Process equipment corrosion

Ease of operation The system is dilute, which reduces process equipment corrosion, and operates at room temperature, which saves energy the digestion product is readily filterable. 

If produced gas contains water vapour it may have to be dried (dehydrated). Water condensation in the process facilities can lead to hydrate formation and may cause corrosion (pipelines are particularly vulnerable) in the presence of carbon dioxide and hydrogen sulphide. Hydrates are formed by physical bonding between water and the lighter components in natural gas. They can plug pipes and process equipment. Charts such as the one below are available to predict when hydrate formation may become a problem. 

BE-M71 Continuous corrosion surveillance of process equipement by new felectrochemicah sensina techninues and devices Dr. 2heng Jian Hua METALOGIC NV... 

Chromium is the most effective addition to improve the resistance of steels to corrosion and oxidation at elevated temperatures, and the chromium—molybdenum steels are an important class of alloys for use in steam (qv) power plants, petroleum (qv) refineries, and chemical-process equipment. The chromium content in these steels varies from 0.5 to 10%. As a group, the low carbon chromium—molybdenum steels have similar creep—mpture strengths, regardless of the chromium content, but corrosion and oxidation resistance increase progressively with chromium content. 

Stainless steel alloys show exceUent corrosion resistance to HCl gas up to a temperature of 400°C. However, these are normally not recommended for process equipment owing to stress corrosion cracking during periods of cooling and shut down. The corrosion rate of Monel is similar to that of mild steel. Pure (99.6%) nickel and high nickel alloys such as Inconel 600 can be used for operation at temperatures up to 525°C where the corrosion rate is reported to be about 0.08 cm/yr (see Nickel and nickel alloys). 

In appHcations as hard surface cleaners of stainless steel boilers and process equipment, glycoHc acid and formic acid mixtures are particularly advantageous because of effective removal of operational and preoperational deposits, absence of chlorides, low corrosion, freedom from organic Hon precipitations, economy, and volatile decomposition products. Ammoniated glycoHc acid Hi mixture with citric acid shows exceUent dissolution of the oxides and salts and the corrosion rates are low. 

Chemical-Process Vessels. Explosion-bonded products are used in the manufacture of process equipment for the chemical, petrochemical, and petroleum industries where the corrosion resistance of an expensive metal is combined with the strength and economy of another metal. AppHcations include explosion cladding of titanium tubesheet to Monel, hot fabrication of an explosion clad to form an elbow for pipes in nuclear power plants, and explosion cladding titanium and steel for use in a vessel intended for terephthaHc acid manufacture. 

Esters of phosphorous acid derived from aUphatic alcohols and unhindered phenols, eg, tris(nonylphenyl)phosphate (24), hydrolyze readily and special care must be taken to minimize decomposition by exposure to water or high humidity. The phosphorous acid formed by hydrolysis is corrosive to processing equipment, particularly at high temperatures. 

The thermal stabiUty of epoxy phenol—novolak resins is useful in adhesives, stmctural and electrical laminates, coatings, castings, and encapsulations for elevated temperature service (Table 3). Filament-wound pipe and storage tanks, liners for pumps and other chemical process equipment, and corrosion-resistant coatings are typical appHcations using the chemically resistant properties of epoxy novolak resins. 

Rupture Disks A rupture disk is a device designed to function by the bursting of a pressure-retaining disk (Fig. 26-15). This assembly consists of a thin, circular membrane usually made of metal, plastic, or graphite that is firmly clamped in a disk holder. When the process reaches the bursting pressure of the disk, the disk ruptures and releases the pressure. Rupture disks can be installed alone or in combination with other types of devices. Once blown, rupture disks do not reseat thus, the entire contents of the upstream process equipment will be vented. Rupture disks are commonly used in series (upstream) with a relief valve to prevent corrosive fluids from contacting the metal parts of the valve. In addition, this combination is a reclosing system. 

Information on the process reaction conditions may be impoi tant to prolonging the lifetime of process equipment. Techniques such as EIS and potentiodynamic polarization can provide just such information without being tied to a specific corrosion-rate measurement. 

Factors may throw off these rates—these are outlined in ASTM G3I, Standard Practice for Laboratory Immersion Corrosion Testing of Metals. Coupon-type tests cannot be correlated with changing plant conditions that may dramaticahy affect process equipment lifetimes. Other methods must be used if more frequent measurements are desired or correlation with plant conditions are necessary. 

Analysis of biological activity does not automatically lead directly to a corrosion-rate measurement. However, with detection and correlation with process conditions, such information may also lead to improvements in the corrosion lifetime of the process equipment. 

The addition of small amounts of alloying materials greatly improves corrosion resistance to atmospheric environments but does not have much effect against liquid corrosives. The alloying elements produce a tight, dense adherent rust film, but in acid or alkaline solutions corrosion is about equivalent to that of carbon steel. However, the greater strength permits thinner walls in process equipment made from low-alloy steel. 

Internal Electrochemical Corrosion Protection of Processing Equipment, Vessels, and Tlibes... 

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