Material Programme. For corrosive, abrasive and hot media.

Transcription

1 Material Programme For corrosive, abrasive and hot media.

2 The right solution. For any fluid. Anyone looking for efficient, lasting and economical solutions to their demanding industrial conveyance applications needs more than just a coherent technical concept. Our extensive knowledge of materials, experience of the application, and dialogue with you, the customer ultimately lead to the optimal solution. A way which Rheinhütte Pumpen has been following for over 150 years. Special materials for special requirements As experts in corrosion and wear resistant materials we offer process and media-specific solutions. We will select the right material for your conveyance requirement and will ensure minimum wear during long operational life even when handling difficult media. Our extensive pump programme is based on three groups of material: metals, plastics and ceramics. Materials which we at Rheinhütte have developed ourselves also extend our materials portfolio. Metals Our range includes over 20 different metals. They differ from each other in terms of their alloying elements, their structure and their manufacturing process. As every alloy has its own characteristic properties, a suitable material can be used for each conveyance task: Rheinhütte Pumpen made from highquality stainless steels and numerous pure metals. Plastics Plastics provide a good supplement to many areas of application. Our pumps are available in six different materials, each tailored to your specific application. All manufactured in-house. Plastics from Rheinhütte Pumpen more than just plastic. Ceramics Ceramic materials achieve universal corrosion and abrasion resistance during long operational lives. For such applications Rheinhütte Pumpen offers you with Frikorund, a FRIATEC ceramic development optimised and proven for pump construction. The specialist for ceramic materials and construction. 02

3 Customised solutions for your application Rheinhütte Pumpen offers a broad selection of pumps in the most varied designs. With the extensive range of materials in metals, plastics, ceramics and designs which are adapted for particular media, our pumps are used for almost every challenging application. The most important areas are: the chemical industry the petrochemical industry the oil and gas industry / refineries the mining and metallurgical industries the iron and steel industry renewable energies environmental management and recycling the consumer goods industry We will develop individual pump designs for you. Always matched with your specific application and therefore providing you with flexible and economic solutions for your special conveyance requirement. 03

4 Application Sulphuric Acid ISO Corrosion diagram for materials in H 2 SO Temperature in C Boiling line Siguss* RHRS* RHSX* 50 R3020* S* Concentration H 2 SO 4 in % * Rheinhütte Pumpen Materials Corrosion-resistant materials for sulphuric acid Sulphuric acid can be conveyed with pumps made of metal or plastic. About all concentrations and temperatures Siguss is the only metallic pump material that can be used. For highly concentrated sulfuric acid stainless steel alloys are especially suitable because of their oxidative property, as they form a passive layer for corrosion protection. Influence of flow rate of H 2 SO 4 on the corrosion rate for Corrosion rate per year in mm/a ,1 0,01 25 C 4 m/s 2 m/s 0 m/s H 2 SO 4 in %

5 Application Phosphoric Acid Materials for Raw Phosphoric Acid SiC Wear Resistance S * PE S* S * Nickel based alloys Stainless steels PP PVDF R3020 * Alloy 20 PFA, PTFE Corrosion Resistance * Rheinhütte Pumpen Materials Materials for Raw Phosphoric Acid S Excellent wear resistance Phosphates are important parts of agricultural fertilisers. They are obtained from phosphoric acid as an intermediate product. In order to obtain phosphoric acid phosphate containing minerals are often digested with sulfuric acid. This process produces extremely corrosive mixtures containing varied chlorides and fluorides as well as phosphoric and sulfuric acids. In addition, a large number of solids are obtained in form of gypsum and sand. Due to the chlorides and fluorides very high grade steels have to be used for metallic materials. A material for this process must resist high corrosion loads and exposure to wear. As there exists no all-purpose material, detailed knowledge of the composition of media as well as material expertise are important to design pumps with long operational life in process (CD4MCuN) High wear resistance and good corrosion resistance R3020 Very high corrosion resistance S Very high corrosion resistance and wear resistance S Excellent corrosion resistance and very good wear resistance Alloy C1 (2.4686) Excellent corrosion resistance and wear resistance 05

6 Application Chloralkali-Electrolysis Medium 310 g/l NaCl Brine Chlorine free Raw brine / Purified brine / Diluted brine Chlorine containing brine 200g/l NaCl Catholyte 31% NaOH Caustic soda Hot Catholyte 31% NaOH Caustic soda Cold caustic soda NaOH Moist chlorine gas Chlorine containing sulphuric acid Materials Super duplex, Super austenite, Titanium, TiPd PTFE, PFA, PVDF, PE 1000 Titanium, TiPd PTFE, PFA, PVDF Nickel PTFE, PFA, ETFE Nickel, Super austenite (R3020) PTFE, PFA, ETFE Super austenite (R3020) PTFE, PFA, ETFE, PE 1000, PP Frikorund Keramik Siguss PTFE, PFA Liquefied chlorine gas Austenite (1.4408) Materials for the chlorine industry When it comes to pumping catholyte solutions (NaOH, 80 C) to protect the electrolysis membranes from Fe-ions only pure, iron-free pump materials can be considered for use. Rheinhütte Pumpen successfully makes use here of centrifugal pumps made from nickel, ETFE, PFA or PTFE. On the anolyte side identical pumps made from titanium, titanium-palladium or PTFE complement our range. The pumping of moist chlorine gas presents supreme demands for the corrosion resistance of all of the components which are used. Solid ceramic liquid ring vacuum pumps have proved their worth for many decades here and they offer an unique alternative to special pumps made from titanium. Sulphuric acid is used to dry the moist chlorine gas. At this point, due to the dry chlorine gas in the sulphuric acid, even titanium is not suitable as a material for pumps. Only the special material SIGUSS which has been developed by Rheinhütte Pumpen guarantees along with PTFE and PFA long lifetimes for centrifugal pumps. 06

7 Application Steel Pickling Plastic Pumps in Pickling Plants Plastics such as PP or PE 1000 have proven themselves especially in the steel pickling in recent decades and have become normal standard. They show no sensitivity to ph values and chloride concentrations. Even pure hydrochloric acid can be handled with these plastics. In solid-containing pickling PE 1000 (UHMW-PE) is the most appropriate material. In very aggressive pickling applications containing hydrofluoric acid or many flourids, PVDF proved to be excellent. Rheinhütte plastic pumps for very aggressive media can be made of solid PTFE or plastic lined with PFA. All plastics can also be used in electrical conductive quality for Rheinhütte pumps. RVKu Medium FRIKORUND PP PE PVDF PFA/PTFE HCI-Steel Pickling up to 120 C 33 % up to 90 C 33% up to 80 C H 2 SO 4 -Steel Pickling up to 120 C HNO 3 / HF- Stainless Steel Pickling Na 2 SO 4 Electropolishing 60 % bis 95 C max. 75 AT max. 10 % HNO AT 80 % up to 80 C max. 97 AT max. 20 % HNO 3 and 15 % HNO % HF up to 60 C resistant up to 100 C 60 % up to 120 C max. 97 AT max. 65 % HNO AT resistant over 100 C resistant over 100 C resistant over 100 C resistant resistant resistant resistant resistant AT = ambient temperature 07

8 100 µm Metallographic cross section on Siguss Analysis of a pump casing of PE 1000 Rheinhütte Pumpen Materials a class of its own Through decades of continuous development of pump materials Rheinhütte Pumpen provides procedural and medium-specific solutions that meet the essential requirements on the resistance of pump materials in use. The realisation of processes often was made possible by specially developed materials from Rheinhütte Pumpen. Material Analysis and Recommendation Our experts select the optimum material for your application - considering all operating parameters and alternative materials. Static tests in our own laboratory and continuous analysis of materials in use are essential for the development of alternatives that ensure safe pump operation. Expertise also plays a crucial role in determining the best seal design and the right pump selection. The close cooperation and regular exchanges with renowned institutes, universities and experts offices guarantee our expertise up to date S The S is a Rheinhuette special cast material, which is an enhanced standard DIN material Rheinhuette Pumpen has gained best experience with S since more than 25 years. This material is a corrosion- and erosion-resistant, high alloyed ferritic cast steel. Typical applications are for example highly oxidising media, like high-concentrated sulphuric acid up to 160 C and oleum. RHRS This material is a further development of the successful material S of Rheinhütte Pumpen. It is ideally suited for use in highly concentrated and very hot sulfuric acid up to 240 C. Compared to S the maximum temperature in hot concentrated sulfuric acid was increased again. The cast material RHRS has a ferritic basic structure, the composition of which is characterised by a low carbon content and alloy content of about 30 % chromium. 2 % molybdenum, and an addition of copper in the alloy, support the excellent resistance in concentrated sulfuric acid. 08

9 500 µm Analysis on a Siguss microstructure Our materials as varied as your areas of applications. Siguss Siguss is a high-silicon cast iron with 15 % alloying content of Silicon and 5 % Chromium. The especially high amount of silicon is the main feature of this cast material. The high content of Silicon secures the formation of a ferrosilicitic micro structure, which is able to form a very stable and tight passive layer. This layer protects the metal against corrosion attack. So the material offers very high resistance against different mineral acids. No other metallic material offers this broad application range in sulphuric acid as Siguss means from 0 to 99% H 2 SO 4 up to 250 C! Additionally Siguss has a high hardness of approximately 350 HB. This high hardness supports the resistance against erosion-corrosion, which is very typical for H 2 SO 4. This hardness makes Siguss to a material which has a better resistance against abrasion than the most austenitic stainless steels. Beside in sulphuric acid, the resistance in nitric acid is remarkable, too. Rheinhütte Pumpen manufacture pumps in Siguss for more then 40 years. R3020 R3020 is a purely austenitic high-alloy material. Due to the chemical composition and the specific heat treatment the structure is practically free of ferretic or carbidic impurities. The material R3020 is effective in many applications where the US-material Alloy 20 can be used. For example, in the field of low and medium concentrated sulfuric acid, the corrosion resistance of R3020 and Alloy 20 is quite similar. However, the material is superior to Alloy 20, because R3020 contains more chromium and molybdenum. This special material of Rheinhütte Pumpen is one of the so-called highly corrosion resistant superaustenites. Frikorund FRIKORUND can be used without any problems in oxidizing and in reducing fluids with or without chlorides or bromides. Even if solids need to be conveyed, the extremely hard material FRIKORUND is better suited than any plastics or many metallic alloys. 09

10 Properties Metallic materials The range of metallic materials encom-passes a wide variety of very different types of material which are distinguished mainly by their alloy composition, their structure and their manufacturing process. This gives each material its characteristic properties and allows an optimal material to be selected to suit the application. Cast iron and cast steel Material V5700 (0.9650) Designation DIN [ASTM] GS-C 25 (GP 240 GH) [A 216 WCA / WCB] GS-17CrMo 5 5 [A 216 WC 6] G-X 260 CrMo 27 1 [A 532 Class 111 Type A 25% Cr] Properties and application High temperature ferritic cast steel, can be used up to 450 C. For use with low or non-corrosive media, such as molten sulphur. High temperature ferritic cast steel, can be used up to 550 C. The most frequent application is the pumping of molten salts. Particularly wear resistant high alloy cast iron. This material is used for suspensions with an abrasive effect such as gypsum, carbonates, carbides. sand, ore or metal oxides. Silicon iron alloys Material Siguss Designation DIN [ASTM] G-X 90 SiCr 15 5 ASTM A518 Properties and application Highly corrosion resistant chromium alloy silicon cast iron with a good resistance to wear and increased chemical resistance. This material is chemically resistant to H 2 S0 4 at all concentrations up to boiling point, therefore for all sulphuric acid applications including the evaporation of waste sulphuric acid, Siguss is virtually indispensable. Pure metals Material Titanium Titanium Pd Zirconium Designation DIN [ASTM] G-Ti Titanium Grade TiPd Grade 7 G-Zr Properties and application Titanium is especially resistant to heavily oxidising and chloride containing media. The material is preferred for use in chloralkali-electrolysis, for pumping bleaching solutions containing chlorine and in the manufacture of acetic acid. Titanium alloyed with palladium. This improves the corrosion resistance in reducing media, e.g. in solutions of iron chloride or aluminium chloride containing hydrochloric acid. Zirconium is particularly suitable for pumping very hot highly concentrated acetic acid, hydrochloric acid at all concentrations up to 200 C and boiling concentrated aluminium chloride solution. Nickel (2.4170) G-Ni 95 Nickel is mainly used for pumping molten alkalis, for the evaporation of alkalis and for pumping highly refined alkalis which must not be contaminated Nickel (RH Ni 98) G-Ni 98 with iron ions. 10

11 High alloy cast steel Material Designation DIN [ASTM] Properties and application S G-X 50 CrMo 29 2 Corrosion and erosion resistant high alloy ferritic cast steel. Typical applications are highly concentrated sulphuric acid up to 180 C, oleum, fertiliser RHRS production, crude phosphoric acid containing solids. RHSX S 304L / A743 CF G-X 2 CrNiSi ANTINIT A610 G-X 6 CrNiMo (316 Nb) [A 743 CF-8 M] G-X 6 CrNiMo R S G-X 5 CrNilMoCu ~ [A 743 CD 4 MCuN] G-X 3 NiCrMoCu Alloy 20 < R3020 < Alloy 28 G-X 3 NiCrMoCu Alloy S GX2 CrNiMoCuN Special high-alloyed material with excellent resistance to erosion-corrosion for pumps operating in the dryer-, intermediate- and end-absorber stage of sulphuric acid plants up to temperatures of 150 C. A specially developed material for the pumping of ammonium nitrate melt, hot nitric acid at medium concentrations and also the vaporisation of waste nitric acid. Low carbon silicon alloy material for pumping strongly oxidising media. Particularly suitable for hot highly concentrated nitric acid, e.g. 98% HNO 3 Fully austenitic chromium nickel molybdenum steels with a good general resistance to corrosion. These materials are suitable for pumping almost all organic liquids, 50% caustic soda up to 90 C, KTL paint, pure phosphoric acid, dry chlorine, liquid sulphur, PTA and many other media. Semi-austenitic, easily welded material with an increased strength and a good general resistance to corrosion. Due to its good welding properties and satisfactory wear resistance it is frequently used for jacketed pumps for handling melts containing solids, such as pitch and tar. Semi-austenitic, molybdenum and copper alloyed material with a high resistance to pitting and stress corrosion. This material is one of the super duplex steels. lt can be used with crude phosphoric acid, containing solids at up to 100 C, hot sea water, many solutions containing chloride, FGD suspensions and sulphuric acid at all concentrations at low temperatures. Fully austenitic special stainless steel with a high molybdenum and copper content. High resistance to pitting, stress corrosion and intercrystalline corrosion. Suitable for 70% caustic soda up to 200 C, sulphuric acid at all concentrations at low and medium temperatures, sulphuric acid pickling solutions, in certain areas of the manufacture of phosphoric acid, for pumping solutions with a high chloride content and in spin baths. A high grade special material having a high resistance to acidic media containing solids and rich in chlorides. Used in absorber and quencher fluids of the FGD, for acidic and chloride containing gypsum slurries, in the manufacture of phosphoric acid, in vaporisation and crystallisation processes and also for hot sea water. Higher austenitic cast material with very high corrosion resistance. Especially in very corrosive phosphoric acid with solids this material is perfectly suitable. Nickel based materials Material Alloy C1 (2.4686) Alloy C22 (2.4602) Alloy B1 (2.4685) Inconel 600 (2.4816) Inconel 625 (2.4856) Inconel 825 (2.4858) Designation DIN [ASTM] G-NiMo 17 Cr G-NiCr 21 Mo 14 W G-NiMo 28 G - NiCr15 Fe NiCr 22 Mo 9Nb NiCr 21 Mo Properties and application Highly resistant nickel-base alloys for special applications such as liquids containing high chloride, hydrochloric acid, FGD liquids, very heavily contaminated phosphoric acid, hypochlorites and solutions with oxidising chlorides. Highly resistant nickel-chromium alloys for chemical process industries. These materials have enhanced heat resistance and are particularly used in acidic salt solutions for axial flow pumps RPROP. 11

12 Properties Plastics In pump engineering the non-metallic materials which are mainly used, are predominantly fluoropolymers and polyolefins. The advantage of these materials is their high resistance to acids and alkalis at low to medium temperatures. To resist external forces these pump types are usually protected by a metal casing. Polyolefins Material Polypropylene PP Polyethylene PE 1000 Properties and application In many applications PP represents an economical alternative to high grade metallic materials. This material is suitable for pumping salt solutions, almost all dilute alkalis and acids and is also frequently used in hydrochloric acid pickling solutions. It can be used for working temperatures between 0 C and 100 C. Ultra high molecular low pressure polyethylene is used exclusively. Its usable temperature range lies between -50 C and 80 C. Its general resistance to corrosion sometimes exceeds that of PP. Due to its very high resistance to wear, centrifugal pumps made of PE are often used for media which have a corrosive and at the same time an abrasive effect, as found in waste gas scrubbing plants. Fluoropolymers Material Polyvinylidene- Flouride PVDF Ethylenetetrafluoroethylene ETFE Perfluoralkoxi PFA Polytetrafluoroethylene PTFE Properties and application PVDF is distinguished by its excellent general corrosion resistance. Its high resistance to stress cracks and its ability to resist UV. Its temperature range lies between -20 C and 130 C. This material is particularly suitable for the pumping of hydrofluoric acid at all concentrations up to boiling point, liquids containing halogens, nitric / hydrofluoric acid pickling solutions, and for the evaporation of waste hydrochloric acid. ETFE is a fluoropolymer that has proven itself as a lining material and largely covers the applications like PFA. It can be used virtually universally in a temperature range from -20 C to 150 C in aggressive and corrosive media. PFA is a perfluorated alkyvinyl ether. Centrifugal pumps lined with PFA can be used up to 180 C. With a few exceptions this material has a universal resistance to chemicals. PTFE shows an outstandy resistance against nearly all organic and inorganic media over a wide temperature range. Centrifugal pumps made of PTFE can be used between -50 C and 180 C. 12

13 Properties ceramics Pumps made of ceramic materials are particularly suitable for media which are highly abrasive and at the same time corrosive, where pumps made from metallic materials and plastics may have a relatively short operational life. Material FRIKORUND Properties and application A silicate ceramic material with very high wear resistance due to its high corundum content. lt can be used up to 120 C. With the exception of strong, concentrated or hot alkalis, hydrofluoric acid and liquids containing fluoride, FRIKORUND can be used in all aqueous media. This material proved suitable eg. in solid-containing pickling liquor with elevated temperature. A wide choice and flexibility in our materials is our strength let us advise you about your process 13

14 OUR services At a glance We offer the right solution for your project. PUMP DESIGN OPERATING CONCEPT INDIVIDUAL APPROVAL The success of an installation starts with selecting the right pump. The type, size and seal must satisfy the requirements presented by the pumped medium. Thanks to modern, computer-optimised hydraulics, Rheinhütte pumps are ideally suited to meet any applications. Whether you want to monitor centrifugal pumps or operate complex vacuum installations, we will work with you to devise the right operating concept which meets your needs from manual to fully automatic. All Rheinhütte centrifugal and vacuum pumps as well as Rheinhütte vacuum compact installations are tested at our factory before they are delivered: Together with our customers, specific details, processes and basic principles are tested and discussed. MATERIAL ADVICE Documentation ON-SITE SUPPORT Which materials are best suited to your particular application? Whether you require pump materials, seal materials or changes in process affecting the pumps our material specialists will offer you an individual recommendation, with full commitment. You need specific documentation? Whether standard or project - according to your requirements we create your individual project documentation. Whether it is for initial start-up or for training your personnel our engineers are also available to assist you on site. 14

15 Success IS BORN OF EXPERIENCE 150 years of Rheinhütte Pumpen As pump manufacturers to the world, Rheinhütte Pumpen is your expert for demanding pump applications and has been for over 150 years. Our experience for designing pumps for conveying abrasive, corrosive and toxic media, our product innovations and the supreme product quality have made Rheinhütte Pumpen a proven component of many major plants all over the world. Your individual requirements are our benchmark Our customers benefit from our customized advisory services on materials, sealing systems and maintenance concepts. Experienced project teams will draw up individualized documentation in line with your requirements. Our customers specifications are what counts for us and are integrated in our Quality Management systems, testing processes and the official approval procedure for pumps and installations. Rheinhütte PumpEN your reliable partner Rheinhütte Pumpen is based in Wiesbaden, Germany. With our manufacturing sites in Wiesbaden and Rennerod and many technical regional offices we can be found everywhere in Germany. And with our manufacturing sites in Brazil, China and the USA plus many international sales and service offices we are your reliable partner everywhere in the world. We specialise in products made from corrosion and wear resistant materials. As a part of the Aliaxis Utilities & Industries Group we have a solid foundation and benefit from the synergies of the world s largest manufacturer of plastic piping systems for the construction, manufacturing and distribution industries. Rheinhütte PumpEN your specialist for sophisticated pumping applications. 15

16 Pump Materials in US standards Part 2 ASTM-/ US-Code UNS code Composition Higher alloys Rheinhütte Code REMARK A217 WC 6 A217 WC 11 SS 316 Nb CF-8M (ACI) ASTM A532 75ª, (IIIA) 25% Cr A53 A / A234 WPA J12072 J11872 J92900 GX 17 CrMo GX5CrNiMoNb No UNS GX 260 Cr 27 V57000 GX6 CrNiMo Cast iron with nickel Steel type P235 G1TH / St35.8 GG-N For high temperature application Weldable cast stainless steel Duplex material Special cast iron A576 Grade 1045 Steel C45 / C45+SH Shaft steel Screws in 304 Cr Ni A2-70 Screws, nuts and bolts Screws in 316 Cr Ni Mo material No US code No UNS X22CrMoV AISI 660 ASTM A SAE 1043 AISI S66286 G10450 G10430 X6NiCrTiMoVB Shaft material for high temperature Low alloyed steel Shaft material ASTM A105 K03504 P250GH AISI 420 S42000 X46 Cr All information is carefully collected. But nevertheless a warranty of correctness of these datas cannot be given.

17 Pump Materials in US standards Part 1 ASTM-/ US-Code UNS code Composition IRONBASED MATERIALS Rheinhütte Code Similar to Rheinhütte 304L A743 CF-3 S GX2 CrNi S ANTINIT A610 S GX2 CrNiSi R4Si 316 A 743 CF-8M J GX5 CrNiMo Ti S X6 CrNiMoTi L N08904 X1 NiCrMoCu R S32100 X6 CrNiTi A890 Grade 1B or A743 CD4MCuN J J GX2 CrNiMoCuN HA28.5 SAF 2205 (Typ F51) S X2 CrNiMoN AL-6XN N08926 X1 NiCrMoCuN Alloy 926 CN-3MN N08926 J94651 GX2 NiCrMoCuN S Alloy 20 A 743 CN7M N08020 GX3 NiCrMoCu R3020 better than Alloy 20! Alloy 28 N08028 X1 NiCrMoCu Alloy 31 N08031 X1 NiCrMoCu SX Comparable S GX6 NiCrSiCu RHSX RHSX is a cast material A 518 (ASTM) No UNS code GX90 SiCr 15 5 Siguss 654 SMO S A 217 (WC11) J J GX2 CrNiMo- CuN S G17 CrMo Cast steel A216 (WCB) J GP240 GH Uranus B6 904L N08904 X1 NiCrMoCu R3020 Higher alloys Alloy C1 N26455 G-NiMo 17 Cr Alloy C4 N06455 NiMo 16 Cr 16 Ti Alloy C22 N06022 NiCr 21 Mo14 W Alloy B1 N30007 G - NiMo Inconel 600 N06040 G - NiCr15 Fe A 494 Grade CZ100 N02100 G-Ni Titanium Grade 2 R50400 > 99 % Ti Titanium Grade 2 R52550 G- Ti Nickel or RH Ni 98 Titan forge material Titan casting material All information is carefully collected. But nevertheless a warranty of correctness of these datas cannot be given. Continued on next page

18 RHEINHÜTTE PUMPEN GLOBAL EXPERTISE Rheinhütte Pumpen sites Group-affiliated-companies Sales companies FRIATEC Aktiengesellschaft Division Rheinhütte Pumpen Rheingaustraße Wiesbaden Germany Tel +49 (0) Fax +49 (0) en.0515