Prediction of metal dusting attack by multi-scale simulation

In the chemical industry, aggressive corrosion known as “metal dusting” is a major factor that negatively impacts process efficiency, plant safety, and resource utilization. Metal dusting occurs at temperatures between 400 and 800 °C in carbon-rich gas mixtures. To avoid the attack, the process gas is often cooled down very quickly and inefficiently, or the components at risk are replaced as a precautionary measure, even if they are still functional. One of the main problems is that it has not yet been possible to accurately predict the occurrence of metal dusting.

The aim of this project is to develop a simulation model to better predict metal dusting attacks. To do this, the processes in the gas, such as reactions and flow, must be linked to those in the components (in the material), such as diffusion in solids, using reaction kinetics models.

This allows not only possible reactions to be described realistically, but also their speed. Combined with extensive material databases and proven equilibrium software, this results in a novel modeling approach. To verify the predictions, the modeling is supported by validation experiments.

The new modeling approach opens up the possibility of mapping complex processes in which gas-solid reactions and transport processes are crucially interlinked. This allows not only corrosion phenomena but also other high-temperature processes in chemistry, energy, and materials engineering, right through to semiconductor manufacturing, to be simulated more reliably. The success is reflected in more accurate predictions, higher efficiency, and better use of resources.