Contributor contact details ............................... xi
Series introduction ....................................... xv
Volumes in the EFC series ............................... xvii
1 Metal dusting .............................................. 1
H.J. Grabke, Max-Planck-Institut für Eisenforschung GmbH,
Germany
1.1 Definition of metal dusting ................................ 1
1.2 Thermodynamics and kinetics of gas-metal reactions ......... 1
1.3 Mechanisms of metal dusting ................................ 4
1.4 Kinetics of metal wastage and coking on iron and
low-alloy steels ........................................... 8
1.5 Metal dusting of high-alloy steels ........................ 10
1.6 Metal dusting of Ni-based alloys .......................... 14
1.7 Protection against metal dusting .......................... 17
1.8 References ................................................ 23
2 The metal dusting corrosion of steels with varying
concentrations of chromium ................................ 25
С.M. Chun, ExxonMobil Research and Engineering Company,
USA and T.A. Ramanarayanan, Princeton University, USA
2.1 Introduction .............................................. 25
2.2 Experimental procedure .................................... 26
2.3 Results ................................................... 28
2.4 Discussion ................................................ 40
2.5 Summary ................................................... 46
2.6 References ................................................ 48
3 Microprocesses of metal dusting on iron-nickel alloys
and their dependence on the alloy composition ............. 49
E. Pippel and J. Woltersdorf, Max-Planck-Institut für
Mikrostrukturphysik, Germany and H.J. Grabke,
Max-Planck-Institut für Eisenforschung GmbH, Germany
3.1 Introduction .............................................. 49
3.2 Experimental procedure .................................... 51
3.3 Results ................................................... 51
3.4 Discussion ................................................ 57
3.5 Acknowledgement ........................................... 58
3.6 References ................................................ 58
4 Metal dusting behaviour of welded Ni-base alloys with
different surface finishes ................................ 59
H.J. Grabke and E.M. Müller-Lorenz, Max-Planck-Institut
für Eisenforschung GmbH, Germany and M. Zinke, Institut
für Füge- und Strahltechnik, Germany
4.1 Introduction .............................................. 59
4.2 Experimental procedure .................................... 59
4.3 Results ................................................... 63
4.4 Conclusions ............................................... 71
4.5 Acknowledgement ........................................... 75
4.6 References ................................................ 75
5 Effect of H2S on metal dusting of iron .................... 76
A. Schneider and H.J. Grabke, Max-Planck-Institut fur
Eisenforschung GmbH, Germany
5.1 Introduction .............................................. 76
5.2 Effect of H2S on carburisation kinetics and graphite
formation ................................................. 77
5.3 Carbon diffusion in cementite and Hдgg carbide ............ 81
5.4 Thermodynamics of Hдgg carbide formation .................. 83
5.5 Decomposition of Fe3C and Fe5C2 ........................... 84
5.6 Iron sulphide formation in atmospheres containing H2S ..... 86
5.7 Practical aspects of sulphur adsorption ................... 86
5.8 Acknowledgement ........................................... 87
5.9 References ................................................ 88
6 Occurrence of metal dusting - referring to failure
cases ..................................................... 90
H.J. Grabke and M. Spiegel, Max-Planck-Institut für
Eisenforschung GmbH, Germany
6.1 Metal dusting - present knowledge ......................... 90
6.2 Failure cases ............................................. 92
6.3 Conclusions ............................................... 99
6.4 References ............................................... 101
7 Protective behaviour of newly developed coatings
against metal dusting .................................... 103
С. Rosado and M. Schütze, Karl-Winnacker-Institut der
DECHEMA e.V., Germany
7.1 Introduction ............................................. 103
7.2 Experimental procedure ................................... 104
7.3 Results and discussion ................................... 109
7.4 Conclusions .............................................. 146
7.5 Acknowledgements ......................................... 152
7.6 References ............................................... 153
8 Metal dusting resistance of high-chromium alloys ......... 154
H.J. Grabke and E M Müller-Lorenz, Max-Planck-Institut
für Eisenforschung, Germany and H.P. Martinz,
Plansee AG, Austria
8.1 Introduction ............................................. 154
8.2 Experimental procedure ................................... 154
8.3 Results .................................................. 155
8.4 Discussion ............................................... 160
8.5 References ............................................... 161
9 Study of the metal dusting behaviour of high-
temperature alloys ....................................... 162
F.Di Gabriele, J.R. Bernstein, M.M. Al-Qhatani, Z. Liu,
M.P. Jordan, and F.H. Stott, Corrosion and Protection
Centre, UK and J.A. Richardson, Anticorrosion
Consulting, UK
9.1 Introduction ............................................. 162
9.2 Experimental procedure ................................... 163
9.3 Results .................................................. 164
9.4 Discussion ............................................... 171
9.5 Conclusions .............................................. 174
9.6 Acknowledgements ......................................... 174
9.7 References ............................................... 174
10 Metal dusting of ferritic Fe-Al-M-C (M = Ti,V,Nb,Та)
alloys in CO-H2-H2O gas mixtures at 650°C ................ 175
A. Schneider and J. Zhang, Max-Planck-Institut für
Eisenforschung, Germany
10.1 Introduction ............................................. 175
10.2 Experimental procedure ................................... 176
10.3 Thermodynamic calculations ............................... 177
10.4 Results .................................................. 177
10.5 Discussion ............................................... 181
10.6 Conclusions .............................................. 185
10.7 Acknowledgements ......................................... 185
10.8 References ............................................... 186
11 α-Fe layer formation during metal dusting of iron in
CO-H2-H2O gas mixtures ................................... 187
J. Zhang, A. Schneider and G. Inden, Max-Planck-
Institut für Eisenforschung, Germany
11.1 Introduction ............................................. 187
11.2 Experimental procedure ................................... 188
11.3 Results .................................................. 188
11.4 Discussion ............................................... 194
11.5 Conclusions .............................................. 197
11.6 Acknowledgements ......................................... 197
11.7 References ............................................... 198
12 Coke formation during metal dusting of iron in
CO-H2-H2O gas with high CO content ....................... 199
J. Zhang, A Schneider and G Inden, Max-Planck-Institut
für Eisenforschung, Germany
12.1 Introduction ............................................. 199
12.2 Experimental procedure ................................... 200
12.3 Results .................................................. 200
12.4 Discussion ............................................... 207
12.5 Conclusions .............................................. 212
12.6 Acknowledgements ......................................... 213
12.7 References ............................................... 213
13 Morphologies and mechanisms of metal dusting on
high-alloy steels ........................................ 214
P. Szakálos, Swedish Institute for Metals Research
(SIMR), Sweden
13.1 Introduction ............................................. 214
13.2 Experimental procedure ................................... 215
13.3 Results .................................................. 216
13.4 Discussion ............................................... 225
13.5 Conclusions .............................................. 235
13.6 Acknowledgements ......................................... 235
13.7 References ............................................... 235
14 Filamentous carbon formation caused by catalytic metal
particles from iron oxide ................................ 237
F. Bonnet and F. Ropital, Institut Francois du Petrole,
France; Y. Berthier and P. Marcus, Laboratoire de
Physico-Chimie des Surfaces, France
14.1 Introduction ............................................. 237
14.2 Thermodynamic calculations ............................... 241
14.3 Experimental procedure ................................... 246
14.4 Results .................................................. 248
14.5 Discussion ............................................... 254
14.6 Conclusion ............................................... 257
14.7 References ............................................... 258
15 Typical failures in pyrolysis coils for ethylene
cracking ................................................. 259
D. Jakobi, Schmidt + Clemens Group, Germany and
R. Gommans, Gommans Metallurgical Services,
The Netherlands
15.1 Introduction ............................................. 259
15.2 Damage mechanisms ........................................ 260
15.3 Metallurgical background of the main failure mechanisms .. 264
15.4 Process technological background ......................... 268
15.5 Conclusions .............................................. 269
15.6 Acknowledgement .......................................... 270
15.7 References ............................................... 270
16 Thermodynamic characteristics and numerical modelling
of internal nitridation of nickel-base alloys ............ 271
H.J. Christ, S.Y. Chang and U. Krupp, Universitдt
Siegen, Germany
16.1 Introduction ............................................. 271
16.2 Experimental procedure ................................... 273
16.3 Results and discussion ................................... 274
16.4 Conclusions .............................................. 284
16.5 Acknowledgement .......................................... 284
16.6 References ............................................... 284
17 Nitridation in NH3-H2O mixtures .......................... 286
H.J. Grabke, S. Strauss and D. Vogel, Max-Planck-
Institut für Eisenforschung, Germany
17.1 Introduction ............................................. 286
17.2 Experimental procedure ................................... 286
17.3 Results .................................................. 287
17.4 Discussion ............................................... 293
17.5 Acknowledgement .......................................... 297
17.6 References ............................................... 297
Index .................................................... 299
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