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Contract No. W-7405-eng-26<br />
METALS AND CERAMICS DIVISION<br />
IRON AND NICKEL CARBONYL FORMATION<br />
IN STEEL PIPES AND ITS PREVENTION -<br />
LITERATURE SURVEY<br />
J. Brynestad<br />
Date Published: September 1976<br />
NOTICE This document conta<strong>in</strong>s <strong>in</strong><strong>formation</strong> of e prelim<strong>in</strong>ary nature<br />
<strong>and</strong> was prepared primerlly for <strong>in</strong>ternal use at the <strong>Oak</strong> <strong>Ridge</strong> National<br />
Laboratory. It is subject to revision or correction <strong>and</strong> therefore does<br />
not represent a f<strong>in</strong>al report.<br />
OAK RIDGE NATIONAL LABORATORY<br />
<strong>Oak</strong> <strong>Ridge</strong>, Tennessee 37830<br />
operated by<br />
UNION CARBIDE CORPORATION<br />
for the<br />
ENERGY RESEARCH AND DEVELOPMENT ADMINISTRATION<br />
ORNL/TM-5499<br />
Distribution<br />
Category UC-4Qd
CONTENTS<br />
ABSTRACT ............................. 1<br />
1. INTRODUCTION ......................... 1.<br />
2. THERMODYNAMIC DATA ...................... 2<br />
2.1. IKON PENTACARBONn .................. 2<br />
2.1.1. Vapor Pressure ................. 3<br />
2.1.2. Thermodynamic Functions ............ 3<br />
2.2. NICKEL TETMCARBONYL ................. 4<br />
2.2.1. Vapor Pressure . ................ 4<br />
2.2.2. Thermodynamic Functions ............ 5<br />
3. KINETICDATA ......................... 6<br />
4. QUANTITATIVE ANALYTICAL METHODS FOR THE DETERMINATION<br />
OF SMALL AMOUNTS OF IRON AND NICKEL CARBONTL IN GASES .... 11<br />
5. PREVENTION METHODS ..................... 13<br />
6. CONCLUSIONS ......................... 14<br />
REFEKENCES . .......................... 1 5<br />
iii
IKON AND NICKEL CARBONYL FORMATION<br />
IN STEEL PIPES AND ITS PREVENTION --<br />
LITERATURE SURVEY<br />
3. Brynestad<br />
AUSTRACT<br />
Data were compiled on the stability <strong>and</strong> <strong>formation</strong><br />
rates of iron <strong>and</strong> <strong>nickel</strong> <strong>carbonyl</strong>s. The data demonstrate<br />
that <strong>carbonyl</strong> <strong>formation</strong> <strong>in</strong> <strong>steel</strong> <strong>pipes</strong> is governed largely<br />
by k<strong>in</strong>etics. The rate of <strong>carbonyl</strong> <strong>formation</strong> is a function<br />
of several factors: temperature, pressure, gas flow<br />
rate, gas composition, impurities <strong>in</strong> the gas, alloy compo-<br />
sition, surface conditions, <strong>and</strong> pretreatment of the surfaces.<br />
An evaluation of techniques for detect<strong>in</strong>g iron <strong>and</strong> <strong>nickel</strong><br />
<strong>carbonyl</strong>s <strong>in</strong> gases showed atomic absorption spectroscopy<br />
to be a highly effective (Q 1 ppb), almost <strong>in</strong>stantaneous<br />
analytical technique. Carbonyl <strong>formation</strong> <strong>in</strong> pipe <strong>steel</strong>s<br />
seems to be prevented ma<strong>in</strong>ly by the use of <strong>steel</strong>s with<br />
high chromium contents, by l<strong>in</strong><strong>in</strong>g the tub<strong>in</strong>g with copper,<br />
or by use of any stable coat<strong>in</strong>g that prevents the carbon<br />
monoxide from directly contact<strong>in</strong>g the metal.<br />
1. INTRODUCTION<br />
A project is under way to determ<strong>in</strong>e the k<strong>in</strong>etics of the <strong>formation</strong><br />
of iron <strong>and</strong> <strong>nickel</strong> <strong>carbonyl</strong>s when carbon monoxide gas, In itlie presence<br />
of hydrogen, contacts structural <strong>steel</strong>s at 100-500°F (4O-26O0C), The<br />
first step <strong>in</strong> the project is a survey of pert<strong>in</strong>ent literature on<br />
related thermodynamics, k<strong>in</strong>etics, <strong>and</strong> analytical chemistry. This is<br />
the report of that survey.<br />
<strong>Iron</strong> <strong>and</strong> <strong>nickel</strong> <strong>carbonyl</strong>s are formed by the action of carbon<br />
monoxide gas upon alloys <strong>and</strong> ores that contaln iron <strong>and</strong> <strong>nickel</strong>.<br />
presence of iron <strong>and</strong>/or <strong>nickel</strong> <strong>carbonyl</strong> <strong>in</strong> process gases may have<br />
serious consequences. Apart from their toxicity, these <strong>carbonyl</strong>s<br />
may cause problems by the deposition of metal oxides <strong>in</strong> gas burners,<br />
1<br />
The
y plat<strong>in</strong>g out metal at higher temperatures by decomposition, or by<br />
the <strong>formation</strong> of depos<strong>its</strong> of reaction products between the <strong>carbonyl</strong>s<br />
<strong>and</strong> other impurities <strong>in</strong> the gases.<br />
Rather little is known <strong>in</strong> detail about the rate of <strong>carbonyl</strong>.<br />
<strong>formation</strong> under various conditions. It seems to be well established,<br />
however, that unless special steps are taken to <strong>in</strong>crease the rate of<br />
<strong>carbonyl</strong> <strong>formation</strong>, the rate of iron <strong>carbonyl</strong> <strong>formation</strong> <strong>in</strong> most cases<br />
is so low that thermodynamic equi.l.ibrium is not reached.<br />
2<br />
In<strong>formation</strong> found <strong>in</strong> the literature pert<strong>in</strong>ent to the <strong>formation</strong><br />
of iron arid <strong>nickel</strong> <strong>carbonyl</strong> from pipe <strong>steel</strong>s is surveyed <strong>in</strong> the<br />
follow<strong>in</strong>g chapters:<br />
2. Thermodynamic data,<br />
3. K<strong>in</strong>etic <strong>in</strong><strong>formation</strong>,<br />
4. Analytical techniques <strong>in</strong>clud<strong>in</strong>g our own. observations,<br />
5. Possible methods for the prevention of <strong>carbonyl</strong> <strong>formation</strong>,<br />
6 a Conclusions.<br />
The compilation of literature references is not exhaustive, as<br />
this would imply a collection of hundreds of pu1d.i-cations that are<br />
only mi2rgiriall.y <strong>in</strong>formative for tliis project, Rather, we have tried<br />
to m<strong>in</strong>imize the number of publications by <strong>in</strong>clud<strong>in</strong>g only those wtth<br />
<strong>in</strong><strong>formation</strong> directly pert<strong>in</strong>ent to the project. By do<strong>in</strong>g this one ad-<br />
mittedly rims the risk of omitt<strong>in</strong>g <strong>in</strong>aterial that the <strong>in</strong>dividual reader<br />
might consider relevant. For example, the preponderance of references<br />
to analytical methods for iron <strong>and</strong> <strong>nickel</strong> <strong>carbonyl</strong> has been om.i.tted<br />
because they are not sensitive enough for this project. However, ChemkaZ<br />
Abstracts <strong>and</strong> Chemical T7:tles have been screened up to mid-April 1976.<br />
2.1. IRON PENTACARBONY'L<br />
2. THERMODYNAMIC DATA<br />
<strong>Iron</strong> penta<strong>carbonyl</strong> at room temperature 5s a viscous, pale yellow<br />
liquid. It crystallizes at about --2OoC, <strong>and</strong> at atmospheric pressure<br />
boils about 102OC.<br />
2<br />
It is very toxic.
2.1.1. Vapor Pressure<br />
3<br />
The data by Trautz <strong>and</strong> Badst6ber3 <strong>and</strong> by Gilbert <strong>and</strong> Sulzmann4<br />
are <strong>in</strong> very good agreement. Gilbert <strong>and</strong> Sulzmann's results for<br />
temperatures between -19 <strong>and</strong> 31'C may be expressed as<br />
where T is <strong>in</strong> Kelv<strong>in</strong>s.<br />
log [p (Pa)] = -2096.7/7'+ 10.6208,<br />
between 0 <strong>and</strong> 104°C may be expressed as<br />
log [p (torr)] = --2096.7/IT -t- 8.4959 ,<br />
Results by 'L'rautz <strong>and</strong> Badstiiber for temperatures<br />
log [p (Pa)] = -2050.7/T +- 10.4347 ,<br />
log [p (torr)] = -2050.7/5!' + 8.3098 .<br />
The critical pojnt is about 285°C at about 29.6 atm, (3.0 Wa).<br />
2.1.2. Thermodynamic Functions<br />
The thermodynamic equilibrium constant for the equilibrium<br />
Fe(s) + SCO(g) Pe(CO)5(g) (3)<br />
has been calculated by Ross et a1.,5 Syrk<strong>in</strong>,<br />
by Ross et al. give for the equilibrium above [Eq. (3)lr<br />
log K = 8940/T- 30.09<br />
<strong>in</strong> terms of pressures <strong>in</strong> atmospheres.<br />
(also <strong>in</strong> atmospheres) for the equilibrium (3) above.<br />
log K = 10204/T - 30.42 .<br />
<strong>and</strong> others. Calculations<br />
Syrk<strong>in</strong>'s data can be written<br />
(4)
4<br />
Pichler <strong>and</strong> Walenda7 also calculated equilibrium constants for<br />
Eq. (3). However, their calculations were based on raLher <strong>in</strong>accurate<br />
data; their values for K arc about two orders of niagnitude larger<br />
than those calculated from (lata of Ross et al.* The same applies to<br />
the values given by Brief et al. :<br />
which was based on estimates by Cooper et al.'<br />
are presumably the most re1iahl.e.<br />
log K = I.Q9QQ/T - 32.672 , (4)<br />
The data of Ross et al.<br />
As will be discussed <strong>in</strong> Chap. 3, an accurate knowl.edge of the<br />
equilibrium constant does not give any <strong>in</strong><strong>formation</strong> as to the rate of<br />
<strong>formation</strong> of iron or <strong>nickel</strong> <strong>carbonyl</strong>. TI: should also be taken <strong>in</strong>to<br />
consideration that gas mixtures contaiaiiig large concentrations of<br />
iron or <strong>nickel</strong> <strong>carbonyl</strong> brill be quite nonideal, so that additional.<br />
<strong>in</strong><strong>formation</strong> (or estimates) must be <strong>in</strong>voked to calcul.ate reliable<br />
equilibrium concentrations from thermodynamic data.<br />
2.2. NICKEL TETRACARBONYL<br />
Nickel <strong>carbonyl</strong> at room temperature is a colorless, volatile<br />
liquid with extreme toxicity.2<br />
at atm0spheri.c. pressure. '<br />
2.2 1. Vapor Pressure<br />
It melts at -17.2OC <strong>and</strong> boils at 42.2'C<br />
Walsh's data" for the vapor pressure over liquid <strong>nickel</strong> tetra-<br />
<strong>carbonyl</strong> <strong>in</strong> the temperature range O to 35.I'C give<br />
log p (Pa) = 10.0092 - 1..578/T .<br />
*Note that the way of present<strong>in</strong>g equilibrium constants used by<br />
Pichler <strong>and</strong> Walenda is the <strong>in</strong>verse of the coriventional presentation.
5<br />
This is <strong>in</strong> good agreement with Sug<strong>in</strong>uma <strong>and</strong> Satozaki's data' *'<br />
<strong>in</strong> the temperature range 0 to 25°C:<br />
log p (torr) = 7.878 - 1574.49/!i"<br />
log p (Pa) = 90.003 - l574.49/T .<br />
The experime.nta1 value of the critical temperature'* lies between'<br />
191 <strong>and</strong> :L95"C.<br />
2.2.2. Thermodynamic Functions<br />
The thermodynamic functions for the equilibrium<br />
Ni(s) + 4CO(g) Ni(CO)b(g) (9 1<br />
have been evaluated by a number of authors, the most recent be<strong>in</strong>g Kipnis<br />
<strong>and</strong> Mikhailova, who f<strong>in</strong>d the most probable values to be:<br />
Ah''29~ = --142.3 kJ/mole = -34.0 kcalt'mole<br />
If one assumes AC to be zero these values give for the equilibrium<br />
P<br />
constant:<br />
Ross et al? obta<strong>in</strong>ed<br />
log K 7430/T - 21.90<br />
log K 8546/T- 21.64<br />
Equations (10) <strong>and</strong> (11) imply pressures measured <strong>in</strong> atmospheres.<br />
(11.)
The discrepancy is due to a difference <strong>in</strong> the assumed value of AH0298.<br />
Experimentally obta<strong>in</strong>ed values for A?l0298 arc. strongly dependent upon<br />
the physical state of the <strong>nickel</strong> metal used <strong>in</strong> t.he experiment, as f<strong>in</strong>ely<br />
divided <strong>nickel</strong>. uniformly gives higher (absolute) values than co<strong>in</strong>pact<br />
<strong>nickel</strong>. Thus Kipnis <strong>and</strong> Mikhailova's data at present seem to be the<br />
most reliable e<br />
3. KINETIC DATA<br />
As early as 1891 Roscoe <strong>and</strong> Scudder14 had reported that water gas<br />
at room temperature <strong>and</strong> 0.8 MPa (8 atm.) pressure <strong>in</strong> a carbon <strong>steel</strong><br />
cyl<strong>in</strong>der reacted with the cyl<strong>in</strong>der walls to form i.ron <strong>carbonyl</strong>. With<strong>in</strong><br />
about a month the gas conta<strong>in</strong>ed about 2,4 mg/l (Q960 ppm*) of iron as<br />
iron <strong>carbonyl</strong>. Stoffel' (1914) <strong>in</strong>vestigated the reaction between<br />
carbon monoxide <strong>and</strong> f<strong>in</strong>ely divided iron (pyrophoric) at gas pressures<br />
of 0.5-2 atm (50 to 200 kPa) <strong>and</strong> <strong>in</strong> the temperature range 20 to 80°C.<br />
He found that adsorbed iron <strong>carbonyl</strong> on the metal surface lowered<br />
the reaction rate drastically, <strong>and</strong> that the reaction rate was approxi-<br />
mately proportional to the square of the carbon monoxide pressure.<br />
Mond <strong>and</strong> Wallis16 (1922) reacted pyrophoric iron with carbon<br />
monoxide <strong>in</strong> the pressure range 100--300 atm (10 to 30 MPa) <strong>and</strong> <strong>in</strong> the<br />
temperature range 130 to 260°C, with a reaction time of 2 hr,<br />
obta<strong>in</strong>ed optimum yields at 200°C at all pressures.<br />
Mitlraschl (1928) reported that even small amc:,unts of oxygen<br />
They<br />
strongly repress iron <strong>carbonyl</strong> formatton, whereas hydrogen <strong>and</strong> ammonia<br />
<strong>in</strong>crease the reaction rate. Pichler <strong>and</strong> Walenda7 (1940) <strong>in</strong>vestigated<br />
<strong>in</strong> some detail the reaction between carbon monoxide <strong>and</strong> various alloyed<br />
<strong>steel</strong>s, as well as unalloyed carbon <strong>steel</strong> <strong>and</strong> cast iron. They worked<br />
<strong>in</strong> the pressure range 150-1000 atm (15 to 100 MPa). The extent of <strong>carbonyl</strong><br />
*p.p.m. will be understood as (volume fraction x lo6) of the gas<br />
<strong>in</strong> question.
~ magnitude<br />
<strong>formation</strong> was determ<strong>in</strong>ed by measur<strong>in</strong>g the welght loss af the metal<br />
samples under both static <strong>and</strong> flow<strong>in</strong>g gas conditions.<br />
7<br />
Their results are <strong>in</strong>terest<strong>in</strong>g <strong>and</strong> wlll be discussed <strong>in</strong> some detail:<br />
1. In agreement with Mond <strong>and</strong> Wallis16 they found that the<br />
reaction rate reached a maximum at 200°C.<br />
used granulated, unalloyed, H g<br />
samples of low-carbon <strong>steel</strong> with a<br />
gra<strong>in</strong> size of 0,15 to 0.30 mm <strong>in</strong> a static atmosphere of CQ) with 10%<br />
N2, at a start<strong>in</strong>g pressure of 300 atm. (30 MPa) <strong>in</strong> a 100-ml autoclave.<br />
The reaction time was 48 hr.<br />
In these experiments they<br />
It: is important to note that equilibrium was not reached under<br />
these conditions except possibly at 250°C.<br />
The authors did not<br />
measure the surface areas of the samples, but one can make an order-of-<br />
estimate by assum<strong>in</strong>g that the granules were all shaped as<br />
cubes of the same size.<br />
metal (%7.8g) a surface area of 2 m2 for a granule edge size of 0.3 mm<br />
<strong>and</strong> G m2 for a granule size of 0.1 nnn.<br />
area/volume for an "average" gra<strong>in</strong> is somewhat larger than for a cube,<br />
so that one may assume that the surface areas of their samples were<br />
<strong>in</strong> the range from 5 to 10 m2,, This implies, that for a weight loss<br />
of about 30% of an 8-g sample, the weight loss per unit surface area<br />
would be of the carder of 0.5g/m2 <strong>in</strong> 48 hr.<br />
This gives for a 1 cm3 net volume of sample<br />
Presumably, the ratio surface<br />
2. A most important observation was that the reaction rate<br />
depended upon the gas flow rate.<br />
Us<strong>in</strong>g a 14-m-ID pressure tube as a<br />
reaction chamber at 150 atm (15 MPa) gas pressure <strong>and</strong> 200"C, they<br />
observed that the attack <strong>in</strong>creased by a factor of 5.3 for untreated<br />
low-carban <strong>steel</strong>, <strong>and</strong> by a factor of 11.2 for "pretreated" samples (i.e.,<br />
heated to a "yellow glow" <strong>and</strong> quenched <strong>in</strong> water), by <strong>in</strong>creas<strong>in</strong>g the gas<br />
flow rate from 2 liters/hr up to 100 liters/hr [referred to 1 a tm<br />
(0.101 MPa) gas pressure]. S<strong>in</strong>ce the cross section of the reaction tube<br />
was l.54 em2 <strong>and</strong> the pressure 150 atm (15 MPa), these flow rates corre-<br />
spond to l<strong>in</strong>ear flow rates of 2.5 to 125 m/m<strong>in</strong> at 150 <strong>and</strong> 200°C,<br />
not count<strong>in</strong>g the reduction <strong>in</strong> the cross section caused by the sample.<br />
Figure 1 shows a plot of their results <strong>in</strong> their Tables 4 <strong>and</strong> 5, <strong>in</strong><br />
terms of iron loss per hour versus l<strong>in</strong>ear flow rate.
R<br />
L<br />
II<br />
\<br />
v<br />
0<br />
70<br />
60<br />
50<br />
40<br />
cn<br />
0<br />
IJ 30<br />
z<br />
0<br />
E<br />
- 20<br />
16<br />
Q<br />
1<br />
G<br />
i<br />
0<br />
8<br />
I<br />
UNTREATED<br />
I<br />
ORNL-DWG 76-8264<br />
4- t<br />
~ .................<br />
- ..........<br />
- ..........<br />
0 2 4 6 8 IO 12 i4<br />
FLOW RAPE (crn/m<strong>in</strong>)<br />
Fig. 1. Attack of Low-Carbon Steel as n Function of Flow Rate.
9<br />
These results show that tests on <strong>carbonyl</strong> <strong>formation</strong> <strong>in</strong> static<br />
atmospheres will not give <strong>in</strong><strong>formation</strong> pert<strong>in</strong>enr. to cond-itions with<br />
flow<strong>in</strong>g gas. Rather, one must keep flow rates high enough to be sure<br />
to be located on the plateau, where the rate of <strong>carbonyl</strong> <strong>formation</strong> is<br />
<strong>in</strong>variant wlth respect to the flow rate. S<strong>in</strong>ce the nature of the<br />
surface may change with the extent of the (corrosive) attack, thus<br />
chang<strong>in</strong>g the <strong>formation</strong> rate, it seems important also to study the<br />
time dependence of the <strong>carbonyl</strong> <strong>formation</strong> under constant external<br />
conditions.<br />
3. There is implicit <strong>in</strong><strong>formation</strong> <strong>in</strong> their data that the reaction<br />
rate depends on pressure. Their Tables 6 <strong>and</strong> 7 give the resul ts for<br />
the attack by (static) CO, at 200'C for four days duration upon various<br />
allayed <strong>steel</strong>s at 300 atm (30 MPa) (Table 6) <strong>and</strong> 450 atm (46 MPa)<br />
(Table 7). A <strong>steel</strong> conta<strong>in</strong>Jtng 1.22% Nb, 0.15% C (test 5, Table 6; test 16,<br />
Table 7) was tested at both pressures.<br />
had the same ratio of surface area to weight, <strong>and</strong> that the surfaces<br />
of the samples were <strong>in</strong> the same "state", the attack (weight<br />
loss/sur€ace area) was 2.04 times larger at 450 atm (46 MPa) than at<br />
300 atm (30 MF'a). This corresponds to a carbon monoxlde pressure<br />
dependence of p e 76 . This is <strong>in</strong> reasonable agreement with Stoffel15<br />
C 0<br />
who found a pressure dependency of about p& <strong>in</strong> the 0.5-2 atm<br />
(50-200 ea) range.<br />
Assum<strong>in</strong>g that the respective samples<br />
4. By chemical analysis of the <strong>carbonyl</strong>s from an alloy wit11 5%<br />
<strong>nickel</strong>, they obta<strong>in</strong>ed the ratio Fe(CQ)S/Ni(C0)4 = 95.4J4.6 (Le., the<br />
<strong>formation</strong> of <strong>nickel</strong> <strong>carbonyl</strong> is not preferred).<br />
5. By compar<strong>in</strong>g their 200°C data of Tables 2 <strong>and</strong> 3 with their<br />
data <strong>in</strong> Tables 6 <strong>and</strong> 7, one arrives at the conclusion that all alloyed<br />
<strong>steel</strong>s tested were much more resjs tant than the "reference" low-carbQn<br />
<strong>steel</strong> they used.<br />
6. The results given <strong>in</strong> their Table 10 for differ<strong>in</strong>g gas<br />
campositions are quite <strong>in</strong>terest<strong>in</strong>g. These experiments were conducted<br />
with rods 6 mm diam <strong>and</strong> 40 mm long (total surface area 8.1 m2), at<br />
1000 atm (100 MPa) <strong>and</strong> 200°C, with a L<strong>in</strong>ear gas flow rate of &out<br />
2.5 mm/m<strong>in</strong> (at 1000 atm, ZOS"C>,
<strong>and</strong> for a 400-hr duration. Two different gas mixtures were used,<br />
10<br />
90% CO, 10% N2 <strong>and</strong> 60% F1zP 30% CO, 10% N2.<br />
One conclusion that can be drawn from these resul-ts ts that the<br />
<strong>carbonyl</strong> <strong>formation</strong> depends upon the nature of the gas mixture. Although<br />
the carbon monoxide partial pressure <strong>in</strong> the EI2-CO-N2 mixture is only<br />
one-third that <strong>in</strong> the CC-N;! mixture, some of the alloys were considerably<br />
more attacked by the H2-CO-Nz-mixture due to a catalytic effect by the<br />
hydrogen, However, no uniform trend can be detected.<br />
The results also <strong>in</strong>dicate that high-.chromium alloys are quite<br />
resistant toward attack <strong>in</strong> both cases.<br />
If one assumes that the rate of <strong>carbonyl</strong> <strong>formation</strong> is proportional<br />
to p1'76, one may extrapolate these data to the conditions of 1000 psi<br />
(7 ma), 200°C. This gives an attack rate of 8.8 x times the rate<br />
at 1.000 atm. Tak<strong>in</strong>g the surface areas of the samples <strong>in</strong>to consideration,<br />
<strong>and</strong> assum<strong>in</strong>g that the system ~7as <strong>in</strong> "steady state'' dur<strong>in</strong>g the e-xperiment,<br />
this gives a calcul.ated iron loss at 1000 psi <strong>and</strong> 200°C:<br />
where A# is the weight loss <strong>in</strong> their Table 10. In the worst case reported,<br />
this would mean a loss of about 64 g m-' year-', for a 0.5% Mo, 0.15% <strong>steel</strong>.<br />
If one assumes that the system was i-n steady state dur<strong>in</strong>g the experiment,<br />
the weight losses AW listed <strong>in</strong> their Table 10 expressed as ppm iron<br />
<strong>carbonyl</strong> <strong>in</strong> the gas, will be<br />
ppm =Z 167 b ( g )<br />
In the ''worst'' case <strong>in</strong> their Table 10, AW = 0.268 g, so that the <strong>carbonyl</strong><br />
content <strong>in</strong> the gas mixture was about 55 ppm. Lf the same experiment had<br />
been run at 1000 psi (7 MPa) <strong>in</strong>stead of at 1000 atm (100 ma), the gas<br />
mixture would have conta<strong>in</strong>ed about 0.5 ppm <strong>carbonyl</strong>.
11<br />
These somewhat speculative extrapolations <strong>in</strong>dicate that <strong>in</strong><br />
order to conduct mean<strong>in</strong>gful k<strong>in</strong>etic experiments at 1000 psi or less,<br />
one must be able to determ<strong>in</strong>e <strong>carbonyl</strong> contents <strong>in</strong> the gas on the<br />
parts-per-billion level with a reasonable accuracy. Moreover, it<br />
seems to be desirable to keep the ratio (metal surface area)/(gas volume)<br />
as large as possible, depend<strong>in</strong>g upon the sensitivity of the analytical<br />
techniques employed.<br />
Hieber <strong>and</strong> Geisenberger” (1950) observed that small amounts of<br />
sulfur, selenium, or tellurium, especially HzS, <strong>in</strong> the gas enhance the<br />
reaction rate between carbon monoxide <strong>and</strong> iron. In their experiments<br />
they used pyrophoric iron at 200°C <strong>and</strong> 200 atm (20 MPa) (<strong>in</strong>itial. pressure).<br />
Ludkum <strong>and</strong> Eischensl’ (1973) reported that the <strong>formation</strong> of<br />
<strong>carbonyl</strong> by the reaction of carbon monoxide with the components of<br />
sta<strong>in</strong>less <strong>steel</strong> (type 304) poses a special problem <strong>in</strong> the Tnfrared<br />
study of adsorbed carbon monoxide because the b<strong>and</strong>s due to <strong>carbonyl</strong>s<br />
are found <strong>in</strong> the same spectral. regions as those due to carbon monoxide<br />
adsorbed on metals. Dur<strong>in</strong>g 1-hr exposure to carbon monoxide at<br />
700 torr (93 kPa) <strong>and</strong> room temperature, about 200 cm2 surEace area<br />
formed about 0.3 mg of adsorbed <strong>carbonyl</strong>s of <strong>nickel</strong>, iron, <strong>and</strong><br />
(presumably) chromium. The <strong>carbonyl</strong>s were easily removed by evacuation<br />
at 25°C.<br />
4. QUANTITATIVE ANALYTICAL METHODS FOR THE<br />
DETEIZMLNATION OF SMALL ANOUNTS OF<br />
IKON AND NICKEL CAKBONYI, IN GASES<br />
A number of analytical methods are reported <strong>in</strong> the literature<br />
for the quantitative determ<strong>in</strong>ation of small amounts o€ iron <strong>and</strong> <strong>nickel</strong><br />
<strong>carbonyl</strong>s <strong>in</strong> gases. Nickel <strong>carbonyl</strong> <strong>and</strong> iron <strong>carbonyl</strong> are extremely<br />
toxic. The maximum allowable exposure to <strong>nickel</strong> <strong>carbonyl</strong>, Xi (GO) I,,<br />
determ<strong>in</strong>ed by an 8-hr weighted average, has been set by the Occupational<br />
Safety <strong>and</strong> Health Adm<strong>in</strong>istration (OSHA)2o at 1 ppb or 7 11g Ni(C0)~+/rn~ air<br />
(2,5 pg Ni/m3 air), <strong>and</strong> for the iron <strong>carbonyl</strong> at ’1.0 ppb or 90 ilg<br />
Pe(C0)5/m3 air (25 l.rg Fe/m3 air).
12<br />
To be useful <strong>in</strong> monitorihg these low concentrations the analytical<br />
method used must respond to much I.ower concen1:rations than the maximum<br />
allowable value, <strong>and</strong> be usable even <strong>in</strong> the presence of other chemicals.<br />
It also iiiust have a short response time, especially if the levels of<br />
<strong>carbonyl</strong> change appreciably with time. S<strong>in</strong>ce <strong>nickel</strong> <strong>carbonyl</strong> is the<br />
more common hazard of these two, auld also by far the most toxic, the<br />
ma<strong>in</strong> effort has been put <strong>in</strong>to develop<strong>in</strong>g monitor<strong>in</strong>g methods for <strong>nickel</strong><br />
carhonyl <strong>in</strong> air.<br />
Wernlund <strong>and</strong> Cohen2 (1975) report that Fourier Transform Infrared<br />
Spectroscopy <strong>and</strong> Pl.asiiia Chromatography show promise for monitor<strong>in</strong>g <strong>nickel</strong><br />
carllonyl. Their plasma chro~rratograph monitor has a m<strong>in</strong>imum detectable<br />
concentration of <strong>nickel</strong> <strong>carbonyl</strong> <strong>in</strong> air of 0.022 ppb, lower than the<br />
OSHA Ihit by a fac.tor of 45. 'The system time constant bras reported<br />
to be 2 sec. Presumably, their technique should be easily adaptable to<br />
iron <strong>carbonyl</strong> as well.<br />
McDowel12' (1971.) described a method for determ<strong>in</strong><strong>in</strong>g <strong>nickel</strong> <strong>carbonyl</strong><br />
vapors by <strong>in</strong>frared spectrophotometry <strong>and</strong> claims that detectabilities<br />
<strong>in</strong> the range of 1 to 10 ppb should be achievable without great difficulty.<br />
However, higli partial pressures of CO can <strong>in</strong>terfere with accurate<br />
measurements.<br />
Brief, et alm8,22 (1965, 1967) evaluatied exist<strong>in</strong>g wet chemical<br />
methods for determ<strong>in</strong><strong>in</strong>g very low levels O€ <strong>nickel</strong> <strong>and</strong> iron <strong>carbonyl</strong>s<br />
<strong>in</strong> gases <strong>and</strong> found it desirable to develop more sensitive <strong>and</strong> reliable<br />
metiliods. We have tested their methods as descr-i-bed, <strong>and</strong> found that<br />
they are as sensitive <strong>and</strong> reliable as reported,<br />
Densham et al. 23 (1963) revi.ewed different tests then available<br />
for determ<strong>in</strong><strong>in</strong>g <strong>nickel</strong> <strong>and</strong> iron <strong>carbonyl</strong>s <strong>in</strong> gas streams, ma<strong>in</strong>ly aimed<br />
at the determ<strong>in</strong>ation of <strong>nickel</strong> aad iron <strong>carbonyl</strong>s <strong>in</strong> town gas, <strong>and</strong><br />
they also described new methods that they had developed. Among these,<br />
atomic absorption spectroscopy seems to be of special <strong>in</strong>terest to this<br />
project, because this method, if applicable, would perrni.t an on-l<strong>in</strong>e,<br />
practically <strong>in</strong>stantaneous monitor<strong>in</strong>g of iron <strong>and</strong> <strong>nickel</strong> <strong>carbonyl</strong> contents<br />
<strong>in</strong> the gas. Consider<strong>in</strong>g that the state of the art <strong>in</strong> atomic absorption.<br />
spectroscopy has been greatly .improved s<strong>in</strong>ce 1963, one would assume
13<br />
that the sensitivity <strong>and</strong> accuracy of modern <strong>in</strong>struments are about an<br />
order of magnitude better than that used by Densham et al.<br />
reported detection lim<strong>its</strong> are 2 ppb for <strong>nickel</strong> <strong>carbonyl</strong> <strong>and</strong> 10 ppb<br />
for iron <strong>carbonyl</strong>.<br />
Their<br />
We have tested the atomic absorption spectroscopy method with<br />
carbon monoxide conta<strong>in</strong><strong>in</strong>g 44 ppb iron <strong>carbonyl</strong>, us<strong>in</strong>g a Perk<strong>in</strong>-Elmer<br />
303 spectrophotometer. The results was encourag<strong>in</strong>g with an estrimated<br />
detection limit of about 0.5 ppb. By optimiz<strong>in</strong>g the conditions, it<br />
should be possible to obta<strong>in</strong> a detection limit of about 0.1 ppb of<br />
iron <strong>carbonyl</strong> <strong>and</strong> similar or lower lim<strong>its</strong> for <strong>nickel</strong> <strong>carbonyl</strong>.<br />
method is ideally suited to carb~nyl reaction ratio studies, s<strong>in</strong>ce it<br />
affords an immediate response to changes <strong>in</strong> the concentration of metals<br />
<strong>in</strong> the gas. This is not possible for wet chemical methods, where one<br />
must collect rather large gas volumes per analysis (" 50 1 gas for a<br />
40 ppb iron <strong>carbonyl</strong> level, <strong>and</strong> correspond<strong>in</strong>gly larger volumes tor<br />
lower levels).<br />
Plasma chromatography probably is a much more sensitive method<br />
for the analysis of iron <strong>carbonyl</strong> than atomic absorption spectros-<br />
copy. However good atomic absorption spectrophotometers are com-<br />
This<br />
merclally readily available <strong>and</strong> require little time to put <strong>in</strong>to operation,<br />
whereas it would require a substantially longer time to establish<br />
plasma chromatography as an operative method for this project.<br />
Fourier transform <strong>in</strong>frared spectroscopy is not feasible for this<br />
project, both from the viewpo<strong>in</strong>t of time as well as cost. In addition,<br />
the method may not be suitable <strong>in</strong> this case because of <strong>in</strong>terference<br />
by the carbon monoxide.<br />
5. PREVENTION METHODS<br />
Very little direct <strong>in</strong><strong>formation</strong> exists <strong>in</strong> the literature about<br />
methods for prevent<strong>in</strong>g the <strong>formation</strong> of iron or <strong>nickel</strong> <strong>carbonyl</strong> from<br />
pipe <strong>steel</strong>s. The usual eng<strong>in</strong>eer<strong>in</strong>g solutions to the problem seem to
e either to use high-chromium <strong>steel</strong>s or to l<strong>in</strong>e the pip<strong>in</strong>g with a<br />
material that is <strong>in</strong>ert to the gas mixture <strong>and</strong> preveritis contact of<br />
CO with the metal.<br />
14<br />
Pichler <strong>and</strong> Walenda' mention the use of copper as l<strong>in</strong>ers. Perhaps<br />
more <strong>in</strong>teresti-mg is their observation that the attack oE carbon monoxide<br />
upon the <strong>steel</strong> see<strong>in</strong>s to be a pure surface area effect, with no special<br />
preference to gra<strong>in</strong> boundaries orientation of the gra<strong>in</strong>s, etc. This<br />
suggests that even a relatively noncoherent coat<strong>in</strong>g of a gas-resistant<br />
<strong>in</strong>aterial may substantially suppress the <strong>carbonyl</strong> <strong>formation</strong>, as the <strong>carbonyl</strong><br />
<strong>formation</strong> would be directlly proportional. to the area of the exTosed<br />
<strong>steel</strong> surface. For example, a chemi-cal treatment of the <strong>steel</strong> surface<br />
with a copper solution, say copper acetate, might cover the <strong>steel</strong>.<br />
surface to 99.9% os better with copper. In the case of a high--chromium<br />
<strong>steel</strong>, oxidation of the surface to form a coherent chromium oxide 1.ayer<br />
might prove very effective <strong>in</strong> prevent<strong>in</strong>g even trace 1.evels of <strong>carbonyl</strong>s<br />
from be<strong>in</strong>g formed.<br />
Clearly a nmiber of effective coat<strong>in</strong>gs can be envisioned, so<br />
that the deci-d<strong>in</strong>g factors presumably will be those of cost <strong>and</strong> lifetime.<br />
6. CONCLUSIONS<br />
Literature data demonstrate that the attack upon pipe <strong>steel</strong>s by<br />
carbon monoxide <strong>in</strong> gas mi-xtures at moderate pressures [l---lOOO atrm (0.1-100<br />
MPa)] <strong>and</strong> moderate temperatures (100-300°C) to form iron <strong>and</strong> <strong>nickel</strong><br />
<strong>carbonyl</strong>s are largely governed by k<strong>in</strong>etics <strong>and</strong> not by equilibrium<br />
thermodynamics. The rate of attack is a function of alloy cumposition,<br />
the surface condition of the metal surface, the gas composition, the<br />
gas flow rate, the gas pressure, <strong>and</strong> the temperature with a maximum at<br />
about 200°C<br />
Modern analytical <strong>in</strong>strumental techniques, such as plasma<br />
chromatography, Fourier transform <strong>in</strong>frared spectroscopy, <strong>and</strong> atomic<br />
absorption spectroscopy are all applicable for fast analysis of trace<br />
amounts of cnrlJonyls <strong>in</strong> gases. The most practical method for this project<br />
appears to be atomic absorption spectroscopy.
15<br />
7. REFERENCES<br />
1. GmeZ<strong>in</strong>s I~uusczbuch Der Anorganhehan Chemic?, Vol. 59, Fe [ B] , p. 490<br />
Verlag Chemic. GMBH. We<strong>in</strong>heimiBergstr.<br />
2. N. Irv<strong>in</strong>g Sax, Dangerous Frtipsrtz'es of Industria?, Materiu%s, 4th 2d.<br />
Van Nostr<strong>and</strong>-Re<strong>in</strong>hold, New York, (1975).<br />
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Crrman)<br />
4. A. G. Gilbert <strong>and</strong> K,G.P. Sulzmann, J. EZectr.ochem. Soe. 121: 832<br />
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5. L. Id, Ross, F. H. Haynie, i%nd R. F. Hochman J. Chem. Erg. Datcx<br />
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6. V. 6. Syrk<strong>in</strong>, liuss. J. Phys. Chm. 48(12): 1718 (1974) [Englifih<br />
translation from Zh. Fiz. Khim. 48: 2927 (1974).<br />
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(English translation: The John Crerar Library Photoduplicatlon<br />
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8. R. S,, Brief, R. S. Ajemian, <strong>and</strong> K, C. Confer Am. Twit. flyg. Ass. J.<br />
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9. I,. S. Cooper, A. B. Densham, <strong>and</strong> M. W. Tanner, Inst. Gas .Zngr. J.<br />
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10 ~ Gmel<strong>in</strong>s<br />
Hcndbueh Der Anorganischen Chemie, Vol. 57, Ni [ R] p .794<br />
Verlag Chemic. GHBH. We-<strong>in</strong>heim/Bergstr, 1966.<br />
11. I(. A. Walsh, Physieul, Properties of nr-iekez Carbony?,, U,S. Atom-ic<br />
Energy Commission, Fubl. LA-1649 [1953/58].<br />
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13. A. Ya Kipiiis <strong>and</strong> N. F. Mikhailova Zh. PKkZ. Kh-im. 45:1450 (1972)<br />
(English translation: UDC 546. 745: 541. 124.16, 1972 Consultants<br />
Bureau).<br />
14. B. E. Roscoe <strong>and</strong> F. Scudder, Rer. Dtsch. Ckm. Gas. 24: 3843 (1891)-<br />
15. A. Stoffel, Z. Anorg. Allgem. C"nem. 84: 56 (1914).<br />
1.6. R. L. Mond <strong>and</strong> A. E. Wallis, J. Chmz. SOC,, London, 121.: 29 (1922).<br />
17. A. Mittasch, z. Angeld. &?m. 41: 827 (1928).
18. W. IIieber <strong>and</strong> 0. Geisenberger, Z. Anorg. Cl&rn~ 262: 1.5 (1950).<br />
(In German).<br />
19. K. H. Ludlum <strong>and</strong> R. P. Eischens sur, sei. 40: 397 (1973).<br />
20. R. %. Wernlund <strong>and</strong> M. J. Cohen Res./Dev. 26(7): 32--35 (1975).<br />
21.. R. S. McDowell, Am. Id. fltjg. Ass. J. 32: 621 (1971).<br />
16<br />
22. R. S. Brief, %. S. Venable, <strong>and</strong> R. S. Ajenian, <strong>in</strong>d. Hyg. J.<br />
26: 72 (1965).<br />
23. A. B. Densham, P.A.A. Bea1.e <strong>and</strong> R. Palmer, J. AppZ. Cherfl. (London)<br />
13: 576 (1963).
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