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    Metal Dusting

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    Faraj Haider
    This document describes Sheldon Dean's calculations of carbon activity (Ac), carbon precipitation temperature (CPT), and metal dusting severity (S) for different gas compositions at various temperatures and pressures. It explains that Ac, CPT, and S can help evaluate metal dusting conditions, with higher Ac, lower CPT, and higher S indicating more severe conditions. The calculations were performed using thermodynamic equations and assumptions about diffusion and equilibrium. The results were provided in a table to aid in understanding experimental metal dusting studies.

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    Metal Dusting

    Uploaded by

    Faraj Haider
    24 views18 pages
    This document describes Sheldon Dean's calculations of carbon activity (Ac), carbon precipitation temperature (CPT), and metal dusting severity (S) for different gas compositions at various temperatures and pressures. It explains that Ac, CPT, and S can help evaluate metal dusting conditions, with higher Ac, lower CPT, and higher S indicating more severe conditions. The calculations were performed using thermodynamic equations and assumptions about diffusion and equilibrium. The results were provided in a table to aid in understanding experimental metal dusting studies.

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    MetalDusting

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    This document describes Sheldon Dean's calculations of carbon activity (Ac), carbon precipitation temperature (CPT), and metal dusting severity (S) for different gas compositions at various temperatures and pressures. It explains that Ac, CPT, and S can help evaluate metal dusting conditions, with higher Ac, lower CPT, and higher S indicating more severe conditions. The calculations were performed using thermodynamic equations and assumptions about diffusion and equilibrium. The results were provided in a table to aid in understanding experimental metal dusting studies.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    24 views18 pages

    Metal Dusting

    Uploaded by

    Faraj Haider
    This document describes Sheldon Dean's calculations of carbon activity (Ac), carbon precipitation temperature (CPT), and metal dusting severity (S) for different gas compositions at various temperatures and pressures. It explains that Ac, CPT, and S can help evaluate metal dusting conditions, with higher Ac, lower CPT, and higher S indicating more severe conditions. The calculations were performed using thermodynamic equations and assumptions about diffusion and equilibrium. The results were provided in a table to aid in understanding experimental metal dusting studies.

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    Metal Dusting Calculations

    Project 138-00
    By
    Sheldon W. Dean
    October 22, 2002
    Project 138 Program
    • Gas compositions based on industrial
    experience
    • 7 different compositions
    • 2 temperatures, 1100o & 1300oF
    • 2 pressures, 1 Atm., 543 psia (36.96
    Atm.)
    Question?
    • How to evaluate severity of conditions?
    • Answer depends on mechanism of
    metal dusting.
    • Most investigators believe that carbon
    deposits and enters the metal.
    • This leads to several possible measures
    of severity
    Carbon Activity
    • Carbon activity is a thermodynamic
    concept.
    • Carbon activity is a relative measure of
    carbon concentration driving force.
    • Carbon activity is based on graphite as
    ground state.
    • Analogy to relative humidity.
    Carbon Activity
    • Carbon activity = Ac

    • Ac = [C] / [CG]

    • A c = pc / p G

    • Ac = 1 for graphite
    Carbon Activity in Syngas
    • 2 CO  CO2 + C Boudouard

    • CO + H2  H2 + C Hydrogenation

    • Two different reactions can deposit


    carbon
    Carbon Activity in Syngas
    • Problem! Which reaction to use?
    • Note that the carbon activity increases
    as temperature decreases.
    • Temperature where Ac = 1 is CPT
    (Carbon Precipitation Temperature)
    • Therefore, the higher the CPT the larger
    the Ac at a fixed temperature.
    Calculating Ac
    • Residence time of gas in process is
    short, a few seconds.
    • Residence time of adsorbed gas on
    metal surface is long
    • So adsorbed phases tend towards
    equilibrium
    • When equilibrium occurs both reactions
    give the same Ac.
    Water Gas Reaction
    • CO + H2O = H2 + CO2

    • When this reaction equilibrates


    composition both reactions give the
    same Ac.
    Methane Formation?
    • C + 2H2  CH4
    • This reaction is possible, but very slow.
    • Three molecule reaction.
    • If this reaction equilibrates, Ac < 1.
    • I assumed that this reaction does not
    occur.
    Carbon in Metal
    • Carbon formed on metal surface must
    diffuse into the matrix.
    • Graphite solubility increases with
    temperature
    • FCC iron assumed for metal. Diffusivity
    increases with temperature.
    • No metal dusting when Ac < 1.
    Diffusion of Carbon in
    Metal
    • Fick’s Law:

    Fc = Dc[C]/x

    Fc = Dc[ (Ac – 1) – f(x,t)]


    Metal Dusting Severity
    • If diffusion is a rate limiting step then the
    following value is a reasonable measure
    of severity:
    S = DcXc (Ac – 1)
    • CPT is also another parameter that can
    be used to judge severity.
    • Ac may also be used, but note
    temperature problem.
    CPT Calculation
    • Trial and error procedure.
    • Start with either 1100 or 1300F
    • Calculate water gas equilibrium
    composition (Appendix)
    • Calculate CPT (Eqn. 5)
    • Use that temperature to recalculate
    water gas equilibrium composition.
    CPT Calculation Cont.
    • Recalculate CPT
    • Recalculate water gas equilibrium
    composition, etc.
    • Usually less than three trials were
    necessary to obtain agreement to within
    1o K
    Additional Calculations
    • Carbon Activity:
    – Use water gas equilibrium compositions at 1100o
    and 1300oF
    – Calculate carbon activity using Eqn. 7

    • Severity:
    S = DcXc (Ac – 1)
    • Values of Dc and Xc were taken from ref.1
    Results of Calculations
    [See Table 1 for numerical values]
    • CPT varies from 990° to 2095°F
    • Ac varies from 0.041 to 7119
    • S varies from <0 to 376,144 x10-12 cm2/sec
    • 1 Atm. values always less than 36.96Atm.
    • Gas #1 at 1Atm and 1300°F is least severe
    • Gas #7 at 36.96Atm and 1300° is most
    severe
    Conclusions
    • The calculated values of Ac, CPT, and S
    should be helpful in understanding the results
    of Argonne Study.
    • Reviewing the damage in the light of the
    calculated values may shed light on the
    mechanism of attack.
    • If agreement is found then this calculation
    approach will have merit in assessing
    environments.

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