to be cut into given dimensions. In order to assure and guarantee the quality of the clad plates, ultrasonic examination and mechanical testing are conducted.”

Roll bonded clad plate process, source: Japan Steel Works, www.jsw.co.jp/en/



The production process for producing roll bonded clad plates requires a lot of additional process steps compared to rolling solid steel plates resulting in higher processing and labour costs.

Source: voestalpine Grobblech GmbH, conference paper “Stainless steel clad plates -Production possibilities and typical applications” held at SMR Conference in Marbella, Spain in November 2009

A ‘sandwich’ clad assembly consists of the following layers:

Base material (shot blasted, bottom side ground)

CRA material (top side ground)

Seperating medium

CRA material (bottom side ground=)

Base material (shot boasted, top side ground)

Afterwards, the clad assembly is basically rolled in a plate mill like a solid plate (re-heating, hot rolling, levelling, and heat treatment). After hot rolling, the plates are separated from each other and processed like individual plates (incl. heat treatment, plasma torch cutting, ultrasonic testing, surface finishing, and packaging).



Materials

The following materials are most often used as base materials for roll bonding:

Carbon steel: ASTM A285 gr A, B, C

C-Mn steel: ASTM A516/ASME SA516 Gr. 60, 65, 70

ASTM A537/ASME SA537 Cl.1, 2

C-Mn-Mo steel: ASME SA204 Gr. A, B, C

Cr-Mo steel: ASTM A387/ASME SA387, Gr. 11, 12, 22, Cl. 1, 2

Cr-Mo-V steel: ASTM A542/ASME SA542, Gr. D

C-Mn-Mo-Ni (Q&T): ASTM A533/ASME SA533 Gr. B, C, E

Cladding materials include stainless steel and nickel alloys most often, but also titanium and copper alloys.

Stainless steel: Ferritic/martensitic: 405, 410S, 430

Austenitic: 304/L, 316/L/LMo/Ti/Cb, 317L/LN/LMN, 309, 310S, 321, 347

Super-austenitic: 6Mo, 254SMO, AL-6XN, 25-6Mo, Alloy 28, 926, 904L

Duplex & Super Duplex: 2304, 2205, 2507, 329, 44LN, 255

Ni alloys: Inconel 600, 625, Incoloy 800, 825, Hastelloy C276, C22, C4, Monel 400, Ni 200, 201

Titanium: Gr. 1, 2, 3, 4, 7, 11

Cu alloys: C10200 (B152), C12200, C61400 (B169), C63000 (B171), C46400 (B171), C70600 (B122, B171), C71500



Roll bonded clad plate, source: Voestalpine, www.voestalpine.com

Dimensions

Plate thickness: 6.0 – 200.0 mm, most common 40.0 – 50.0 mm

Cladding thickness: Typically 0.5 – 12.0 mm, most common 2.0 – 3.5 mm

Theoretically 5% – 40% from plate thickness

Stainless steel: 0.5 – 12.0 mm

Nickel alloys: 1.5 – 12.0 mm

Titanium: 1.0 – 8.0 mm

Plate width: 1,000 – 4,800 mm, most common > 2,500 mm

Plate length: 2.5 – 17.0 m

Plate weight: Up to 17 t

Usually the clad plate is supplied with the base material as rolled or shot blasted and the cladding material ground with a grain size of 80.




1.1.2 Explosion Clad Plates

Explosion bonded plates are produced by means of explosion welding, which involves the bonding of two or more dissimilar metals with the aid of explosives. The metal surfaces are compressed together under high pressure from the explosion, which causes the valence electrons of the metals to cross into each other’s sphere of influence. The entire process is carried out at ambient temperature, thus there is no heating of the metals.

During the explosion, a shockwave is created which is transmitted through the two metal layers which can produce a slight wave effect in the material which can be seen with the naked eye in the area where the metals join. This wavy structure constitutes according to roll bonding plate producers a disadvantage in regards with precision, while explosion bonding plate producers argue that this is a sign of better bonding.

Explosion bonding is used to weld compatible metals such as stainless steel and nickel alloys to carbon steel, but especially metals that cannot be welded by conventional processes, such as titanium to steel, aluminium to steel and aluminium to copper or refractory metals to steel.

Explosion cladding process, source: NobleClad presentation “Explosion Welding in the Energy Industry” by Warren Salt, February 2014, www.nobelclad.com



Dimensions

Plate thickness: 6.0 – 500.0 mm, most common > 50.0 mm

Up to 625.0 mm in Korea

Cladding thickness: 1.0 – 30.0 mm, most common 1.5 – 16 mm

Stainless steel: 1.0 – 30.0 mm

Nickel Aluminium/Copper alloys: 1.0 – 25.0 mm

Titanium: 1.0 – 10.0 mm

Zirconium/Tantalum: 1.0 – 8.0 mm

Plate width: 100 – 5,000 mm

Plate length: 1 – 13 m, up to 16 m in China

Weight: Up to 50 t

In theory there is no limit to the thickness of the base metal, but rather the limitation comes from the weight capacity of the producers.

Explosion bonded clad plate producers tend to be more competitive compared to roll bonded plate producers in thicknesses above 50 mm. For thicknesses above 100 – 150 mm, end users (pressure vessel manufacturers) often prefer forgings for vessel shells which are then cladded with weld overlay.

Testing

Shear strength test

Tensile strength test

Bending test (face bend test, reverse face bend test)

Hammer bend test

Hardness test (for explosion cladding, annealing is necessary for stress relief)

Ultrasonic testing




1.1.4 Size Range Comparisons

The following chats summarize the size ranges for roll bonded and explosion clad plate. Typically, roll bonded plates have lower thicknesses (most common 25 – 75 mm) compared to explosion bonded plates (most common 75 – 150 mm). As the sizes of explosion bonded plate are limited by the maximum weight per plate (up to 35 t), plates with heavier thicknesses are only available in narrower widths and/or shorter lengths.

Pla

te T

hic

kn

es

s

Plate Width

Clad Plate Production – Size Range

(assumed plate length 12 m, weight limitation explosion 35 t, rolled 17 t )

Roll Bonded

Explosion Bonded

Most Common

Solid STS

< 50 mm

Weld-

overlay

incl.

forgings

with weld-

overlay

> 100 mm

Competing

Products

Rolled

Explosion



1.2 CLAD PIPES

Clad pipes constitute a major end use segment (volumes heavily fluctuating depending on number of pipe projects) application for clad plates as they are used across most of the industries, especially in the oil & gas industry. The adoption of clad pipes as a solution began in the 1990s and the demand in oil & gas is expected to continue to increase.

One reason for choosing clad pipe over solid CRA pipe is the higher strength of the carbon steel host material allowing thinner walls and less weight. The second reason is lower costs with the same corrosion resistance compared to solid CRA material.

There are several production processes for clad pipes. Considering the entire pipe laid since the early 1970s, approximately 50% by length is metallurgically clad (longitudinally welded and seamless) and 50% is lined. However, an emergency replacement project in Kazakhstan brought unexpected demand for metallurgical clad pipe in 2015.

Another technique to manufacture clad pipes is weld overlay where the clad metal layer is deposited on the base metal using arc welding type processes. Weld overlay offers a long life and high reliability corrosion resistance. However, due to the fact that it is very labour intensive and time consuming, weld overlay is used only for small surfaces and niche applications. The main suppliers of weld overlay pipes are ProClad and IODS.

The following table summarizes the main sizes available for each clad pipe process.

Clad Pipe TypeNB

[in inch]

WT

[in mm]

Length

[in m]Suppliers

Metallurgically Bonded 4" - 100" 6- 80 12.8Butting, Canadoil, EEW, EBK,

Gieminox, JSW, Inox Tech,

Mechanically Bonded 4" - 40" 5 - 65 12.0Butting, Cladtek, Kuroki, PCC Klad,

Proclad

Co-Extruded Seamless 2" - 14" 6 - 35 12.8 Schulz USA




2 CLAD PLATE PRODUCTION

2.1 LONG TERM TREND

2.1.1 Correlation to Nickel and Oil Prices

The volumes of clad plate tends to correlate with nickel prices, as high nickel prices make cladding more economical compared to solid plates. However, major projects like Kashagan in 2015 can distort this picture.

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

0

25

50

75

100

125

150

[Cla

dP

late

Pro

du

cti

on

in

1,0

00

to

nn

es

]

Rolled Clad Plate Market vs. Nickel Price Fluctuations (2000 – 2015)

[Nic

kel P

rice U

SD

/to

nn

e]

Correlation Coefficient (Excl.

Kashagan Project in 2015):

75%



[in

1,0

00

to

nn

es

]

China ROW

Roll Bonded Clad Plate Production Development in China vs. ROW (2000 – 2015)

European and Japanese suppliers are still leading the market for roll bonded clad plate but Chinese producers are steadily entering the market, building up capacities that could potentially exceed the volumes of today’s top producers.



2.3 PRODUCTION BY PRODUCER (2015)

2.3.1 Roll Bonded Clad Plate

[in

1,0

00

to

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es

]

Top Roll Bonded Clad Plate Producers (2015)




2.3.2 Explosion Bonded Clad Plate

0

10

20

30

40

50

60

[in

1,0

00

to

nn

es

]

Top Explosion Bonded Clad Plate Producers (2015)




0% 25% 50% 75% 100%

6 - 50 mm

51 - 120 mm

121 - 250 mm

> 250 mm

<1,500 mm 1,500 - 2,000 mm 2,001 - 2,500 mm >2,500 mm

Explosion Bonded Clad Plate Consumption by Thickness and Width (2015)

Explosion Bonded Clad Plate Consumption by Thickness and Width (2015)

<1,500 mm1,500 -

2,000 mm

2,001 -

2,500 mm>2,500 mm Total <1,500 mm

1,500 -

2,000 mm

2,001 -

2,500 mm>2,500 mm Total

< 6 mm 0,0 0,0 0,0 0,0 0,0 0% 0% 0% 0% 0%

6 - 50 mm 8,5 29,9 34,9 12,0 85,3 22% 30% 27% 44% 29%

51 - 120 mm 16,4 49,9 81,8 15,0 163,0 43% 51% 64% 56% 56%

121 - 250 mm 10,0 15,0 8,0 0,0 32,9 26% 15% 6% 0% 11%

> 250 mm 3,0 4,0 3,0 0,0 10,0 8% 4% 2% 0% 3%

Total Clad Plate 37,8 98,7 127,7 26,9 291,2 100% 100% 100% 100% 100%

<1,500 mm1,500 -

2,000 mm

2,001 -

2,500 mm>2,500 mm Total <1,500 mm

1,500 -

2,000 mm

2,001 -

2,500 mm>2,500 mm Total

< 6 mm 0,0 0,0 0,0 0,0 0,0 0% 0% 0% 0% 0%

6 - 50 mm 8,5 29,9 34,9 12,0 85,3 10% 35% 41% 14% 100%

51 - 120 mm 16,4 49,9 81,8 15,0 163,0 10% 31% 50% 9% 100%

121 - 250 mm 10,0 15,0 8,0 0,0 32,9 30% 45% 24% 0% 100%

> 250 mm 3,0 4,0 3,0 0,0 10,0 30% 40% 30% 0% 100%

Total Clad Plate 37,8 98,7 127,7 26,9 291,2 13% 34% 44% 9% 100%

Plate Thickness

Plate Width

[in 1,000 tonnes] [in %]


Plate Thickness

Plate Width






5.2 MARKET BY GRADE

5.2.1 Total Clad Plate

Clad Plate Consumption by Cladding Grade (2015)

Roll

Bonded

Clad Plate

Explosion

Bonded

Clad Plate

Total

Roll

Bonded

Clad Plate

Explosion

Bonded

Clad Plate

Total

304/L 19,5 66,6 86,0 13% 23% 20%

316/L 30,5 64,6 95,1 21% 22% 22%

Other 300 3,8 9,7 13,5 3% 3% 3%

Super Austenitic 1,0 2,9 3,8 1% 1% 1%

400 Series 3,9 12,5 16,4 3% 4% 4%

Duplex/Super Duplex 2,3 4,1 6,4 2% 1% 1%

Other Stainless Steel 0,7 2,3 3,0 0% 1% 1%

Total Stainless Steel 61,56 162,64 224,2 42% 56% 51%

600 0,6 2,3 2,9 0% 1% 1%

625 68,1 7,4 75,5 47% 3% 17%

825 3,1 2,7 5,8 2% 1% 1%

C276 1,6 5,2 6,7 1% 2% 2%

Monel 400 0,6 1,6 0% 1%

Other Nickel Alloys 0,7 1,9 2,6 0% 1% 1%

Total Nikel Alloys 74,59 21,05 95,6 51% 7% 22%

Titanium 8,5 86,5 95,0 6% 30%

Aluminium & Aluminium Alloys 0,3 10,6 10,8 0% 4%

Copper & Copper Alloys 1,2 5,6 6,8 1% 2% 2%

Other 0,1 4,8 4,8 0% 2% 1%

Total Clad Plate 146,1 291,2 437,3 100% 100% 100%

Cladding Grade





5.3.2 Clad Plate Consumption by Industry

0

50

100

150

200

250

[in

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Explosion Bonded Clad Plate

Roll Bonded Clad Plate

Clad Plate Consumption by Industry (2015)

*Including: Building & Construction, Yellow Goods, Hydrometallurgy, Defence

Clad Plate Consumption by Industry (2015)

Roll Bonded

Clad Plate

Explosion

Bonded Clad

Plate

TotalRoll Bonded

Clad Plate

Explosion

Bonded Clad

Plate

Total

Oil & Gas Upstream 20,9 27,0 47,9 14% 9% 11%

Refineries, Petrochemical, Chemical 58,7 154,9 213,6 40% 53% 49%

Power Generation 10,3 26,1 36,4 7% 9% 8%

Environmental Control, FGD 10,6 9,1 19,7 7% 3% 5%

Desalination 4,5 9,5 14,0 3% 3% 3%

Pulp & Paper 9,6 9,4 18,9 7% 3% 4%

Food & Beverage 5,4 7,8 13,2 4% 3% 3%

Shipbuilding 21,3 15,2 36,5 15% 5% 8%

Yellow Goods, Mining 0,6 0,1 0,7 0% 0% 0%

Building & Construction 2,8 0,5 3,3 2% 0% 1%

Transition Joints 0,0 13,6 13,6 0% 5% 3%

Others (Metallurgy, Defence, etc.) 1,3 18,1 19,4 1% 6% 4%

Total 146,1 291,2 437,3 100% 100% 100%

Roll Bonded

Clad Plate

Explosion

Bonded Clad

Plate

TotalRoll Bonded

Clad Plate

Explosion

Bonded Clad

Plate

Total

Oil & Gas Upstream 20,9 27,0 47,9 44% 56% 100%

Refineries, Petrochemical, Chemical 58,7 154,9 213,6 27% 73% 100%

Power Generation 10,3 26,1 36,4 28% 72% 100%

Environmental Control, FGD 10,6 9,1 19,7 54% 46% 100%

Desalination 4,5 9,5 14,0 32% 68% 100%

Pulp & Paper 9,6 9,4 18,9 50% 50% 100%

Food & Beverage 5,4 7,8 13,2 41% 59% 100%

Shipbuilding 21,3 15,2 36,5 58% 42% 100%

Yellow Goods, Mining 0,6 0,1 0,7 81% 19% 100%

Building & Construction 2,8 0,5 3,3 84% 16% 100%

Transition Joints 0,0 13,6 13,6 0% 100% 100%

Others (Metallurgy, Defence, etc.) 1,3 18,1 19,4 7% 93% 100%

Total 146,1 291,2 437,3 33% 67% 100%

Industry

[in 1,000 tonnes]

[in 1,000 tonnes]

[in %]

Industry

[in %]





6 DESCRIPTION OF APPLICATIONS

6.1 OVERVIEW

Clad plates are used for the following industries and applications:

Oil & Gas: separators, absorbers, slug catchers, flowlines, pipelines, catenary risers (SCR), fittings

Refineries/Petrochemical Industry: columns, reactors, fractionators, vacuum towers, distillation towers, hydrocrackers, hydrosulfurisers, coke drums

Fertilizer Industry (Urea, Ammonia): strippers, reactors, heat exchangers

Chemical Industry: columns, pressure vessels, reactors, polymerisers, pipes, heat exchangers, evaporators, washers

Power Generation: condenser tube sheets, geothermal plants, coal gasification, hydroelectricity (dam gates, shield plates), nuclear plant components, biofuels

Environmental Technology: flue gas desulphurization (flue gas channels, chimney, scrubbers, ducts), garbage incineration plants

Seawater Desalination: pipes, heat exchangers, evaporator shells, water boxes, pump vessels, flash chambers

Pulp & Paper: pulp boilers, bleaching plants, steaming vessels, digesters, evaporators, evaporator pipe plates

Food Industry: boiling pans for breweries, equipment for industrial kitchens, fermenters, premium induction cookware

Shipbuilding: chemical tankers, ice breakers, propeller systems

Others: e.g. transition joints, hydrometallurgy (reactors), metallurgy (electro galvanizing rolls, nitriding salt baths), defence, electrical equipment



Clad Plate Materials & Grades Used by Industry

304/L 316/L 317/L 309 310 321 347 301 904L6Mo/254

SMO405 410/S 1Cr13

Duplex/

Super

Duplex

Flowlines & Pipelines

Steel Catenary Risers

Subsea Jumpers

Slug Catchers

Subsea Manofold Piping

Topside Pressure Vessels & Separators

Topside Process Pipes & Fittings

Splash Zone Sheathing

Refineries, Petrochemical, Chemical Pressure Vessels

Fertilizer Pressure Vessels

Storage Tanks Storage Tanks

Shell & Tube, Plate

Thin Film Evaporators

Air Gas Coolers

Condensers

Geothermal

Coal Gasification

FGD Scrubbers, Chimneys

Evaporators

Water Boxes

Deaerators

Venting Systems

Steaming Vessels

Digesters

Bleaching

Impergnators

Evaporators/Boilers

Tanks

Paper Machine

Chemical Tankers

Icebreakers

Structural Transition Joints

Cryogenic Transition Joints

Electrical Transition Joints

Hydrometallurgy

Polysilicon

Stainless Steel

Other Industries

Industry Application

Heat Exchangers

Oil & Gas Upstream

Power Generation

Desalination, Water Treatment

Pulp & Paper

Shipbuilding

Transition Joints

Clad Plate Materials & Grades Used by Industry

600 625 800 825 C276Monel

400Ni 200 Alloy 20

Other

Nickel

Alloys*

TiAl & Al

Alloys

Cu & Cu

Alloys**Zr Ta

Flowlines & Pipelines

Steel Catenary Risers

Subsea Jumpers

Slug Catchers

Subsea Manofold Piping

Topside Pressure Vessels & Separators

Topside Process Pipes & Fittings

Splash Zone Sheathing

Refineries, Petrochemical, Chemical Pressure Vessels

Fertilizer Pressure Vessels

Storage Tanks Storage Tanks

Shell & Tube, Plate

Thin Film Evaporators

Air Gas Coolers

Condensers

Geothermal

Coal Gasification

FGD Scrubbers, Chimneys

Evaporators

Water Boxes

Deaerators

Venting Systems

Steaming Vessels

Digesters

Bleaching

Impergnators

Evaporators/Boilers

Tanks

Paper Machine

Chemical Tankers

Icebreakers

Structural Transition Joints

Cryogenic Transition Joints

Electrical Transition Joints

Hydrometallurgy

Polysilicon

*B3, C22, Alloy 59 **Cu-Ni

Nickel Alloys Other Metals & Alloys

Other Industries

Industry Application

Heat Exchangers

Oil & Gas Upstream

Power Generation

Desalination, Water Treatment

Pulp & Paper

Shipbuilding

Transition Joints





6.2.5 Slug Catchers

A slug catcher, which is a part of the gas pipeline system, is essential equipment at the receiving terminal of a multiphase-flow processing plant. Slug catchers can be broadly classified into three following categories:

Vessel type

Stored-loop type

Finger (multiple-pipe) type

A vessel-type slug catcher is a simple two-phase separation vessel.

In a stored-loop-type slug catcher the gas/liquid separation occurs in the vessel, while the liquid is stored in the stored-loop-shaped fingers.

A finger-type slug catcher uses pieces of large-diameter pipe instead of a conventional vessel to provide a buffer volume. Since pipe can be more easily designed to withstand high pressures compared to a vessel, this design is better suited for large-diameter pipes.

Stored-loop-type slug catcher and finger-type (multiple-pipe) slug catcher, source: “A new approach for sizing finger-type (multiple-pipe) slug catchers” by H. R. Kalat Jari, P. Khomarloo and K. Assa, Gas Processing Magazine, www.gasprocessingnews.com

In 2010 NobleClad supplied clad plate (carbon steel API 5L X65M cladded with Inconel 625) for slug catchers in the Gorgon gas project, Australia's largest resource project:

17 plates, thickness 37 mm, width 3.2 m, length 12.6 m

136 plates, thickness 37 mm, width 3.2 m, length 12.3 m



In 2016, Belleli Energy/Exterran is set to supply several slug catchers to the Al Dabb'ya onshore pipeline project (for natural gas) in UAE:

Slug catcher: ID 6.4 m, thickness 48 mm carbon steel SA516 Gr.70N cladded with 3 mm nickel alloy 825, total weight 270 t

1st stage separator: ID 6.9 m, thickness 44 mm carbon steel SA516 Gr.70N cladded with 3 mm nickel alloy 825, total weight 270 t

2nd stage separator: ID 6.4 m, thickness 26 mm carbon steel SA516 Gr.70N cladded with 3 mm nickel alloy 825, total weight 168 t

Separator equipment, source: NobleClad, www.nobleclad.com

Italian equipment maker Bremaba & Rolle e.g. produced the following slug catcher vessels. Weld overlay was used as competing technology to clad plate. The left one was supplied for a refinery project in Qatar and had a weight of 140 t.; A516 Gr. 70 + 316L (76 + 5 mm) were used. The vessel on the right was delivered for a gas plant in the UAE. The weight was 400 t; thickness of 135 mm (SA5126 Gr. 65 + 625).

,

Source: Brembana&Rolle, www.brembanarolle.com

http://www.nobleclad.com/



Dimensions:

Thickness: 26 – 150 mm plus cladding; e.g. 26 + 3, 37 + 3, 40 + 4, 44 + 3, 48 + 3, 76 + 5, 135 + 3, 150 + 3 mm

Length: around 12 m

Materials

Base: Carbon steel (e.g. SA516 G70)

Cladding: 316L, 825, 625



10 AUTHORS OF THIS REPORT

WOLFGANG LIPP

Wolfgang is the Managing Director of Austrian based Steel Market Intelligence GmbH. He holds a degree in International Marketing from the University of Applied Sciences, Kufstein, Austria. He had pursued a part of his studies at the California Lutheran University in the USA. In 2002, he joined SMR as a Market Analyst and later he was promoted to the position of Managing Director of the newly created SMI GmbH. Wolfgang has been following and analysing the stainless and special steel industry for more than 10 years and has been responsible for all tube & pipe related projects of the SMR Group.

ALINA RACU

Alina Racu joined the SMI team in late 2010 as a Research Analyst and assists Wolfgang Lipp in conducting market studies. In 2014, she was promoted to the position of Market Analyst and now is responsible also for her own projects. Prior to working at SMI, she earned a double degree in Business Administration and Political Science in Bucharest, Romania, and then pursued a graduate programme in Business Consultancy with focus on Marketing at the University of Applied Sciences Wiener Neustadt, Austria.

MARKUS MOLL

Markus is the Managing Director of Austrian based Steel & Metals Market Research GmbH (SMR) which he founded in 1994. He has been analysing the stainless and special steel markets for more than 20 years. Markus holds a degree in mechanical engineering and a degree in economics from the University of Innsbruck, Austria.



11 HOW TO ORDER THIS REPORT?

If you would like to order this report or learn more about the content of the report, please contact us:

SMI - Steel Market Intelligence GmbH Kohlplatz 7 6600 Reutte Austria

Tel. +43 (5672) 64262

Wolfgang Lipp Managing Director

[email protected]

mailto:[email protected]

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