Cost-efficient and Sustainable Solutions with Duplex

Outokumpu Customer Seminar, Middle East, November 2012

www.outokumpu.com

Do you know your maintenance cost?

Actual coating cost? Maintenance repair of coatings? Lost production during maintenance? Safety issues? Environmental issues? Short service life?

1000 m2
Wouldn't be better to eliminate the coating

Duplex!

2 November 2012

Contents

1. The Duplex business case

2. Cost-efficient tank design 3. Case: Cost analysis of storage tank shell

4. Successful tank solutions in Duplex

5. Conclusions: Sustainable tank solutions in Duplex

2 November 2012

80 years of Duplex experience

Outokumpu is the leader of duplex innovations: Avesta Steelworks in Sweden produced the first commercial duplex grades starting around 1930 In more recent years the pioneer of lean duplex grades

The LDX family!

Autoclave in duplex 453S for production of gunpowder. Delivered in 1933.

2 November 2012

Positioning of Duplex grades

600 550 LDX 2404

An excellent combination of high strength and corrosion resistance

Hot coil

2507 LDX 2101 2205

Strength, Rp0.2 [MPa]

500 450 400 350 300

Duplex

2304

4565

4439

Austentic

250 200 150

4307 (304L)

4404 (316L)

4438 (317L)

254 SMO 904L

4436

Corrosion Resistance, CPT typical [C]

2 November 2012

Chemical composition and properties

Steel grade Outokumpu
EN ASTM

Typical chemical composition,% Cr Ni Mo N Others

PRE*

Rp0.2min, RT** MPa

Duplex stainless steels LDX 2101 1.4162 S32101 LDX 2404 1.4662*** S82441 2304 2205 2507 1.4362 1.4462 1.4410 S32304 S32205 S32750

21.5 1.5 24 3.6 23 22 25 4.8 5.7 7

0.3 1.6 0.3 3.1 4

0.22 5Mn 0.27 3Mn 0.10 0.17 0.27 -

26 34 26 35 43

450 480*** 400 460 530

Austenitic stainless steels 4307 1.4307 304L 4404 1.4404 316L 904L 1.4539 904L 254 SMO 1.4547 S31254

18.1 17.2 20 20

8.1 10.1 2.1 25 4.3 18 6.1

1.5Cu 0.20 Cu

18 24 34 43

200 220 220 300

* Pitting resistance equivalent, PRE = %Cr + 3.3x%Mo + 16x%N

** Values in accordance with EN 10088 for hot rolled plate. *** 1.4662 is not yet included in EN 10088. Rp0.2 min. value according to ASTM A240 for t >10 mm.

2 November 2012

Characteristics of the Duplex grades

Duplex = Austenitic-ferritic structure

Higher mechanical strength than standard grades

Good resistance to pitting and crevice corrosion Good weldability Higher fatigue resistance than standard grades High resistance to stress corrosion cracking and corrosion fatigue Low price for pitting and crevice corrosion resistance (price for PRE very low) High wear resistance

Low thermal expansion

High energy absorption

2 November 2012

The Duplex business case

Opportunity

Improved Cost Efficiency!

Benefits

Thinner gauges due to higher strength Weight savings! Better durability and reduced maintenance Longer service life! Cost efficient alloying (High N, low Ni) Cost stability! Customer service and prefabrication Support and added value!
Characteristics

Brings multiple sustainability benefits!

Excellent mechanical properties High corrosion resistance Good fabricability

2 November 2012

Cost efficiency
Cost Efficiency = Maximum Performance of the Investment
Minimize Total Material Cost Minimize Total Fabrication Cost Minimize Total Life Cycle Cost
Total Life Life Cycle Cost Cost
Operating Operation and and Total Maintenance Maintenance Initial Initial Cost Cost Cost Cost Fabrication Fabrication Cost Cost Material Material Cost Cost

2 November 2012

Successful solutions in Duplex

Desalination Evaporators Storage tanks Pressure vessels

The high corrosion resistance and strength of Flexible lines LDX 2404 mean it can be used as a complement orCost Superior cost efficient solutions Superior Efficiency strength constructions for high constructions in corrosive substitute in applications in corrosive environments environments where austenitic molother duplex grades such as 2205 Roofing and wall panels Bridges Chemical tankers have traditionally been used.

Courtesy of Kvaerner

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2 November 2012

Contents

1. The Duplex business case

2. Cost-efficient tank design 3. Case: Cost analysis of storage tank shell

4. Successful tank solutions in Duplex

5. Conclusions: Sustainable tank solutions in Duplex

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2 November 2012

Cost-efficient design Utilize strength!

Mechanical and physical properties, RT, minimum values Grade LDX 2101 2205 4307 (304L) 4404 (316L) Rp0.2 [MPa] 450 450 170 170 Rm [MPa] 650 655 485 485 E [GPa] 200 200 200 200 [x103kg/m3] 7.8 7.8 7.9 8.0

*Hot rolled plate at ambient temperature according to ASTM A 240

Factors influencing how the strength can be utilized:

Function: cylinder with internal pressure, plate in bending etc. Constraints:
Shape (diameter, height etc.) Loading condition (wind loads, seismic loads, fatigue loads etc.) Material standards and design codes (allowable design stresses etc.)

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2 November 2012

Utilize strength Structural efficiency

Critical design criteria

Pinternal >> Pexternal

Structural stability!

Tank - base

Rp0.2

Pexternal >> Pinternal

Structural instability!

Tank - top

P=Pressure

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2 November 2012

Utilize strength Structural efficiency

Critical design criteria

Rp0.2

304L/316L

LDX 2101/2205

~21

~58

Weight saving potential more than 50%

304L/316L

LDX 2101/2205

~25

~26

Weight saving potential less than 3%

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2 November 2012

Allowable design strength

Design strength at RT (MPa)
600
LDX 2404
LDX 2101 2205 2304 4404 (316L)

500

400

Storage tank codes

Pressure vessel codes

300

200

100

0 Proof strength, Rp0,2 API 650* EN 14015** EN 13445** * ASME VIII-1****

* Design stresses in accordance with API 650, Appendix X (Duplex stainless steel), which refers further to ASTM A240. ** Design stresses in accordance with EN 14015, which refers further to EN 10088-2. Maximum design stress is limited to 260 MPa. *** Design stresses in accordance with EN 13445, which refers further to EN 10028-7 (EAM or PMA if not included in EN 10028-7). **** Design stresses in accordance with ASME VIII-1, which refers to ASME II-D, code cases, and ASME SA-240. Note: LDX 2101 and LDX 2404 are pending for inclusion in EN 10088-2. They are not yet included in EN 10028-7 (EAM-0045-01 is applicable for LDX 2101, thicknesses up to and including 10 mm). ASME code case 2418-1 is applicable for LDX 2101. ASME code case is pending for LDX 2404. LDX 2404 is not yet included in API 650 Appendix X.

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2 November 2012

Size matters Tank shell design

Potential weight savings *
45% 40% 35% 30%
D H

API650

EN14015

25%

20%
15% 10% 5% 0%

Storage tank D=28m, Storage tank D=20m, Storage tank D=14m, Storage tank D=12m, H=28m H=20m H=14m H=12m

*Based on minimum allowable thicknesses for tank shell in accordance with specified design code.

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2 November 2012

Duplex any value for smaller tanks?

Benefits: Higher durability: wear, dent (permanent deformation) resistance Cost efficient alloying (High N, low Ni) for highest corrosion resistance High pressure tanks strength utilization possible

Constraints: Limited strength utilization critical design criteria: stiffness/buckling resistance Design codes: allowable design stresses, minimum shell thickness requirements

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2 November 2012

Fabrication of Duplex
Welding Weldability of duplex is good Most welding methods can be used Welding characteristic deviates from austenitic steel Always use appropriate filler metal and procedures Welding personnel must be informed and qualified according to the demands of the application Machining Duplex steels generally more difficult to machine than austenitic grades LDX 2101 has excellent machinability! Cold forming Higher strength of duplex grades: Greater working forces and spring-back during forming Somewhat lower ductility (fracture elongation, A5): Avoid sharp bend radii and more demanding forming techniques

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2 November 2012

Welding of Duplex
Welding of duplex is different from welding austenitics in terms of: Joint angle (larger opening for duplex) Shielding gas/Purging gas Speed (lower for duplex) Filler recommendations (overalloyed) Autogenous welding with TIG Heat input When changing from austenitic to duplex qualify the operators and the procedures.

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2 November 2012

Contents

1. The Duplex business case

2. Cost-efficient tank design 3. Case: Cost analysis of storage tank shell

4. Successful tank solutions in Duplex

5. Conclusions: Sustainable tank solutions in Duplex

20

2 November 2012

Case: Cost analysis of storage tank shell

Tank height: Tank diameter: Volume: Surface area: Density of content: Temperature: Design code: Joint factor: 20 m 20 m 6280 m3 1260 m2 1 g/ml 20C API 650 1

Maximum allowable design stress: A537-2 (S420) Sd=234 MPa LDX 2101 Sd=260 MPa

A516-60 (S235) Sd=147 MPa

4307 (304L) Sd=145 MPa

Find out more: www.outokumpu.com Products >> Tools >>

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2 November 2012

Basic shell design Structural efficiency

mm mm mm mm

7.5 7.5 7.5 7.5 7.5 7.5 7.5 8.1 8.9

7.5 7.5 7.5 7.5 8.0 9.3 10.6 12.0 13.3 14.6

6.0

6.0 6.0 6.0

Basic shell design in accordance with API 650: Minimum shell thickness:
td = 4.9D(H-0.3)G Sd + CA

-26%

LDX 2101 61.6 mt

-22%

6.0 6.0 6.0

Ref.

304L 82.7 mt
S235 97.0 mt S420 78.6 mt

+5%

6.0

6.5

6.0 6.0 6.0 6.0 6.7 7.4

H = 20 m

+23%

7.9 9.2 10.6 11.9

15 D 30 m min. td = 6 mm Plate width: 2000 mm (10 shell courses H = 20 m) Corrosion allowance, CA = 1.5 mm added to the carbon steels

Ref.

9.8

13.3

D = 20 m

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2 November 2012

Duplex improves both durability and manufacturability Improved fatigue, wear

Duplex grades not difficult to weld, but different: - Follow welding recommendations! and corrosion resistance: Wider, longer and = Longer service life! thinner plates: Less corrosion Less - Less joint preparation! maintenance compared - Less welding! to coated carbon steel! - Shorter welding time! Smooth 2B surface finish suitable for the food industry available up to 6 mm!

1,28 kg/m* 14 4307/304L

4307/304L

0,47 kg/m* 8
LDX2101 LDX2101

~40% Thickness Reduction ~60% Weld Metal Reduction

*Filler metal consumption (FCAW) according to The Avesta Welding Manual 2:ed 2005

Standards

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2 November 2012

Initial investment High cost level

Material cost (USD/mt): Based on average hot rolled coil prices per unit of weight, 5-year-period (2005-2009). LDX 3200 2101 304L 3000 A516-60 A537-2 750 1000 301 69 175 69 117 207 141 200 301 400 -27% -6% +14% Ref.
x1000

USD 600

Weight of plate materials (mt): LDX 2101 304L A516-60 A537-2 61.6 -22% 82.7 +5% 97.0 +23% 78.6 ref. Welding and assembly cost: Based FCAW wire, typical welding and labor costs for e.g. Northern Europe. Wire consumption (kg): LDX 2101 304L A516-60 520 -37% 940 +13% 1210 +46% Welding and assembly time (h) LDX 2101 304L A516-60 1400 -33% 2300 +10% 3000 +43% A537-2 830 ref. A537-2 2100 ref.

199
LDX 2101

249
304L

91
A516-60

81
A537-2

Internal surface treatment cost (USD/m2): LDX 2101 304L A516-60 A537-2 22 22 180 180 External surface treatment cost (USD/m2): LDX 2101 304L A516-60 A537-2 22 22 60 60 24 2 November 2012

Higher strength Weight savings Less welding Less surface treatment:

Improved Cost Efficiency!

Initial investment Low cost level

Material cost (USD/mt): Based on average hot rolled coil prices per unit of weight, 5-year-period (2005-2009). LDX 2101 3200 304L 3000 A516-60 A537-2 750 1000 +20% +49% +11% Ref. USD
x1000

22 43 22 33

300

Weight of plate materials (mt): LDX 2101 304L A516-60 A537-2 61.6 -22% 82.7 +5% 97.0 +23% 78.6 ref. Welding and assembly cost: Based FCAW wire, typical welding and labor costs for e.g. China, South-East Asia. Wire consumption (kg): LDX 2101 304L A516-60 520 -37% 940 +13% 1210 +46% Welding and assembly time (h) LDX 2101 304L A516-60 1400 -33% 2300 +10% 3000 +43%

100 100
200

43
A537-2 830 ref. A537-2 2100 ref. 29 100

199
LDX 2101

249
304L

91
A516-60

81
A537-2

Internal surface treatment cost (USD/m2): LDX 2101 304L A516-60 A537-2 7 7 60 60 External surface treatment cost (USD/m2): LDX 2101 304L A516-60 A537-2 7 7 20 20 25 2 November 2012

Higher strength Weight savings Less welding Less surface treatment:

Improved Cost Efficiency!

Life cycle cost Maintenance cost

Initial investment cost (x1000 USD)
LDX 253 +20% 2101 304L 314 +49% A537-2 211 ref.
-22% -12% -18% Ref.
X1000

USD 400

Maintenance cost
Cost analysis data: Real interest rate: 4% Life cycle duration: 30 yrs. Complete recoating after 10 and 20 yrs. Internal surface treatment cost (USD/m2): LDX 2101 304L A537-2 60 External surface treatment cost (USD/m2): LDX 2101 4307(304L) S235S420 20 253 314 211 100 113 300

200

Note: Lost production time and its cost at maintenance stop, as well as final scrap value, are additional favorable factors for stainless steel to consider in the life cycle cost analysis.

LDX 2101

304L

A537-2

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2 November 2012

Life cycle thinking with Duplex

A sustainable product:
Scrap-based production 100% recyclable Low level of metal ion release into the environment High durability, longer lifetime less maintenance No need for environmentally harmful protective coatings Avoid unsafe maintenance work Using Duplexs strength to reduce weight: Lower energy consumption, lower CO2 emission levels.

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2 November 2012

Contents

1. The Duplex business case

2. Cost-efficient tank design 3. Case: Cost analysis of storage tank shell

4. Successful tank solutions in Duplex

5. Conclusions: Sustainable tank solutions in Duplex

28

2 November 2012

Successful tank solutions in Duplex

Food industry: LDX 2101 in tank farm for edible oils, The Netherlands Chemical industry: 2304 in acetic acid tank, Spain Chemical industry: 2205 in phosphoric acid tank, Sweden Mining and Minerals: 2507 in tanks for zinc processing, Spain

600

Hot coil

LDX

2404 2507

Mining and Minerals: 254 SMO in mix and collection tanks for copper processing, Chile

550
500 LDX 2101 2205

Strength, Rp0.2 [MPa]

450 400 350 300

Duplex

2304

4565

4439

254 SMO 904L

Austentic

250

4404 4307

4438

200
150

4436

Corrosion Resistance, CPT typical

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2 November 2012

Successful tank solutions in LDX 2101

Wine tank park, Spain

Fabrication of storage tanks for honey and edible oils etc., Spain

Superior cost efficiency provided with LDX 2101 for tank applications in a variety of industries

Waste water treatment tank, Poland

Tank transportation, The Netherlands

Palm oil tank farm, The Netherlands

Pulp and Paper liquor tank, Finland

Corn silos, Hungary

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2 November 2012

New tank solutions with LDX 2404

Our customers

Cr% 24

Ni% 3.6

Mo% 1.6

Mn% 3.0

N% 0.27

Were enthusiastic about the potential of duplex as a construction material Required corrosion resistance beyond 316 Were not entirely satisfied with the mechanical strength of 2304 Could not fully benefit from the alloy content of 2205

... were the starting point for LDX 2404

Tank Specification:
Height = 20 m Diameter = 22 m Content density = 1,0 kg/dm3 Temperature = 20C Design code = API 650 Joint efficiency = 0,85 Allowable design stress: 4404 (316L) = 145 MPa 2205 (S32205) = 262 MPa LDX 2404 (S82441) = 296* MPa
* Not yet included in API 650 Appendix X. The design stress shall be 0.4Rm.

[m] Required thickness Duplex LDX 2404 20 18 16 Required thickness Duplex 2205 14

72 tons

75 tons
Required thickness Austenitic 4404

12
10 8

117 tons Potential weight saving as a substitute for 4404 :

6
4 2

~40%
31 2 November 2012

Contents

1. The Duplex business case

2. Cost-efficient tank design 3. Case: Cost analysis of storage tank shell

4. Successful tank solutions in Duplex

5. Conclusions: Sustainable tank solutions in Duplex

32

2 November 2012

Conclusions: Cost-efficient and sustainable solutions in Duplex

Enhanced Structural Efficiency
due to higher allowable design strength No corrosion allowance Weight savings!

Enhanced Durability
due to higher corrosion and mechanical resistance Less maintenance Less lost production time less environmental impact Longer and safer service life!

Enhanced Manufacturability
with good weldability and thinner gauges Less joint preparation and less welding Shorter fabrication time!

Improved Cost Efficiency and Sustainability!

33 2 November 2012

Thank You!
www.outokumpu.com