Ethylene Furnace Training

PEQUIVEN Olefinas II
23 rd to 27th March 2009
Cracking Furnace Tube Metallurgy
Part I: Materials and Failure Mechanisms

LE TAW Pullach
Dr. Hubert Kpf

Cracking Furnace Tube Metallurgy

Agenda:

Part I:

Window rupture
of a Catalyst
Tube

Materials and Failure Mechanisms

Part II:
Inspection and Evaluation/Failure analysis

Cracked Catalyst
Tube

Part III:
Troubleshooting and Repair Methods
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Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms

Usable strength

1. Tube Materials
Oxidation Protective Coatings Required

Oxidation Stability

Single
Crystals

Titanium
Composites

Conventional
Titanium
Alloys

Superalloys

Directionally Solidified Eutectics

Rapid Quenched Metals

Ceramics / Graphite

Graphite
C/C

Aluminium Alloys
Aluminium
Composites
Advanced
Titanium Alloys

500

-Titanium
Aluminide
based Alloys

Refractory Metals
ODS-Superalloys
PM 1000 / PM 2000

1000

1500

2000

Temperature [C]

In Ethylene Cracking metal surface temperatures up to 1100C in combination with

carburization and oxidation stability have to be managed by the tube materials. The
materials shall be weldable and economic. This requirements are fulfilled by high Ni,
Cr austenics (superalloys).
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Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanismus
1. Tube Materials
Centrifugally cast tubes of these alloys are selected due to their enhanced high
temperature strength compared to wrought alloys

However, the ductility properties of the cast materials at ambient

temperatures are reduced compared to the wrought alloys.

Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
1. Tube Materials
The table below shows typical cast alloys used by LINDE in Ethylene Cracking Furnaces

Its important that Si is high to improve the carburization resistance.

Impurities such as As, Sn, Zn, Sb and Pb shall be low; these elements
are indications for the amount of scrap used in the tube production
process

Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
1. Tube Materials
The design of Tubes follows the general rules for all equipment in high temperature
service (example for power stations acc. to VGB)
Operation in range of yield strength
at elevated temperature

Operation in creep range

stress

= stress
Rp0.2/ = yield strength at temperature
Rm/time/ = rupture strength at time and temperature

Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
1. Tube Materials

Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes

Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes

Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes

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Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes

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Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes

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Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes

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Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes
Creep damage: Time-dependent strain occurring under stress. The creep strain
occurring at a diminishing rate is called primary creep; that occurring at a minimum
and almost constant rate, secondary creep; and that occurring at an accelerating
rate, tertiary creep. Below please find a principle Master curve for creep damage.

= Elongation
Au= Creep elongation at fracture
t= time
tm= time to fracture

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Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes
At temperatures above approximately 50% of the reformer tube alloy melting
(approx. 1350 C) creep is determined by relocation of micropores and lattice
defects (dislocations) towards the grain boundary.

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Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes
Cracks resulting from this mechanism are intergranular / interdendritic
(Example: X5NiCrTi 26-15, 1.4980)

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Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes

Stage 2
(Magnification X 200)

Stage 3 - 4
(Magnification X 200)
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Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes

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Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes

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Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes

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Cracking Furnace Tube Metallurgy

Part I: Materials and Failure Mechanisms
2. Failure Mechanisms for Radiant Tubes

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