Over the last few decades the corrosion control of alloys exposed to severe and complex conditions has been a great challenge for industrial applications since decades. Currently corrosion costs are increasing and preventive strategies have become the main industrial demand. The SCAPAC project is proposed by energy savings and environmental concerns for two separate processes: Steam Methane Reforming (SMR) and Waste to Energy (WtE). Although the operating conditions of both processes are very different the scientific approaches and the solutions proposed to solve corrosion issues can be similar.Metal dusting is a catastrophic form of corrosion affecting iron low and high alloy steels and Ni or Co-based alloys exposed to reducing highly carburising gases (carbon activity aC>1) at elevated temperatures (400–800 °C). Deposition of carbon on and within these metals is accompanied by disintegration of the substrate. The coke formation impairs heat transfer efficiency and reduces metal catalyst lifetime as well as damaging structural materials [1].Metal dusting corrosion is commonly found in the petroleum and petrochemical industries such as reforming and syngas production systems. It is considered one of the production unit’s most critical phenomena as it has led to worldwide material loss for 50 years. However the mechanism of this complex process is still not well understood although several models have been proposed [1]. Moreover the effect of some process parameters such as temperature alloy chemical composition carbon activity and gas composition requires more study because current literature on the subject is insufficient or not enough data is accessible. Nevertheless a basic understanding of the degradation mechanisms is available and a set of critical parameters to follow in an experiment can be defined.Likewise Fireside Corrosion is the main limiting factor in energy recovery efficiency in the Waste to Energy (WtE) process. The growing world population requires increasing quantities of energy. Consequently the EU encourages the Waste-to-Energy industry to play an essential role in both sustainable energy supply and environmental waste management. In municipal solid waste incineration (MSWI) facilities there are options for increasing the energy recovery efficiency which consist of: the promotion of combined heat and power (CHP) generation instead of condensing power generation reducing boiler loss and optimizing the water/steam process. The latter one implies an increase in steam pressure and temperature to improve electrical efficiency. Such changes in operating conditions are expected to result in higher fireside corrosion rates and reduce the design life of these critical components [234]. A considerable amount of literature has been published on high temperature corrosion over the last decades and the mechanisms are well documented. In fact many materials and coatings have been developed over the last years however their performances in different environments have not been sufficiently well understood to define suitable criteria for predicting lifetime models regarding operating conditions.It has been demonstrated that both phenomena are complex and the risk of corrosion leads to frequent shutdowns for repairs. In order to limit the degradation impact by metal dusting and high temperature corrosion on the operating costs of the installations it has become necessary to understand both corrosion mechanisms. This is important in order to identify key parameters that govern them and to optimize the materials selection for the operational units as well as to adopt a preventive maintenance strategy through methodologies of prediction.Bibliographic research was made in order to review available modeling approaches for the quantitative description and degradation kinetics of metal dusting and high temperature corrosion on structural materials in corrosive environments. Numerous studies have attempted to explain the degradation mechanisms the modeling approaches in different kinds of complex conditions and applications the parameters or environmental conditions to consider for modeling the methods for ranking parameters in the case of having too many of them the incertitude treatment of data and statistical treatment for those results that could not be fitted to any well-known kinetics behavior.However there are no lifetime models currently available in the open literature for commercial materials and coated materials under a wide range of conditions. In this sense the main purpose of this study is to start to propose and discuss life prediction modeling in the simplest cases of these complex environments.To develop lifetime prediction models for materials submitted to metal dusting and high temperature corrosion atmospheres two databases have been built respectively in order to integrate experimental data resulting from the SCAPAC project as well as data from literature. The use of these databases has allowed the statistical analysis of 2500 data points for metal dusting and 1200 data points for high-temperature corrosion by several statistical methods. The statistical procedure of Principal Component Analysis (PCA) has allowed us to identify the output data which describes the betterthe materials degradation rate the key parameters which show a bigger correlation with the degradation rate and the existing correlations between the parameters.It has been performed the analysis of the statistical correlations based on experimental and theoretical data in order to build a lifetime prediction model by Multiple Linear Regression (MLR) with a physical sense in a domain of validity defined.The main goal of the current study was to create a quantitative tool for evaluating material corrosion performances based on adapting corrosion tests and the definition of accurate criteria for life assessment and materials selection which will improve decision making for operational plant parameters and will help to adapt preventive maintenance strategies in company’s operational policy resulting in economic savings and resource optimization.References1- J.E. Strutt J.R. Nicholls and B. Barrier. Corrosion Science Vol.25 N° 5 pp.305-315 (1985)2- J.M Brossard F. Nicol X. Chaucherie. Materials Science Forum Vols. 595-598 pp. 281-288 (2008)3- J.M. Brossard I. Diop X. Chaucherie F. Nicol C. Rapin and M. Vilasi. Materials and Corrosion 61 N° 9999(2010)4- D. J. Young J. Zhang C. Geers and M. Schutze. Materials and Corrosion 62 N°1 pp.7-28 (2011)5- A.U. Syed N.J. Simms J.E. Oakey. Fuel 101 pp.62–73 (2012)
