Analysis and prevention of metallurgical failures at a major direct coal liquefaction pilot plant

• Published in: Journal of materials for energy systems Vol. 6; no. 2; pp. 87 - 99
• Main Authors: SAGUES, A. A, SETHI, V. K, GANESAN, P, RAGLE, H. V, SEARLES, R. C
• Format: Journal Article
• Language: English
• Published: Metals Park, OH American Society for Metals 01-09-1984
• Subjects: Applications; Applied sciences; Cross-disciplinary physics: materials science; rheology; Energy; Engineering techniques in metallurgy. Applications. Other aspects; Exact sciences and technology; Fuel processing. Carbochemistry and petrochemistry; Fuels; Materials science; Metals, semimetals and alloys; Metals. Metallurgy; Physics; Solid fuel processing (coal, coke, brown coal, peat, wood, etc.); Specific materials; Pitting(corrosion); Pilot plant; United States; Liquefaction; Materials; Stress corrosion cracking; Experimental study; Prevention; Martensitic stainless steel; Corrosion; Analysis; Carbochemistry; Damage; Component; Repair
• ISSN: 0162-9719; 2168-8133
• DOI: 10.1007/BF02833418

The H-Coal Pilot Plant in Catlettsburg, Ky., was the largest-capacity direct coal liquefaction project operating in the U.S. Since the start of operations, performance of its components was carefully monitored and occasional failures were examined and documented. The results of the examinations were used to develop remedial steps and improve the design of scale-up units. The metallurgical aspects of the following incidents are described: stress corrosion cracking of martensitic stainless steel bolting on the waterside of a heat exchanger; stress corrosion cracking of a superalloy seal ring; brittle failure of a low-alloy nut in a block valve body; corrosion damage in the fractionator and side stripper; erosion/corrosion of a coal liquid transfer line in the atmospheric fractionation area; pitting corrosion in a deaerator carbon steel inlet pipe; brittle failure of a martensitic stainless steel ball in a block valve handling coal liquids; and cracking of Co-base alloy seat rings in block valve applications. Remedial steps and preventive measures leading to successful performance after repair are also briefly described. 11 ref.--AA