Advanced Centrifugal Castings - Schmidt+Clemens

Schmidt + Clemens
HIGH PERFORMANCE ALLOYS
Advanced
Centrifugal Castings
FOR DIRECT REDUCTION INDUSTRY

Schmidt + Clemens
2
1879
foundation of a steel
trading business in Frankfurt
am Main on 1 st
of May,
1879 by Ludwig Schmidt and
Wilhelm Clemens
foundation of the
Lindlar-Kaiserau location
procurement of the
first hydraulic
hammers
further development of
the forging technology
1900
1950
beginning of
horizontal centrifugal
casting
beginning of
vertical
centrifugal casting
1963
1974
foundation of
CENTRACERO S.A.,
Murieta/Navarra, Spain,
centrifugal casting
foundation of
Schmidt & Clemens Inc.,
Houston /
Texas, USA
1982
1996
semi-automatic
horizontal
centrifugal casting
equipment
in Lindlar-Kaiserau,
Germany
1997
foundation of
Schmidt + Clemens GmbH + Co
India,
Liaison Office,
Mumbai (Bombay), India
2000
foundation of
Schmidt + Clemens
Brasil Ltda.,
Jundiai/Sao Paulo,
Brazil
foundation of
Schmidt + Clemens
(Asia) Sdn. Bhd.
Shah Alam / Selangor,
Malaysia
2001
2004
new layout at Lindlar-Kaiserau,
Germany
•
extensive investment
program for centrifugal
casting in Germany and Spain
•
expansion of
Schmidt + Clemens
(Asia), Sdn. Bhd.,
Malaysia
•
expansion of
Schmidt + Clemens Brasil
Ltda. at a new location in
Jundiai,
Sao Paulo

Advanced Centrifugal
Casting Alloys for DRI
Schmidt+Clemens are the Market
leaders for centrifugally cast tubes
for DRI thanks to the trust of many
customers around the world, which
has allowed us to provide more than
18,000 assemblies since 1986. Our
leading position is the result of:
High metallurgical product quality,
ensured by our stringent quality
systems, which constitutes the
basis for achieving the required
product performance and lifetime.
S+C Bowers & Jones Ltd.
Patrick Gregory Road
Wednesfield
Wolverhampton, WV11 3DU Great Britain
Rolls
Schmidt - Clemens Spain, S.A.U.
Ctra. Estella-Vitoria, Km. 12
31280 Murieta, Navarra, Spain
Spuncasting
Highly efficient manufacturing
methods including unique melting,
machining and welding techniques,
as the result of a major ongoing
investment programme in manufacturing
development.
Product improvement boosted by
specialists in our R&D departments,
who are responsible for developing
new materials with the specific
objective of meeting the most demanding
operational requirements.
• A new generation of Microalloys
was introduced in the year 2001
for Direct Reduction Reformer
tubes with excellent performance
regarding creep properties.
Schmidt + Clemens GmbH + Co. KG
Edelstahlwerk
S+C MÄRKER GmbH
51789 Lindlar-Kaiserau, Germany
Casting, Spuncasting, Machining, Research and
Engineering, Management
Schmidt + Clemens Brasil Ltda.
Av. Beta, 351 - Jundiai - SP
CEP 13213-070
Brazil
Spuncasting
Tube elongation is drastically
reduced while tube life will be
extended because of increased
creep rupture strength.
• The new Centralloy® 60HTD
was also developed in order to
increase maximum operating
temperatures to 1200° C and is
proving very successful.
Customer Service offered through
our worldwide network of facilities.
Our high quality products, innovative
developements and our complete
range of services are the basis for
our company objectives: complete
Customer satisfaction and confidence.
S+C ALFANAMETAL k. s
CZ-78357 Trisce ˘ c 126, Czech Republic
Casting
Schmidt + Clemens (Asia) Sdn. Bhd.
No. 15 Jalan Pemaju U1/15, Section U1
Hicom Glenmarie Industrial Park
40000 Shah Alam, Malaysia
Spuncasting
3

Schmidt + Clemens
Alloy Selection
Features
Chemical composition of alloys designed
for DRI include
0.40-0.50% carbon and nickel
higher than 35 % for mechanical
resistance and structural stability
at high temperatures.
Chromium contents higher than
25% for necessary oxidation
resistance.
Aluminium, included in Centralloy ®
60 HTD as a source for oxide layers
build-up against carburization and
metal dusting. Unique in the world of
centricast products, our Centralloy ®
4
Description Chemical Composition
No Trade Mark Designation according to Approximate values in % Mass
Centralloy® ASTM Type DIN EN 10027 Part 1 C Si Mn Cr Ni Nb W Others
1 4852 HP-Nb GX40NiCrSiNb35-25 0,40 1,50 1,50 25,00 35,00 1,50 - -
2 4852Micro HP-Nb Ti GX45NiCrSiNbTi35-25 0,45 1,50 1,00 25,00 35,00 1,50 - +Add
3 4879 NA 22H/HV G-NiCr28W 0,45 1,50 1,50 28,00 48,00 - 5,00 -
4 4879Micro NA 22H/HV (MA) G-NiCrTi28W 0,50 1,00 0,75 28,00 48,00 - 5,00 +Add
5 ET45Micro - GX45NiCrSiNb45-35 0,45 1,60 1,00 35,00 45,00 1,00 - +Add
6 ET45LC - GX13NiCrNb45-35 0,13 0,80 1,50 35,00 45,00 0,80 - +Add
7 60HTD - - 0,45 - - 27,00 Bal 0,70 - Fe, Al, +Add
60 HTD constitutes the latest alloy
development in our group of companies.
Balanced compositions lead to material
structures with optimised physical
and mechanical properties.
Carbon content leads to the formation
of
Primary M 7 C 3 -type carbides during
casting, which are transformed into
M 23 C 6 upon ageing,
Secondary carbides of the M 23 C 6 -
and M 6 C-type during ageing.
High Temperature Mechanical Properties
Primary and secondary niobium
carbides.
Fine carbides precipitation results in
improved high temperature mechanical
properties including creep strength.
Further improvement is possible by
the addition of strong carbide forming
elements like titanium. Creep strength
is increased by 15-20%. Because of
the small amounts of carbide-forming
elements used, such alloys are called
micro-alloys.
200°C 400°C 600°C 800°C 900°C 1000°C 1100°C
No Trade Mark YS UTS e YS UTS e YS UTS e YS UTS e YS UTS e YS UTS e YS UTS e
Centralloy ® MPa MPa % MPa MPa % MPa MPa % MPa MPa % MPa MPa % MPa MPa % MPa MPa %
1 4852 290 475 11 280 470 12,5 230 400 17 150 240 26 100 150 33 70 80 41 56 58 52
2 4852Micro 270 475 12 265 460 13 230 385 17 155 230 24 115 145 30 75 80 39 59 67 46
3 4879 320 480 8 300 480 11,5 280 420 14,5 200 250 23 130 150 32 75 80 37 53 63 40
4 4879Micro 335 520 7 310 510 8,5 285 445 11 210 290 15 140 210 21 85 120 29 63 85 43
5 ET45Micro 250 450 7 196 401 9 179 391 10 140 260 26 105 155 39 70 85 45 63 78 52
6 ET45LC 245 500 26,5 210 485 34 195 435 31 175 280 24 105 140 37 60 85 39 49 72 42
7 60HTD 580 700 4 570 680 4 560 660 4 510 620 5 220 300 20 100 150 37 50 80 50
YS = Yield Strength
UTS = Ultimate Tensile Strength
RT: Room Temperature

Minimum Mechanical
Properties at RT
Physical Properties
YS UTS Elongation Density Thermal Conductivity Mean Coefficient of Thermal Expansion in 10 -6 /ºC Max Recommended
MPa MPa % g/cm 3 W/(m K) 20-400ºC 20-800ºC 20-1000ºC Temperature ºC
230 450 8 8,0 14,6 16,0 17,0 18,5 1100
230 470 8 8,0 14,6 16,0 17,0 18,5 1130
270 480 4 8,2 14,6 14,5 16,0 17,0 1150
290 490 4 8,2 14,6 15,5 17,0 17,5 1175
245 450 6 8,1 14,0 16,0 17,0 18,0 1150
250 440 16 8,1 14,0 16,6 18,1 18,4 1100
330 520 4 8,1 11,3 14,5 16,6 17,5 1200
5

Schmidt + Clemens
Creep Properties
Decrease (%)
6
Stress (MPa)
100
10
1
Decrease in Minimum
Creep Rate of
Centralloy ® 4852Micro
vs. Centralloy ® 4852
80
70
60
50
40
30
20
10
0
Average Stress to Rupture vs. Temperature
800 850 900 950 1000 1050 1100
Temperature (°C) Time to Rupture = 100.000 hours
Decrease at 1000°C
Decrease at 1050°C
Decrease at 1100°C
10 13
Initial Stress (MPa)
Creep Resistance
Considerable efforts have been
made in order to combat a major
cause for life exhaustion, namely
creep damage.
Schmidt + Clemens supplies tailormade
Micro Alloys for DRI, which
have considerably improved material
resistance against creep elongation
and rupture.
The increase in Creep strength
allows higher operating temperatures
or thinner tube walls, providing
various advantages:
Lower thermal gradients across
tube walls resulting in:
• Increased tube life due to lower
stress concentration
• Higher gas heating efficiency
and therefore fuel cost savings
• Increased resistance to thermal
shock
®
®
Centralloy 4852 Micro
Centralloy 4852
Increased catalyst volume resulting
in higher output and/or efficiency
LMP graphs indicate that the creep
rupture strength of micro-alloys is
increased up to 20% over standard
HP-Nb and HV alloys.
Creep elongation also decreases when
micro-alloys are compared to nonmicro
alloys.
Graphs showing results from laboratory
tests indicate that Centralloy ®
4879 Micro -alloy designed for use
as top section- elongates up to
almost 67% less than the standard
metallurgy Centralloy ® 4879, depending
on temperature and stress conditions.
A similar comparison for
alloys designed for bottom sections
indicates that Centralloy ® 4852 Micro

Stress (MPa)
100
10
1
900 950 1000 1050 1100 1150 1200
elongates up to 70% less than the
corresponding non-micro version.
Higher resistance to creep elongation
results in the following major
advantages:
Less tube elongation, therefore
less empty space at the top of the
reformer tube after the settle down
of the catalyst - avoiding overheating
of the catalyst-free tube section
and frequent toppings.
Less reduction of the tube wall thickness
resulting in longer tube life
Reduced detrimental effects on
adjacent components like feed
hoses and compensators
All the above contribute towards
extending the service life of reformer
tubes made with S+C new
generation of micro-alloys.
Average Stress to Rupture vs. Temperature
Time to Rupture (h)
4000
3500
3000
2500
2000
1500
1000
500
0
Temperature (°C) Time to Rupture = 10.000 hours
Time to
Rupture Comparison
at 1100°C
Centralloy 4879
Centralloy 4852 Micro
Centralloy 60 HTD
15,9 13,5
Stress (MPa)
Centralloy 60 HTD
Centralloy 4879 Micro
Centralloy 4879
Decrease (%)
Decrease in
Minimum Creep Rate
of Centralloy ® 4879Micro
vs. Centralloy ® 4879
68
67
66
65
64
63
62
61
Decrease at 1050°C
Decrease at 1100°C
Decrease at 1150°C
10 15
Initial Stress (MPa)
7

Schmidt + Clemens
High Temperature Corrosion Properties
Carburization Resistance
Oxidation Resistance
8
Weight Change, mg/cm 2
Weight Change, mg/cm 2
14
12
10
8
6
4
2
0
10
5
0
-5
-10
ISOTHERMAL CARBURIZATION in CH / H Atmosphere
4 2
Centralloy ® 60 HTD
Centralloy ® ET 45 Micro
Centralloy ® 4852 Micro
16 h, 1000°C 48 h, 1000°C 48 h, 1045°C
CYCLIC OXIDATION
at 1150°C in Air
Cycle: 45 min at 1150°C/ 15 min at RT
Centralloy ®
60 HTD
Centralloy ® ET 45 Micro
Centralloy ® 4852 Micro
0 50 100 150 200
Number of Cycles

Metal Dusting Resistance
Alloy Designation Incubation Time, hours
800H 400
25/35 Nb LC 1500
Centralloy ® ET 45 Micro 6200 (*)
Centralloy ® 60 HTD 2300 (*)
Centralloy ® ET 45 Micro 300
Centralloy ® 60 HTD 1200
Resistance to High
Temperature Corrosion
S+C alloys rely on the formation of
protective oxide layers as barriers
against high temperature corrosion.
While alloys with 25%Cr and silicon
provide reasonably good protection
in mild atmospheres, Centralloy ® ET
45 Micro forms continuous Cr-Si,
which is stable at higher temperatures
and more aggressive environments.
Furthermore, the combined effect of
chromium and aluminium given by
Centralloy ® 60 HTD outperforms the
aforementioned oxide barriers with
respect to stability against thermal
cycling and also offers excellent protection
against coking, carburization
and metal dusting.
Exposure to Gas Mixture 1
Exposure to Gas Mixture 2
(*) Samples were not attacked after indicated exposure
Gas 1 Gas 2
H 2 (%) 74 60
CO (%) 24 31
CO 2 (%) 3,5
H 2O (%) 2 5,5
P (bar) 1,5 20
T (°C) 600 600
Carbon activity 76 290
Metal Dusting Attack in High Ni/Cr Alloy
9

Schmidt + Clemens
Customer Service
Many years of experience in centrifugal casting led
S+C to develop a specific Customer Service Policy,
which is continuously evolving to better meet our
customers latest expectations and needs.
Schmidt-Clemens is keen to offer technical assistance,
and the resulting knowledge of our Customers
needs, determines the direction for the development
and improvement of our materials performance.
In such respect, Schmidt + Clemens provides:
Reformer Tube Inspections.
Plant Data Collection and Evaluation.
Reformer tubes performance evaluation, as
described in our specification for reformer tube
assemblies monitoring SCS-MON-001.
Technical assistance during major shutdowns.
Material selection consultancy.
All of the above follows the purpose of acting as your
Problem-Solving Partner.
10

Complete package supplier
S+C supplies complete reformer tube
assemblies. Accessories provided as part
of tube assemblies may include:
Tee pieces
Ceramic fibres
Refractory castable concrete
Flanges and cones
Top and bottom canister assemblies
Compensators
Backing rings
Static casting fittings
11

Schmidt + Clemens
Centrifugal Casting Division
Production Plants and Sales Companies
Schmidt + Clemens GmbH + Co. KG
Edelstahlwerk Kaiserau
51789 Lindlar, Germany
Phone: +49 22 66 92 258
Fax: +49 22 66 92 369
E-Mail: spuncasting@schmidt-clemens.de
P.O. Box 1140, 51779 Lindlar, Germany
Schmidt - Clemens Spain, S.A.U.
Ctra. Estella-Vitoria, Km. 12
31280 Murieta, Navarra, Spain
Phone: +34 948 53 4646
Fax: +34 948 53 4684
E-Mail: sales-es@schmidt-clemens.com
P.O. Box 67, 31200 Estella, Spain
Schmidt + Clemens Brasil Ltda.
Av. Beta, 351 - Jundiai - SP,
CEP 13213-070, Brazil
Phone: +55 11 4815 3900 200
Fax: +55 11 4582 9888
E-Mail: a.cortines@schmidt-clemens.com.br
P.O. Box 20, 13201-973
Schmidt + Clemens (Asia) Sdn. Bhd.
No. 15, Jalan Pemaju U1/15, Seksyen U1
Hicom-Glenmarie Industrial Park
40150 Shah Alam, Selangor Darul Ehsan, Malaysia
Phone: +603 55691945 / +603 55692241
Fax: +603 55691425
E-Mail: scasia@schmidt-clemens.com
Schmidt & Clemens, Inc.
9618 Green Valley Lane
USA-Houston, Texas 77064
Phone: +1 281 807 5880
Fax: +1 281 807 5889
E-Mail: sales-us@schmidt-clemens.com
Schmidt + Clemens GmbH + Co. KG
India Liaison Office
A 214 Mahindra Gardens, S.V. Road
Goregaon (W)
Mumbai 400 062, India
Phone: +91 22 28 74 84 45
Fax: +91 22 28 79 13 36
E-Mail: scindia@vsnl.net
Contact us:
Schmidt - Clemens Spain, S.A.U. • Phone: +34 948 53 4646 • Fax: +34 948 53 4684
E-Mail: sales-es@schmidt-clemens.com • www.schmidt-clemens.com