SEMINAR TOPIC: HIGH TEMPERATURE CORROSION & ITS PROPERTIES

NAME : NAYAK DILIPKUMAR SOMABHAI

ROLL NO: 930

FACULTY OF TECH & ENGG M.S.U

MET & MAT ENG DEPARTMENT

TOPICS

INTRODUCTION
CLASSIFICATION TYPES OF HIGH TEMPERTURE CORROSION MECHANISM

CORROSION PREVENTIONS.

INTRODUCTION

Damage from corrosion & metallurgical mechanisms often leads to failures in various equipment, which interrupt the routine operations create safety hazards.

The existence as well as the degree of damage is dependent on the particular process operating conditions & contaminants present in the process stream. Everyone in the refining industry today, mechanical engineer, metallurgist, &process engineer is looking for ways to prevent the effects of corrosion. Corrosion control is paramount to the safe & productive operation of a facility.

INTRODUCTION OF CORROSION

The deterioration of a material, usually a metal, because of a reaction with its environment, is termed as corrosion. The definition is very general & recognizes that some forms of corrosion are not chemical or electrochemical in nature. The definition also recognizes that materials other than metals may corrode. These materials include concrete, wood,ceramics, & plastics. In addition , in some forms of corrosion the properties of the material as well as the material itself deteriorate. A material may experience no weight change or visible deterioration yet, due to property changes promoted by corrosive action , the material may fail unexpectedly

CLASSIFICATION OF CORROSION

1. LOW TEMPERATURE CORROSION

below 260 c & in the presence of water. Example: Corrosion of steel by water.

- Occurs at temperatures

temperature refinery corrosion is also called aqueous corrosion, wet corrosion, or electrochemical corrosion. It requires the S presence of an aqueous solution , including water even in very small amounts, or an electrolyte in hydrogen stream.

LOW

High temperature corrosion

2.High temperature corrosion :

Occurs at temperatures above 260c , with no water present.

Example: Corrosion on steel by furnaces gases. High temperature corrosion is referred to as dry corrosion or direct chemical combination. It occurs above the environment dew point and is normally associated with high temperatures. Gasses are the typical corrosive agents.

Although oxidation generally refers to an electron producing reaction, this term is also employed to designate the reaction between a metal & air or oxygen in the absence of water or an aqueous phase. Scaling tarnishing and dry corrosion are also sometimes used to describe this phenomena of HIGH TEMPERATURE CORROSION.
Since virtually every metal & alloy reacts with air at elevated temperatures, oxidation resistance must be considered in most metallurgical engineering applications.

HIGH TEMPERATURE CORROSION MECHANISM

As with low temperature corrosion , high temperature corrosion is an electrochemical process consisting of two or more partial (oxidation or reduction) reaction. When metal is exposed to air , it is oxidized to an ion at the metal scale interface according to the following equation: M M+n + neAt the same time ,oxygen is reduced at the scale surface as shown in the equation below 1/2 O2 + 2eO-2

The overall corrosion reaction is obtained by combining the oxidation & reduction reaction to form a metal oxide as follow:

HIGH TEMPERATURE CORROSION CONDITIONS

temperature corrosion is related to nature of scale that is formed. Many processes at elevated temperatures involve vapor or liquid streams at high flow velocities, high temperature corrosion often results in fatigue,erosion, & cavitations damage. Carbon steel may be used in high temperature conditions without excessive scaling up to a temperature of about 565 'C .
Above this temperature ,various alloys must be used to increase oxidation resistance & to provide adequate mechanical properties.

High

TYPES OF HIGH TEMPERATURE CORROSION

1. HIGH TEMPERATURE OXIDATION
2. HIGH TEMPERATURE SULPHIDE CORROSION 3. HIGH TEMPERATURE HYDROGEN ATTACK

HIGH TEMPERATURE OXIDATION

OXIDATION IS ATYPE OF CORROSION INVOLVING THE REACTION BETWEEN A METAL & OXYGEN AT HIGH TEMPERATURE IN THE ABSENCE OF WATER OR AN AQUEOUS PHASE. It is also called dry corrosion .At nomal temperatures, the oxides of the metals are more stable than metals. Metals being in the metastable state are bound to form oxides. The rate of oxidation o a metal at high temperatures depends on the nature of the oxide layer that forms on the surface of metal.

MECHANISM OF OXIDATION

a fresh surface of metal like gold comes in contact with oxygen, the latter forms a loosely bound layer on the surface of gold due to secondary van der waals attractive forces arising between the atoms of the metal surface & the oxygen molecules. This layer is said to be adsorbed oxygen layer, & no further chemical bonding occurs. This layer is easily removed by applying ultra high vacuum. The first oxygen molecules coming in contact with the clean surface of metal. Dissociate into oxygen atoms & then, these oxygen atoms bond chemically with the atoms of the metal surface.

When

High Temperature Sulfide corrosion

the areas of energy conversion & environmental protection become increasingly concerned with processing & cleanup of sulfur bearing fossil fuels & their combustion products , the attack of metal by sulfer compounds at high temperatures has become a major corrosion problem. the term sulfidation is used to describe the gaseous attack of metals by H2S, S2, SO2, & other gaseous sulfur species. High Temperature Sulphide corrosion with Hydrogen present is more severe than high temperature sulfide corrosion without hydrogen present hydrogen converts organic sulfur compounds to hydrogen sulfide & corrosion becomes a function of H2S concentration or partial pressure.

As

HIGH TEMPERATURE HYDROGEN ATTACK

HTHA is primarily a problem in downstream
operations in which carbon & low alloy steels are exposed to 221'c &m partial pressure above 200 psi. when damaged, the steel losses tensile strength & ductility & if under stress , can crack.

With in steel , the hydrogen reacts with other elements, such as carbon , to form gases , primarily methane. The reaction follows
Fe3C + 2H2 3Fe + CH4

CORROSION PREVENTIONS

1.High temperature corrosion prevention. 2.High 3.High

temperature sulphide corrosion prevention. temperature hydrogen attack prevention.

HIGH TEMPERATURE CORROSION PREVENTION

1.High resistance to oxidation is possible if the oxide film has pilling bedworth ratio slightly greater than one so that it is continuous, compact & adhering. 2.Chromium , silicon & aluminium when added as alloying agents give good corrosion resistance. 3.A resistance alloy containing sufficient Cr can be used.

HIGH TEMPERATURE SULFIDE CORROSION PREVENTION

1. Alloying elements usually contains Fe, Ni & Cr as the major components with Al, Mn,Si,Mo & c as important constituents. 2.High temperature scaling resistance in oxidizing gases is generally provided by the formation & maintenance of a slow growing , protective layer of Cr2O3 or Al2O3.

HIGH TEMPERATURE HYDROGEN ATTACK PREVENTION

1. HTHA is usually not uniform throughout an affected component. Attack is first initiated in areas where Hydrogen diffuses. 2. Alloying elements like Mo, Cr, W are used to limit the amount of C available for the formation of methane.

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