Development of materials resistant to metal dusting degradation.

Metal dusting corrosion has been a serious problem in the petroleum and petrochemical industries, such as reforming and syngas production systems. This form of deterioration has led to worldwide material loss for 50 years. For the past three years, we have studied the mechanism of metal dusting for Fe- and Ni-base alloys. In this report, we present a correlation between the weight loss and depth of pits that form in Ni-base alloys. Nickel-base alloys were also tested at 1 and 14.8 atm (210 psi), in a high carbon activity environment. Higher system pressure was found to accelerate corrosion in most Ni-base alloys. To reduce testing time, a pre-pitting method was developed. Mechanical scratches on the alloy surface led to fast metal dusting corrosion. We have also developed preliminary data on the performance of weldments of several Ni-base alloys in a metal dusting environment. Finally, Alloy 800 tubes and plates used in a reformer plant were examined by scanning electron microscopy, energy dispersive X-ray, and Raman spectroscopy. The oxide scale on the surface of the Alloy 800 primarily consists of Fe{sub 1+x}Cr{sub 2-X}O{sub 4} spinel phase with high Fe content. Carbon can diffuse through this oxide scale. It was discovered that the growth of metal dusting pits could be stopped by means of a slightly oxidized alloy surface. This leads to a new way to solve metal dusting problem