Alloy Solutions to Metal Dusting Problems in the Chemical Processing Industry.pdfVIP

Alloy Solutions to Metal Dusting Problems in the PetroChemical Industry Brian A. Baker and Gaylord D. Smith, Special Metals Corporation, Huntington, WV, USA Producing chemical derivatives of the refining process often involves the creation of a synthesized gas syngas stream consisting of a mixture of CO, H and H O with lower levels of CO and some CH . The synthesis and 2 2 2 4 reducing gases derived by reforming processes are used as the basic feedstock in the production of plastics, synthetics, fertilizers, fibers and pharmaceuticals. When such gas mixtures are present in the process stream in the critical temperature range of about 400° to 800°C, the phenomenon labeled “metal dusting” can potentially be a severe corrosion problem. Past and present failures resulting from metal dusting have prompted end users and material producers alike to examine the causes of and potential solutions to this often-disastrous problem. Metal dusting can be described as a catastrophic carburization phenomenon which occurs under conditions where the carbon activity of the gaseous atmosphere is greater than one. Metal dusting is manifested by the disintegration of the affected metal into a powdery mixture of graphite and metal particles. Oxides and carbides are also often present in the powdery mixture or dust. Special Metals corporation, which includes the business formerly known as Inco Alloys International, has been actively involved in characterizing and developing new materials to cope with the increasing demand on equipment in harsh metal dusting environments. Research has been conducted on a number of alloys, apart from the traditionally used primary and secondary reformer material INCOLOY? alloy 800H, to better understand the role of alloying in resisti