Skip to main content
SpringerLink
Log in

Metal Dusting of Process Gas Heater Convection Tubes

  • Case History---Peer-Reviewed
  • Published:
Journal of Failure Analysis and Prevention Aims and scope Submit manuscript

Abstract

An investigation was conducted into a failure of convection section tubes in a process gas heater in a steel-making company. Thorough study using various characterisation techniques showed that the failure of the tubes, which were made of low-alloyed steel ASTM A335 P22, was attributed to metal dusting. The attack was accelerated because of the use of incompatible tube material for the intended operating conditions. Moreover, thermal fatigue cracks were discovered on the tube surfaces. Such cracks might have been caused by the high number of plant start-ups and shutdowns. Failure contributing factors and recommendations to avoid similar failure are discussed in this article.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10

Similar content being viewed by others

References

  1. B.A. Baker, G.D. Smith, Metal Dusting Behaviour of High Temperature Alloys, NACE International, Corrosion 99, Paper No. 54

  2. H.J. Grabke, M. Spiegel, Occurrence of metal dusting-referring to failures cases. Mater. Corros. 54(10), 799–804 (2003)

    Article  Google Scholar 

  3. J. Kelly, J. Wilson, D. Wachowiak, Metal Dusting a.k.a Carbon Rot in the Heat Treat Industry, 50 years (2004)

  4. R.T. Jones, K.L. Baumert, Metal Dusting-An Overview of Current Literature, NACE International, Corrosion 2001, Paper No. 01372

  5. H. J. Grabke, Metal Dusting, Materials and Corrosion 2003, 54, No. 10

  6. M.H. Ravestein, Metal Dusting in Catalytic Reforming Furnace Tubes, NACE International, Corrosion 97, Paper No. 496

  7. R. Kirchheiner, J.L. Jimenez Solar, Correlation of Oxidation, Carburisation and Metal Dusting; “Controlling Corrosion by Corrosion”, NACE International, Corrosion 2001, Paper No. 01374

  8. P. Szakalos, Mechanisms of Metal Dusting, Doctoral Thesis, Department of Material Science and Engineering, Division of Corrosion Science, Royal Institute of Technology, Sweden AND Swedish Institute for Metals Research, Sweden (2004)

  9. H.J. Grabke, E.M. Muller-Lorenz, S. Strauss, E. Pippel, J. Woltersdorf, Effects of grain size, cold working, and surface finish on the metal dusting resistance of steels. Oxid Met 50(3/4) (1998)

  10. H.J. Grabke, E.M. Muller-Lorenz, A. Schneider, Review-carburisation and metal dusting on iron. ISIJ Int. 41(Suppl), S1–S8 (2001)

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Materials, Corrosion, Static Equipment Domain, SABIC Technology Centre, P.O. Box 11669, Jubail Industrial City, 31961, Saudi Arabia

    Abdulaziz Al-Meshari, Gys van Zyl & Mazin Al-Musharraf

Authors
  1. Abdulaziz Al-Meshari
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Gys van Zyl
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Mazin Al-Musharraf
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Abdulaziz Al-Meshari.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Al-Meshari, A., van Zyl, G. & Al-Musharraf, M. Metal Dusting of Process Gas Heater Convection Tubes. J Fail. Anal. and Preven. 17, 363–369 (2017). https://doi.org/10.1007/s11668-017-0241-3

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11668-017-0241-3

Keywords

Search

Navigation