Add-on converter material selection

From various studies, it is revealed that low alloy steel in NH3 converter application mostly degrade or
failed due to any of these phenomena: H2 embrittlement, temper embrittlement and nitriding effect. It
can also fail due to fabrication defect occurred at during welding at site or shop or for improper PWHT.

Fig-A
Nitriding on Low alloy under high temperature

FIG-B
Reheat Cracking (fabrication defect)
FIG-C

FIG-D

From the above, it is understood, HTAS has avoided operating temp near 370 degC and lowered the shell
temp at about 335 degC (in typ-1 converter) offered to KFL. They have chosen 2.25Cr 1Mo material for
shell construction which has excellent resistance against hydrogen embrittlement and may be temper
embrittlement. However, in terms of nitriding effect at similar operating temp (370 degC), 2.25Cr 1Mo
(HV385) hardens more than 1.25Cr 0.5Mo steel (HV262) as indicated in FIG-B.

The issue of fabrication defects like reheat cracking etc are more manageable in fabrication of 1.25Cr
0.5Mo steel than 2.25Cr 1Mo variety.

We came to know similar construction used by various fertilizer industries like Madras Fertilizer (340
degC), TCL, Babrala (370 degC), IFFCO Phulpur (340 degC), IFFCO Aonla (370 degC), Indogulf (370 degC
later on 340 degC) etc., who have experienced welding cracks, which is not entirely linked to vanadum
modified steel, or shell construction (monolayer vs multiwall) but certainly has strong corelation to
workmanship defect.

It is evident that HTAS has considered material selection with respect to specific design temp., keeping in
view the H2 embrittlement. From the lab test and industry experience 1.25Cr 0.5Mo steel works out to
be fine for shell material over 2.25Cr 1Mo steel. In hot wall converter operating at 370 degC, design
temp is to be considered as 430 degC as there is no annular space between catalyst and wall thereby
localized rise in temp beyond 370 degC in certain process upsets. However for cold shell design (340degC
as well as 240 DegC) there is a catalyst basket and annular space, through which cooling gas of 335 degC
always passes, keeping shell wall interface temp remains around 320 degC. Any abnormality in catalyst
bed cannot change the shell temp. Therefore, even 1.25Cr 1Mo steel would have performed well for
340degC type-1 converter.

However, considering proven material in 370 degC and reduction in weight due to less wall thk, 2.25 Cr
1Mo materials is recommended. In order to ensure the quality of raw material and fabrication, the
following quality controls are recommended:

1. QAP shall be prepared by HTAS and to be ensured in stage wise inspection at manufacturer’s shop.

Check/test shall include but not limited to following:

2. Material shall be tested to gurantee shift FATT<10 degC to ensure material is free from temper
embrittlement. Or other wise J factor ( J = (Mn + Si). [(P + Sn) x 10 4]) Shall be as low as
possible; in any case, it must be lower than 100 for 2.25Cr 1Mo material. Test like slow
bend test shall be suggested by HTAS to be performed by L&T.

3. WPS and PQR shall be made keeping in view the preheating requirement, interpass temp,
PWHT specification. Detailed PWHT procedure shall be laid down for strict compliance.

4. Hardness of base metal, weldment before PWHT and after PWHT shall be monitored and
acceptance standard must be furnished by HTAS to L&T.

5. Toughness of welded coupons shall be tested and accepatnace standard (in terms of
impact energy in charpy V-notch) shall be furnished.