JLT AT EIT, eeee:
eee
BRC-CORP 37-74. 207
Section 38. SULFURIC ACID CORROSION
Definition of the Problem
The primary problem encountered in sulfuric acid corrosion is general
metal loss, although sulfuric acid can groove corrosion in veld heat
affected vmes. Another problem associated with oulfuric acid te corrosiou Liu
sulfur-bearing flue gases contacting metal surfaces below the dew point (see Sec-
tion 11 on Condensate Corrosion).
Discussion of the Problem
Carbon steel is widely used to contain concentrated sulfuric acid,
but 18 not considered compatible with sulfuric acid at strengths of 60%w and
lower. In concentrated acid the carbon steel ie covered by a relatively
insoluble FeSO, film (corrosion product), which protects the metal against
further correoion. In fact, the corrosion rate 1 equal to che rare of removal
(by physical or chemical means) of this film. Increasing temperature accelerates
corrosion of carbon steel by concentrated sulfuric acid, In dilute sulfuric acid,
the FeSO, film is so soluble that the protective film ran not form and high
corrosion rates result.
Fluid flow dramatically accelerates corrosion of carbon steel in
concentrated (greater than 60%w) sulfuric acid, by increasing the dissolution
rate of the protective film, Corrosion rates are approximately proportional to
acid flow rates. Corrosion rates are generally highest in regions of disturbed
flow ouch ae elbows vi valves or in highly turbulent flow.
Occasionally, because of localized variations in composition and
thermal history, accelerated attack of carbon steel occure in the heat affected
zone of a weld. This attack leads to formation of a groove in the heat affected
zone and is sometines called groove corrosion. Groove corrosion can be pre-
vented by normalizing the steel.
Alternate materials of construction for sulfuric acid service are
available. Because low alloy steels do not provide any significant increase
im corrosion resistance in sulfuric acid over carbon steels, the alloy 20 type
materials (Worthite, Durimet 20, Carpenter 20-Cb 3, Incoloy 825, Hastelloy ¢)
generally consitute the next step up from carbon steel. If these materials are
not cuffiedently recdetant, higher alloye ouch ee Hastclivy B are required.
Methods of Checking for the Problem
For carbon steel, the most severe corrosion problem generally occurs
in regions of highest temperature and turbulence. The corrosion problem is
usually general metal thinning, which often can be detected by ultrasonic and
Fadiograpnic inspection, and by visual inspections during dom time. For
the alternate materials of construction, the corrosion is generally most
Severe in regions of highest temperature.BRC-CORP 37.74.F
Methods of Eliminating the Probl
Corrosion of carbon steel by sulfuric acid can often be controlled by
the lowering of acid velocities. Reduced temperature and relatively large
amounts of hydrocarbon in the acid also decrease corrosion rates. If carbon
steel is unacceptable for prevailing process conditions, a more resistant material
of construction 18 required. Figure 38-1 is a general guideline for materials
selection in sulfuric acid. Anodic protection of sulfuric acid storage tanks
has been used with success.
Pletal
Sulfuric acid 1s a complicated corrosive. Plant acids generally
contain impurities which can affect corrosion rates significantly. It ia
recomended that summaries of corrosion performance of materials in sulfuric
acid (such as in the attached Figure 38-1) be regarded only as general guidelines.
They should not be relied upon for final materials selection.
.
Pocccccccccccceseeeoeeoeeseseees eo oe
‘Temperature, “F
BRC-CORP 37-74.F
600}—
400}—
100
‘Avoid Hantelloy B and D in
this Range at Boiling Point
Boiling Point
40 60
Concentration in Water, %
Figure 38-1
Sulfuric Acid Corrosion
Cae eee ary
100
100210
Figure 38-41
BRC-CORP 37-74.F
(Cont'd)
Code for Sulfuric Acid Chart
on rate lots than 0.020" per yeer
Zone 1 Zone 3 Zone 6
20-30 Ni 20 Cr- 30 Ni? 62Ni- 28 Mi
66 Ni-32 ut 66 Ni - 32 Cu! Gola
62 Ni - 28 Mo 62 Ni - 28 Mo Pravioun
Type 316? Gold Silicon tron
‘A Bronze 10%! Lend Tantalum
Copper! Molybdenum
Gold Platinum Zone 7
Lewd sare to
Molybdenum Tantalum Gola
Nickel Cast Iron Zirconium Platinum
Platinum Sticon fron
Siver Zone 4 Tantalum
Tantalum
Zirconium 20 Cr -30 Ni Zone 8
62 Cr - 28 Mo
Zone 2 Type 316° 20 Cr- 30Ni
oid 18Cr-8Ni
wer sue Lesa D4 Ni 1B Cr-16 Mo
66 Ni- 32. Gu! Nickel Cast tron Gold
62 Ni- 28 Mo Pratioun Platinum
Type 316° Silicon tron Stel
A Bronze 10%! Steet
Coppes* Tantalum Zone 9
Gold Zirconium?
Led 20 Cr 20 Ni
Molybdenum Zone § 180-8 Ni
Nickel Cast tron* Gold
Platinum 20 Cr - 30 Ni Platinum
Silicon Cast tron 62 Ni-28 Mo
Siver God Zone 10
Tontaum Lead?
Zirconium Pratinum Gold
Silicon Iron Pratioum
Tantalum
No Air * <86% Concentr
2 < 10% Aerated 7 >80% Concentration
> Sree 8 00m Acted
* <20% a 25°C * < 75%, <20%
5 <25% Aerated at 25°C °° 20 10 60 mpy
a