Avesta Finishing Chemicals - · PDF file• Applications Petrochemical Industry 3 | Company...

Avesta Finishing Chemicals

How to keep stainless – 100%!

Within Petrochemical Industry

AFC / Anders Bornmyr July 2012

| Company | Presentation Title I Date

Introduction of Speaker Anders Bornmyr

Product Manager : Avesta Finishing Chemicals

Age: 46 years old

Social Status : Married with 3 boys

Education : Chemical Engineer

(Master in Sience )

Working Experience:

22 years with the company

Working Task:

Technical sales support to

• Sales Companies

• Distributors

• Agents

• Contractors

• End customers

Markets: Global support to all markets except Nordic Markets

2


Content of presentation

• Corrosion problems

• How to solve corrosion problems by cleaning & pickling

• Corrosion during the life cycle of a stainless steel

equipment

• Applications Refinery Industry

• Applications Petrochemical Industry

3


How to keep Stainless 100% Stainless

within Refinery and Petrochemical Industry

Clean & passivate

Prevent loss of production & safety issues due to corrosion


How to keep Stainless 100% Stainless

Worldwide, the cost of corrosion in the process

industries is about US$50 billion per year.

Corrosion causes

• Failure of equipment and parts

• Decomposition of raw material

• Loss of production

• Health & safety issues

• Environmental issues like higher CO2 emissions

• Legal liabilities

In many cases the entire production facility have to be shut

down and be cleaned.

By using stainless steel and keeping it 100% Stainless – corrosion is minimized

http://en.wikipedia.org/wiki/Corrosion


Why take the risk of corrosion?

6


Why take the risk of corrosion break down ?

7


Corrosion

WHAT IS

CORROSION?

Attack on a material by a chemical, often electrochemical, reaction with surrounding medium.

Pure physical or mechanical processes does not count as corrosion.


Decreasing pH and increased chloride

content gives a accelerated attack. Inside the

pitt.

A galvanic cell between the passive layer

and the pure metal is established.

Chlorides attack the

passive film at weak points.

Corrosion – Pitting corrosion

Resistance against pitting corrosion

are improved with increased content

of Cr, Mo and N.


Small, deep attacks that grow with high speed

Quick perforation of the metal

Corrosion – Pitting corrosion


Corrosion problems –

Even Super Duplex need cleaning !


Stainless corrosion Welding


Stainless corrosion Bending


Stainless corrosion Scratching


Stainless corrosion Cutting


Stainless corrosion Polishing


Stainless corrosion In process


Solving corrosion problems Before & After Cleaning


Stainless Steel basic facts

Base metal

Passive layer

● Cr > 12%, Nickel,

Molybdenum, Manganese,

Titanium

● Thin protective chromium

oxide layer – The passive

layer

● Self-healing if not

contaminated

Passive layer, thickness 0.00025 μm (0.00000025 mm)


Stainless Steel basic facts

Stainless steel is only stainless on

top layer/surface

You cannot

●Hard grind

●Weld

●Shape

●Use carbon steel tools

without destroying the corrosion-

resistant properties

Grinding Polishing Pickling


Stainless

Not a precious metal

Corrosion resistance = protective oxide layer


Passive layer - Corrosion resistant layer


Passive layer

At least 12% chromium

To some extent self-healing


Defects


Cleaning methods

MECHANICAL

• Grinding

• Blasting

• Brushing

CHEMICAL

• Pickling

• Electropolishing

What to choose?

• Damage

• Contamination

• Quality


Corrosion resistance

CORROSION RESISTANCE

0

100

200

300

400

500

600

1

Punktf

rätn

ingspote

ntial m

V /

SC

E

Pickling

Grinding 360

Grinding-220

Grinding-120

Grinding-80

Brushing

Blasting


Pickling and passivation.

Definitions

Pickling (descaling): Pickling is the removal of defects and the inherent or

thickened oxide film from the surface of the stainless steel using chemicals.

Passivation: Passivation is the chemical treatment of a stainless steel with a mild

oxidant (or acid), such as Avesta FinishOne Passivator 630, with the purpose

of removing free iron from the surface and speed up the process of forming a

protective/passive layer.


Thickness of the passive film Immediately after passivation

After exposure in sulphuric acid


Cleaning of stainless steel


With Avesta Finishing

treatment

Without Avesta

Finishing treatment

Before and after cleaning


Pickling with Avesta RedOne Pickling Spray 240


Finished vessel- Avesta Finishing Chemicals


The stainless steel span in time

Welding

Forming

Heat treatment

Surface contamination

Cutting

Grinding


Scratching

Atmospheric corrosion

Chemical corrosion

FABRICATION

STORAGE

TRANSPORT

USE

Lifecycle

Corrosion shortens the life time of the fabricated equipment


Manufacture – Welds corrode

Poor post-weld treatment


Do not repeat the mistakes of others

Manufacture - Corrosion problems

Corrosion problems due to insufficient

post-weld cleaning


3

Manufacture – Reason for problem

Heat treatment

Needs to be removed

Welding oxide Cr >10%

2-8 μm chrome-depleted zone Cr < 10%

Base metal Cr = 18%

Heat treatment or welding disturbs

the chromium content of the metal


Chromium depleted zone


Manufacture – Welds – Solutions

● Pickling is the superior post-

weld treatment

● Pickling with a paste is the

best way of cleaning weld

seams

● Brush on – Rinse off

Chemical cleaning


Manufacture – Cladding – Solutions

GEA Spain


Manufacture – Cladding – Solutions

GEA Spain


Quality of pickling agents

Don’t use pickling agents that creates corrosion

Avesta Finishing chemicals

pickling paste

Pickling paste with chlorides

Corrosion


Manufacture – Surface defects from

welding and forming

● Welding oxides

● Impurities on the surface

● Scratches

● Inclusions

● Surface rust


Manufacture – Surface Solution

Pickling is the best method

Spray on – rinse off


Manufacture - Spray pickling of

storage tanks after production

Before, during and after pickling



reactor after production



heat exchanger after production

Before, during and after pickling


Manufacture – Spray pickling of

pipes

After cleaning Before cleaning


Manufacture - Pickling of Duplex

2205 pipes after fabrication

Bath pickling


Storage – Carbon steel contamination

After cleaning

The free iron particles must be removed immediately or else will they rust quickly and break the self healing ”passive film” on the stainless steel surface resulting in pitting corrosion.


Transportation – problems with

chlorides

● Localized pitting

corrosion

● Surface rust

● Airborne contamination

● Marine environment –

chlorides from seawater

● Chlorides from road salt


Corrosion during sea transport


Transportation – Solution

● Acidic cleaning will not

remove light pitting

corrosion

● Pre-acid cleaning

● Spray pickling


In use –Atmospheric / Chemical

Corrosion


Corrosion problems in service

•Chlorides

•Sulphur

•Seawater

•Galvanic effects, contact between stainless steel and carbon steel

Need for proper pickling and passivation of stainless steel and regular cleaning


Corrosion problems: Stains from

sea water (chlorides)


Corrosion problems: Stains from

sea water (chlorides)

Corrosion on pipes pumping oil on an oil rig

| Company | Presentation Title I Date 58

Corrosion problems on the tube side of heat exchanger due to fouling


In use – Solution

● Acid cleaning

● For instant restoration of

the passive layer –

passivate

● Spray or wipe on – rinse

off


The solution

● Weld seams

Pickling paste

● Larger surfaces

Pickling spray / bath

● Maintenance cleaning

Acid cleaning

● Restoration of passive layer

Passivation

FABRICATION

STORAGE

TRANSPORT

USE

How to keep the stainless steel 100% stainless


Welding

Forming

Heat treatment


Cutting

Grinding


Scratching

Atmospheric corrosion

Chemical corrosion

FABRICATION

STORAGE

TRANSPORT

USE

Maintenance Cleaning

One treatment

At least one treatment per

YEAR

Stainless steel cleaning trends

PPreventive Maintenancereventive Maintenance

Cleaning costs and the risk of damage to the stainless steel can be

minimized with regular cleaning.Otherwise the material will suffer

damage i the long terms

Treated Surface

Untreated Surce

100% Corrosion resistance

Time

Maintenance cleaning


Before

cleaning

After

cleaning

Efficient chemical cleaning

Maintenance cleaning of Alfa Laval

heat exchanger


Maintenence cleaning of Duplex 2205 pipes

at Mannesmann cleaning hub

Before cleaning After cleaning


Maintenence cleaning of Offshore tanks at

Sure Tanks cleaning hub


Maintenence cleaning of gas storage pipe system on site by US contractor Kiewit

Before maintenance cleaning in May 2011

After cleaning in June 2011

3 months after cleaning


Maintenence cleaning of pipe system on an oil rig

Cleaning is done on the oil rig with Cleaner 401 & Passivator 630 during service pumping oil with a temp of +70oC


Maintenance cleaning on-site

For maintenance cleaning procedures for stainless steel in service and

advice on cleaning intervals applications contact BWG/Avesta Finishing

Chemicals.


Refinery applications


Refinery applications

• A typical refinery operation may have in excess of 3,000 processing vessels of varying size and about 3,200 km of pipeline mostly in carbon steel

• Stainless steel is used in compact heat exchangers, fluid catalytic cracking (FCC), catalytic hydro-desulfurization (CHD), hydrogen plants and sea water applications

• Galvanic effects, contact between stainless steel and carbon steel can give corrosion



Condenser

Refinery applications – Amine

system for capture of H2S and

CO2

Lean cooler

Lean/rich

interchanger Reboiler

Sweet gas

Sour gas

Sour water

Stripping

column

Absorption

column

• Stainless steel in piping, internals, tube side of condenser, reboiler and other heat

exchangers or use of compact heat exchangers with stainless steel plates.

//seluws0186.ad.alfalaval.org/Department_SELU/PEE_MUO/Sommarjobbsprojekt uppdatering referenser/Old/Training/Presentations (Heat exchange)/





Refinery applications – ”Sour

environments”

Need for proper pickling and passivation of stainless steel and regular cleaning due to scaling and corrosion issues

Production fluids and gases in the oil & gas industry in “sour” environments contains hydrogen sulphide which may cause sulphide stress cracking


Pipe systems

73


Corrosion of pipe systems

Natural gas from wells is becoming

increasingly sour and requires higher

corrosion resistance from pipes than carbon

steel can provide. To assure the

transportation;

1-stainless steel pipes

2-cladded carbon steels pipe with stainless

filler metal


LNG Pipes made in stainless steel

Stainless steel pipes of Outokumpu 12.7mm thick plate (grade 1.4301/1.4307

(304/304L))has been made to supply 18km of liquified natural gas pipe for a

dock loading facility in the Qatar Gas project


LNG Pipes made by cladding / over lay welding

The company Proclad in Dubai are cladding 12 m long carbon steel pipes in

4-40 inch size by TIG welding of Inconel 625 for Adco Abu Dhabi Oil

Company .

These pipes are then being spray pickled with Avesta Products.


Corroded seawater intake made

in Duplex 2205

Sea water cooling – risk for corrosion due to • High chloride content • Deposits and biofouling • Chemical treatments such as chlorination • Erosion due to entrained solids • Pollution by sulphides



Petrochemical applications

Typical Stainlees Steel

Process Equipment:

- Heat exchangers

- Destillation / stripper

coloumns

- Reactors

- Pressure vessels

- Piping

- Storage tanks

- Cooling water / sea

water intakes



Ethylene

Propylene

Benzene

Toluene

Xylene

Butadiene

Ethylene oxide

Ethylene glycol

THF

Styrene

Propylene oxide

Acrylic acid

Polycarbonate

Formaldehyd

Vinyl Chloride

Phenol

TDI & MDI

Nafta

LNG

Cr acker


Petrochemical applications Condenser

Feed

preheater

Dis

tilla

tion c

olu

mn

Reboiler

Condenser

Corrosion and deposits leading to fouling of heat transfer surfaces is

• Lowering the operating efficiency in petrochemical plants

• Increasing the use of steam / energy

• Increasing the CO2- foot print


Stainlees Equipment (reactors,distillation towers, reboilers, condensers etc) and piping



H2O2

PO

Propylene

MeOH H2O,

Glycols

Extraction Hydration Oxidation

Antrakinons

H2 O2 H2O

316/316L/Duplex

316/904L/254SMO

HPPO (propylene oxide)

Poor cleaning and passivation of welds, equipment and pipe lines increase risk for

• Decomposition of HP due to contamination -> loss of production or in worst case a safety issue

• Fouling/corrosion of heat transfer surfaces -> leackage/higher energy usage 1 m3 (50%) HP -> 1000 m3 gas


Petrochemical applications HPPO

• Equipment (reactors,distillation towers, reboilers, condensers etc) and piping should be cleaned and passivated with the right type of chemicals and procedures before the system is taken in operation

• Mechanical treatment for surface finish should be avioded Not high enough corrosion resistance -> decomposition and corrosion -> loss production and safety issues

Stainless steel spareparts for HP systems stored separate, degreased and

passivated

During maintenance always clean and passivate equipment/surfaces before starting up the process.

Have a plan for preventive maintenance when it comes to cleaning and use the right chemicals and procedures Contact BWG/Avesta Finishing Chemicals for advice



Distillation column

Cleaned & Pickled with Avesta Finishings Products

A 62 m long distillation coloumn made by Felguera Pesada in Gijon, Spain for Interquisa Canada in Montreal, Canada.



Distillation coloumn


Made by Bachiller in Barcelona, Spain



Distillation coloumn

Made by Bama in Italy


Made by Bachiller in Barcelona, Spain


Before cleaning After cleaning

Efficient chemical cleaning

Maintenance cleaning of heat boilers


Storage tanks made in Duplex LDX

2101 at Barcelona Harbour

Cleaned with Avesta Cleaner 401


Products and solutions

● Pickling Paste

● Pickling spray

● Pickling bath

● Special pickling solutions

● Maintenance Cleaning


EXPERTS IN THE CLEANING & PICKLING OF STAINLESS STEEL

PRE-CLEANING/ MAINTENECE CLEANING

RUST REMOVER 410 Pre-cleaning before Pickling; Rust & Oxides; Salt Stains; Rouging

CLASSIC CLEANER 401 Acidic Pre- and All-Around Cleaner; Restores & Brightens Stainless Steel Finishes

PASSIVATION FINISHONE™ FINAL RINSE 630

Reduced Smut and water marks Accelerated Cleaning & Passivation.

PASSIVATING AGENT 601

Decontaminant with Passivation

PICKLING - Standard Steels GREENONE™ PICKLING PASTE 120

BLUEONE™ PICKLING PASTE 130

REDONE™ PICKLING SPRAY 240

CLASSIC PICKLING PASTE 101 / 122

PICKLING BATH 300-SERIES

PICKLING - Special Steels REDONE™ PICKLING PASTE 140

REDONE™ PICKLING SPRAY 240

CLASSIC PICKLING SPRAY 204

PICKLING BATH 300-SERIES

Please visit www.avestafinishing.com for additional information.

SAFETY

FIRST AID SPRAY 910

Unique first aid solution for injuries caused by Avesta Pickling

Paste/Spray/Gel

http://www.avestafinishing.com/


Products

401 Classic Cleaner Acidic Precleaner and all round. Hydrocarbons plus Fe contamination Restores and brightens stainless steel surfaces

410 Rust Remover Acid Cleaner for cleaning of sensitive bright finishes

502 Neutralizer For neutralisation of pickling residuals

630 FinishOne Passivator Accelerated cleaning and Passivation. Reduced Smut. Disinfection. NOx Reducer.

Main

tan

an

ce

Cle

an

ing

601 Passivating Agent 601 De-contaminant (Hydrocarbon + Fe) with Passivation

101 Classic Pickling Paste Good consistency / adhesion to difficult surfaces. Reduced Splash.

120 GreenOne Paste NOx Free. Non toxic. Bright and Sensitive Surfaces. Colour

130 BlueOne Paste Virtually NOx Free. Universal Paste. Economic. Colour

140 RedOne Paste Less NOx. Higher Steel Grades. Fast. Colour

Po

st

Weld

Treatm

en

t

122 Classic Pickling Gel Gel form, All-rounder

204 Classic Pickling Spray Good Adhesion. Very Strong.

240 RedOne Spray All Rounder

Su

rfa

ce

Treat-

men

t

302 Bath Pickling 302 For pickling baths with all grades


Avesta standard operating

procedures


We take care

● Information that helps

- Product Data Sheet

- Safety Data Sheet

- Pickling Handbook

● ISO 9001:2008 and

ISO 14001:2004 certified

● Responsible Care Programme

● Products certified by NSF

● Back-up from our specialists


A recognized leader and

innovator in stainless steel

technology, Avesta Finishing

Chemicals is one of the largest

European producers of refined

chemicals for stainless steel

surface treatment.

Thank you for listening

– to Avesta Finishing Chemicals

For more information, please visit

www.avestafinishing.com

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