Special Stainless Steels for FGC and CCS ATI Milan, 13/4/2011 Dr Pascale Sotto Vangeli, Avesta Research Centre Eng. Jim Augustsson, Special Plate www.outokumpu.com
Chemical composition and properties Typical chemical composition weight % Outokumpu EN ASTM Cr Ni Mo N PRE* R p0.2 ** LDX 2101 1.4162 S32101 21.5 1.5 0.3 0.22 26 450*** Lean Duplex LDX 2404 1.4662 S82441 24.0 3.6 1.6 0.27 33 480 Lean Duplex 2304 1.4362 S32304 23.0 4.8 0.3 0.10 26 400 Duplex 2205 1.4462 S32205 22.0 5.7 3.1 0.17 35 460 Duplex SAF 2507 1.4410 S32750 25.0 7.0 4.0 0.27 43 530 Super Duplex 4501 1.4501 S32760 25.4 6.9 3.8 0.27 42 530 Super Duplex 4307 1.4307 304L 18.1 8.1 - - 18 200 Austenitic 4404 1.4404 316L 17.2 10.1 2.1-24 220 Austenitic 4432 1.4432 316L 16.9 10.7 2.6-25 220 Austenitic 904L 1.4539 N08904 20.0 25.0 4.3-34 220 Austenitic 254 SMO 1.4547 S31254 20.0 18.0 6.1 0.20 43 300 Super Austenitic 654 SMO 1.4652 S32654 24.0 22.0 7.3 0.50 56 450 Super Austenitic 4529 1.4529 N08926 20.5 24.8 6.5 0.20 45 300 Super Austenitic 4565 1.4565 S34565 24.0 17.0 4.5 0.45 46 * PRE = %Cr + 3.3x%Mo + 16x%N ** [MPa] Hot rolled plate, min values at 20 o C according to EN 10088 ***Not yet in EN 10088, Rp0.2 according to ASTM A240 2 April 13, 2011 Pascale Sotto Vangeli 420 5.5 Mn Super Austenitic
Corrosion indicators: PRE and CPT PRE Pitting Resistance Equivalent CPT Critical Pitting Temperature Corrosion Resistance, CPT typical 100 90 80 70 60 50 40 30 20 10 0 Outokumpu 654 SMO has the highest PRE value (56). It is completely resistant to corrosion in standard CPT tests. duplex austenitic 4307 LDX 2101 4404 2304 LDX 2404 2205 904L 2507 254 SMO 4565 654 SMO PRE 18 26 24 26 33 35 34 43 43 46 56 3 April 13, 2011 Pascale Sotto Vangeli
Characteristics of Outokumpu 654 SMO Outstanding resistance to pitting, crevice and uniform corrosion Extremely high resistance to stress corrosion cracking High erosion resistance Excellent formability Good ductility and toughness Almost twice the strength of common austenitic stainless steels Price advantage alternative to Ni-base alloys Price stablility compared to Ni-based alloys Excellent choice when superior corrosion resistance and high mechanical properties are required 4 April 13, 2011 Pascale Sotto Vangeli
Corrosion indicators: CCT tests Crevice corrosion: laboratory and field tests to compare Outokumpu 654 SMO at least as resistant as C-276 to crevice corrosion in oxidizing, highchloride solutions 5 April 13, 2011 Pascale Sotto Vangeli
Duplex and austenitic grades Yield Strength R p0.2 [MPa] 750 duplex 500 LDX 2101 2304 LDX 2404 TM 2205 2507 4565 654SMO austenitic 250 4301 4404 4439 904L 254SMO C-276 Corrosion resistance 6 April 13, 2011 Pascale Sotto Vangeli
Structural efficiency utilize strength of duplex grades Weigth saving potential 60% 50% 40% LDX 2101 weigth saving potential to 304L 2205 weigth saving potential to 316L 30% 20% 10% 0% Cylinder with internal pressure Hollow section loaded in bending Plate loaded in bending Local buckling 7 April 13, 2011 Pascale Sotto Vangeli
Case: Duplex as substitute for austenitic in storage tank Benefits: Weight reduction Improved cost efficiency Material cost Initial investment cost Maintenance cost Life Cycle Costing Increased service life 4301 61.5 ton LDX 2101 43.5 ton [m] 18 16 14 12 10 Duplex potential weight saving: ~30% 8 6 4 2 8 April 13, 2011 Pascale Sotto Vangeli [mm] 0 12 10 8 6 4 2 0
9 April 13, 2011 Pascale Sotto Vangeli Flue Gas Desulfurization System
Economical concept in absorbers Increasing Corrosion Resistance 317LMN 904L 2205 SAF 2507 254 SMO 4565 654SMO adjust transitions according to operating conditions 10 April 13, 2011 Pascale Sotto Vangeli
Guideline for material selection in FGD applications Different colours represent different operating conditions in term of acidity and Cl-/F- concentration. Based on long-term industrial experience, field and laboratory testing. Other factors such as design, processing of material, workmanship, etc. will also have an influence on the materials behaviour.
La Spezia, Italy 2001 chloride - max 30 000 ppm Cl - in quencher recycle - max 15 000 ppm Cl - in absorber recycle - 20 000 ppm in demister area (during demister cleaning with sea water) acidity: - quencher ph 3,5 5 / 4,5 - absorber ph 5 6,4 / 6 temperature: 5 50 / 42,5 C flue gas entry: 2.4819 / alloy C-276 gas outlet: wall plates 1.4439 / 317L demister area: demister support structure and wall plates 1.4565 / UNS 34565 absorber recycle: box ring girder top side, shell plates, spray pipes 1.4565 / UNS 34565 collection bowle area: collection bowl, discharge pipe, bowl plates, box ring girder bottom side 1.4565 / UNS 34565 quencher recycle: shell plates, floor plates, spray pipes and other internals (sieves, sparger pipes,...) 1.4565 / UNS 34565 12 April 13, 2011 Pascale Sotto Vangeli
FGC applications Spray system in 1.4565 Abb.: Fisia Babcock Absorber module in 2205 Abb.: Babcock & Wilcox 13 April 13, 2011 Pascale Sotto Vangeli
CCS - stainless opportunities Flue gas cleaning austenitic & duplex Solvent separation systems Amine standard or lean duplex Cryogenic applications 304L, 201LN Tubes & pipes high pressure piping, PSA duplex duplex Compressors part?? Pipe High lines temperature material Burners, High temperature casing, cyclones, material Burners, supports, casing, tube protection cyclones, 153 MA, 253 MA, 304H, 321H supports, Standard tube grades protection 153 MA, 253 MA, 304H, 321H Internals, Standard heat grades exchangers, piping Internals, Clad material heat exchangers, piping standard cladding Clad material solutions standard or duplex Solid or cladding solutions standard or duplex 14 April 13, 2011 Pascale Sotto Vangeli
Cooperations Vattenfall, Sweden - Germany Siemens, USA Doosan Power Systems, UK Alstom Power, Germany Hitachi Power Europe, Germany 15 April 13, 2011 Pascale Sotto Vangeli
Conclusions FGC Environments in wet cleaning systems are hard to predict and can be very aggressive. Need of corrosion resistant grades. There are large variations in environments between different plants and different locations within plants. Material selection has to be done for each plant/application individually. The main risks for stainless steel are pitting and crevice corrosion. The following ranking applies: 316L < 317L~904L~2205 < 2507~254SMO < 4565 < 654SMO 16 April 13, 2011 Pascale Sotto Vangeli
Conclusions CCS By choosing the correct stainless steel grade, it is possible to meet a wide range of demands on corrosion resistance. Need to test in the demanding environments to select the most suitable grade. Utilize the strength of the duplex in big amine towers. Tools on www.outokumpu.com. 17 April 13, 2011 Pascale Sotto Vangeli
Pascale.vangeli@outokumpu.com Jim.augustsson@outokumpu.com Enrico.casiraghi@outokumpu.com