Integrated data reconciliation with generic model control for the steel pickling process

To implement an advanced control algorithm, measurements of process outputs are usually used to determine control action to a process. Nevertheless, measurements of process outputs are often subjected to measuring and signal errors as well as noise. Therefore, in this work, Generic Model Control (GMC), an advanced control technique, with data reconciliation technique has been applied to control the pH of the pickling process consisting of three pickling and three rinsing baths. Here, the data reconciliation problem involves six nodes and fourteen streams. The presence of errors in the data set is determined and identified via measurement test, In addition, the measurement error covariance is initially assumed to be a known variance matrix and is updated every iteration. Simulation results have shown that the reconciled process data give a better view of the true states of the process than raw measuring data. With these reconciled process data, the GMC controller can control the process at a desired set point with great success.     

Cationic gemini surfactant as corrosion inhibitor for mild steel in 1 M HCl and synergistic effect of organic salt (sodium tosylate)

Synergistic result of cationic gemini surfactant (GS) 1,2-bis(N-hexadecyl-N,N-dimethylammonium) ethane dibromide (16-2-16) and organic salt (Sodium tosylate; NaTos) on mild steel corrosion in 1?M HCl solution at various temperatures (30, 40, 50 and 60?°C) has been examined using gravimetric, electrochemical and surface morphology measurement. Investigational result shows that the inhibition efficiency (η) of 16-2-16 GS enhanced in the existence of a set quantity of NaTos. The synergism parameter (S_θ) values are larger than unity, representing large inhibition efficiency, generated via the accumulation of NaTos to 16-2-16 GS is owing to adsorption supportive. The electrochemical results revealed that the 16-2-16 GS in the absence and presence of NaTos act as mixed-type inhibitors. The inhibitor adsorption on the mild steel surface in 1?M HCl solution obeys Langmuir adsorption isotherm. Surface morphology was studied using scanning electron microscopy (SEM).     

Synergistic inhibition between the gemini surfactant and bromide ion for steel corrosion in sulphuric acid

The inhibitive synergistic effect between a cationic gemini surfactant, 1,3-propane-bis(dimethyl dodecylammonium bromide) (12-3-12), and bromide ion for the corrosion inhibition of cold rolled steel in 0.5 mol L⁻¹ H₂SO₄ was investigated by weight loss, potentiodynamic polarization method and electrochemical impedance spectroscopy (EIS). The inhibition system composed by 12-3-12 and bromide ion is efficient. The adsorption mechanism of the 12-3-12 and bromide ion on steel in acidic medium is discussed on the basis of experimental data and an adsorption model is proposed. Adsorption of inhibitor system on the mild steel surface in acidic medium obeys Langmuir’s adsorption isotherm. In addition, potentiodynamic polarization studies show that the system acts as a mixed-type inhibitor. Electrochemical impedance spectroscopy also suggests the formation of a protective layer on the steel surface by the adsorption of surfactant molecules and bromide ions.     

Novel Synthesized Gemini Surfactant as Corrosion Inhibitor for Carbon Steel in HCl Solution

A quaternary ammonium gemini surfactant containing an ester spacer, namely (diethylhexanedioate)diyl‐α,ω‐bis(dimethyl myristyl ammonium bromide) ( 14‐DEHA‐14 ) was synthesized using a two‐step procedure with dimethyl hexanedioate, dimethylaminoethanol, and 1‐bromotetradecane. The chemical structure of the compound was confirmed by infrared (IR) spectrum, ¹H nuclear magnetic resonance (NMR), and elemental analysis. The critical micelle concentration was determined by conductivity and tensiometry measurements, and its inhibition effect on corrosion of carbon steel in dilute (1.0 M) hydrochloric acid solution was investigated by weight loss measurements. The results show that the synthesized gemini surfactant acts as an excellent corrosion inhibitor in 1.0 M HCl solution. The adsorption of the inhibitor via chemical adsorption onto the carbon steel surface obeyed the Langmuir adsorption isotherm. A possible corrosion mechanism of the compound is discussed in relation to the calculated thermodynamic parameters and adsorption isotherm.     

复合盐酸酸洗液在钢丝热镀锌生产中的应用

常温盐酸酸洗能耗小,对钢丝基体腐蚀性小,酸雾少,但去除铁锈和氧化皮速度较慢。盐酸酸洗液浓度较高时,酸雾逸出多,给生产环境造成了污染;同时对钢丝基体造成过腐蚀,易形成钢丝氢脆现象。在试验的基础上,优选出一种常温复合盐酸除锈酸洗液配方及浓度控制范围。生产使用结果表明,添加TX-10、SLS活性剂,含羧酸有机添加剂和磷酸都有利于提高酸洗速度,同时起到了抑制酸雾的逸出及其对钢丝的过腐蚀作用。     

Preparation of a salt-responsive Gemini viscoelastic surfactant for application to solids-free drilling fluids

In order to solve the problem of poor rheological properties of solid-free drilling fluids in salt-bearing formations and prevent drilling accidents such as lost circulation, formation collapse, and wellbore instability, it is crucial to develop a new type of viscosifier. In this study, a salt-responsive Gemini viscoelastic surfactant (NT-1) was synthesized by using erucamide as a hydrophobic chain and introducing a benzene ring and a carboxyl group into the linker. In addition, it is used as a viscosifier for solid-free drilling fluids. The structure of the surfactant was characterized by ¹H nuclear magnetic resonance (NMR), ¹³C NMR, Fourier transform infrared spectroscopy, and electrospray ionization tandem mass spectrometry (ESI-MS), and its physicochemical properties were determined by surface tensiometer, thermogravimetric-differential scanning calorimetry, dynamic lighting scattering and rheometer. Its performance in solid-free drilling fluids was evaluated according to the American Petroleum Institute (API) standard. The results show that the surfactant has a low critical micelle concentration (31.74 μmol/L), excellent thermal stability and water solubility. In particular, NT-1 can self-assemble into worm-like micelles under the action of salt, and the spatial network structure formed by the interweaving of these micelles can endow the drilling fluid with good rheology and viscoelasticity. NT-1 is compatible with conventional drilling fluid polymer additives, which can effectively improve solid-free drilling fluids' rheological properties and fluid loss properties in salt layers. The temperature resistance in drilling fluid systems can reach 120°C. This work verifies the feasibility of using viscoelastic surfactants as viscosifiers in solid-free drilling fluids and provides new ideas for developing salt-responsive smart drilling fluids.     

新型磺酸基Gemini表面活性剂的合成及其在油气井中的应用性能

以油酸酰胺丙基叔胺、3-氯-2-羟基丙磺酸钠和1,4-二溴丁烷为原料,通过两步反应合成了一种甜菜碱双子表面活性剂B18-4-18,通过傅里叶变换红外光谱仪和核磁共振波谱仪对合成产物进行了结构表征,用表面张力仪测定不同浓度下的双子表面活性剂（B18-4-18）的表面张力,用携液率装置测定了其在清水中、矿化水中、凝析油溶液中、甲醇溶液中的携液率,用罗氏泡高仪测定不同类型表面活性剂的泡沫高度。结果表明：合成产物与预期目标产物结构一致,在25℃时,B18-4-18的临界胶束浓度CMC为5.0×10^-6mol/L,相应的表面张力γ_cmc为31.67mN/m;质量分数为0.5%的B18-4-18在清水、矿化水、凝析油溶液、甲醇溶液中的最高携液率分别可以达到90%、87%、78%、87%;对比不同的表面活性剂的泡沫性能,优选出在泡沫酸中使用最佳的起泡剂为B18-4-18。     

Experimental investigation of methyl tert-butyl ether dissolution in saturated porous media

This study aims to investigate methyl tert-butyl ether (MTBE) dissolution in saturated porous media. A series of 1D columnexperimentswere conducted in laboratory to obtain MTBE dissolution datawith different groundwater velocity, initial MTBE saturation and grain size of porous medium, and in the presence of other nonaqueous liquids. Results indicate that higher groundwater velocity increases MTBE dissolution rate and higher initial MTBE saturation reduces effective permeability to slow MTBE dissolution rate. Smaller grain size medium gives higher MTBE dissolution rate because of higher permeability. The addition of trichloroethylene enhances MTBE dissolution, with an optimal mass ratio of 10:2, while the presence of p-xylene prolongs complete dissolution of MTBE. Mass transfer correlations are developed for MTBE dissolution rate based on the degree of MTBE saturation Sn. Mass transfer rate is characterized by Re' with a high exponent for 0.3000 b Sn b 0.5482, while it is related to medium grain size and Sn for Sn ≤ 0.3000.     

EIS investigation of zinc dissolution in aerated sulphate medium. Part II: zinc coatings

The kinetics of anodic dissolution and corrosion of zinc coatings deposited onto steel sheet either by electrodeposition or by hot dipping are investigated by electrochemical impedance spectroscopy in aerated sulfate medium. The results are compared with those obtained previously on pure bulk zinc and interpreted on the basis of the model derived in the first part of this paper. It is shown that zinc coatings are less sensitive to corrosion than pure bulk zinc and changes of their behavior with time are not identical. Important differences are observed between the various coatings in the respective contributions of the three parallel paths of the dissolution process. Three kinds of oxidation products were identified by Raman spectroscopy. A compact non-stoichiometric zinc oxide was formed by surface reaction on zinc. Above it, a thick and porous layer made of zinc hydroxi-sulfate and stoichiometric ZnO, was formed by precipitation from a local saturation of the solution. A strong correlation was evidenced between the oxidation products and the various paths of the reaction model. It was assumed that the impurities, initially present in the metal, may affect the interfacial reactions, the increase of the micro-roughness, and may also reinforce the protective properties of oxidation product layers. The differences between the various zinc coating behaviors result mainly from their impurities. Their crystal preferred orientations have no significant influence.     

Novel Amide-Based Cationic Surfactants as Efficient Corrosion Inhibitors for Carbon Steel in HCl and H2SO4 media

A variety of surface active compounds were synthesized by the quaternization of some straight chain amide derivatives with triethylamine or pyridine. Their structure FT-IR and ¹H-NMR spectra were recorded. In addition their physical properties and corrosion prevention efficiencies were investigated. All compounds were tested with steel coupons in acidic media by the gravimetric method. As acidic media 1.5 M HCl and 1.5 M H₂SO₄ were used and the corrosion inhibition tests fulfilled at room temperature for 24 h. Almost all prepared cationic surfactants showed efficient inhibition around their critical micelle concentrations. The effects of HCl concentration on corrosion inhibition of some synthesized compounds were also investigated. The corrosion tests were supported by contact angle measurements.     

Corrosion protection of 1Cr18Ni9Ti stainless steel by polypyrrole coatings in HCl aqueous solution

Electrically conducting polypyrrole (Ppy) coatings doped with sodium dodecylsulfate (SDS) have been deposited on 1Cr18Ni9Ti stainless steel by anodic polymerization from aqueous solutions of pyrrole and sodium dodecylsulfate. The corrosion behavior of Ppy coated steel was investigated in 0.3 M HCl aqueous solution at room temperature by a combination of electrochemical measurement techniques and scanning electron microscopy. The steel is in active state at the open circuit potential and suffers from pitting corrosion when the polarization potential is higher than 210 mV versus SCE. The Ppy coating can increase the corrosion potential of the steel by more than 600 mV versus SCE, and the pitting corrosion potential by more than 500 mV versus SCE. Fifty-day exposure experiments indicated that the Ppy coating shows high stability, and can inhibit effectively the corrosion of the steel.     

奥氏体不锈钢在Cl~-介质中应力腐蚀研究

评述了奥氏体不锈钢在氯化物介质中应力腐蚀开裂。从环境、冶金和力学等方面论述了ＳＣＣ的主要因素,综合论述了控制奥氏体不锈钢ＳＣＣ的工程参量和安全评定的方法。提出了预防奥氏体不锈钢应力腐蚀的一些措施。     

Acetyl thiourea chitosan as an eco-friendly inhibitor for mild steel in sulphuric acid medium

Acetyl thiourea chitosan polymer (ATUCS) has been synthesized and evaluated as corrosion inhibitor. The electrochemical behavior of mild steel in naturally aerated 0.5 M H₂SO₄ acid containing different concentrations of ATUCS has been studied by potentiodynamic polarization, electrochemical impedance spectroscopy (EIS) measurements and surface examination via scanning electron microscope (SEM) technique. The results of EIS showed that the resistance (R_t) increases slightly with increasing immersion time indicating a slight decrease in corrosion rate of the steel with time. Also, the corrosion rate increases with either increasing temperature or decreasing the polymer concentration as observed by polarization technique. Electrochemical impedance spectroscopy measurements under open-circuit conditions confirmed well polarization results. ATUCS has shown very good inhibition efficiency (IE) in 0.5 M sulphuric acid solution reaches to 94.5% for 0.76 mM concentration. IE of this compound has been found to vary with the concentration of the polymer solution, immersion time and temperature.     

Carboxymethylchitosan + Cu mixture as an inhibitor used for mild steel in 1 M HCl

The inhibition effect of Carboxymethylchitosan (CMCT), Cu²⁺, and CMCT + Cu²⁺ mixture on the corrosion of mild steel in 1 M HCl has been investigated using gravimetric and electrochemical techniques. CMCT + Cu²⁺ mixture acts much more effectively than the inhibiting action of each additive separately. In addition, higher efficiency is achieved for the mixture of 20 mg L⁻¹ CMCT + 10⁻⁴ M Cu²⁺. The efficiency of the optimal mixture increases with the temperature in the range 298-353 K. Activation energy of corrosion reaction in the presence of the optimal mixture of the inhibitors is much lower than that exhibited in 1 M HCl solution. The inhibition mechanism proposed in this paper is based on the results of conductometric investigations.     

Inhibition of mild steel corrosion in acidic medium using starch and surfactants additives

The corrosion inhibition of mild steel in 0.1M H₂SO₄ in presence of starch (polysaccharide) was studied using weight loss and potentiodynamic polarization measurements in the temperature range of 30–60°C. Starch inhibits the corrosion rates of mild steel to a considerable extent; the maximum inhibition efficiency (%IE) being 66.21% at 30^oC in presence of starch concentration of 200 ppm. The effect of the addition of very small concentration of sodium dodecyl sulfate and cetyl trimethyl ammonium bromide on the corrosion inhibition behavior of starch was also studied. The IE of starch significantly improved in presence of both the surfactants. The effect of surfactants on the corrosion inhibition behavior of starch appears to be synergistic in nature. Starch alone and in combination with surfactants is found to obey Langmuir adsorption isotherm from the fit of the experimental data of all concentration and temperature studied. Phenomenon of physical adsorption is proposed from the trend of IE with temperature and also the values E_a, ΔG_ads, and Q_ads obtained. The results obtained by potentiodynamic polarization measurements are consistent with the results of the weight loss measurement. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

Application of an improved testing device for the study of alumina dissolution in silicate slag

This study entailed a dissolution study of alumina fine ceramics in a CaO–Al₂O₃–SiO₂–MgO silicate slag system with a CaO/SiO₂ weight ratio of 0.65. Finger-test experiments with several corrosion steps were carried out in a contemporary continuous wear testing device at 1450, 1500, and 1550 °C with 200 rpm. The corroded sample profiles were measured using a high-resolution laser scanner, and the processed measurement data were used to extract the dissolution parameters (i.e. corroded volume, surface area, mean radius, tip radius and immersion length). The diffusivity determination method using Sherwood relations was developed for the dynamic finger-test setup. The diffusivities for all corrosion steps were determined from these dissolution parameters, and those obtained from the Sherwood relations were compared with the ones received by a simulation approach that includes deviations from the cylindrical shape. The results obtained using Sherwood relations are sufficiently accurate in several cases.     

关于炼钢用耐火材料优化的几个问题

概述了现代炼钢生产发展与优化的主要特点。为适应这些发展特点的要求 ,提出了耐火材料向“更长寿、无污染、功能化”方向发展的必要性观点