zecor casestudy 002 1008

1
No. 002 ZeCor ® Alloy Case Study www.mecsglobal.com MECS ZeCor ® materials intrinsic to CF Industries and JR Simplot plant success Physical Properties Mechanical Properties Density = 0.275 lb/in 3 Min. Yield Strength (0.2% offset) = 37.0 ksi Min. Ultimate Tensile = 78.0 Ksi Min. Elongation = 30% 90% 91% 92% 93% 94% 95% 96% 97% 98% 99% 100% 1 mpy (1 mil per year = .001 inch/yr = .0254 mm/yr) 1 mpy Concentration H 2 SO 4 % 320 300 280 260 240 220 200 180 160 Temperature (deg. F) ZECOR COMPONENTS MECS offers a complete line of major components and maintenance upgrade accessories fabricated from ZeCor Alloys, including: Towers Pump Tanks Piping Systems Uniflo Distributors Acid Coolers TowerGard Mesh Pads Packing Support Grids Inlet Acid Strainers Nozzle Sleeves Outlet Acid Strainers Outlet Sleeves Vortex Breakers Orifice Plates HRS Equipment ZECOR®-Z ISO CORROSION CURVE ZECOR®-Z PROPERTIES Industry leaders choose ZeCor® equipment MECS developed a family of corrosion resistant high performance metals known as ZeCor (which stands for Zero Corrosion) in 1998. ZeCor was designed for use in strong sulfuric acid applications ranging from 93 percent to 99 percent with temperatures from 140 degrees F (60 degrees C) to 260 degrees F (127 degrees C). The corrosion rate for ZeCor is less than 1 mpy or 0.025 mm per year. This rate is dependent on the acid concentration and temperature for typical drying and absorbing acid circuits. ZeCor — an excellent choice for hot sulfuric acid CF Industries of Plant City, Florida, conducted in-house laboratory studies of ZeCor and found the material to be an excellent choice for hot concentrated sulfuric acid. “ We did short term laboratory tests with ZeCor, SX ® and SARAMET ® in 93-percent sulfuric acid at approximately 200 degrees F (93 degrees C),” Allen Hearn, chief engineer of CF Industries, said. “We also did a comparison test of the same materials in 87-percent sulfuric acid to represent a diluted condition, also at 200 degrees F. The side-by-side test of these materials indicated that ZeCor was superior to the other two materials.” Amry Tayebi, senior plant engineer for CF Industries, concurred, noting, “ZeCor ended up being the lowest corrosion rate in both of these environments.” As a result of these convincing test results, CF installed a pump tank constructed of ZeCor in their ‘A’ Sulfuric Acid Plant. “In the beginning, we performed ultra-sonic thickness monitoring of the metal on a monthly basis… we have since gone to monitoring every three months because zero corrosion is all that has been detected,” Tayebi said. ZeCor offers outstanding corrosion resistance JR Simplot’s Pocatello, Idaho facility has also utilized ZeCor in its systems. Two MECS UniFlo distributors and the acid piping system for the company’s ‘400’ plant — which runs a sulfuric acid concentration of 98.5 percent — is constructed of ZeCor alloys. “We have done some internal inspections of the distributors and so far we have not seen any visible corrosion. Prior to installing the ZeCor piping we had anodically protected 304 and have been pleased with ZeCor’s perforance,” said Stein Simonsen process engineer for JR Simplot. An advantageous addition to the sulfuric acid industry, ZeCor is less expensive than many other stainless steel alloys and, when installation and field labor costs are considered, is competitive with the traditional materials of cast iron and carbon steel. SX® is a trademark of Sandvik Materials Technology SARAMET® is a trademark of Chemetics, an Aker Solutions company These components can be fabricated from any of these high performance metals, which include ZeCor-Z, ZeCor-310M, ZeCor-310MT, ZeCor-C, ZeCor-CL and ZeCor-CL29. They are available exclusively from MECS.

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Page 1: ZeCor CaseStudy 002 1008

No. 002ZeCor® Alloy Case Study

www.mecsglobal.com

MECS ZeCor® materials intrinsic to CF Industries and JR Simplot plant success

Physical Properties Mechanical Properties

Density = 0.275 lb/in3 Min. Yield Strength(0.2% offset) = 37.0 ksiMin. Ultimate Tensile = 78.0 KsiMin. Elongation = 30%

90% 91% 92% 93% 94% 95% 96% 97% 98% 99% 100%

1 mpy (1 mil per year = .001 inch/yr = .0254 mm/yr)

1 mpy

Concentration H2SO4%

320

300

280

260

240

220

200

180

160

Tem

pera

ture

(deg

. F)

ZECOR COMPONENTS MECS offers a complete line of major components and maintenance upgrade accessories fabricated from ZeCor Alloys, including: • Towers • Pump Tanks • Piping Systems • Uniflo Distributors • Acid Coolers • TowerGard Mesh Pads • Packing Support Grids • Inlet Acid Strainers • Nozzle Sleeves • Outlet Acid Strainers • Outlet Sleeves • Vortex Breakers • Orifice Plates • HRS Equipment

ZECOR®-Z ISO CORROSION CURVE

ZECOR®-Z PROPERTIESIndustry leaders choose ZeCor® equipmentMECS developed a family of corrosion resistant high performance metals

known as ZeCor (which stands for Zero Corrosion) in 1998. ZeCor was designed for use in strong sulfuric acid applications ranging from 93 percent to 99 percent with temperatures from 140 degrees F (60 degrees C) to 260 degrees F (127 degrees C). The corrosion rate for ZeCor is less than 1 mpy or 0.025 mm per year. This rate is dependent on the acid concentration and temperature for typical drying and absorbing acid circuits.

ZeCor — an excellent choice for hot sulfuric acid

CF Industries of Plant City, Florida, conducted in-house laboratory studies of ZeCor and found the material to be an excellent choice for hot concentrated sulfuric acid. “ We did short term laboratory tests with ZeCor, SX® and SARAMET® in 93-percent sulfuric acid at approximately 200 degrees F (93 degrees C),” Allen Hearn, chief engineer of CF Industries, said. “We also did a comparison test of the same materials in 87-percent sulfuric acid to represent a diluted condition, also at 200 degrees F. The side-by-side test of these materials indicated that ZeCor was superior to the other two materials.” Amry Tayebi, senior plant engineer for CF Industries, concurred, noting, “ZeCor ended up being the lowest corrosion rate in both of these environments.” As a result of these convincing test results, CF installed a pump tank constructed of ZeCor in their ‘A’ Sulfuric Acid Plant. “In the beginning, we performed ultra-sonic thickness monitoring of the metal on a monthly basis… we have since gone to monitoring every three months because zero corrosion is all that has been detected,” Tayebi said.

ZeCor offers outstanding corrosion resistance

JR Simplot’s Pocatello, Idaho facility has also utilized ZeCor in its systems. Two MECS UniFlo distributors and the acid piping system for the company’s ‘400’ plant — which runs a sulfuric acid concentration of 98.5 percent — is constructed of ZeCor alloys. “We have done some internal inspections of the distributors and so far we have not seen any visible corrosion. Prior to installing the ZeCor piping we had anodically protected 304 and have been pleased with ZeCor’s perforance,” said Stein Simonsen process engineer for JR Simplot. An advantageous addition to the sulfuric acid industry, ZeCor is less expensive than many other stainless steel alloys and, when installation and field labor costs are considered, is competitive with the traditional materials of cast iron and carbon steel.

SX® is a trademark of Sandvik Materials TechnologySARAMET® is a trademark of Chemetics, an Aker Solutions company

These components can be fabricated from any of these high performance metals, which include ZeCor-Z, ZeCor-310M, ZeCor-310MT, ZeCor-C, ZeCor-CL and ZeCor-CL29. They are available exclusively from MECS.