Corrosive environment temperature

Atmospheric corrosion results from a metal s ambient-temperature reaction, with the earth s atmosphere as the corrosive environment. Atmospheric corrosion is electrochemical in nature, but differs from corrosion in aqueous solutions in that the electrochemical reactions occur under very thin layers of electrolyte on the metal surface. This influences the amount of oxygen present on the metal surface, since diffusion of oxygen from the atmosphere/electrolyte solution interface to the solution/metal interface is rapid. Atmospheric corrosion rates of metals are strongly influenced by moisture, temperature and presence of contaminants (e.g., NaCl, SO2,. ..). Hence, significantly different resistances to atmospheric corrosion are observed depending on the geographical location, whether mral, urban or marine. 

Other alloys have been developed for use in particular corrosive environments at high temperatures. Several of these are age-hardenable alloys which contain additions of aluminum and titanium. Eor example, INCONEL alloys 718 and X-750 [11145-80-5] (UNS N07750) have higher strength and better creep and stress mpture properties than alloy 600 and maintain the same good corrosion and oxidation resistance. AHoy 718 exhibits excellent stress mpture properties up to 705°C as well as good oxidation resistance up to 980°C and is widely used in gas turbines and other aerospace appHcations, and for pumps, nuclear reactor parts, and tooling. 

The first commercial use of tantalum was as filaments ia iacandescent lamps but it was soon displaced by tungsten. Tantalum is used ia chemical iadustry equipment for reaction vessels and heat exchangers ia corrosive environments. It is usually the metal of choice for heating elements and shields ia high temperature vacuum sintering furnaces. In 1994, over 72% of the tantalum produced ia the world went iato the manufacturiag of over 10 x 10 soHd tantalum capacitors for use ia the most demanding electronic appHcations. 

If the production of vinyl chloride could be reduced to a single step, such as dkect chlorine substitution for hydrogen in ethylene or oxychlorination/cracking of ethylene to vinyl chloride, a major improvement over the traditional balanced process would be realized. The Hterature is filled with a variety of catalysts and processes for single-step manufacture of vinyl chloride (136—138). None has been commercialized because of the high temperatures, corrosive environments, and insufficient reaction selectivities so far encountered. Substitution of lower cost ethane or methane for ethylene in the manufacture of vinyl chloride has also been investigated. The Lummus-Transcat process (139), for instance, proposes a molten oxychlorination catalyst at 450—500°C to react ethane with chlorine to make vinyl chloride dkecfly. However, ethane conversion and selectivity to vinyl chloride are too low (30% and less than 40%, respectively) to make this process competitive. Numerous other catalysts and processes have been patented as weU, but none has been commercialized owing to problems with temperature, corrosion, and/or product selectivity (140—144). Because of the potential payback, however, this is a very active area of research. 

Oxygen concentration is an especially important parameter to metals exposed to aqueous environments. Temperature and temperature gradients should also be reproduced as closely as possible. Concentration gradients in solutions also should be reproduced closely. Careful attention should be given to any movement of the corrosive medium. Mixing conditions should be reproduced as closely as possible. 

Steel is the most common constructional material, and is used wherever corrosion rates are acceptable and product contamination by iron pick-up is not important. For processes at low or high pH, where iron pick-up must be avoided or where corrosive species such as dissolved gases are present, stainless steels are often employed. Stainless steels suffer various forms of corrosion, as described in Section 53.5.2. As the corrosivity of the environment increases, the more alloyed grades of stainless steel can be selected. At temperatures in excess of 60°C, in the presence of chloride ions, stress corrosion cracking presents the most serious threat to austenitic stainless steels. Duplex stainless steels, ferritic stainless steels and nickel alloys are very resistant to this form of attack. For more corrosive environments, titanium and ultimately nickel-molybdenum alloys are used. 

Certain environments containing nitrate, cyanide, carbonate, amines, ammonia or strong caustic, due to the risk of stress corrosion cracking. Temperature is an important factor in assessment of each cracking environment ... 

Figure 4.35 illustrates the effect of temperature on the rate of development of pitting, measured as a corrosion current in an acidic solution containing Cl it is seen that quite small increments in temperature have large effects. The influence of temperature is of considerable significance when metals and alloys act as heat transfer surfaces and are hotter than the corrosive environment with which they are in contact. In these circumstances. 

The extent to which low alloy steels react to high temperature corrosive environments is the subject of this chapter. In view of the commercial importance of these steels, the published literature on this topic is extensive and is being continually enlarged. The reader is encouraged to refer to the many excellent papers and current issues of the journals, referenced at the end of the chapter, for more detailed and contemporary information on the topic. 

This is a prolific field for inhibitors although the main types remain as grouped by Bergmanm (see p. 17). In this application of inhibitors, probably more than in any other, the methods of introducing the inhibitor into the corrosive environment receive as much attention as the nature of the inhibitor. The most severe conditions are those met in acidising treatments, typically with 15-35% hydrochloric acid at high downhole temperatures. 

Inhibitors must be chosen after taking into account the nature and combinations of metals present, the nature of the corrosive environment and the operating conditions in terms of flow, temperature, heat transfer, (see Principles p. 17 14). 

It is often difficult to conduct laboratory tests in which both the environmental and stressing conditions approximate to those encountered in service. This applies particularly to the corrosive conditions, since it is necessary to find a means of applying cyclic stresses that will also permit maintenance around the stressed areas of a corrosive environment in which the factors that influence the initiation and growth of corrosion fatigue cracks may be controlled. Among these factors are electrolyte species and concentration, temperature, pressure, pH, flow rate, dissolved oxygen content and potential (free corrosion potential or applied). 

Sensitisation susceptibility to intergranular attack in a corrosive environment resulting from heating a stainless steel at a temperature and time that results in precipitation of chromium carbides at grain boundaries. 

Make environment less aggressive by removing constituents that facilitate corrosion decrease temperature, decrease velocity where possible prevent access of water and moisture. 

A prerequisite of long-life sodium/sulfur batteries is that the cells contain suitable corrosion-resistant materials which withstand the aggressively corrosive environment of this high—temperature system. Stackpool and Maclachlan have reported on investigations in this field [17], The components in an Na/S cell are required to be corrosion-resistant towards sodium, sulfur and especially sodium polysulphides. Four cell components suffer particularly in the Na/S environment the glass seal, the anode seal, the cathode seal, and the current collector (in central sodium arrangements, the cell case). 

Corrosive wear results from a chemical reaction of the wear surface with the environment. In this section, only corrosion that occurs in conjunction with mechanical wear is considered. Purely corrosive wear is reviewed in Sec. 4.0 below. The chemical resistance of a given coating material must be assessed if the application involves a corrosive environment. A typical example is the environment found in deep oil and gas wells (over 500 m.), which usually contain significant concentrations of CO2, H2S, and chlorides. The corrosive effect of these chemicals is enhanced by the high temperature and pressure found at these great depths. 

Applications. CVD ceramic powders such as SiC and Si3N4 are used to produce ceramic bodies for a wide variety of applications, either experimentally or in production. These include structural applications in high temperature or corrosive environments where metals are not suitable, in such areas as reciprocating engines, gas turbines, turbochargers, bearings, machinery, and process equipment. 

We close discussion of the GS process with the comment that it is dangerous. A GS plant requires a very large inventory of highly toxic H2S employed at elevated temperature and pressure in a corrosive environment. The safety of operating personnel and of the population in the area surrounding the plant is a major concern. 

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