Materials Technology in Steam Reforming Processes (eBook)

Front Cover 1
Materials Technology in Steam Reforming Processes 4
Copyright Page 5
Table of Contents 6
PREFACE 8
CHAPTER 1. 
10 
INTRODUCTION 10
APPLICATION OF THE PROCESS 10
TECHNOLOGICAL ASPECTS OF REFORMING 14
DEVELOPMENT OF THE PROCESS 18
CHAPTER 2. SOME FUNDAMENTAL ASPECTS OF THE CREEP DEFORMATION OF METALS 20
MODES OF CREEP DEFORMATION 21
CREEP FRACTURE AND CREEP DUCTILITY 23
THE STRUCTURE OF CREEP-RESISTANT ALLOYS 24
SOME OTHER FACTORS INFLUENCING THE BEHAVIOUR OF METALS AT HIGH TEMPERATURES 27
CHAPTER 3. FACTORS AFFECTING CHOICE OF MATERIALS AND DESIGN OF UNITS FOR PRESSURE STEAM REFORMING 30
REFERENCES 37
CHAPTER 4. HIGH TEMPERATURE ALLOYS FOR USE IN REFORMER FURNACES 38
1. INTRODUCTION 38
2. CREEP-RUPTURE OF 18/37 CR-NI ALLOYS 38
3. CREEP-RUPTURE OF 25/20 CR-NI ALLOYS 48
4. AGE-HARDENING OF CAST 18/37 CR-NI ALLOYS 52
5. HOT STRENGTH OF WELDING MATERIALS USED IN REFORMER FURNACES 58
6. METALLOGRAPHIC EXAMINATION OF TUBES AFTER SERVICE 59
7. MATERIAL SPECIFICATIONS 64
REFERENCES 69
CHAPTER 5. THE RESEARCH BACKGROUND OF THE THERMALLOY GRADES OF CHROMIUM-NICKEL-IRON HEAT-RESISTING ALLOYS 70
1. INTRODUCTION 70
2. THE CURRENT STATUS OF CAST ALLOYS 72
3. HIGH-TEMPERATURE EVALUATION 74
4. RESEARCH FOR HIGH QUALITY 75
5. HOT GAS CORROSION RESISTANCE 79
6. ENGINEERING PROPERTIES 81
7. METALLOGRAPHY 90
8. LOAD-CARRYING ABILITY 94
9. CAST VERSUS WROUGHT HEAT-RESISTANT ALLOYS 99
10. CARBURIZATION 103
11. CONCLUSION 107
REFERENCES 107
CHAPTER 6. THE TENSILE PROPERTIES AT ROOM AND ELEVATED TEMPERATURES OF SOME CAST AUSTENITIC STEELS 110
INTRODUCTION 110
EXPERIMENTAL PROCEDURE 110
EXPERIMENTAL RESULTS 114
DISCUSSION 124
CONCLUSIONS 127
ACKNOWLEDGMENT 128
REFERENCES 128
CHAPTER 7. THE PROPERTIES OF CAST 25 PER CENT CHROMIUM-20 PER CENT NICKEL AUSTENITIC STEELS IN RELATION TO THEIR USE AT ELEVATED TEMPERATURES 130
INTRODUCTION 130
I. EFFECT OF COMPOSITION ON STRUCTURAL STABILITY 131
II. STEELS OF PREFERRED COMPOSITION 139
III. WELDABILITY 143
DISCUSSION 147
CONCLUSIONS 148
ACKNOWLEDGMENTS 149
REFERENCES 149
CHAPTER 8. INTRODUCTION TO THE USE OF CAST ALLOY MATERIAL FOR HYDROCARBON PROCESSING IN THE U.S.A. 152
REFORMER PROCESSES 152
REFORMER TUBE DESIGN 155
FAILURES 157
HEADERS AND TRANSFER LINES 158
MISCELLANEOUS 159
CONCLUSION 160
CHAPTER 9. NOTES ON THE PROPERTIES AND WELDING OF CENTRIFUGALLY CAST 25 PER CENT CHROMIUM 20 PER CENT NICKEL ALLOY STEEL TUBE 162
SYNOPSIS 162
INTRODUCTION 162
EXPERIMENTAL MATERIALS AND PROCEDURE 163
DISCUSSION OF DATA 169
REFERENCES 196
CHAPTER 10. INTRODUCTION TO THE METALLURGY OF CAST HEAT-RESISTING ALLOYS 198
EFFECT OF COMMON ELEMENTS ON VARIOUS ALLOYS 203
ALLOY SELECTION 205
DUCTILITY OF CAST HEAT-RESISTING ALLOYS 210
WELDING CHARACTERISTICS 213
REFERENCES 215
CHAPTER 11. FORMS OF SUPPLY OF CENTRIFUGALLY CAST REFORMER TUBING 216
SPECIFICATIONS 218
CHAPTER 12. DEVELOPMENT OF IMPROVED WROUGHT ALLOYS FOR REFORMER TUBES 222
INTRODUCTION 222
PRELIMINARY STUDY OF ALLOYING ADDITIONS 223
FURTHER COMBINATIONS OF ALLOYING ADDITIONS 228
DISCUSSION 232
CHAPTER 13. WELDING METALLURGY OF CAST AUSTENITIC MATERIALS 236
INTRODUCTION 236
2. PREVIOUS WORK 237
3. POTENTIAL WELDING PROBLEMS IN AUSTENITIC MATERIALS 237
4. SUMMARY AND CONCLUSIONS 245
ACKNOWLEDGEMENTS 245
REFERENCES 246
CHAPTER 14. THE WELDING OF HIGH ALLOY MATERIALS RELEVANT TO PRESSURE STEAM-REFORMING OF NAPHTHA 248
1. BASIC PROCESSES AND MATERIALS 248
2. WELDING SPUN CAST TUBING 254
3. WELDING OF SAND CASTINGS (18-37) 255
4. WELDING OF TUBES AND HEADERS AFTER SERVICE 255
CHAPTER 15. FAILURES OF HEADER SUPPORT BRACKET ASSEMBLIES 258
CHAPTER 16. 
264 
1. GENERAL 264
2. WELDING PROCESSES 265
3. FILLER METALS AND ELECTRODES 265
4. FAILURES 266
5. ALTERNATIVE METHODS OF ASSEMBLY 267
CHAPTER 17. BLANKING-OFF REFORMER TUBES DURING PLANT OPERATION 268
1. INTRODUCTION 268
2. BACKGROUND 268
3. G-CLAMP SQUEEZER 269
4. LABORATORY TESTS 270
5. PLANT EXPERIENCE 272
CONCLUSION 273
CHAPTER 18. EXPERIENCES IN CONSTRUCTION AND OPERATION OF THE ICI TUBULAR REFORMER AT THE EFFINGHAM STREET WORKS OF THE EAST MIDLANDS GAS BOARD 274
INTRODUCTION 274
SUMMARY 275
DETAILS OF MATERIALS, WELD PREPARATIONS, WELDING RODS AND INSPECTION TECHNIQUES 275
SUMMARY OF MATERIAL SPECIFICATION 291
WELDING ROD SPECIFICATIONS 292
CHAPTER 19. HIGH TEMPERATURE STRENGTH AND DELAYED FRACTURE IN CERAMIC MATERIALS 298
INTRODUCTION 298
EXPERIMENTAL 299
METHODS OF TEST 300
GENERAL RELATIONSHIPS 301
CREEP 302
CONCLUSION 302
CHAPTER 20. SOME PRINCIPLES GOVERNING THE PERFORMANCE OF REFRACTORY CONCRETES (REFRACTORY CASTABLES) 304
I. INTRODUCTION 304
II. THE HARDENED CASTABLE BEFORE FIRING 305
III. THE CASTABLE FIRED TO INTERMEDIATE REFRACTORY TEMPERATURES 307
IV. THE EFFECT OF HYDRATE STRUCTURE ON SOME OTHER CASTABLE PROPERTIES 311
REFERENCES 313
CHAPTER 21. 
314 
INTRODUCTION 314
DESIGN OF LINING AND METHOD OF INSTALLATION 315
SHELL OVERHEATING 315
METHODS OF AVOIDING OVERHEATING 323
CHAPTER 22. REFRACTORY CONCRETE LININGS FOR SECONDARY REFORMERS 326
INTRODUCTION 326
REFORMER PROCESS 326
CHOICE OF REFRACTORIES 326
TYPES OF MONOLITHIC LININGS 328
TYPE OF LINING CHOSEN 329
ANCHORAGE AND LAYOUT 329
VAPOUR STOPS 330
DEVELOPMENT WORK 331
METHOD OF CONSTRUCTION 336
WATER CURING 336
DRYING OUT THE LINING 337
INSPECTION 339
ACKNOWLEDGEMENT 339
CHAPTER 23. 
340 
PLUG JOINTING 340
CHAPTER 24. THERMAL INSULATION FOR STEAM-REFORMING PLANTS 344
APPENDIX 348
REFERENCES 348
CHAPTER 25. TRANSFER OF SILICA IN THE PRESSURE STEAM REFORMING PROCESS 350
INTRODUCTION 350
PLANT EXPERIENCE 350
ANALYSES OF CONDENSATE 351
TRANSFER AS SILICON MONOXIDE 352
TRANSFER BY SOLUTION IN STEAM 352
REMEDIAL ACTION 355
REFERENCES 355
CHAPTER 26. NICKEL CARBONYL FORMATION IN STEAM REFORMING PROCESSES 356
INTRODUCTION 356
CONDITIONS FOR CARBONYL FORMATION 356
PLANT TESTS 358
LABORATORY WORK 360
CARBONYL FORMATION FROM CATALYSTS 365
CONCLUSIONS 366
REFERENCES 366
CHAPTER 27. PREVENTION OF VANADIUM PENTOXIDE ATTACK OF REFORMER TUBES BY MAGNESIUM COMPOUNDS 368
CHAPTER 28. CORROSION OF MILD STEEL DUE TO IMPINGEMENT IN THE MAKE-GAS STREAM 370
INTRODUCTION 370
SERVICE EXPERIENCE 371
PROTECTIVE MEASURES 375
EXPERIMENTAL WORK 376
RESULTS 378
DISCUSSION 380
CONCLUSIONS 382
CHAPTER 29. 
384 
INTRODUCTION 384
CONDENSATION 384
REPAIR OF COMPRESSOR SHAFTS 385
PROTECTION OF INTERSTAGE COOLERS 386
COMPRESSOR CASINGS 386
CONSTRUCTION OF IMPELLERS 387
RIVETTED IMPELLERS 387
WELDED IMPELLERS 387
CONCLUSIONS 391
CHAPTER 30. CORROSION PROBLEMS ON FINNED AIR-COOLED HEAT EXCHANGER TUBING 392
INTRODUCTION 392
PROBLEMS ASSOCIATED WITH FINNED TUBING 392
THE PROTECTION OF ALUMINIUM FINNED TUBES 393
CONCLUSION 396
CHAPTER 31. 
398