Document DGkDNbzEz7Q8y8bYYe68GYXL4

nwij .ii;;iw WWHJIWW.; i*a.meo LIA10209 or* .** ' w t o c t rr ciu&i t o "c h u *t LEAD INDUSTRIES ASSOCIATION o b a it 4i imin NIWTOM IT, N.Y. Deoeaber U, 1?J7 CKDCCkl BClinil Ho, 6? a c id mat r e a c h ow nwo Supplement vo Cheatcal Bulletin* Ko*. 6 A ?1 (Sont to Heater* on Dec. 16, l?u6 and July 1$, 151,8, Respectively) The bond catalytic crickin' catalyst manufacturin' procot used by the Soeony Hcfcll 0U Cc., Inc, it R*ul*bcro, V. J. affords the condition* of *rrloo ^ lch c o t j tltut* * a* jar toit cf load1* ability In containin' eh*cl cal correeive*. In particular the add-alua raactlon tanka Kara resitted to data the effort* Mdt to successfully alll'al* the corrosive condition* encountered tha rain for the past 1) year*. Thla la net to lcply that lead ha* failed thla teat but an attaapt will be cade to Indicate the chronulotQr of recorded erente which lead alternately to the nee cf loot* lead 11 nine;*, trlcc-plaJtle aeahrin* llntr.?*, brick-lead mi. trar.e linin'* and finally tc date a Hart' caapoeltlon linin', and the clrcuastenoe* eurround In' the alternate uae and dleute at lead. Thla bulletin vumarltes and *uppl#a*nt* Koa. 6 and ?1, heretofore coverin' thli Installation, Although lead 1* not In uie at present la the alua reactor, the applica bility of lead haa b*en sutely evl_*cc*d. It la cr.ly a case where tha expedition* ere cf * material had been prevented by a lack of test cethod* or deal'n developants applicable to alti'atin' expected failuree encountered aooe ti years ape. In this esse hletcry, there la excellent aaUrlal on the eequenee of erects and stepa i taken In lap rovin' the eerrloeablllty of lead tgr proper dasirn In the alia reactor, aa well as Information on the various other usee for lead la this area* I IMTROCVCTCKT HI3T0ST In 1$L!, a total of 12$ tons of lead was Installed to handle the eorroeire alua solution* in the Bead Catalyst Plant at Paulsboro where nearly two billion beads or $0 tons of finished catalyst per day are produced. The syr.thevlc bead catalyat Is used In th.s ICC procsss which st the'time had recently ece* Into extenrlre use In the production cf hi jh-octane (asoilre. The beede are produced In lead lined fa-cine towers frers 'el forsrlo' eolutlone eonslsllr.' of sodlua si Il ea be and acld-alu* (al-xEirru* tulpihate), Alua It produced la t boilin' tank freo aluelr.ua trlhydrel* reacted with sulphuric acid. PTtOCISS cwra11 *d water is first introduced to the alua reactor whereupon eu'phirle acid (WTw) la added until the solution It 50 peroent *cld, fillip the tank to s depth ef 18 In, The tec;*rsture resultin' froa the exothersdc r act Ion l further increased by the addition of alualnua trlhydrat* (purified f" .' lA *UJ, Bff 'i - geev^wf*eeswwwi(iw*m*cpfraw1 y *.'V T!mns,).w<w - I m .eewiiWiewe.japwijeaeesyeEeywWV^eiB^jSSIWISI " .... - `-*- LIA10210 4*<fcuu . * I .CHEW CAL BtfLLSTT* HO. 69 -K- D*c<rrt*r 11, 1957 alumina' to 21/) to 260 ?, Additional alumina 1> addod to maintain this tempera ture, and the reaction Is continued for 1$ to 2 hour* while continually *~ltetod with stoas which knp*s iht alur-lrut ealthitw nbov Its solvdlfyln* temperature of 2105 T, kttrr th-- n-actlon Is cccplnd, the batch Is then diluted to sake 23 percent alusdrruB *ul:hntr which Is k^pt for li ho- r* et 1J0 to liuO0 T, Further dilution produces s 20 p'-reon*. slua solution which fills the tank to 9/10 full and ie liquid it ra ltrq>.raturca. Th*. solution Is then pumped cut of tbe tank into a lead-Urv.-d solution preparation ta-.k where it is further diluted to 10 percent. The avcrafi. Survio# cf tho reactor la on* bitch per da/. It la readily Stvn that the combined ef/.-cti cf differential or cyclic hcatlor, constant *fltatlon, and abrasion and U-sqeratur* level contribute to what Is one of lead's sore rest tost*. i ryjifviff k*o vtvuKjjirz The reaction tank la 17 ft., 7 In. on the 10 and 7 ft., 3 la. in dspth, and was lined with lead Initially after prorlou* trial* with a plastic llninf 1b Vcvtabcr of 15U with 16-lb. ch< cl cal lead supported by vertical strap* li ft. apart. Ihl# preeed unaatiafaetcry after only 5 month* operation and was Coni*, quer.tly ripped out, Severe physical distortion of tho lead had occurred and subsequent penetration of th* alun solution resulted la replacement of tho steal bottom and aid.* to a height of 19 la. Since corrective atepa were obvious and wwrs dictated by the physical limitation* of lead and not its specific resistance to the corrosive, a new tank lining was Installed in Kerch 19.5 and put Into a.nrlce in Juns of 19L5* Its bottom and aide* wore lined with 22-lb, tsllurlua chemical load, and th* allvhtly eenvex top, with 12-lb, cbwslcal 1**1. Th* additional straps eotislatinf of half, oval atewl covered by 16-lb. t^llurlux oheulral lead 7 In. wld* were installed to five evpp.rt every 2u In. on tho eldo wall In contrast with f original L9-ln. spneinf. The bettoa was r.cured b7 parallel straps sh-etbc.d with 16-lb. tellurlum-cboaltal lead 16 to 16 In, ^art and $ In. wide boltrd through th* I steel tank to stpportinp ateol T* beans beneath. Vo repair* of this llninf were required until October of the following year, 16 north* later,when aporallo patchlnv bee-r.e Increasingly frequent. Ill repair* were awl# with chemical load rods. The wall* shewed the least amount of bulvir.f or aatflnf between the straps and required the least repair*. Corrosion was least In the lower third of the vessel wall but above that, the wall area was exposed to hot corrosive few in th* presence of air, and ic b j cerro*Ion had taken place aloof th* crest* cf U>> bulfed llnlnv. On tbe bet too, cracks and perforations had caused considerable trouble. Load between th* atrappinf had bulged In coos cat.* a* hlfh as 3 In, above the tank bettoo. Trcuhlo with the llnlnv ws severe beenasa th* product foraod la liquid aimed not sulph-.fc- which seep* throiph occurring hair cracks Into th* oevity under a load bolej, filllnf It, and later clldlfylnw when th* ruactlcn euaeoa. nat ter,lrw of thu buleis 1* prevurted therefore and th* bulv* ha* to be out open, and tho solidified aluxlnua sulphate noeved. Leaks were detected by weep hole*) th* presence of aiuclhua sulphate be'nt noted by the appearano* of stalactite*. This difficulty at the tottv* eas duo primarily to the a pearance of flno cracks adjacent to tho w*ld.>d i u i, on the area*, on or adjacent to welds frnn earlier repairs, or alon* errata of the bulvos. An article hleh appreared In `Corrosion hmvir.tlon A Control,4 !Vc4*Ur 1955, atteat* to the predominance of this type of failure. rv^-ke,.: VWf*! IPJM twigB-->|I" .1.1. .1 # ,n LIA10211 CHE1CCJLL SOLIZrrX 0. 69 -)- Deoesbsr 11, 1957 (It 1* interesting to r.ct* that the ir> Surroanllng the notsl* of tha doctor jot m fro* of failure*. lh* lead m tr.affs-ied by the tie an jot and the securing Botion of th* reacting Solution.) An alt**'; t mo Mi. to ccrroet the situation by using a brick lining to protlu* url/orm o,s,t-trt tf tbs lining and also to lfJaUto tjiirjV tho txtre*a of temperature anC /!'V-ati tr.e thereof. Kcwttr tho oeaentlng compoundi uood did -ot wltbitanri Uti 7 tha s-i.-iion and aw.ntually tho bricks loosened and proceeded Vc r* &r 1 eg 6/saeg* to the l**d lining (or acbrar.t) ond to tho agitating equipment 40 well, lo 19.< the lod lining waa r#cved and replaced with h$-ln. brick and fctlloo mem'jrt t *" l cb r*v3 only 2 years with frequsnt potchlr.j whereupon on* of three reert'-r# *i rellned with o brick-Isad Dembrana lining which was in- t etallsd wolf* reeer*.. Thl* trial 1 no toll sf*r o few Initial leakages regained la service practically trcwtle-froo until 195L gluing approximately 5 years* #*r\le, Is fart, failures aftor 5 years of thlo typo of service wore expected and for. TV* cr.ly real difficulty presented ot tho tin* woa not duo to tt* repairs ne:* site ted Kit rothor in tho difficulty encountered in finding th* Isak*. the ( j .`.m wore to no avail end tho brick lining prevented the exact lor oil or, cf tho leaks. Allespt* code In repairing the lining resulted In a great wutag* of a*n hour* a-ni exter.sive unnecessary tearing up of different parte of the Hr.1/,-, Ic short, Usi >thuds i the tine were Insufficient to cope with the prob- lea of lot at leg a leak trader a brick lining, and resulted In the discontinuance in use of a serviceable brick-leai wembran* lining. In eentrast te the situalien l or 5 years ago, nuffielsnt Information non haj been reported lr the literature tksleh preclude* the pceslblllty of reaovlng a r.-rlceatl* brick-lead lining far wa-.t cf sufficiently adequate teat sethoda or Vvhnlq-aa for deUrwlnlfg the location of flaws or leaks. The radiographic inepeotint. procedures as reco>*M>r*]*d by Skit- and Bracken ('Radiographic Inspection of lead Linings,* fwper ko, Sr-itT-l*'* AoME Ccnf., Jirw Ck-leana, Sept. 2-k6, 1555, and as covered lr. Chealeel Bulletins Bo*. () and 67, sent on April 3, 1956 and Dec. 26, 195& respectively) are eultahle. then properly utilised all but a minlxxia of tear ing up of brickwork to take repairs is preventable, further improver* rrt In the technique* for determining leaks In add bricklead lining* way be had possibly lr. the use of lew level rebloactlv* tracer-solvent Method* which would be dependent upon the amplifying effect that the lead netbran* would have on a radlation-lnducod signal frd* a radioactive fluid ewirc* puaped behlrd end leaking through break* in the lining. Scintillation counter* could be used to codtor the inside surface* of s wtssl in cs-dr to dstect any lntonaifleatlon that would be Indicative of a leak. After or before effecting repair* In this Banner, detergent cleansing or chelation could be erpleywd to reaov* vest!gee of tbs tracer used where It presents a problem. It* advantage* of such a technique are lrd x! provocative. Actually the 1 retaliation although eatlafactory waa (till capable of being ligprowd. dialler installation* by the Psr.naylventt Salt Co, g*v* up to 15 year*' trcaible-fr** esrvlee unrlvr elxllar condiiion* of service. Onderstendlbly, producUon rvqulrsw-nt# did not perwlt * wore oxurelv* drllUretloo of the problem. The long-itr* solution still even* to be in terse of lsed but the present Heveg lrml'.l.ttlot. has not lean sufficiently tested to amjnstrst* its adsqua^1 In thl* 'r. vice, But, it aay wsll b* noted tbs*. Hswg in evsr (W psrcsnt sulphuric add 1* not ccreldsred goed usage. In fact a rsoent inspection revssled that frequent leakegst are r.o occurring after thsir appsarano* Initially s year ago after cnly 2 year*1 esrvioe. LIA10212 .> r ----- uNv - i I craac X BOIXETI* HO. 69 - I* - Berber 11, 1957 i To s u b up the situation at tho Bead Cetalyst PI net, . bead forcing tosrs lined lth 3A6-ln. ehoalcil lead supported by single (tool (trap si ths top is still ay corrosion froa t*w dilute sold and tlisnirao sul- phato solution, 5 prjer.t H2DC*U, 5 furcer.t .U2(S0])i, 90 percent docineral lead vx'.vr at roc.i tocpcesturo, oftor 13 year* uneventful servloe. Load lined storage tanka containing acid alma solutions diluted to 20 percent strength, aid solutions further diluted for Introduction to the b*ed fortij* towera, are atill giving good aanrt.ee to daU after 13 yeara. A large proportion of the piping In thia Installation la lead wfcieh har bean extendod beyond the design a tree a levels without erentrul failure and la still in good shape attesting to the durability of lead in tnls application Lead pipe| Tsires and fittings in pucp connections and lead return bends of sluice pipes under forcing towers are all shoeing excellent usage. f [ l In added point of interest is soaoehat apart froo tbs corrosion resis tance of load but still wortiy of aenticn. In one of the storage tonka holding a solution containing 3 percent R^SC^, I percent alunlnun sulphate and water, ths land adductor la hold in place and supported by stainless atool bolts and claepe. In toy 1956 after ono yoar's service the bolts wore corroded badly end ths claope were found on the bottom of the Vnk. This seeaod Incongruous since an Inco 6o-day test ravoalod the following corrosion rstoa under these condition I for 30b typo sta'oisss - .0007 ln./yr. 316 - .0003 Carpenter 20 - .00006 0 iapoo-3 - .0210 * lead - .0025 Ths above results would hardly anticipate the piwciplterra failure of tho stainless steal bolts. Oolvanlcally, ths Biodie behavior of stainless with load was -till unexpected but seers to answer for tho failure. It has boon known that In tio ebocnce of air, or oxygen, acid solutions can causa a reversal of lead-stainless positions in ths eaf scries such that stainless bocooes anodic, bait ths teeporaturas miaunt* rod, 123 to 130 T., end tho prosonco of air precluded this possi bility. It it mother anomalous occurrence which cannot be explained readily. The bolt# were aubsequor.tly chtngod and Insulated with no further occurrence to date etteeting to tho galvanic nature of the problea. SWART In *hi* case hlatory it la indicated that leed-acld brick linings can be uaed probably bo .-, effectively than anything alss in acid-elm reaction tanka and under einllar conditions by the uss of improved kathode now at cur eosnand. This type of construction has been handicapped, not by ccrrcjlon or MChanieal failure, hut fcy the difficulty cf locating leaks and Baking repairs. In locating Suoh leaka rsdlograjhy has offered a solution. Another solution, possibly Bore oonr*ical and positive, is sup Tested through ths uss of redlo-actlvs tracers. Although this Bethod has not been tried or proven in preotlo*, the Aesnoistlon li anxious to ooporate with anyone having this prcblso in the hope of finding the s k st sonvenient and econowlral Bethod of detection.