SilcoTek Corporation Coatings for inertness and corrosion resistance

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SilcoTek CorporationCoatings for inertness and
corrosion resistance

• Information, Questions and where coatings are
  being used

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Topics

• Vision
• Questions
• The process and the coating
• Products and Applications
• Conclusion/Future Product Development

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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.

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Questions

• What is the maximum tubing length that you can
  work with
• 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

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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? Were 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 were focused

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Questions

• What is new with your company since the last time
  you visited us?
• Weve 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

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Questions

• Where do you see industry going with these
  special materials and processes?
• As the need for knowing whats in streams
  increases, there will be more demand
• 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

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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

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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

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• MARKET AREAS

• APPLICATION AREAS
• SilcoNert Inertness (Silcosteel,
  Sulfinert/Siltek)
• Sulfinert SilcoNert 2000
• Silcolloy Anti-Corrosion (Silcosteel-CR)
• SilcoKlean Anti-Coking (Silcosteel-AC)
• SilcoGuard Ultra-High Vacuum (Silcosteel-UHV)

Analytical Pharmaceutical Environmental
Petrochemical Chemical Process
Semiconductor/Research
Automotive
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Brand Names

• SilcoNert 2000
• Used to be Sulfinert and Siltek
• SilcoNert 1000
• Used to be Silcosteel
• Silcolloy 1000
• Used to be Silcosteel-CR

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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

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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

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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-per-billion of
  hydrogen sulfide

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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

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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

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Substrates Which Coat Well

• 300 and 400 grade stainless steel
• High carbon steel
• Titanium
• Ceramics
• Borosilicate glass
• Inconel
• Hastelloy

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Substrates with Issues

• Nickel / Nickel plating
• Aluminum
• Monel
• Copper
• Brass
• Gold and Silver plated components
• Chrome Plated components
• Magnesium
• Elastomers
• No Bases!
• heat-dependent

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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

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SilcoNert 2000 surface improves storage

• Reduces adsorption effects
• Improves analytical reliability
• Faster cycle times and
• increased accuracy
• 17ppbv H2S Containment in 500ml Cylinders

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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

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Effectiveness of coated transfer systems to
reduce hold-up Methyl Mercaptan
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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

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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.

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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. 70F
• Test Cycle Day 0,7,19,50
• Direct Interface Gas Sampling
• Atomic Absorption Detector
• SilcoNert 2000 treated Regulator and Tubing

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Mercury 50 Day StabilityChemisorption greatly
reduced
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Comparison of Hg Stability in 304SS vs.SilcoNert
2000 Coated Cylinders

Test Day Avg response Loss vs. Day 0 Avg response Loss vs. Day 0
  304 SS cylinders   Functionalized  
  ug/m3   Silicon ug/m3  
0 5.65 - 6.45 -
7 3.25 42 6.1 5
19 2.05 64 6 7
50 1 82 5.8 10
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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

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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)

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Wet-Up 50 faster response
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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

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Dry-Down 50 faster response
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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

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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

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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

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SilcolloyCorrosion 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)

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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)

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ASTM G48 B Data Pitting and Crevice Corrosion

• 6 Ferric Chloride solution
• 72hrs, 20ºC
• Gasket wrap

Sample Initial Weight (g) Final Weight (g) Weight Loss (g) Weight Loss (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
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ASTM G48 B (cont.)

• Bare 316L Stainless Steel coupon (left) showing
  severe crevice corrosion. Coated coupon shows
  light pitting

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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

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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

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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

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SilcoKlean Anti-Coking Data

• Semih Eser PSU Prof. Fuel Sciences
• 8x improvement over raw 316L

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SilcoKlean Advantages

• High temperature stability up to 1000c
• Thin layer does not impact tolerances
• Reduce fouling improves machine reliability
• Extend maintenance cycles improved up time
• Improved component performance without material
  or design change

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SilcoKlean Applications

• Aerospace
• Coating fuel nozzles to decrease buildup
• Coating lubrication systems to decrease
  maintenance
• Chemical/Petrochemical
• Increasing lifetimes of Ethylene and Propylene
  Plug Flow reactors
• Reduces fouling in heat exchangers
• Automotive/Heavy Equipment/Trucking
• Reduce fouling in gasoline/diesel EGR systems
• Reduce fouling in diesel turbo systems

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SilcoGuard

• Ultra-High-Vacuum (UHV) environments are
  characterized as having a vacuum of 1x10-7 Torr
  or better
• Materials trapped to the surface of and inside
  the steel outgas into the vacuum environment.
• Outgassing of material increases pressure in the
  environment (directly related to dry down data)
• Large pumps and long pump down times are
  required to achieve UHV environments
• SilcoGuard treatment produces a barrier that
  blocks materials from outgassing into the vacuum
  environment.

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Comparative Evacuation Rates
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SilcoGuard Advantages

• Consistently outperforms cleaned parts for
  ability to pump down faster No need to clean
• Eliminates bake out of components as received
  from manufacturer
• Ability to achieve lower base pressure with
  smaller pumps
• Faster process cycle time vs. uncoated systems
• Superior high temperature stability up to 600c

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SilcoGuard Applications

• University/Research
• Coating of accelerator chambers to create higher
  vacuum environment
• Semiconductor
• Use in coating of semi-conductor manufacturing
  equipment to decrease defect rate
• Analytical
• Reduce time needed to achieve high vacuum
  environments in analytical equipment (SEM, XPS,
  etc.,.)
• Manufacturing
• Reduce cycle time of vacuum pass-through chambers

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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!