Corrosion Performance of 3CR12 Steel Wagons in Coal Conveying

Applications

By

Mashudu Ramovha (u27371736)

Date: 10/11/2019
 Contents
1. Introduction
2. The 3CR12 steel
3. Literature review
4. Design of the CCR wagon
5. Atmospheric corrosion
6. The effect of pollutants in and around Ermelo
7. Atmospheric corrosion at the port of Richards Bay
8. Corrosion resistance of 3CR12 at the coastal area
9. Conclusion
References
Appendix: Response to instructor’s comments
 1. Introduction
• Corrosion, in general, is a subject of great interest all over the world, as it may lead to economic harm as
well as human safety concerns due to potential failure of structures. In dealing with the effects of corrosion,
new materials have been developed and the application of the materials to reduce corrosion has been
adequately researched.
• One of the materials developed in the last half century is the 3CR12 steel, which immediately found its
identity as a corrosion resistance steel with good fabrication properties.
• Following its development, this steel found itself in various applications as its much acclaimed good
properties were being put to practical tests.
• One of those applications was the construction of the Transnet Freight Rail (TFR) wagons, the CFRs in the
early 2000s and later on the CCR jumbo wagons carrying coal between the Coal Fields and Richards Bay.
• The manufacturing of the body structure of these TFR wagons has seen a change of materials over the years
with Mild Steel, Corten A and currently, 3CR12 being used.
• There has been various reasons driving the change in the material for these wagons but they can all be
summed into one of economic sense. It is therefore important to review the performance of these materials
and whether the changes have been economically sound.
 2. The 3CR12 Steel
• The 3CR12 steel is a corrosion resistant steel with 11 – 12 % of chromium as an alloying element which gives
it its basic corrosion resistant properties.
• Beyond the corrosion resistance properties, 3CR12 steel has good fabrication properties when compared to
other stainless steels [1]. This is perhaps one of its most selling factor when competing with other stainless
steels.
• The chemical composition of the 3CR 12 steel is shown in table 1.1 below
Table 1-1: Chemical composition for 3CR12 [1]
%C %Mn %P %S %Cr %Si %Ni

0.030 max 2.00 max 0.04 max 0.30 max 10.5 – 12.5 1.00 max 1.50 max

• As for all stainless steels and corrosion resistance steels, chromium is an important alloying element for
3CR12 for the promotion of its ferritic structure and resistance to oxidation at high temperature whilst
silicon gives the metal its oxidation resistance at both high and low temperatures. Although the presence of
Nickel is mainly for the stabilization of austenitic structure, it also helps in reducing the rate of corrosion [2].
 3. Literature review
To review the performance of 3CR12 steel-manufactured wagons, the following areas are covered:
• Design of the wagon structure and the operational manner of loading and unloading of coal into and off the
wagons.
• Atmospheric corrosion on the CCR wagons manufactured using 3CR12 steel.
For comparisons sake, other steels with similar applications are drawn into the literature discussion.
 4. Design of the CCR wagon
• The design of a structure as complex as a wagon is critical in defining how the chosen material will perform. A
good design may ensure the expected optimum performance of the material whilst a bad design will give rise
to unexpected issues that the material may not be able to endure.
• The TFR CCR Jumbo wagons have been found to be developing cracks on the bottom part of the underframe,
propagating to the side of the body structure. The cracks range anywhere between 10 and 15 cm, with far
between cases of bigger cracks of 20+ cm. Cracks formed on the surface of the material gives rise to
discontinuities and cavities that may potentially expose the material to localized corrosion.
• Initial investigations have linked the problem to the design short-falls of the underframe which have caused
the wagon to experience excessive vibrations. A repair programme was established to repair these cracks. The
CCR wagon is shown in Figure 1-2.

Figure1-2: Transnet Freight Rail CCR wagon

 Continues…
• Cyclic loads such as vibrations can give rise to cyclic stress concentrations which can potentially make the
material susceptible to stress corrosion cracking (SCC), provided that the temperature and concentrations of
chlorides are ideal.
• During fabrication, poor welding on the 3CR12 steel may give rise to sensitization of the heat affected zone
which may subsequently make the structure vulnerable to intergranular pitting corrosion and stress corrosion
cracking.
• This is however a rare occurrence unless the steel is exposed to corrosive chlorides at high temperatures [3, 4]. In
the case of these CCR wagons, the media is not at high temperatures nor is the material exposed to high
concentrations of chlorides.
• The initiation of a crack also give rise to cavities which are likely to lock moisture and corrosive chlorides when
the wagons are at the port. This may potentially make the crack area vulnerable to corrosion and propagate the
crack at a higher rate than expected.
• Since Mampheko et al.[5] found evidence of pitting corrosion on the CCR wagons which was attributed to the
use of unpickled 3CR12 steel, there has not been any other a case of localised corrosion found on CCR wagons
transporting coal or any other TFR wagon manufactured using 3CR12 to date.
• Generally, localised corrosion is not a concern for these 3CR12 manufactured wagons due to the passivating
effect of the sulphite ions from coal [6].
 Continues…
• There is a direct correlation between wetness of the commodity (i.e. coal) and abrasion. As the wet coal
slides on the surface of the wagon, it has the potential to damage the protective lining layer that protects
the material from corrosion. Therefore, designing for maximum drainage and less cavities that will
potentially collect and retain moisture is important to minimize corrosion of these structures [7, 8].

3CR12 steel
Commodity (coal)
Sliding direction

Figure1-1: Abrasion wear corrosion

 5. Atmospheric corrosion
• The coal-carrying wagons travel between Ermelo and Richards Bay as illustrated in Figure 1-3. The area in and
around Ermelo is a highly industrial owing to the coal mines and power stations situated in close proximity to
one another.

Figure 1-3: Research area map

• Figure 1-3 shows the railway route the wagons travel between Ermelo and Richards Bay. The concentration of
power stations and coal mines is also shown.
 6. The effect of pollutants in and around Ermelo
• The concentration of the air pollutants around these area is constantly and significantly changing ranging
from 8 - 44 μg/m3 of (Sulphur dioxide) SO2 concentrations [9].
• However, the average air in Ermelo is still considered to be non-harmful to humans and the particle
concentrations to be below the annual limit value [10].
• The corrosion of 3CR12 steel in Sasolburg during a corrosion exposure programme by Callaghan [11] for a
period of over ten years can somewhat be compared to the expected corrosion behaviour in Ermelo.
• The similarities (Relative humidity, air pollutants, etc.) between the two industrial areas gives something to
compare. It is clear from these results that 3CR12 performs very well against corrosion in heavy industrial
areas such as Sasolburg.
• The same performance can be expected in Ermelo given similarities in air pollutants as well as RH and high
temperatures.
 7. Atmospheric corrosion at the port of Richards Bay
• At the coast in Richards Bay, the area is a subtropical marine environment with a medium to severe
corrosion rating mostly on unprotected non corrosion resistant steels such as mild steel.
• The wagons line-up less than two meters away from the coastline before being shunted to the tippler. The
distance from the sea to the wagons is presented in Figures 1-4.
• The position of wagons at the port of Richards Bay puts them within reach (<2 km) of the sea chlorides
carried by winds.

Figure 1-5: Wagon’s distance from the sea [12]

 8. Corrosion resistance of 3CR12 at the coastal area
• The CSIR exposure programme by Callaghan has shown that 3CR12 steel performs fairly well even in the very
aggressive sites of Bluff and Walvis Bay.
• Only pitting corrosion was to be given attention albeit for very thin structures like roofs.
• Electrification masts made from 3CR12 steel and located a stone-throw from the sea shore in Port Elizabeth,
were assessed after thirty years and found to have shown no sign of corrosion concern or need for
maintenance [13].
• The same good corrosion resistance performance was found in coal wagons manufactured using 3CR12 steel
[14]. These wagons were assessed after being in service for almost thirty years and the only noticeable
activity was 10 micron a year abrasion wear.
• There is a good case to make on the success of 3CR12 steel along the coastal area based on the performance
of the structures that have withstand these aggressive environment from a close distance to the coast.
 9. conclusion
• The application of 3CR12 steel in the manufacturing of CCR, CFR and other wagons carrying coal between
Ermelo and Richards Bay has been successful in corrosion resistance perspective.
• However, these wagons have faced other challenges such as cracks which needs to be continuously repaired.
This continuous repairing of cracks have prevented most of these wagons from seeing their expected service
life.
• From an economical point of view, the wagons manufactured using 3CR12 can be regarded as more
economical than the previously used Mild Steel and Corten A.
• This is based on the fact that the first two steels required maintenance such as re-painting and re-plating
every 4 to 5 years whilst none of this is required on the 3CR12 steel for at least 15 years, if we do not
consider the unexpected cracking which is fairly attributed to design flaws.
• The 3CR12 steel has shown to have good corrosion resistance in coal conveying applications as well as
exposure to chlorides from the coastal areas such as Richards Bay.
• There is potential for further investigation on the subject regarding these wagons and the application of the
3CR12 steel. More detailed investigations involving tests of loss of material per year due to corrosion as well
as detailed financial benefits as compared to other steels in the same application.
 References
[1] Columbus stainless [Pty] Ltd, 3CR12 technical data 2007; pp. 4-13.
[2] World Stainless 2019, The stainless steel family,viewed 20 August 2019,
<http://www.worldstainless.org/Files/ISSF/non-image-files/PDF/TheStainlessSteelFamily.pdf >.
[3] Sandenbergh R F, The Stress Corrosion Properties of 3CR12, Anti-Corrosion, Jan 1987.
[4] Du Toit M, Van Rooyen G T, Smith D, An overview of the heat-affected zone sensitization and stress
corrosion cracking behaviour of 12 % chromium type 1.4003 ferritic stainless steel, Welding in the World, Vol.
51, No. 9/10, 2007
[5] Mamphekgo T C, Matjeke V J and Pillay K, Investigation of abnormal corrosion of 10.5 – 12.5 chromium
ferritic stainless steel used to fabricate railway coal wagons, IOP Conference Series: Materials Science and
Engineering, 2018.
[6] Mursalo N, Tullmint M, and f.p.a. Robinson F. P. A., The corrosion behaviour of mild steel, 3CR12, and AISI
type 316L in synthetic minewaters, Journal of the South African Institute of Mining and Metallurgy, August
1988.
[7] Paik J K, Kim K S and Lee K S, Probabilistic corrosion rate estimation model for longitudinal strength
members of bulk carriers, Ocean Engng, Vol. 25, No. 10, 1998; pp. 837–860.
[8] Lazenby H, Transnet delivers last 98 wagons to Rio’s Mozambique operations, Creamer media, North
America, March 2012.
[9] Air Visual, Ermelo - Mpumalanga air quality index (AQI) and air pollution, viewed 18 September 2019,
<https://www.airvisual.com/south-africa/mpumalanga/ermelo>
[10] Department of Environmental Affairs 2019, Chapter 10 Air quality, viewed 18 September 2019,
<https://www.environment.gov.za/sites/default/files/reports/environmentoutlook_chapter10.pdf>
[11] Callaghan B G, Atmospheric corrosion testing in Southern Africa – Results of a twenty year national
exposure programme. Division of material science and technology, CSIR 1991.
[12] Google Earth 2019, Port of Richards Bay, viewed 22 August 2019,
<https://www.google.com/maps/search/port+of+richards+bay/@-
28.8087638,32.0313323,1711m/data=!3m1!1e3>
[13] Tarboton J, Stainless steels in structural applications, Steel Construction Vol. 38 No. 4 2014.
[14] Sassda 2019, Stainless steel, second quarter 2014, viewed 22 August 2019,
<http://www.sassda.co.za/wp-content/uploads/Stainless%20Steel%20June%202014.pdf
 Appendix: Response to instructor’s comments
• Instructor comment: Change of research focus and topic name to “Corrosion performance of 3CR12 steel in
coal conveying application”.
• Response: The name was accordingly changed and the research was focused on the corrosion performance of
CCR wagons carrying coal between Ermelo and Richards Bay.
• Instructor comment: “Discussion on localised corrosion not convincing and should be done in more depth.
Correct use of capital letters. Improve line of argument to clearly make the case for materials choice
optimization. References must be complete and in consistent format.”
• Response: The threat of localised corrosion is discussed in the context of the material being in constant contact
with the coal. Research shows that sulphite ions from the coal have a passivating effect against chlorides and as
a result 3CR12 steel is protected from localised corrosion that has been found to be prominent in mild steels.
However, formation of cracks on the surface of the steel may give rise to discontinuities and cavities that may
potentially expose the material to localised corrosion.
• Material choice optimization is discussed in a comparison context with the Mild Steel and Corten A, both of
which have been previously used in the manufacturing of the CCR wagon.
• Instructor comment: Challenges of using 3CR12 as material of construction
• Response: It has been clearly stated in many research papers as well as in this research that the 3CR12 steel
has great fabrication properties, especially when compared to other corrosion resistant steels of its kind.
However, the high initial costs (as compared to Mild Steel and Corten A) may not be justified if the wagon does
not survive to an expected lifespan because of unexpected damages such as cracks seen on the CCR wagons.
Technically, there are no major fabrication challenges which cannot be easily mitigated.