INTRODUCTION

ABSTRACT

Progress in controlling corrosion is discontinuous. Eight breakthroughs in corrosion control or materials engineering in the pulp and paper industry during the last 80 years have been examined to discover keys to success in research and implementation. Successful cooperative research programs have focused goals, well-planned research and organization structures that involve both funding managers and the engineers who will implement the results. Entrepreneurial breakthroughs by supplier companies confirm that catastrophes are not a prerequisite for success. However, for novel technologies to be implemented, their operation and benefits must be well understood by the engineers who will implement them. Recognizing hidden problems and applying developments from other industries can have breakthrough benefits but requires a type of thinking not normally sought in mill engineers. Because of reduced research funding by pulp and paper companies, future breakthroughs in corrosion control and materials engineering will depend on research and development largely funded by governments, equipment suppliers or other industries. Technology roadmaps may be the best tool for prioritizing precompetitive research that has broad industry support

Progress in controlling corrosion is discontinuous. For long periods engineers continue to use familiar and well-tried solutions to corrosion problems. When new research results or new products make new solutions available, these engineers and their managers or clients are typically reluctant to take risks with unfamiliar approaches that do not have a track record of success. However, new solutions are implemented by pioneering engineers who face critical problems, see substantial financial benefits and understand the new approach well enough to trust it. After a few of these few pioneers have benefitted from a new approach, it is more broadly adopted and becomes the standard solution to the problem until a better approach is developed. This paper presents a personal view of some corrosion control and materials technology breakthroughs that have been implemented in the pulp and paper industry in the last 80 years. Four were enabled by focused research sponsored by the industry or its consortia. Three involve products developed by suppliers to the industry, such as manufacturers of alloys or equipment. The last involves the application of technology developed in other industries. The remainder of this manuscript will discuss the following breakthroughs in corrosion control or materials engineering and the way they enabled the pulp and paper industry to avoid safety hazards, cut costs or implement better processes:

1. Understanding the causes of thinning in kraft batch digesters

2. Understanding the electrochemical basis of cracking in continuous pulp digesters

3. Development of composite tubes to eliminate accelerated fireside corrosion in recovery boiler waterwall tubes

4. Understanding causes of and cures for composite tube cracking in recovery boilers

5. Development of precipitation-hardened duplex stainless steel suction rolls

6. Application of duplex and lean duplex stainless steels in kraft pulping environments

7. Replacement of alloys subject to localized corrosion by equipment manufactured from reinforced thermosetting resin (FRP)

8. Institution of pressure vessel and tank inspection programs

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