FERRITIC STAINLESS STEEL SHEET FOR UREA SCR CASING (AS AMENDED)

- JFE STEEL CORPORATION

Provided is a ferritic stainless steel sheet for a urea SCR casing which is excellent in terms of corrosion resistance in a urea SCR environment and which increases the durability of a urea SCR casing. The steel sheet has a chemical composition containing, by mass %, C: 0.020% or less, Si: 0.01% or more and 0.50% or less, Mn: 0.01% or more and 0.50% or less, P: 0.040% or less, S: 0.010% or less, Al: 0.01% or more and 0.20% or less, Cr: 20.5% or more and 24.0% or less, Cu: 0.40% or more and 0.80% or less, Ni: 0.05% or more and 0.6% or less, N: 0.020% or less, one or both selected from among Ti: 0.01% or more and 0.40% or less and Nb: 0.01% or more and 0.55% or less, and the balance being Fe and inevitable impurities, in which the relationship Ti+Nb×48/93≥8×(C+N) (in the relational expression, Ti, Nb, C, and N denote the contents (mass %) of the corresponding chemical elements) is satisfied.

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Description
CROSS REFERENCE TO RELATED APPLICATIONS

This is the U.S. National Phase application of PCT International Application No. PCT/JP2015/003735, filed Jul. 27, 2015, and claims priority to Japanese Patent Application No. 2014-177911, filed Sep. 2, 2014, the disclosures of each of these applications being incorporated herein by reference in their entireties for all purposes.

FIELD OF THE INVENTION

The present invention relates to a ferritic stainless steel sheet for the casing of a urea SCR catalyst carrier.

BACKGROUND OF THE INVENTION

Urea SCR (SCR: Selective Catalytic Reduction) is an environmental technology for making NOx harmless by reducing NOx into nitrogen (N2) and water (H2O) in the presence of a catalyst through the use of ammonia (NH3) which is derived by decomposing aqueous urea and is used mainly for diesel powered trucks.

It is known that, in the process of deriving NH3 by decomposing this aqueous urea at a high temperature, a highly corrosive material called ammonium carbamate (NH2COONH4) is generated.

A conventional urea SCR catalyst carrier is composed mainly of ceramic, and such a ceramic urea SCR catalyst carrier having a circular cylinder form is wrapped with a ferritic stainless steel sheet which is used as a casing for supporting the carrier. Therefore, the inner side (the side facing the ceramic) of such a ferritic stainless steel sheet is required to be resistant to corrosion caused by ammonium carbamate. For example, Patent Literature 1 discloses a technique in which a ferritic stainless steel sheet which contains 10.0 mass % to 20.0 mass % of Cr and which has been subjected to dip pickling in nitric acid is used for the parts of a urea SCR system.

PATENT LITERATURE

PTL 1: Japanese Unexamined Patent Application Publication No. 2012-112025

SUMMARY OF THE INVENTION

Here, it is supposed that, since diesel powered trucks equipped with a urea SCR system are used for various purposes ranging from short-distance transportation in a town to long-distance transportation, the amount of corrosive ammonium carbamate generated varies depending on the temperature of the exhaust gas and the amount of the exhaust gas. In addition, it is thought that, in the case where a large amount of ammonium carbamate is generated, the corrosion of a ferritic stainless steel sheet tends to progress.

From this point of view, in the case of the ferritic stainless steel sheet according to Patent Literature 1, there is a problem of severe corrosion occurring in a urea SCR casing due to its insufficient corrosion resistance against ammonium carbamate in some cases. Therefore, there is a demand for a ferritic stainless steel sheet for a urea SCR casing having higher corrosion resistance.

Therefore, an object of the present invention is to provide a ferritic stainless steel sheet for a urea SCR casing excellent in terms of corrosion resistance in a urea SCR environment.

The present inventors, in order to solve the problem described above, conducted investigations regarding the influences of various alloy elements on corrosion resistance in a urea environment by performing a Huey test, which is used for evaluating a material for a urea manufacturing plant, and, as a result, found that it is possible to obtain a steel sheet excellent in terms of corrosion resistance which can preferably be used for a urea SCR casing by adding 20.5 mass % or more of Cr, 0.40 mass % or more of Cu, and an appropriate amount of Ti or Nb to a steel sheet.

The subject matter of the present invention includes the following.

[1] A ferritic stainless steel sheet for a urea SCR casing, the steel sheet having a chemical composition containing, by mass %, C: 0.020% or less, Si: 0.01% or more and 0.50% or less, Mn: 0.01% or more and 0.50% or less, P: 0.040% or less, S: 0.010% or less, Al: 0.01% or more and 0.20% or less, Cr: 20.5% or more and 24.0% or less, Cu: 0.40% or more and 0.80% or less, Ni: 0.05% or more and 0.6% or less, N: 0.020% or less, one or both selected from among Ti: 0.01% or more and 0.40% or less and Nb: 0.01% or more and 0.55% or less, and the balance being Fe and inevitable impurities, in which the relationship Ti+Nb×48/93≥8×(C+N) . . . (1)

(in relational expression (1), Ti, Nb, C, and N denote the contents (mass %) of the corresponding chemical elements) is satisfied.

[2] The ferritic stainless steel sheet for a urea SCR casing according to item [1] above, the steel sheet having the chemical composition further containing, by mass %, Mo: 0.01% or more and 0.25% or less.

[3] The ferritic stainless steel sheet for a urea SCR casing according to item [1] or [2] above, the steel sheet having the chemical composition further containing, by mass %, one, two, or all of V: 0.01% or more and 0.20% or less, Zr: 0.01% or more and 0.20% or less, and Ca: 0.0002% or more and 0.0020% or less.

The ferritic stainless steel sheet for a urea SCR casing according to the present invention is excellent in terms of corrosion resistance in a urea SCR environment and capable of increasing the durability of a urea SCR casing.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The ferritic stainless steel sheet for a urea SCR casing according to the present invention has a chemical composition containing, by mass %, C: 0.020% or less, Si: 0.01% or more and 0.50% or less, Mn: 0.01% or more and 0.50% or less, P: 0.040% or less, S: 0.010% or less, Al: 0.01% or more and 0.20% or less, Cr: 20.5% or more and 24.0% or less, Cu: 0.40% or more and 0.80% or less, Ni: 0.05% or more and 0.6% or less, N: 0.020% or less, one or both selected from among Ti: 0.01% or more and 0.40% or less and Nb: 0.01% or more and 0.55% or less, and the balance being Fe and inevitable impurities, in which the relationship Ti+Nb×48/93≥8×(C+N) (in the relational expression, Ti, Nb, C, and N denote the contents (mass %) of the corresponding chemical elements) is satisfied. The ferritic stainless steel sheet for a urea SCR casing according to the present invention is excellent in terms of corrosion resistance against ammonium carbamate and capable of increasing the durability of a urea SCR casing.

Hereafter, the reasons for the limitations on the chemical composition of the ferritic stainless steel sheet for a urea SCR casing according to the present invention (hereinafter, referred to as “the steel sheet according to the present invention”) will be described. Here, “%” related to the constituent chemical elements in the steel sheet according to the present invention denotes “mass %”, unless otherwise noted.

[C: 0.020% or Less]

Since C is a chemical element which decreases the workability and toughness of a steel sheet, and since such negative effects become noticeable in the case where the C content is more than 0.020%, the C content is limited to be 0.020% or less. In particular, from the viewpoint of workability and toughness, it is preferable that the C content be 0.017% or less, or more preferably 0.012% or less.

[Si: 0.01% or More and 0.50% or Less]

Si is a chemical element which is necessary as a deoxidizing agent. Such an effect is realized in the case where the Si content is 0.01% or more. However, since there is a decrease in pickling capability by forming a SiO2 film on the surface of a steel sheet as a result of being oxidized when cold-rolled-sheet annealing is performed, the upper limit of the Si content is set to be 0.50%. It is preferable that the Si content be 0.20% or less from the viewpoint of pickling capability.

[Mn: 0.01% or More and 0.50% or Less]

Mn is a chemical element which is necessary as a deoxidizing agent. Such an effect is realized in the case where the Mn content is 0.01% or more. However, since there is a decrease in the workability of a steel sheet in the case where the Mn content is excessively large, the Mn content is limited to be 0.50% or less. It is preferable that the Mn content be 0.30% or less, or more preferably 0.20% or less, from the viewpoint of the workability of a steel sheet.

[P: 0.040% or Less]

Since P is a chemical element which decreases the workability and toughness of a steel sheet, it is preferable that the P content be as small as possible, and the P content is set to be 0.040% or less, or preferably 0.030% or less.

[S: 0.010% or Less]

Since S is a chemical element which decreases toughness, it is preferable that the S content be as small as possible, and the S content is set to be 0.010% or less. It is preferable that the S content be 0.006% or less from the viewpoint of toughness.

[Al: 0.01% or More and 0.20% or Less]

Al is a chemical element which is effective as a deoxidizing agent. Such an effect is realized in the case where the Al content is 0.01% or more. However, since there is a decrease in surface quality as a result of, for example, scab flaws occurring due to an excessive amount of Al2O3-based inclusions being formed in the case where the Al content is excessively large, the Al content is limited to be 0.20% or less. It is preferable that the Al content be 0.05% or less from the viewpoint of surface quality.

[Cr: 20.5% or More and 24.0% or Less]

Cr is a chemical element which is effective for increasing corrosion resistance against ammonium carbamate in a urea SCR environment, which characterizes the present invention, because it suppresses the occurrence of corrosion by strengthening a passivation film, which is formed on the surface of a stainless steel sheet. Since it is necessary that the Cr content be 20.5% or more in order to achieve sufficient corrosion resistance, the lower limit of the Cr content is set to be 20.5%. It is more preferable that the Cr content be 21.0% or more. On the other hand, since Cr decreases the toughness of a steel sheet, and since there is a significant decrease in toughness, in particular, in the case where the Cr content is more than 24.0%, the Cr content is limited to be 24.0% or less. It is preferable that the Cr content be 22.0% or less from the viewpoint of toughness.

In addition, the present inventors found that, by adding 20.5% or more and 24.0% or less of Cr and, as described below, 0.40% or more and 0.80% or less of Cu simultaneously to a steel sheet, since Cr suppresses the occurrence of corrosion, and since Cu suppresses the progress of corrosion, a steel sheet has significantly excellent corrosion resistance against ammonium carbamate from the synergy of such effects.

[Cu: 0.40% or More and 0.80% or Less]

Cu is a chemical element which has a function of suppressing the progress of pitting corrosion (the progress of corrosion) in the case where pitting corrosion occurs due to corrosion and which is accordingly effective, in particular, of increasing corrosion resistance against ammonium carbamate in a urea SCR environment. Such an effect is realized in the case where the Cu content is 0.40% or more. On the other hand, since there is a decrease in toughness in the case where the Cu content is more than 0.80%, the Cu content is set to be 0.80% or less. It is preferable that the Cu content be 0.60% or less from the viewpoint of toughness.

[Ni: 0.05% or More and 0.6% or Less]

Ni is effective for increasing corrosion resistance and toughness, and such effects are realized in the case where the Ni content is 0.05% or more. However, since Ni increases material costs, the Ni content is set to be 0.6% or less.

[N: 0.020% or Less]

Since N is, like C, a chemical element which decreases workability and toughness, and since such negative effects become noticeable in the case where the N content is more than 0.020%, the N content is limited to be 0.020% or less. In particular, it is preferable that the N content be 0.015% or less, or more preferably 0.012% or less, from the viewpoint of workability and toughness.

[One or both selected from among Ti: 0.01% or more and 0.40% or less and Nb: 0.01% or more and 0.55% or less] and [Ti+Nb×48/93≥8×(C+N)]

Ti and Nb inhibit a sensitization phenomenon, in which the corrosion resistance is decreased due to the combination of Cr with carbon and nitrogen, as a result of forming carbonitrides. Such an effect is realized in the case where the Ti content or the Nb content is 0.01% or more and where


Ti+Nb×48/93≥8×(C+N)   (1)

is satisfied (in relational expression (1), Ti, Nb, C, and N denote the contents (mass %) of the corresponding chemical elements). In addition, from the viewpoint of inhibiting sensitization, it is preferable that the Ti content be 0.20% or more or that the Nb content be 0.30% or more while relational expression (1) is satisfied. However, in the case where the Ti content or the Nb content is excessively large, the effect of inhibiting sensitization becomes saturated, and there is a decrease in toughness. Therefore, the Ti content is set to be 0.40% or less, and the Nb content is set to be 0.55% or less. It is preferable that the Ti content be 0.35% or less and that the Nb content be 0.45% or less from the viewpoint of toughness.

In the case of the steel sheet according to the present invention, the remainder other than the constituent chemical elements described above is Fe and inevitable impurities.

In addition, in the present invention, Mo, V, Zr, and Ca may be added for the purposes described below and within the ranges described below, although these chemical elements are not essential constituent chemical elements.

[Mo: 0.01% or More and 0.25% or Less]

Mo is a chemical element which is effective for increasing corrosion resistance, and such an effect is realized in the case where the Mo content is 0.01% or more. However, since there is a decrease in toughness in the case where the Mo content is more than 0.25%, the Mo content is set to be 0.01% or more and 0.25% or less in the case where Mo is added.

[V: 0.01% or More and 0.20% or Less]

V is a chemical element which increases workability in the case where V is added. Such an effect is realized in the case where the V content is 0.01% or more. However, since there may be a decrease in surface quality due to the occurrence of surface defects in the case where the V content is more than 0.20%, the V content is set to be 0.01% or more and 0.20% or less in the case where V is added.

[Zr: 0.01% or More and 0.20% or Less]

Zr is a chemical element which increases workability in the case where Zr is added. Such an effect is realized in the case where the Zr content is 0.01% or more. However, since there may be a decrease in surface quality due to the occurrence of surface defects in the case where the Zr content is more than 0.20%, the Zr content is set to be 0.01% or more and 0.20% or less in the case where Zr is added.

[Ca: 0.0002% or More and 0.0020% or Less]

Since Ca has a deoxidizing effect, Ca is added as needed. In order to realize such an effect, the Ca content is set to be 0.0002% or more, or preferably 0.0005% or more. However, in the case where the Ca content is more than 0.0020%, the deoxidizing effect becomes saturated, and there may be a decrease in surface quality due to scab flaws occurring as a result of Ca forming inclusions. Therefore, in the case where Ca is added, the Ca content is set to be 0.0020% or less.

[Manufacturing Method]

There is no particular limitation on what method is used for manufacturing the ferritic stainless steel sheet for a urea SCR casing according to the present invention as long as the chemical composition of molten steel is controlled as described above at the molten steel stage, and a method which is generally used for manufacturing a ferritic stainless steel sheet may be used.

Preferable conditions for the manufacturing method described above will be described hereafter.

In a steel-making process in which molten steel is prepared, it is preferable to manufacture steel containing the essential constituent chemical elements described above and the constituent chemical elements which are added as needed by performing secondary refining on molten steel, which has been prepared by using a converter, an electric furnace, or the like, by using, for example, a VOD method. Although the prepared molten steel may be made into a steel material (slab) by using a known method, it is preferable that a continuous casting method be used from the viewpoint of productivity and product quality. Subsequently, the steel material is heated to a temperature of 1000° C. to 1250° C. and then hot-rolled into a hot-rolled steel sheet having a desired thickness. It is needless to say that the steel material may be formed into shapes other than a sheet shape by performing hot working. The hot-rolled steel sheet obtained as described above may be subjected to descaling by performing, for example, pickling after continuous annealing has been performed at a temperature of 850° C. to 1100° C. In addition, although there is no particular limitation on cooling rate after annealing has been performed, it is preferable that the cooling time be as short as possible. Here, scale may be removed as needed by performing shot blasting before pickling is performed.

Moreover, the hot-rolled and annealed steel sheet or the hot-rolled steel sheet described above may be made into a cold-rolled product by performing processes such as a cold rolling process. In this case, although cold rolling may be performed only once, cold rolling may be performed twice or more with interposing process annealing between cold rolling from the viewpoint of productivity and desired product qualities. It is preferable that the total rolling reduction of the cold rolling process, in which cold rolling is performed once, twice, or more, be 60% or more, or more preferably 70% or more. It is preferable that the cold-rolled steel sheet be made into a cold-rolled product by then performing continuous annealing (finish annealing) at a temperature of 850° C. to 1150° C., or more preferably 900° C. to 1100° C., and pickling. Also, in this case, although there is no particular limitation on a cooling rate after annealing has been performed, it is preferable that the cooling rate be as large as possible. Moreover, in the case of some purposes of use, for example, skin pass rolling may be performed after finish annealing has been performed in order to control the shape, surface roughness, and material quality of a steel sheet.

EXAMPLE 1

Hereafter, the present invention will be described on the basis of examples. As examples, cold-rolled steel sheets used as samples were obtained by using the following methods.

By preparing steel ingots having a weight of 50 kg and the chemical compositions given in Table 1 by using a vacuum melting furnace, by heating the steel ingots to a temperature of 1200° C., by then performing hot rolling using a reverse rolling mill in order to obtain hot-rolled steel sheets having a thickness of 3 mm, by annealing the hot-rolled steel sheets at a temperature of 930° C. to 1100° C., and by performing descaling through pickling the annealed steel sheets, hot-rolled and pickled steel sheets were obtained. Subsequently, by performing cold rolling using a reverse rolling mill on the hot-rolled and pickled steel sheets in order to obtain a thickness of 1.0 mm, by performing finish annealing at a temperature of 880° C. to 970° C., and by dipping the annealed steel sheets in a mixed acid (containing 10 mass % of nitric acid and 3 mass % of hydrofluoric acid) having a temperature of 60° C. in order to remove scale, cold-rolled steel sheets were obtained.

In order to investigate corrosion resistance in a urea SCR environment, by performing a test in accordance with JIS Z 0573 (Method of 65 percent nitric acid test for stainless steels) on samples, that is, the cold-rolled steel sheets described above, corrosion rate (g/m2/h) over 48 hours was derived. A case where the corrosion rate was 0.35 g/m2/h or less was judged as a satisfactory case. The results are given in Table 1.

TABLE 1 Chemical Composition (Unit: mass %) No. C Si Mn P S Al Cr Ni N Ti Nb 1 0.0095 0.09 0.45 0.038 0.002 0.033 23.8 0.21 0.0070 0.35 — 2 0.0015 0.35 0.10 0.023 0.001 0.080 20.5 0.05 0.0168 0.35 — 3 0.0155 0.05 0.38 0.038 0.003 0.020 21.5 0.40 0.0051 0.29 0.06 4 0.0020 0.45 0.12 0.018 0.003 0.045 21.0 0.10 0.0144 0.25 — 5 0.0071 0.11 0.33 0.030 0.003 0.028 21.2 0.21 0.0111 — 0.40 6 0.0089 0.13 0.16 0.029 0.001 0.038 20.6 0.25 0.0070 0.30 — 7 0.0092 0.15 0.15 0.031 0.002 0.030 20.8 0.23 0.0091 0.33 — 8 0.0113 0.09 0.12 0.028 0.003 0.033 21.4 0.21 0.0101 0.29 — 9 0.0080 0.11 0.16 0.029 0.002 0.030 20.8 0.22 0.0098 0.31 0.01 10 0.0110 0.12 0.15 0.019 0.002 0.031 20.7 0.19 0.0115 0.26 0.22 11 0.0189 0.05 0.48 0.021 0.008 0.021 23.5 0.17 0.0111 0.39 — 12 0.0101 0.47 0.10 0.040 0.001 0.150 20.5 0.45 0.0191 0.35 — 13 0.0083 0.12 0.11 0.028 0.002 0.033 20.6 0.21 0.0099 0.32 — 14 0.0095 0.15 0.15 0.025 0.001 0.035 19.3 0.15 0.0093 0.29 0.10 15 0.0091 0.14 0.19 0.031 0.002 0.031 20.7 0.23 0.0095 0.12 — 16 0.0113 0.11 0.18 0.028 0.003 0.028 20.6 0.16 0.0103 — 0.25 Urea SCR Ti + Nb × Environment Chemical Composition (Unit: mass %) 48/93 − Corrosion No. Mo Cu V Zr Ca 8 × (C + N) Test Result 1 — 0.53 — — — 0.22 Satisfactory Example 2 — 0.50 — — — 0.20 Satisfactory Example 3 — 0.43 — — 0.0002 0.16 Satisfactory Example 4 — 0.40 0.05 — — 0.12 Satisfactory Example 5 — 0.48 0.15 — 0.0008 0.06 Satisfactory Example 6 0.25 0.41 — — 0.0011 0.17 Satisfactory Example 7 0.15 0.44 0.08 — — 0.18 Satisfactory Example 8 — 0.42 0.05 0.08 0.0012 0.12 Satisfactory Example 9 0.08 0.44 0.03 — 0.0011 0.17 Satisfactory Example 10 — 0.42 0.03 — 0.0009 0.19 Satisfactory Example 11 — 0.70 0.15 — — 0.15 Satisfactory Example 12 — 0.78 0.08 — 0.0002 0.12 Satisfactory Example 13 — 0.36 0.05 — 0.0009 0.17 Unsatisfactory Comparative Example 14 0.12 0.44 0.08 — — 0.19 Unsatisfactory Comparative Example 15 — 0.41 0.03 — 0.0011 −0.03 Unsatisfactory Comparative Example 16 — 0.40 0.05 — — −0.04 Unsatisfactory Comparative Example

All the examples of the present invention were satisfactory in the urea SCR corrosion test, which means these examples had excellent corrosion resistance. On the other hand, No. 13, whose Cu content was less than the range according to the present invention, No. 14, whose Cr content was less than the range according to the present invention, and No. 15 and No. 16, whose Ti content and Nb content did not satisfy the relationship expressed by relational expression (1) according to the present invention, that is, “Ti+Nb×48/93≥8×(C+N)”, were unsatisfactory in the urea SCR corrosion test. As described above, it is clarified that the steels according to the present invention are excellent in terms of corrosion resistance in a urea SCR environment.

As described above, since the steel sheet according to the present invention is excellent in terms of corrosion resistance in a urea SCR environment, the steel sheet can preferably be used as a material for a casing supporting a urea SCR catalyst carrier.

Claims

1. A ferritic stainless steel sheet for a urea SCR casing, the steel sheet having a chemical composition containing, by mass %,

C: 0.020% or less,
Si: 0.01% or more and 0.50% or less,
Mn: 0.01% or more and 0.50% or less,
P: 0.040% or less,
S: 0.010% or less,
Al: 0.01% or more and 0.20% or less,
Cr: 20.5% or more and 24.0% or less,
Cu: 0.40% or more and 0.80% or less,
Ni: 0.05% or more and 0.6% or less,
N: 0.020% or less,
one or both selected from among Ti: 0.01% or more and 0.40% or less and Nb: 0.01% or more and 0.55% or less, and
the balance being Fe and inevitable impurities,
wherein the relationship Ti+Nb×48/93≥8×(C+N)   (1)
is satisfied, wherein in relational expression (1), Ti, Nb, C, and N denote the contents (mass %) of the corresponding chemical elements.

2. The ferritic stainless steel sheet for a urea SCR casing according to claim 1, the chemical composition further containing, by mass %, Mo: 0.01% or more and 0.25% or less.

3. The ferritic stainless steel sheet for a urea SCR casing according to claim 1, the chemical composition further containing, by mass %, one, two, or all of

V: 0.01% or more and 0.20% or less,
Zr: 0.01% or more and 0.20% or less, and
Ca: 0.0002% or more and 0.0020% or less.

4. The ferritic stainless steel sheet for a urea SCR casing according to claim 2, the chemical composition further containing, by mass %, one, two, or all of

V: 0.01% or more and 0.20% or less,
Zr: 0.01% or more and 0.20% or less, and
Ca: 0.0002% or more and 0.0020% or less.
Patent History
Publication number: 20180195157
Type: Application
Filed: Jul 27, 2015
Publication Date: Jul 12, 2018
Applicant: JFE STEEL CORPORATION (Tokyo)
Inventors: Junichiro Hirasawa (Chiba), Takayoshi Yano (Chiba), Shin Ishikawa (Chiba), Chikara Kami (Kurashiki)
Application Number: 15/508,201
Classifications
International Classification: C22C 38/42 (20060101); C22C 38/50 (20060101); C22C 38/48 (20060101); C22C 38/06 (20060101); C22C 38/04 (20060101); C22C 38/02 (20060101); C22C 38/00 (20060101); C21D 9/46 (20060101); F01N 3/28 (20060101);