Avesta Finishing Chemicals
How to keep stainless – 100%!
Within Petrochemical Industry
AFC / Anders Bornmyr July 2012
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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
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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
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How to keep Stainless 100% Stainless
within Refinery and Petrochemical Industry
Clean & passivate
Prevent loss of production & safety issues due to corrosion
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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
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Why take the risk of corrosion?
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Why take the risk of corrosion break down ?
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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.
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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.
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Small, deep attacks that grow with high speed
Quick perforation of the metal
Corrosion – Pitting corrosion
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Corrosion problems –
Even Super Duplex need cleaning !
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Stainless corrosion Welding
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Stainless corrosion Bending
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Stainless corrosion Scratching
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Stainless corrosion Cutting
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Stainless corrosion Polishing
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Stainless corrosion In process
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Solving corrosion problems Before & After Cleaning
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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)
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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
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Stainless
Not a precious metal
Corrosion resistance = protective oxide layer
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Passive layer - Corrosion resistant layer
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Passive layer
At least 12% chromium
To some extent self-healing
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Defects
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Cleaning methods
MECHANICAL
• Grinding
• Blasting
• Brushing
CHEMICAL
• Pickling
• Electropolishing
What to choose?
• Damage
• Contamination
• Quality
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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
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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.
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Thickness of the passive film Immediately after passivation
After exposure in sulphuric acid
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Cleaning of stainless steel
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With Avesta Finishing
treatment
Without Avesta
Finishing treatment
Before and after cleaning
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Pickling with Avesta RedOne Pickling Spray 240
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Finished vessel- Avesta Finishing Chemicals
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The stainless steel span in time
Welding
Forming
Heat treatment
Surface contamination
Cutting
Grinding
Surface contamination
Scratching
Atmospheric corrosion
Chemical corrosion
FABRICATION
STORAGE
TRANSPORT
USE
Lifecycle
Corrosion shortens the life time of the fabricated equipment
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Manufacture – Welds corrode
Poor post-weld treatment
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Do not repeat the mistakes of others
Manufacture - Corrosion problems
Corrosion problems due to insufficient
post-weld cleaning
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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
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Chromium depleted zone
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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
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Manufacture – Cladding – Solutions
GEA Spain
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Manufacture – Cladding – Solutions
GEA Spain
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Quality of pickling agents
Don’t use pickling agents that creates corrosion
Avesta Finishing chemicals
pickling paste
Pickling paste with chlorides
Corrosion
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Manufacture – Surface defects from
welding and forming
● Welding oxides
● Impurities on the surface
● Scratches
● Inclusions
● Surface rust
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Manufacture – Surface Solution
Pickling is the best method
Spray on – rinse off
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Manufacture - Spray pickling of
storage tanks after production
Before, during and after pickling
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Manufacture - Spray pickling of
reactor after production
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Manufacture - Spray pickling of
heat exchanger after production
Before, during and after pickling
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Manufacture – Spray pickling of
pipes
After cleaning Before cleaning
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Manufacture - Pickling of Duplex
2205 pipes after fabrication
Bath pickling
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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.
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Transportation – problems with
chlorides
● Localized pitting
corrosion
● Surface rust
● Airborne contamination
● Marine environment –
chlorides from seawater
● Chlorides from road salt
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Corrosion during sea transport
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Transportation – Solution
● Acidic cleaning will not
remove light pitting
corrosion
● Pre-acid cleaning
● Spray pickling
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In use –Atmospheric / Chemical
Corrosion
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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
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Corrosion problems: Stains from
sea water (chlorides)
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Corrosion problems: Stains from
sea water (chlorides)
Corrosion on pipes pumping oil on an oil rig
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Corrosion problems on the tube side of heat exchanger due to fouling
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In use – Solution
● Acid cleaning
● For instant restoration of
the passive layer –
passivate
● Spray or wipe on – rinse
off
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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
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Welding
Forming
Heat treatment
Surface contamination
Cutting
Grinding
Surface contamination
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
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Before
cleaning
After
cleaning
Efficient chemical cleaning
Maintenance cleaning of Alfa Laval
heat exchanger
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Maintenence cleaning of Duplex 2205 pipes
at Mannesmann cleaning hub
Before cleaning After cleaning
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Maintenence cleaning of Offshore tanks at
Sure Tanks cleaning hub
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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
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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
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Maintenance cleaning on-site
For maintenance cleaning procedures for stainless steel in service and
advice on cleaning intervals applications contact BWG/Avesta Finishing
Chemicals.
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Refinery applications
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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
Need for proper pickling and passivation of stainless steel and regular cleaning
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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.
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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
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Pipe systems
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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
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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
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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.
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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
Need for proper pickling and passivation of stainless steel and regular cleaning
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Petrochemical applications
Typical Stainlees Steel
Process Equipment:
- Heat exchangers
- Destillation / stripper
coloumns
- Reactors
- Pressure vessels
- Piping
- Storage tanks
- Cooling water / sea
water intakes
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Petrochemical applications
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
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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
Need for proper pickling and passivation of stainless steel and regular cleaning
Stainlees Equipment (reactors,distillation towers, reboilers, condensers etc) and piping
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Petrochemical applications
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
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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
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Petrochemical applications
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.
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Petrochemical applications
Distillation coloumn
Cleaned & Pickled with Avesta Finishings Products
Made by Bachiller in Barcelona, Spain
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Petrochemical applications
Distillation coloumn
Made by Bama in Italy
Cleaned & Pickled with Avesta Finishings Products
Made by Bachiller in Barcelona, Spain
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Before cleaning After cleaning
Efficient chemical cleaning
Maintenance cleaning of heat boilers
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Storage tanks made in Duplex LDX
2101 at Barcelona Harbour
Cleaned with Avesta Cleaner 401
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Products and solutions
● Pickling Paste
● Pickling spray
● Pickling bath
● Special pickling solutions
● Maintenance Cleaning
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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
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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
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Avesta standard operating
procedures
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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
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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