C. Bevas, M. Abel, Ivo Jacobs, Peter Muller, Karin van Oudgaarden, John F. Watts
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Industrial scale fouling of heat exchangers in isocyanate production
The fouling of a commercial stainless steel (AISI 316L) during the manufacture of polymeric methylene diphenyl diisocyanate (pMDI) has been studied using laboratory‐based fouling apparatus that simulates commercial production conditions. The goal of the work is to understand the mechanisms behind the corrosion and fouling during isocyanate production with a view to improving process efficiency, not only in this process, but also others using similar plant and processes. Steel coupons were exposed to a solution of pMDI and solid amine hydrochloride, with hydrogen chloride gas being bubbled through the reaction cell. A number of different conditions were investigated, the variables being pMDI concentration, HCl gas flow duration, immersion time and temperature. Following the fouling experiments the coupons were removed from the fouling rig, photographed, and examined by XPS and ToF‐SIMS; principal component analysis was used to extend the ToF‐SIMS analysis to identify organic fouling products. The extent of fouling is shown to be relatively insensitive to pMDI concentration, but significantly influenced by continual HCl flow and increased temperature, features which increase the extent of substrate corrosion thought to be a precursor to the fouling process itself. Both XPS and ToF‐SIMS confirm the formation of various nickel chlorides in the corrosion process. Urea and metal corrosion products are found to co‐exist on certain (random) areas of the coupon surface.
期刊介绍:
Surface and Interface Analysis is devoted to the publication of papers dealing with the development and application of techniques for the characterization of surfaces, interfaces and thin films. Papers dealing with standardization and quantification are particularly welcome, and also those which deal with the application of these techniques to industrial problems. Papers dealing with the purely theoretical aspects of the technique will also be considered. Review articles will be published; prior consultation with one of the Editors is advised in these cases. Papers must clearly be of scientific value in the field and will be submitted to two independent referees. Contributions must be in English and must not have been published elsewhere, and authors must agree not to communicate the same material for publication to any other journal. Authors are invited to submit their papers for publication to John Watts (UK only), Jose Sanz (Rest of Europe), John T. Grant (all non-European countries, except Japan) or R. Shimizu (Japan only).