S-TEN

Technical Document
TM
Sulfuric Acid and Hydrochloric Acid
Dew-point Corrosion-resistant Steel
Features
SS-TEN is a sulfuric acid and hydrochloric acid
dew-point corrosion-resistant steel developed by
Nippon Steel using proprietary technology.
S-TEN exhibits the best resistance to sulfuric acid and hydrochloric acid
dew-point corrosion found in the flue-gas treatment equipment used with
coal-fired boilers, waste incineration plants, etc. (This steel has the finest
application record in the field of thermal power generation and waste
incineration plants, according to surveys conducted by Nippon Steel)
S-TEN exhibits the best resistance to sulfuric acid and hydrochloric
acid dew-point corrosion found in hydrochloric acid pickling, industri-
al sulfuric acid and other tanks.
SS-TEN has strength, workability and weldability
that are comparable to ordinary steel.
SS-TEN is more economical than stainless steel.
SS-TEN of fers a rich product line ranging from hot-
rolled sheets (plates), cold-rolled sheets and pipe
and tubes to welding materials.
Hot-rolled sheets (plates) conform to JIS G 3106 SM400A (S-TEN 1)
and SM490A (S-TEN 2).
SS-TEN products are easily available because they
are constantly stocked by retailers.
CONTENTS
1. Characteristics of S-TEN
Sulfuric Acid and Hydrochloric Acid Dew-point Corrosion 1
Sulfuric Acid Dew-point Corrosion 2
Advantages of S-TEN 3
Examinations in Applying S-TEN 4
Application Examples for S-TEN 7
Precautions in the Use of S-TEN 8
Field Test Results of S-TEN 8
2. Specifications and Available Sizes of S-TEN
Specifications of S-TEN 12
Available Sizes for S-TEN 13
3. Characteristic Properties of S-TEN (Examples)
Chemical Composition and Mechanical Properties 14
High-Temperature Characteristics 14
Physical Properties 15
Corrosion Resistance 15
4. Welding of S-TEN
Welding Materials 17
Welding Characteristics 18
Sulfuric Acid and Hydrochloric Acid Resistance of Welded Joints 19
Galvanic Corrosion in Corrosive Atmosphere 20
Property Qualification Test Results 20
5. Application Examples 21
Hydrochloric acid Sulfuric acid
Chlorides
Heavy-oil firing Hydrochloric acid

Coal firing
Waste incineration



Excellent
Notice: While every effort has been made to ensure the accuracy of the information contained within this publication, the use of the information is
at the readers risk and no warranty is implied or expressed by Nippon Steel Corporation with respect to the use of information contained herein.
The information in this publication is subject to change or modification without notice. Please contact the Nippon Steel office for the latest information.
S-TEN
Technical Document

Sulfuric Acid and Hydrochloric Acid

Dew-point Corrosion-resistant Steel
1
Flue-gas temperature
130150C
1. Characteristics of S
-
TEN
Recently, environmental issues are becoming pressing concerns. In parallel with this,
construction of tall smokestacks, air preheaters, electrostatic precipitators and flue-gas
desulfurizers and other treatment equipment has shown great strides.
Meanwhile, the mainstay industrial fuel has shifted from conventional coal to heavy
oil, which poses a large problem of corrosion at the low-temperature section of flue-
gas treatment equipment (in particular, air preheaters, flues and smokestacks) due to
sulfur oxides.
The low-temperature section corrosion is the corrosion caused by high-
temperature, highly-concentrated sulfuric acid, called sulfuric acid dew-point corro-
sion. This kind of corrosion differs from general atmospheric corrosion and causes
heavy corrosion of not only ordinary steel but even stainless steel.
Further, because of the remarkable technological developments recently seen in
dioxin countermeasures, flue-gas temperatures are increasingly being reduced from
previous levels.
In conventional facilities where, formerly, only sulfuric acid dew-point corrosion
occurred, there are now cases of hydrochloric acid dew-point corrosion that is caused
by lower flue-gas temperatures resulting from remodeling with countermeasures
against dioxins.
Developed to solve these problems is S-TEN steel for welded structures, highly
resistant to sulfuric acid and hydrochloric acid dew-point corrosion.
Flue-gas temperature
180C
136C
72C
Rapid cooling and lowering
of temperature of flue gas
for reducing dioxins
Sulfuric Acid and Hydro-
chloric Acid Dew-point
Corrosion
Fig. 1.1 Waste Incineration Facility: Mechanism of Sulfuric
Acid and Hydrochloric Acid Dew-point Corrosion
Occurring in Flue-gas Treatment System
Photo 1.1 Example of Hydrochloric Acid Dew-point Corrosion
in Internal Cylinder of Stack
High
Low
S
t
e
e
l

p
l
a
t
e

s
u
r
f
a
c
e

t
e
m
p
e
r
a
t
u
r
e
C
o
n
v
e
n
t
i
o
n
a
l

f
l
u
e
-
g
a
s

t
r
e
a
t
m
e
n
t

e
q
u
i
p
m
e
n
t
C
o
n
d
e
n
s
a
-
t
i
o
n

o
f

h
y
d
r
o
-
c
h
l
o
r
i
c

a
c
i
d
C
o
n
d
e
n
s
a
t
i
o
n

o
f

s
u
l
f
u
r
i
c

a
c
i
d
Occurrence of
hydrochloric acid
dew-point corrosion!
Occurrence of
sulfuric acid dew-
point corrosion!
R
e
c
e
n
t

f
l
u
e
-
g
a
s

t
r
e
a
t
-
m
e
n
t

e
q
u
i
p
m
e
n
t
In the case of flue-gas composition (SO3: 6 ppm, HCR: 300 ppm, H2O: 30%)
3 2
1. Characteristics of S-TEN 1. Characteristics of S-TEN
Fig. 1.2 Relation between Sulfur Content and SO2 Content in
Combustion Gas
Fig. 1.4 Relation between SO3 Content in Combustion Gas
and Dew Point
Fig. 1.5 Relation between Wall Surface Temperature and
Sulfuric Acid Concentration
Fig. 1.3 Relation between Sulfur Content in Fuel and SO2 to
SO3 Conversion Rate
Sulfuric Acid Dew-point Corrosion
Because sulfur is contained in heavy oil used as fuel, combus-
tion of heavy oil generates sulfur oxides (SOx), an extremely
small portion of which becomes SO3.
Fig. 1.2 shows the relation between the sulfur content of
fuel and the amount of SO2 generated, and Fig. 1.3 the conver-
sion rate from SO2 to SO3. When high-sulfur heavy oil contain-
ing about 3% sulfur is burnt, about 0.15% SO2 is generated
(Fig. 1.2), about 2% or about 30 ppm of which becomes SO3
(Fig. 1.3).
When the flue gas temperature reaches the dew point or
lower or the gas contacts the lower-temperature wall surface,
SO3 and H2O in the gas combine to produce highly-
concentrated sulfuric acid.
Fig. 1.4 shows the relation between the SO3 inclusion and
the dew point in the case of 10% of H2O concentration in the
gas (normal heavy-oil combustion gas).
In the case of about 30 ppm of SO3 inclusion, the dew
point reaches 130150C, and at a temperature below this
level sulfuric acid dew-point corrosion occurs.
Fig. 1.5 shows the relation between the gas or wall surface
temperature at the time of dew condensation and the sulfuric
acid concentration. Sulfuric acid with a maximum concentra-
tion of 80% is produced.
Advantages of S-TEN
Ordinary or stainless steel cannot be used in applications in
which sulfuric acid dew-point corrosion is a governing factor.
Neither can weathering steels such as COR-TEN

provide satis-
factory performance in these applications.
The material appropriate for these applications is S-TEN.
Fig. 1.6 shows the results of sulfuric acid immersion tests
conducted under the conditions of temperature and concentra-
tion obtained from Fig. 1.5.
Extremely severe corrosion occurs under the conditions of
70C and 50% H2SO4. However, under such conditions, S-TEN
exhibits corrosion resistance about five times greater than both
ordinary steel and COR-TEN and about 10 times that of stain-
less steel. It is in such severe application environments that
S-TEN shows the best performance.
In this way, corrosion caused by high-temperature, highly
concentrated sulfuric acid differs from common atmospheric
corrosion. Not only ordinary steel but stainless steel, as well, is
heavily corroded in environments of high-temperature, highly
concentrated sulfuric acid (in some cases, exceeding a corro-
sion rate of 5 mm/year).
Fig. 1.7 shows the clear differences in corrosion resistance
demonstrated by ordinary steel, COR-TEN, and S-TEN during
long-term tests conducted in actual 60% H2SO4 or higher envi-
ronments at 80C with sufficient oxygen to produce sulfuric
acid dew-point corrosion.
Fig. 1.6 Sulfuric Acid Immersion Test Results under the
Atmosphere-solution Equilibrium State of Sulfuric
Acid and Hydrogen Fig. 1.7 Corrosion Mass of Steel in H2SO4
Grade
(equivalent)
SUS 410 (13%Cr) (equivalent)
SUS 430 (18%Cr) (equivalent)
SUS 304 (18Cr-8Ni) (equivalent)
SUS 316 (18Cr-12Ni-2Mo) (equivalent)
SS 400
S-TEN 1
S-TEN 2
COR-TEN O
C
0.10
0.07
0.08
0.08
0.16
0.03
0.10
0.09
Si
0.38
0.51
0.58
0.68
0.03
0.28
0.21
0.46
Mn
0.46
0.34
1.42
1.62
0.23
0.91
0.75
0.38
P
0.019
0.040
0.029
0.030
0.008
0.011
0.014
0.110
S
0.012
0.006
0.008
0.008
0.013
0.009
0.012
0.017
Cu
0.12
0.11
0.20
0.24
0.08
0.27
0.36
0.32
Ni
0.19
0.27
9.21
11.72

0.30
Cr
12.53
17.29
18.56
17.05

0.63
0.52
Sb

0.10

Others

Mo: 2.20

Ti : 0.04

Chemical composition (%)

Table 1.1 Chemical Composition of Test Specimens
180
0.01 0.10 1.0 10 100 1,000
200
220
240
260
280
300
320
340
360
380
400
420
D
e
w

p
o
i
n
t

(

F
)
SO3 content (ppm)
S content (vol%)
S
O
2
+
S
O
3
(
%
)
S
O
3
0 1 2 3 4 5
0
2
4
6











0
20
40 60 80 100 120 140 160
60
80
100
40
Wall surface temperature (C)
S
u
l
f
u
r
i
c

a
c
i
d

c
o
n
c
e
n
t
r
a
t
i
o
n

(
%
)
0
0 1 2 3 4 5
0.1
0.2
0.3
S
O
2

(
%
)
S content (vol%)
0
2
4
6
8
O
2

(
%
)


0
20 40 60 80 100
200
400
600
SUS 430
SUS 410
SUS 304
SUS 316
S-TEN 1
S-TEN 2
C
o
r
r
o
s
i
o
n

m
a
s
s

(
m
g
/
c
m
2
)
Test hours (hrs)
SS 400
COR-TEN O
0
10
20
30
40
50
60
70
80
90
100
150
200
250
C
o
r
r
o
s
i
o
n

r
a
t
e

(
m
g
/
c
m
2
/
h
r
s
)
20
10
40
20
60
40
70
50
80
60
100
70
120
75
140
80
Temperature (C)
H2SO4 concentration (%)
Rotating immersion tests
Test specimen speed32.8 m/min.
Testing conditions Temperature125C
Concentration75%
H2O10%
(150C)
(100C)
(200C)







SUS 430
SUS 410
SUS 304
SS 400
SUS 316
COR-TEN O
(6 hours)
S-TEN 1
S-TEN 2
13 12
2. Specifications and Available Sizes of S-TEN
Table 2.1
Table 2.2
Table 2.3 Cold-rolled Sheets and Bars
2. Specifications and Available Sizes of S-TEN
Specifications of S-TEN 1 Grade Designation
Grade designations are shown in Table 2.1.
2 Chemical Composition
The chemical composition is determined by ladle analysis as shown in Table 2.2.
3 Mechanical Properties
Grade
S-TEN 1
S-TEN 2
Product
Cold-rolled sheet
Hot-rolled sheet and plate
1)

ERW pipe and tube
2)

Large-diameter pipe
Cold-rolled sheet
Hot-rolled sheet and plate
1)

Bar and bar-in-coil
Thickness diameter(mm)
0.6t 2.3
1.6t 20
Outside dia.: 19.0114.3 Wall thickness: 2.08.9
Outside dia.: 4002,500 Wall thickness: 6.020
0.6t 2.3
2.0t 20
t 38

Grade
S-TEN 1
S-TEN 2

C
0.14
0.14

Si
0.55
0.150.55

Mn
1.60
1)

1.60

P
0.025
0.035

S
0.025
0.035

Cu
0.250.50
0.250.50

Cr

0.501.00

Sb
0.15

Ti

0.15
Chemical composition (%)

Grade
S-TEN 1
S-TEN 2
Yield point
(N/mm
2
)
235
325
Elongation
(%)
23
22
Thickness
(mm)


Test specimen
(JIS)
No. 5
No. 5
1)

Tensile strength
(N/mm
2
)
400
440
Note) Bars: No. 2 for the diameters 25 mm or less; No. 14A for the diameters more than 25 mm

Grade
S-TEN 1
S-TEN 2
Yield point
(N/mm
2
)
245
235
325
315
Elongation
(%)
23
23
18
23
22
22
22
17
22
21
Thickness
(mm)
5
16

20.2
5
16

20.2

Test specimen
(JIS)
No. 5
No. 5
No. 1A
1)

No. 5
No. 1A
1)

No. 5
No. 5
No. 1A
1)

No. 5
No. 1A
1)

Tensile strength
(N/mm
2
)
400510


490610


Note) Applied in the case of production as JIS G 3106 (applied in all production of plates)
Table 2.5 ERW Pipes and Tubes

Grade
S-TEN 1
Yield point
(N/mm
2
)
230
Elongation
(%)
35
Thickness
(mm)

Test specimen
(JIS)
No. 11 or 12
Tensile strength
(N/mm
2
)
380
Available Sizes for S-TEN
1 Hot-rolled Sheets and Plates (S-TEN 1, S-TEN 2)


1.6t 2.0
2.0t 2.5
2.5t 3.0
3.0t 4.5
4.5t 5.0
5.0t 6.0
6t 7
7t 8
8t 9
9t 12
12t 20
500
3.6
6.0
9.7 16
20
23
1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500
Plate
Thickness (mm)
Width (mm)
0.6, 0.7
0.8, 0.9, 1.0, 1.2, 1.6
2.0, 2.3
400
290 530 1,470 1,845
600 800 1,000 1,200 1,400 1,600 1,800 2,000
Plate
Thickness (mm)
Width (mm)
Length: 0.794.92 m
2 Cold-rolled Sheets (S-TEN 1, S-TEN 2)
0.8
2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 25.4
3 Pipes and Tubes (S-TEN 1)
Wall thickness (mm)
19.0
21.7
25.4
27.2
31.8
34.0
38.1
42.7
45.0
48.6
50.8
54.0
57.0
60.5
76.2
88.9
101.6
114.3
15
20
25
32
40
50
65
80
90
100
1,540
600 2,400 4,000 4,500 3,200 3,400 3,600 3,000 1,2501,350 1,550
ERW pipes and tubes
(as-rolled)
ERW pipes and tubes
(cold-finished)
4.5
5.5
6.8
7.9
8.5
8.9
16
16
Notes 1) Hot-rolled sheets and plates (all plates; specification required for sheet) conform to JIS G 3106 (S-TEN 1:
SM400A; S-TEN 2: SM490A). JIS is inscribed on the steel product inspection sheet when specified.
2) ERW pipe and tubes are registered in the technical standards for thermal power generation facilities (METI
KA-STB380J2) and ASME Code Case 2494.
Notes 1) 2.5CMn
2) Alloying elements other than those shown in the table may added as occasion demands
Note) For this size range, please consult us in advance.
Table 2.4 Hot-rolled Sheets and Plates, and Spiral Welded Pipe
Notes 1) Figures in the table show the maximum length.
2) Minimum length: 3 m for the thicknesses 6 mm or more; 1.5 m for the thicknesses less than 6 mm
3) For this size range and the plate thicknesses up to 50 mm, please consult us in advance.
Note) The following sizes are subject to negotiation. Available products are SAW pipe (BR or SP). Outside diameter (nominal diameter A):
138.9125, 165.2150, 216.3200, 267.4250, 318.5300, 355.6350, 406.4400; maximum outside diameter: 2,500 mm
Outside dia-
meter (mm)
Nominal
diameter A
15 14
2. S-TEN 3. Characteristic Properties of S-TEN (Examples)
1 Chemical Composition
Examples of chemical composition of S-TEN are shown in Table 3.1.
2 Mechanical Properties
Examples of mechanical properties of S-TEN are shown in Tables 3.2, 3.3 and 3.4.
High-temperature Short-time
Strength
Results of high-temperature tensile
tests are shown in Fig. 3.1.
Fig. 3.1 High-temperature Tensile Test Results

Grade
S-TEN 1
S-TEN 2

Product
Cold-rolled sheet
Hot-rolled medium plate
Plate
ERW pipe and tube
Cold-rolled sheet
Hot-rolled medium plate
Plate

C
0.04
0.04
0.04
0.04
0.09
0.12
0.14

Si
0.30
0.30
0.28
0.20
0.24
0.26
0.22

Mn
0.91
0.91
1.00
1.00
0.76
0.76
0.75

P
0.015
0.015
0.012
0.011
0.017
0.016
0.018

S
0.010
0.010
0.012
0.010
0.013
0.007
0.012

Cu
0.30
0.30
0.28
0.27
0.32
0.28
0.34

Cr
-
-
-
-
0.68
0.70
0.65

Others
Sb: 0.10
Sb: 0.10
Sb: 0.09
Sb: 0.10
Ti: 0.03
Ti: 0.03
Ti: 0.03
Chemical composition (%)
Table 3.3 Cold-rolled Sheets
Yield point
(N/mm
2
)
295
305
380
380
Plate
thickness
(mm)
1.2
1.6
0.8
1.2
Tensile strength
(N/mm
2
)
410
440
490
490
Elongation
(%)
36
36
32
32

Grade

S-TEN 1
S-TEN 2
Tensile test
Table 3.4 ERW Pipes and Tubes
Yield point
(N/mm
2
)
298
293
Tensile strength
(N/mm
2
)
403
418
Elongation
(%)
61
41

Grade

S-TEN 1
Tensile test
3. Characteristic Properties of S-TEN (Examples)
Physical Properties
Physical properties are shown in Table 3.5. Specific heat, thermal conductivity and ther-
mal expansion coefficient of S-TEN are similar to those of SS400, SM400A, SM490C,
etc.
Table 3.5 Physical Properties

Grade
S-TEN 1
S-TEN 2
Youngs modulus
(GPa)
207.4
203.7
198.3
192.0
184.0

211.0
207.0
202.0
196.0
188.0
179.0
Thermal
conductivity
(W/mK)
44.2

45.5

36.8

45.1
41.2
40.8
40.2
37.7
34.1
Temperature
(C)
25
100
200
300
400
500
25
100
200
300
400
500
Thermal expansion
coefficient 20CT
(10
-6
/C)

12.8
13.2
13.6
14.0

12.8
13.1
13.5
13.8
14.2
Specific heat
(J/kgK)
0.450

0.491

0.532

0.456
0.486
0.520
0.553
0.590
0.644
High-temperature
Characteristics
Table 3.1 Chemical Composition (Example)
Measurement method Youngs modulus: Resonance method; Specific heat and thermal conductivity: Laser flash method; Thermal expansion coefficient:
Measurement of thermal expansion
Table 3.6 Chemical Composition of Test Specimens for Hydrochloric Acid Resistant and High-temperature Oxidation Tests
(Figs. 3.23.5)
Corrosion Resistance 1 Weather Resistance
S-TEN surpasses ordinary steel in weather resistance:
S-TEN 1: About 2 times (similar to Cu-containing steel)
S-TEN 2: 46 times (similar to COR-TEN 490)
2 Hydrochloric Acid Resistance
Corrosion caused by hydrochloric acid gas contained in the exhaust gas of gar-
bage disposal incinerators has recently become a social problem. S-TEN 1 has
greater resistance to hydrochloric acid corrosion than ordinary steel, and thus per-
mits effective application in this field (for example, hydrochloric acid tanks for galvan-
izing). Figs. 3.23.5 show the results of tests pertaining to hydrochloric acid corro-
sion.
1) S-TEN 1 exhibits corrosion resistance 510 times that of ordinary steel.
2) In dilute hydrochloric acid (about 3% or less), the corrosion rate of S-TEN is high-
er than that of SUS, and thus the use of S-TEN in such environments is not rec-
ommended.
3) In hydrochloric acid with a concentration of 10% or more, S-TEN 1 exhibits high
corrosion resistance.
4) As the temperature and concentration of hydrochloric acid increases, S-TEN 1
exhibits higher corrosion resistance.
5) Please pay attention to the fact that when alien substances are mixed in the acid,
characteristic properties may vary in some cases.

Grade
S-TEN 1
S-TEN 2
SS 400

C
0.02
0.09
0.15

Si
0.26
0.24
0.14
Mn
0.90
0.69
0.70

P
0.011
0.009
0.014
S
0.010
0.014
0.005

Cu
0.27
0.29
0.01

Cr

0.54

Sb
0.09

Ti

0.03

Chemical composition (%)

Table 3.2 Hot-rolled Sheets and Plates
Yield point
(N/mm
2
)
345
383
382
368
440
440
420
410
Plate
thickness
(mm)
2.3
6.0
12.0
16.0
2.3
6.0
9.0
13.0
Tensile strength
(N/mm
2
)
470
458
452
441
540
530
520
510
Elongation
(%)
36
38
42
47
33
35
39
41

Grade

S-TEN 1
S-TEN 2
Tensile test
Test specimen: JIS No. 5
Outside
diameter
Wall thickness
(mm)
48.63.5
89.15.0
S
t
r
e
n
g
t
h

(
N
/
m
m
2
)
0
100 200 300 400 500 600
100
200
300
400
500
Test temperature (C)
S-TEN 1
S-TEN 2
Tensile strength
Yield strength
Chemical Composition
and Mechanical Properties
17 16
4. S-TEN
The carbon and manganese contents of S-TEN are kept low to
secure high corrosion resistance. Therefore, S-TEN offers excel-
lent weldability and can be welded under the same conditions
as those for ordinary steel of the same strength level.
However, because sulfuric acid and hydrochloric acid dew-
point corrosion resistance similar to that of the base metal is
required for welds, it is necessary to use welding materials for
exclusive use for S-TEN.
1 Covered Arc Welding Electrodes
2 Gas Shielded Metal Arc Welding wire
Welding Materials
As the welding material for exclusive use for S-TEN, Nippon Steel & Sumikin Welding
Co., Ltd.* supplies the following products.
*Inquiry: Nippon Steel & Sumikin Welding Co., Ltd.
Tsukiji KY Bldg., 7-5, Tsukiji 4-chome, Chuo-ku, Tokyo 104-0045
Tel: 81-3-3524-3407 Fax: 81-3-3524-3401
Grade
S-TEN 1
S-TEN 2
Type
Flux-cored wire
Flux-cored wire
Brand
NITTETSU SF-1ST
NITTETSU FC-23ST
Shielding gas
CO2
CO2
Current source
Direct current (wire +)
Direct current (wire +)
Welding position

All position
3 Chemical Composition and Mechanical Properties of Various Welding Materials (Example)
4 Welding Materials for Dissimilar Welding with Stainless Steels (Example)
Welding
method
SMAW
SAW
FCAW
GMAW
GTAW

Brand
NITTETSU 309R
NITTETSU Y-309
NITTETSU BF-300M
NITTETSU SF-309L
NITTETSU YM-309
NITTETSU YT-309
C
0.06
0.06
0.03
0.05
0.05
Si
0.33
0.45
0.65
0.35
0.40
Mn
1.51
1.64
1.54
1.74
1.65
P
0.020
0.020
0.023
0.021
0.020
S
0.006
0.010
0.009
0.007
0.006
Cr
24.2
24.0
24.4
23.6
23.8
Ni
13.2
13.5
12.7
13.3
12.4
YS
(N/mm
2
)
460
375
429
447
517
TS
(N/mm
2
)
582
558
566
618
620
EL
(%)
37
38
37
33
34
vEo
(J)
64
89
36
92
166
4. Welding of S-TEN 3. Characteristic Properties of S-TEN (Examples)
Fig. 3.2 Relation between Hydrochloric Acid Concentration
and Corrosion Rate
Fig. 3.4 Relation between Hydrochloric Acid Concentration
and Corrosion Rate
Fig. 3.3 Relation between Hydrochloric Acid Concentration
and Corrosion Rate
Fig. 3.5 Relation between Hydrochloric Acid Concentration
and Corrosion Rate
After
test
Before
test S-TEN 1
S-TEN 1 STB 340 SUS 316L SUS 304
SUS 304 SS 400
4 Appearance of Various Steel Products after
Accelerated Corrosion Tests
Photo 3.1 10.5% Hydrochloric Acid, 60C, 72 Hrs
Photo 3.2 10.5% Hydrochloric Acid, 80C, 144 Hrs
(Initial size of test specimen: 4t2525 mm)
Table 4.2
Table 4.3
Table 4.4
Welding
method
SMAW
GMAW
GTAW
SAW

Brand
NITTETSU ST-16M
NITTETSU ST-16Cr
NITTETSU ST-03Cr
NITTETSU SF-1ST
NITTETSU FC-23ST
NITTETSU FCT-1ST
NITTETSU YFC-1ST
NITTETSU YF-15B
C
0.04
0.05
0.06
0.05
0.04
0.02
0.02
Si
0.62
0.50
0.15
0.60
0.38
0.28
0.31
Mn
0.50
0.48
0.56
1.41
0.81
0.84
1.12
P
0.009
0.012
0.014
0.012
0.016
0.008
0.013
S
0.004
0.006
0.011
0.013
0.013
0.011
0.016
Cu
0.42
0.20
0.23
0.39
0.35
0.29
0.28
Cr

0.73
0.79

0.74

Sb
0.08

0.10

0.10
0.10
YS
N/mm
2

471
481
463
581
512
386
389
TS
N/mm
2

568
550
532
640
585
465
486
EL
%
31
29
28
27
27
36
30
vEo
J
165
203
112
71
52
303*
73
* 20C
3 Sulfuric Acid Resistance Fig 3.6 Sulfuric Acid Resistance of Various Steel Products (50%, 70C, H2SO4)
C
o
r
r
o
s
i
o
n

r
a
t
e

(
g
/
m
2
/
h
r
s
)
0
S-TEN 1 S-TEN 2 SUS 304 SUS 316L SS 400
100
200
300
400
500
700
600
800
0
0 5 10 15 20
(Temperature: 80C, 6 hrs)
C
o
r
r
o
s
i
o
n

r
a
t
e

(
m
g
/
c
m
2
/
h
r
s
)
HCR concentration (%)
10
5
20
15
0
0
30
15
60
45
5 10 15 20
(Temperature: 80C, 6 hrs)
C
o
r
r
o
s
i
o
n

r
a
t
e

(
m
g
/
c
m
2
/
h
r
s
)
HCR concentration (%)
0
0
4
3
2
1
5 10 15 20
(Temperature: 40C, 6 hrs)
C
o
r
r
o
s
i
o
n

r
a
t
e

(
m
g
/
c
m
2
/
h
r
s
)
HCR concentration (%)
SS 400
S-TEN 1
SS 400
S-TEN 1
0
0
0.4
0.6
0.2
5 10 15 20
(Temperature: 40C, 6 hrs)
C
o
r
r
o
s
i
o
n

r
a
t
e

(
m
g
/
c
m
2
/
h
r
s
)
HCR concentration (%)
SUS 316L
SUS 304 S-TEN 1
SUS 316L
SUS 304
S-TEN 1

Grade
S-TEN 1
S-TEN 2
Submerged arc welding
(SAW)
NITTETSU YFC-1ST
NITTETSU YF-15B
(JIS Z 3183 S502-H)

TIG welding (GTAW)
NITTETSU FCT-1ST
4)
(JIS Z 3313 T49J0TG-1GA-U)

MAG welding (GMAW)
NITTETSU SF-1ST
3)
(JIS Z 3313 T49J0T1-1CA-UH5)
NITTETSU FC-23ST
3)
(JIS Z 3313 T49J0T1-1CA-U)
Shielded metal arc welding
(SMAW)
NITTETSU ST-16M
1)
(JIS Z 3211 E4916U)
NITTETSU ST-16Cr
1)
(JIS Z 3212 E5716)
NITTETSU ST-03Cr
2)
JIS Z 3212-E4940-G
Kind of shielding material
Gas shielded metal arc welding
Table 4.1
Notes 1) Low-hydrogen type 2) Lime titania type 3) Cord arc weldeing wire (Flux) 4) Cord arc weldeing wire (Metal)
19 18
4. Welding of S-TEN 4. Welding of S-TEN
Photo 4.1 Corrosion Conditions of S-TEN 1 Weld Joint
2 Field Test Results
Immersion condition: 17.5% hydrochloric acid, 32C, fully immersed
Immersion period: 4 months
SS 400
(S-16)
S-TEN 1
(*ST-16)
S-TEN 1
(ST-16M)
BM: Base metal: WM: Weld metal *ST-16: Brand name of conventional
weld material for S-TEN (production discontinuation)
BM: Base metal: WM: Weld metal *ST-16: Brand name of conventional
weld material for S-TEN (production discontinuation)
Corrosion rate (mm/yr/side)
2 0 4 6 8
BM
WM
BM
WM
BM
WM
1 Example of S-TEN 1
Immersion tests were conducted using the test specimen,
consisting of both base metal and weld metal, shown in
Fig. 4.2 and under the conditions shown in Photo 4.1.
Cross sections of the corroded specimen are shown in Pho-
to 4.1.
Sulfuric Acid and
Hydrochloric Acid
Resistance of Welded
Joints
Sulfuric acid and hydrochloric acid immersion test of welded joints was conducted to
determine the sulfuric acid resistance of welded joints, the results of which are shown
below.
The test results indicate that the welded joints made using welding rods for exclu-
sive use for S-TEN exhibit corrosion resistance similar to that of the base metal. But in
the case of using welding rods for use for mild steel, the results clearly indicate that the
welded joints only are severely corroded.
Hydrochloric acid: 10.5% hydrochloric acid80CImmersion
for 24 hrs
Sulfuric acid: 50% sulfuric acid70CImmersion for 24 hrs
NITTETSU 16 (Low hydrogen-type welding rod for mild steel)
Base metal (SS 400)
NITTETSU 16 (Low hydrogen-type welding rod for mild steel)
Base metal (SS 400)
NITTETSU ST-16M (Welding rod for exclusive use for S-TEN)
Base metal (S-TEN 1)
NITTETSU ST-16M (Welding rod for exclusive use for S-TEN)
Base metal (S-TEN 1)
Welding Characteristics
Maximum hardness tests and y-groove weld cracking tests prescribed by JIS were per-
formed to confirm the weldability of S-TEN. S-TEN 1 and 2 having the characteristics
shown in Tables 4.5 and 4.6 were used as the test specimens.
Table 4.5 Chemical Composition of Test Specimens
Table 4.7 Maximum Hardness Test Results
1 Maximum Hardness Test
Table 4.7 shows the results of HAZ maximum hardness tests in accordance with
JIS Z 3101 (Testing Method of Maximum Hardness in Weld Heat-Affected Zone).
2 y-groove Cracking Test
To determine the crack sensitivity of welds, the test was conducted using the test
specimens, shown in Fig. 4.1, in accordance with JIS Z 3158 (Method of y-Groove
Cracking Test). The test results are shown in Table 4.8.
Table 4.6 Mechanical Properties of Test Specimens
Tensile test specimen: JIS No. 5
Welding conditions: Welding Electrodes 4 mm in dia.; current 170 A; voltage 24 V; speed 150 mm/min
Grade
S-TEN 1
S-TEN 2
Initial temperature of specimen (C)
Room temperature
Room temperature
Thickness (mm)
16
16
Maximum hardness (Hv)
189
242
Elongation (%)
47
43
Tensile strength (N/mm
2
)
441
500
Yield point (N/mm
2
)
368
380
Thickness
(mm)
16
16
Grade

S-TEN 1
S-TEN 2
Tensile test

Grade

S-TEN 1
S-TEN 2

C
0.04
0.09
Thickness
(mm)
16
16

Si
0.28
0.21
Mn
1.00
0.74

P
0.012
0.023
S
0.012
0.010

Cu
0.28
0.35

Cr

0.70

Ti

0.02

Sb
0.09

Chemical composition (%)

Welding conditions: Welding Electrodes 4 mm in dia.; current 170 A; voltage 24 V; speed 150 mm/min

Grade
S-TEN 1
S-TEN 2
1
0
0
0
0
2
0
0
0
0
3
0
0
0
0
Average
0
0
0
0

Thickness
(mm)
16
16

Initial temperature
of specimen (C)
0
25
0
25
Surface crack rate (%)
1
0
0
0
0
2
0
0
0
0
3
0
0
0
0
Average
0
0
0
0
Section crack rate (%)
1
0
0
0
0
2
0
0
0
0
3
0
0
0
0
Average
0
0
0
0
Root crack rate (%)
Table 4.8 y-groove Weld Cracking Test Results
Fig. 4.1 Configuration of y-groove Weld Cracking Test Specimen
BM BM WM
BM BM WM
BM BM WM
SS 400S-16
Base metalWeld metal
S-TEN 1*ST-16
S-TEN 1ST-16M
crevice corrosion
(unit: mm)
Fig. 4.2 Configuration of Sulfuric Acid Immersion Test
Specimen
Photo 4.2 Cross Sections of Joint Specimens Immersed in
Hydrochloric Acid Pickling Tank for 4 Months
Fig. 4.3 Test Results for Weld Joint Test Specimens
Immersed in Hydrochloric Acid Pickling Tank
25
4
60
10
A-A B-B
20.2
60
60
200
1
5
0
8
8
Restraint welding
Test welding
23 23
60 80 60
A B
A B
21 20
4. Welding of S-TEN 4. S-TEN
(SS 400)
Distance from weld (mm)
(S-TEN 1)
Distance from weld (mm)
0
0.1
0.2
0.3
0.4
400 300 200 100 0 0 100 200 300 400
C
o
r
r
o
s
i
o
n

m
a
s
s

(
m
m
)
400
SS 400
400
S-TEN 1
Test specimen
configuration
(S-TEN 1)
Distance from weld (mm)
0
0.1
0.2
0.3
0.4
100 0 0 100 200 300 400 500 600 700 800
C
o
r
r
o
s
i
o
n

m
a
s
s

(
m
m
)
SS 400 S-TEN 1
Test specimen
configuration
800
80
(SS 400)
Distance from weld (mm)
5. Application Examples
Waste melting furnace
Economizer and air preheater of thermal power plant
Tubes for air fin cooler
Fin tubes
Fig. 4.5 Corrosion Mass of S-TEN 1/ Different Material Weld
Joint
Fig. 4.6 Corrosion Mass of S-TEN 1/ Different Material Weld
Joint
(Dotted line: Average corrosion mass of base metal)
Area ratio 1:1
(Dotted line: Average corrosion mass of base metal)
Area ratio 1:10
Example: Corrosion mass
of SS 400 in fillet welding Example: Corrosion mass
of SS 400 in fillet welding
Weld
Weld
W
e
l
d
W
e
l
d
Example: Corrosion mass
of S-TEN 1 in fillet welding
Example: Corrosion mass
of S-TEN 1 in fillet welding
Property Qualification Test Results
S-TEN 1
The following property qualification tests were conducted in the
laboratory. In preparing test specimens, it was thought that cor-
rosion of SS 400 would be accelerated when the area of SS
400 was less than that of S-TEN 1. Taking this into account,
the test specimens were prepared so that the ratio of the area
of SS 400 to S-TEN 1 became 1:1 and 1:10 for butt-welded
joints.
The tests were conducted by immersing the specimens in
40%-concentrated sulfuric acid at 55C for 5 hours. As a
result, as shown in Figs. 4.5 and 4.6, it was found that the cor-
rosion of specimens was nearly the same as that of S-TEN
itself and that, in such sulfuric-acid corrosive environment, con-
tact of different metals with an electrical potential difference of
approximately 20 mV can be disregarded.
Fig. 4.4 Natural Electrode Potentials of S-TEN 1 and SS 400
in 40% Sulfuric Acid (60C)
N
a
t
u
r
a
l

e
l
e
c
t
r
o
d
e

p
o
t
e
n
t
i
a
l
(
m
V
,

V
s
,

S
.
C
.
E
)
0 1 2 3 4
-390
-380
-370
-360
-350
Immersion time (hrs)
S-TEN 1
SS 400
Galvanic Corrosion in Corrosive
Atmosphere
Galvanic corrosion is caused by the difference in electrical
potential between different metals.
S-TEN 1 and SS 400 show the trend of natural electrode
potential in a 40% sulfuric acid solution at 60C, as shown in
Fig. 4.4. In other words, S-TEN 1 shows 20 mV higher poten-
tial than SS 400. Therefore, joining of SS 400 with S-TEN 1
would make SS 400 a cathode and the corrosion of S-TEN 1
(anodic dissolution) would be accelerated. It has been con-
firmed, however, that such slight difference in potential is practi-
cally insignificant, as introduced below.
New York
Chicago
Duesseldorf
Sydney
Nippon Steel U.S.A., Inc., New York Office
1251 Ave of the Americas, Suite 2320
New York, NY 10020-0080, U.S.A.
Phone: 1-212-486-7150
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Chicago, Illinois 60611, U.S.A.
Phone: 1-312-751-0800
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Am Seestern 8, 40547 Desseldorf,
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Phone: 49-211-5306680
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Level 24, No.1 York Street, Sydney
N.S.W. 2000, Australia
Phone: 61-2-9252-2077
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Bangkok
So Paulo
Beijing
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Phone: 65-6223-6777
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1MD Tower, 4th Fl., Room C3 E F,
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Phone: 55-11-3736-4666
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Company Ltd., Beijing Office
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Phone: 86-10-6513-8593
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Company Ltd., Shanghai Office
Room No.808, UNITED PLAZA
1468 Nanjing Road West,
200040 Shanghai, P.R. China
Phone: 86-21-6247-9900
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Company Ltd., Guangzhou Office
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Phone: 86-20-8386-8178
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Phone: 91-11-4610-6880, 6881
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Marunouchi Park Building,
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Phone: 81-3-6867-4111 Fax: 81-3-6867-5607
NIPPON STEEL CORPORATION 2007 All Rights Reserved. AC307 2001.12 Printed in Japan
Sulfuric Acid and Hydrochloric Acid Dew-point Corrosion-resistant Steel S-TEN
TM
Cat. No. AC307 2009.11 2011.12 2
Notice: While every effort has been made to ensure the accuracy of the information contained within this publication, the use of the information is at
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