The document discusses corrosion issues and solutions for urea and nitric acid plants. It describes the different corrosion phenomena in these plants and the special stainless steels required. These include grades 316L UG, 25.22.2, 304L, 1.4361, and 1.4335. The presentation covers projects, shut downs, revamping, debottlenecking, repairs and improvement of supply chain management for these plants. It also discusses urgent material needs, tailor made products, technical and logistic support, and contractor services.
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Gemaco Nitrogen Syngas Kuala Lumpur 2012
1. UREA AND NITRIC ACID PLANTS:
Projects, Shut down, Revamping,
Debottlenecking, Repairs
Improvement of Supply Chain
Management
Jean-Marc Sluyters
GEMACO S.A.
(Belgium)
International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia
2. Agenda
Introduction: Urea & Nitric Acid Plants:
different corrosion phenomena >> different solutions
Special stainless steels for Urea & Nitric Applications
Urgent needs
Projects & packages
Tailor made products
Technical & Logistic support
Contractor services
Conclusions
International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 2
3. Urea & Nitric Acid plants
Different corrosion phenomena > different
solutions:
Process / concentration / temperature / pressure
=> Special stainless steels vs standard material
! Risks: - Safety
- Unplanned shut down
- Impact down stream
International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 3
4. Special stainless steels for
Urea & Nitric applications
UREA
Cocktail corrosion + T° + pressure
Special grades:
316L UG – WNR. 1.4435/1.4406/1.4429
25.22.2 – UNS S31050 – 310Mo LN – WNR. 1.4466
Specifications from licensors
International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 4
5. Special stainless steels for
Urea & Nitric applications
NITRIC
Concentration and temperature
⇒ Special stainless steel
304L
WNR. 1.4361 – Uranus S1® - UNS S30600
WNR. 1.4335 – Uranus 65® - 310L – UNS 31002
International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 5
6. CORROSION RATE vs HNO3 CONCENTRATION
At boiling temperature
1.0 Corrosion rate
304L
(mm/yr)
0.8
316L
0.6
0.4
UR S1
0.2
UR 65
0.0
0 20 40 60 80 100
HNO 3 (%)
7. GUIDE TABLE FOR THE SELECTION OF STAINLESS
STEELS FOR NITRIC ACID SERVICE
< 50 % 50- 70 % >7 0 %
PURE NITRIC U R 16 / 3 0 4 L N A G / WN R . 1. 4 3 0 6 S
ACID 3 0 4 L / WN R . 1. 4 3 0 6 U R S 1 / WN R . 1. 4 3 6 1
T = 60°C U R 6 5 / WN R . 1. 4 3 3 5
PURE NITRIC
ACID U R 16 / 3 0 4 L N A G / WN R . 1. 4 3 0 6 S U R 6 5 / WN R . 1. 4 3 3 5 U R S 1 / WN R . 1. 4 3 6 1
BOILING
NITRIC ACID
+ U R S 1 / WN R . 1. 4 3 6 1 U R 6 5 / WN R . 1. 4 3 3 5 U R S 1 / WN R . 1. 4 3 6 1
OXIDIZING ( up t o 30% Boiling)
(de pe nding on R e dox )
IMPURITIES
NITRIC ACID
+ U R 6 5 / WN R . 1. 4 3 3 5 U R 6 5 / WN R . 1. 4 3 3 5
FLUORIDES
NITRIC ACID UR B 66 UR 65
+ U R 2 5 . 2 2 . 2 / WN R . 1. 4 4 6 6 U R 2 5 . 2 2 . 2 / WN R . 1. 4 4 6 6
CHLORIDES
7
8. Urgent needs
5 Mio € (± 6 Mio $) stock material:
Raw material
Bars
Pipes: thin or heavy wall
Tubes: heat exchangers, strippers or condensers
Fittings
Plates & sheets
International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 8
9. International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 9
10. International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 10
11. Projects & packages
Complete range of products
Single source of supply
Mill advantages with stock flexibility
International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 11
12. International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 12
13. Tailor made products
Bendings
Isometrics
Special fittings
International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 13
14. Technical support
European mills & approved suppliers
Right choice, right procedures
Quality requirements
Licensors
Engineers
Producers
Sub-contractors
International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 14
15. Logistic support
GEMACO 002904
Order N° : 4500948622
Client : Yara
Project Name : Urea 2000
Average Huey test Inspection Delivered
Item JE Item N° JE Code N° Qty (M-pces) Nominal Dia 1 Description Material Delivery time Heat N° Certificate N°
Thck (mm) results date Qty
1 17 HS56-PIPP ± 90 DN 25 (33,4 mm) 6,35 Smls pipes A312 TP316 L UG 29/01/2010 week 06/10 29/01/2010 I45151 1.000.178 92,93
3 19 HS56-PIPB ± 30 DN 50 (60,3 mm) 8 Smls pipes A312 TP316 L UG 28/12/2009 week 51/09 2/12/2009 I47293 0913991 32,03
I45150 0977996/2 6,202
4 20 HS56-PIPB ± 18 DN 65 (88,9 mm) 11,1 Smls pipes A312 TP316 L UG 28/12/2009 week 51/09 2/12/2009
37723 0598003/1 9,835 (2 pces)
8 24 HS56-PIPB ± 18 DN 200 (273,1 mm) 33 Smls pipes A312 TP316 L UG 28/12/2009 week 51/09 2/12/2009 47301 1468/09 16,87
9 25 HS56-FLWN 36 DN 25 (33,4 mm) 6,35 WN Flanges A182 F316 L UG 28/12/2009 week 49/09 2/12/2009 801842 14204 36
13 29 HS56-FLWN 10 DN 125 (168,3 mm) 22,2 WN Flanges A182 F316 L UG 28/12/2009 week 49/09 2/12/2009 801842 14204 10
14 30 HS56-FLWN 3 DN 175 (219,1 mm) 27,5 WN Flanges A182 F316 L UG 28/12/2009 week 49/09 2/12/2009 801842 14204 3
15 31 HS56-CAPB 2 DN 25 (33,4 mm) 6,35 Caps A182 F316 L UG 28/12/2009 week 49/09 2/12/2009 801842 14204 2
16 32 HS56-E45B 2 DN 25 (33,4 mm) 6,35** Elbow 45° LR BW A 403 WP 316 L UG 28/12/2009 week 52/09 2/12/2009 512584 53931 2
International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 15
16. International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 16
17. Contractor services
One single place
One point of responsibility
Follow up
Internal testing & controls
Spider
International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 17
18. Conclusions
Expertise + Efficiency + Flexibility + Reactivity
= No stress + Financial advantage
PERFORMANCE: higher quality for less
maintenance
PRICE®:
Professional
Reliable
Intelligent
Customized
Execution
International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 18
19. Thank you for your attention
I stay at your disposal for any
questions you may have
International Conference & Exhibition NITROGEN + SYNGAS 2012 November 9-11, 2012 > Kuala Lumpur - Malaysia 19
Editor's Notes
Good afternoon & thank you for this short review of my career; it’s maybe better than a long review of a short career! You will immediately discover that Shakespeare language is not my mother’s one but I will do my best SLIDE SUIVANT
Urea & Nitric Acid plants have to face with different kind of corrosion, different problems and need different solutions Therefore special stainless steels have been developed but are sometimes unknown or difficult to locate. What do you need? What are you expecting? Sometimes, it’s urgent to repair or modify an installation. You may have a project, brand new, for a turn around, a revamping, debottlenecking and you will need a complete package including different grades, different shapes. You will certainly require tailor made products, customized pieces acc. to drawings And you will expect technical & logistic assistance … Somebody to support you as a services provider We will finalize with conclusions & questions … Maybe answers, if I can SLIDE SUIVANT
It would take too much time to read my paper Therefore we can resume shortly as follows: Depending on the process, the concentration, the temperature, the pressure, different kind of corrosion can appear and occur the production To avoid most of those problems, special stainless steels are dedicated to those applications (exist) and prove their efficiency since many years Using standard grades is a more attractive solution regarding availability, price, welding but … it can lead to RISKS regarding safety, unplanned shut down or impact on the downstream SLIDE SUIVANT
We are facing with a nice cocktail made of corrosion, temperature up to 200°C and high pressure up to 200 bars Different solutions exist but we will focuse this time on special stainless steel grades with low Carbon, full austenitic structure, low ferrite level: 316 L UG, is a modified 316 L with low Carbon + higher C > 17 % + higher Moly content – The corrosion rate is controlled through Huey Tests 25.22.2, specially designed to improve corrosion resistance in urea carbamate environment Well known licensors like ENTER LICENSORS Snamprogetti/Saipem, Stamicarbon, Toyo, Urea Casale, and others, sometimes end users like BASF, BOREALIS, etc. consider their own specification regarding the chemical composition, the mechanical properties and the corrosion resistance SLIDE SUIVANT
The right choice for the right material is depending on the concentration & the temperature In the following graphics, you will see clearly the limit of each grade; we will make a comparison between: 304 L WNR. 1.4361 is a modified 304 L with addition of Silicon - mostly used for concentrated nitric acid (98 %) at high temperatures. The target of addition of Si is to create a silicate protection lay to reinforce the passive resistance to corrosion. WNR.1.4335 is a heat resisting 310 with Low Carbon, Low Phosphorus & Low Silicon, to keep a more stable austenite microstructure, free of intermetallic or carbide precipitations and avoid intergranular corrosion URANUS ® are trade marks of Arcelor Mittal, formerly Creusot Loire SLIDE SUIVANT
SLIDE SUIVANT
You can choose your material depending on the services conditions UR S 1 = 1.4361 UR 65 = 1.4335 UR 16 is a 304 L NAG but sole available in big production quantities > 30 Tons and not in every shape 25.22.2 – 1.4466 is also used for urea applications SLIDE SUIVANT
You need reaction; we keep about 5.0 Mio Euros material from stock as: Raw material: slabs, billets and round bars ready to be forged or extruded Solid round bars Pipes (thin or heavy wall), tubes (for heat exchangers, strippers or condensers) Fittings (elbows, tees, reducers, lens gaskets….), flanges, … Plates & sheets from 2 to 50 mm as full sizes or cut by plasma, water jet or laser SLIDE SUIVANT (Photos)
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We cover a complete range in many shapes & conditions, including forgings and gaskets, offering a single source of supply, combining mill advantages with flexibility. We can use our stock material to: Anticipate the manufacturing of fittings or flanges during the mill production of pipes or plates Provide items with smaller quantities Add, decrease or modify initial quantities (no delay, no stock surplus) Reduce the delivery time Deliver spare parts after erection SLIDE SUIVANT
ENTER PHOTO 2 ENTER PHOTO 3 ENTER SLIDE SUIVANT
You need a partner for specialties & special products; that’s why we propose also machined pieces, bendings, ENTER PHOTO - ENTER TITRE isometrics ENTER PHOTO – ENTER TITRE or special fittings made in accordance with your requirements – ENTER PHOTO SLIDE SUIVANT
We are used to work with European mills & sub-suppliers able to realize a maximum of specific or strategic assemblies, offering workshop possibilities for PWHT, pickling & passivation Thanks to our main suppliers & partners, we can provide all necessary information to guide you to the right choice, to help you in using the right procedure for forming, welding or heat treating. We analyze, comment and transmit the different requirements between licensors, engineers, producers & sub-contractors SLIDE SUIVANT
If you have good eyes or brand new spectacles, you can see how me manage & follow projects. At every stage you can have a clear status of the required & delivered quantities, the delivery time, the different places of deliveries (plant or sub-contractors), the certificates, the producer names, the controls, etc. You need a full service including traceability? We record all cert. on DVD with a link to the delivery note. We organize in compliance with your requirements marking, tagging, packaging & expediting by road, sea or airfreight, standard or urgent. SLIDE SUIVANT
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1 single place, ENTER TITRE 1 single point of 1 responsibility From the 1 st step, we support you, offering the most efficient solution corresponding to your dreams (I mean your needs) From the negotiation & the 1 st KOM, we participate actively to fix targets, including witness & hold points ENTER TITRE During the realization phase, we ensure a follow up of all sub-suppliers, organizing inspections and reporting to you ENTER TITRE We perform the final controls by GEMACO (visual, dimensional ENTER PHOTO, PMI ENTER PHOTO, Ferrite, etc …) ENTER TITRE We are the spider between engineers, project managers, end-users, producers & sub-contractors SLIDE SUIVANT
References défilent Lire ppt RELY ABLE SLIDE SUIVANT
I would like to thank Pierre Soulignac (now retired) from Arcelor Mittal, Mark Brouwer from Urea Knowhow, Giel Notten for his last minute advices and the GEMACO team for their assistance, support & collaboration. Thank you very much for your attention
