Questions

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SilcoTek Corporation
Coatings for inertness and
corrosion resistance
Information, Questions and where coatings
are being used
Topics
•
•
•
•
•
Vision
Questions
The process and the coating
Products and Applications
Conclusion/Future Product Development
Vision
• “Easy” Button for customers needing
coating
– Work together to identify repeat items
– Have these items ready for customers to
order
– Working with suppliers to figure out a
method for having product ready
– Stock, Consignment, Drop shipping, etc.
Questions
•
What is the maximum tubing length that you
can work with
–
–
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•
Straight lengths: 6 footers (Coat internal &
external)
Coiled tubing: Up to 2000 feet (Coat Internally)
Can coated coil tube be straightened to produce
20’ sticks?
Is every valve sent to you disassembled?
–
–
Yes, the process temperatures would
compromise any lubricants and seals inside of
the valves.
Also, to properly clean all the components
Questions
• What is the time frame we can use to give to
customers if we send a valve to get treated?
– 10 days from the time of receipt
– Is there enough demand to predict some repeat
items that can be stocked or consigned?
– Can factory hold inventory? We’re trying on our
end.
• Is the process different now with the company
name change or is it the same?
– Same coatings and people
– We will be more flexible now that we’re focused
Questions
• What is new with your company since the last
time you visited us?
– We’ve become an independent company focused
on coatings
– New brand names
• SilcoNert for inertness (1000 and 2000)
• Silcolloy for corrosion
– More people, 17 dedicated to customers &
coatings
• Are the lubricants replaced after the parts are
treated?
– No
Questions
• Where do you see industry going with these
special materials and processes?
– As the need for knowing what’s in streams
increases, there will be more demand
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•
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Sulfurs
Mercury
Ammonia
Corrosion
Low level alcohols and other impurities
– More methods specifying need for coatings
– Working with suppliers to offer coated products as
stock items
– Growing volume of NeSSi systems
Questions
• Are there certain industries that are moving
more quickly than others with the sulfinert
process?
– Refining, the most mature and familiar with the
coating: Rule 1118 coming
– Concern for Mercury, gas wells
– Power generation growing quickly (coal fired
power plant stack monitoring)
– Off shore applications, can we provide the
inertness and corrosion resistance. Need 20’
sticks coated inside and outside
Questions
• Is pressure and temperature affected
when the part is treated?
– Pressure ratings are still maintained
– Maximum temperature rating of coating is
450C.
– There are coatings that can be applied for
use up to 600C on stainless
APPLICATION
AREAS
• SilcoNert: Inertness
(Silcosteel, Sulfinert/Siltek)
– Sulfinert = SilcoNert 2000
• Silcolloy:
Anti-Corrosion
(Silcosteel-CR)
MARKET AREAS
Analytical
Pharmaceutical
Environmental
Petrochemical
Chemical
Process
• SilcoKlean: Anti-Coking
(Silcosteel-AC)
Semiconductor/Research
• SilcoGuard: Ultra-High
Vacuum (Silcosteel-UHV)
Automotive
Brand Names
• SilcoNert 2000
– Used to be Sulfinert and Siltek
• SilcoNert 1000
– Used to be Silcosteel
• Silcolloy 1000
– Used to be Silcosteel-CR
Basic Manufacturing Process
• Receive items
• Document – digital, customer contact
• Clean
– Standard: caustic ultrasonic bath, 2 systems
– Custom: solvation via other means
• Chemical Vapor Deposition (CVD) Process
– Vacuum
– 400ºC
– silicon-based deposition
• Clean
• Document – digital, customer contact
• Pack, ship
Properties
• Max operating temp.
– 450C: SilcoNert 2000
– 600C: SilcoNert 1000; Silcolloy
• Hardness: Equivalent to stainless steel
• Thickness
– SilcoNert 2000: 0.12 microns
– Silcolloy 1000: 2 microns
SilcoNert 2000 Properties
• Improves surface inertness by
capping active sites.
• Needed when sulfurs are analyzed
in the part-per-million level
• Performance down to 1 part-perbillion of hydrogen sulfide
Coating Capabilities: Substrates
• Tubing:
– 0.004” to 0.5” ID
– 2000+ ft. continuous lengths
• Complex geometry parts (inside and out)
– Fittings, valves, frits
– Block manifolds, sample vessels
– custom parts
Sizes of reaction chambers
• “Standard” vessels:
– 10” diameter cylinder w/ 48” height
– 3” diameter cylinder w/ 72” height
– 10” diameter cylinder w/ 18” height
• Large processing oven:
– 27” diameter x 26” deep
– 4’ diameter x 6’ deep
• Walk-in Oven:
– 4 feet by 4 feet by 5 feet
– 6 feet by 4 feet by 5 feet
Substrates Which Coat Well
•
•
•
•
•
•
•
300 and 400 grade stainless steel
High carbon steel
Titanium
Ceramics
Borosilicate glass
Inconel®
Hastelloy®
Substrates with Issues
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•
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Nickel / Nickel plating
Aluminum*
Monel®
Copper
Brass
Gold and Silver plated components
Chrome Plated components
Magnesium
Elastomers
No Bases!
*heat-dependent
Benefits of coating?
• Reduce loss of active compounds
– Saves costs from re-testing
– Avoid false negatives because sulfur compounds
can be quickly lost without coatings
– Sample stable from field to lab.
– Immediate response during process changes
creates savings when used in feedback / feed
forward monitors
SilcoNert 2000 surface
improves storage
• Reduces adsorption effects
• Improves analytical reliability
• Faster cycle times and
• increased accuracy
(H2S to DMS)
RRF
– 17ppbv H2S Containment in 500ml Cylinders
2
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
Coated/functionalized steel cylinders
Uncoated steel cylinders
0
1
2
3
Day
6
7
Sulfur Flow-through data
• 100’ 1/8” x .020” tubing
• Standard seamless 316L
• Electropolished 316L
• Sulfinert® coated EP 316L
• 0.5ppmv methylmercaptan in
Helium
• SCD detection
• Data courtesy of Shell Research
Technology Centre, Amsterdam
Effectiveness of coated transfer systems
to reduce hold-up: Methyl Mercaptan
Inertness: Mercury
• Mercury is growing concern in environment:
– Coal fired power plants
– Natural Gas
• CMMS (Continuous Mercury Monitoring
System) manufacturers currently using
SilcoTek technology with success to transfer
mercury
• Starting to see need from well sampling firms,
Halliburton, Schlumberger
Mercury in oil and gas wells
• Mercury in oil and gas wells is common in
many geographic areas.
• Mercury in these streams must be monitored
to reduce damage to pump vanes and
pipeline equipment.
• SilcoNert technology required to eliminate
loss of mercury samples during testing.
Mercury Adsorption by
Stainless Steel
• 5 µg/m3 Hg Standard (5PPT)
• Spectra Gasses Inc.
• 1 Gallon Sample Cylinder 1800psi DOT rated
• Swagelok Corp
•
•
•
•
•
•
NIST Traceable
Nominal Temp. 70°F
Test Cycle Day 0,7,19,50
Direct Interface Gas Sampling
Atomic Absorption Detector
SilcoNert 2000 treated Regulator and Tubing
Mercury 50 Day Stability
Chemisorption greatly reduced
Average Mercury
Concentration (ug/m 3)
Average Mercury Response Comparison of Stainless
Steel vs. Silicon Functionalized Surfaces
7
6
5
4
3
2
1
0
0
10
20
30
40
50
Days after fill
Untreated cylinders (n=2)
Functionalized cylinders (n=2)
60
Comparison of Hg Stability in 304SS vs.
SilcoNert 2000 Coated Cylinders
Test
Loss vs.
Day Avg response
Day 0
Avg
response
304 SS
cylinders
Functionalized
ug/m3
Silicon ug/m3
Loss vs.
Day 0
0
5.65
-
6.45
-
7
3.25
42%
6.1
5%
19
2.05
64%
6
7%
50
1
82%
5.8
10%
Effect of moisture
• Hydrophobic silicon based coatings decrease
adsorption of water
• Quicker removal of moisture
• Components less susceptible to corrosion
• Faster cycle times and increased accuracy
Moisture Data
• 1ppm moisture, 0.35slpm
• Amount of time to equilibrate a 1ppm
moisture sample through 100 feet of dry
tubing:
– Commercial Seamless 316L tubing
• 180 minutes (96% equilibrated)
– Electropolished Seamless 316L tubing:
• 60 minutes (98% equilibrated)
– Functionalized a-silicon coated e-polished
seamless 316L tubing
• 30 minutes (98% equilibrated)
Wet-Up 50% faster response
Moisture Data (cont)
• Time to dry 100’ tubing wetted with 1ppm of
moisture when connected to a dry purge
– Commercial Seamless 316L tubing:
• 175 minutes
– Electropolished Seamless 316L tubing:
• 65 minutes
– Functionalized a-silicon coated e-polished
seamless 316L tubing
• 35 minutes
Dry-Down 50% faster response
SilcoNert 2000 Applications
• International Society of Beverage
Technologists (ISBT): Fountain Carbon
Dioxide Quality Guideline
– Sulfurs contaminants
• Rule 1118: Control of Emissions from
Refinery Flares
– Sulfurs emissions
• Ethylene/Propylene feedstock testing
– Sulfurs as catalyst poisons
SilcoNert 2000 Applications
• Exhaust gas testing, stack emissions testing
– Ammonia release as a result of injection
• Acid Rain Precursors
– NOx and SOx compounds from coal fired plants
• Natural Gas well testing
– Mercury and H2S Concentrations
• Clean Air Mercury Rule
– Emissions of Mercury from Coal Fired plants
SilcoNert 2000 Applications
• Water quality testing: Headspace + Purge &
Trap systems
– Moisture release and overall inert pathway
• EPA TO-15 method: Toxic organics
– Create overall inert surface in stainless vessels
• Homeland Security
– Chemical Warfare Agents
– Explosive detection
Silcolloy
Corrosion Resistance
• Stainless steel surfaces susceptible to
attack from substances such as
chlorinated environments and acidic
exhaust environments.
• Corrosion resistant deposition is a
heavier amorphous silicon layer
insoluble in hydrochloric acid and
unaffected in salt water environments
(marine applications)
Corrosion Resistance studies:
• External Evaluation
– Certified corrosion engineers (Matco)
– Spectroscopic analysis
– Mechanical testing
– Electrochemical Cyclic Polarization in neutral,
acidic, alkaline
– Atmospheric corrosion
• ASTM moisture condensation
• Salt spray ASTM B117
– Stress corrosion cracking (MgCl2; ASTM G36)
ASTM G48 B Data: Pitting and
Crevice Corrosion
– 6% Ferric Chloride solution
– 72hrs, 20ºC
– Gasket wrap
Sample
Initial
Weight (g)
Final
Weight (g)
Weight Weight Loss
Loss (g)
(g/m2)
Silcolloy Sample 17
10.4105
10.3710
0.0395
19
Silcolloy Sample 28
10.1256
10.0743
0.0513
25
Silcolloy Sample 47
10.1263
10.0742
0.0521
25
Bare Sample 27
10.0444
9.5655
0.4789
231
Bare Sample 34
10.1265
9.6923
0.4342
209
Bare Sample 37
10.1007
9.6276
0.4731
228
ASTM G48 B (cont.)
• Bare 316L Stainless Steel coupon (left)
showing severe crevice corrosion.
Coated coupon shows light pitting
ASTM B117 Data: Salt Spray
• 4000 hour exposure
– 100 degree Fahrenheit
– 3.5% by weight sodium chloride
• No effect on Silicon coating
• Reproduces exposure to marine
environments.
• Oil-in-water monitors/produced water
applications
Silcolloy Advantages
• Longer Life:
– Extend lifetimes of equipment exposed to
corrosive environments
• Low Cost
• Protection:
– Protection of high value equipment
• Inert:
– Provide enhanced corrosion resistance to
analytical equipment
– Maintain inert sample pathway
– More inert than Inconel, Hastelloy, or glass. Ideal
for 10ppm levels or higher
• High Temperature:
– High temperature stability up to 1000c
Silcolloy Applications
• Process streams
• Process sampling
• Continuous Emissions Monitoring
Equipment
• Automotive Exhaust
• Semiconductor Gas transfer
• Fasteners in Marine Environments
• Off-shore drilling platform equipment
• Produced water management
Conclusions/Future
• Continual process improvement and new product
development for coatings:
– Improving the hardness of coatings
– Improved corrosion resistant coatings
– Hydrophobic surfaces for moisture sensitive
applications
– Protection of high nickel alloys such as Hastelloy®
and Inconel®
– Hydrogen embrittlement resistance.
– New generation process systems on line in FY08
• Additional manufacturing capacity
– New manufacturing facility!
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