Corrosion Inspections at Nueva Aldea Pulp Mill During 2011 Shutdown

15397 COLUMBIA AVENUE Tel.
+1-604-536-2053
ANGELA WENSLEY WHITE ROCK, BC, CANADA Fax. +1-604-536-2078
E N G I N E E R I N G V4B 1K1 Email: awensley@uniserve.com
CORROSION INSPECTIONS
DURING THE GENERAL
PLANT SHUTDOWN
AT NUEVA ALDEA
AUGUST 2011
Prepared for:
Celulosa Arauco y Constitución S.A.

Planta Nueva Aldea
Autopista del Itata – km 21
Nueva Aldea
Chile
Attention: Mario Ávila G.

Jefe de Análisis Sintomático
Date: 9 October 2011 Dr. Angela Wensley, P.Eng.

Project No. AWE1106 Pulp & Paper Corrosion Specialist
G:\ALL WORK FILES\Neuva Aldea\2011\Report Text Nueva Aldea 2011.doc

ANGELA WENSLEY Corrosion Inspections During the General Plant Shutdown
E N G I N E E R I N G at Nueva Aldea – August 2011
TABLE OF CONTENTS
SUMMARY . . . . . . . . . . 3
RECOMMENDATIONS . . . . . . . . 9
1.0 INTRODUCTION . . . . . . . . 12
2.0 EVAPORATORS . . . . . . . . 13
2.1 Superconcentrator S-1 . . . . . . 14
2.2 Concentrator Effect E-1 A, B, C, D . . . . . 15
2.3 New concentrator Effect E-1 F, G . . . . . 18
2.4 Evaporator Effect E-2 . . . . . . 19
2.10 New Evaporator E-7 . . . . . . 24
2.11 Surface Condenser . . . . . . . 25
3.0 DIGESTERS. . . . . . . . . 25
3.1 Line 1 (Pine) . . . . . . . . 25
3.2 Line 2 (Eucalyptus) . . . . . . . 27
4.0 BLEACH PLANT . . . . . . . . 28

4.1 Line 1 (Pine) . . . . . . . . 29
4.2 Line 2 (Eucalyptus) . . . . . . . 30
5.0 PULP MACHINES . . . . . . . . 31

5.1 Line 1 (Pine) . . . . . . . . 31
5.2 Line 2 (Eucalyptus) . . . . . . . 33
6.0 DISCUSSION . . . . . . . . 34
6.1 Corrosion and Cracking in the Superconcentrator . . 34
6.2 Corrosion and Cracking in the Concentrator . . . 35
6.3 Corrosion in the Evaporators . . . . . 36
6.4 Erosion in the Digesters . . . . . . 37
6.5 Corrosion in the Bleach Plant . . . . . 38
6.6 Corrosion in the Pulp Machines . . . . . 39
7.0 REFERENCES . . . . . . . . 41
FIGURES . . . . . . . . . . F-1
2
SUMMARY
Evaporator Effect S-1 (Superconcentrator)
New duplex stainless steel plugs were installed in the tubes to repair the
previous plugs that had been installed in 2010 but had failed. The cause of
leaking of the tubes was evidently due to poor quality control of the tube-to-
header welds during original manufacture.
The elbow in the condensate drain that was replaced in 2010 was intact. The
problem with the elbow was improper heat treatment.
Evaporator Effect E-1 A, B, C, D (Concentrator)
No new stress corrosion cracking (SCC) was found in the concentrator. There
was no initiation of SCC in the areas adjacent to the weld seams that were
cleared of cracking in 2010. Existing SCC of the shell in locations away from the
weld seams and in the non-pressure parts did not appear to have grown in
extent.
Evaporator Effect E-2
No corrosion or cracking problems were observed. The liquor zones in the top
and bottom are now all 304L stainless steel and should resist corrosion.
3
The carbon steel top head was replaced with a new 304L stainless steel top head.
The liquor zones in the top and bottom are now all 304L stainless steel and
should resist corrosion.
The top head and the liquor zone are carbon steel, but have resisted corrosion
since this effect sees the weakest black liquor. The corrosion rate will likely
remain low after the 2011 shutdown when this effect is converted to E-3.
No appreciable galvanic corrosion was observed in the carbon steel top head.
Corrosion of the carbon steel in the bottom liquor zone was observed. A
stainless steel lining installed during the 2011 shutdown was incomplete
(covering only the cylindrical section and one ring in the conical section). The
remaining carbon steel may experience a slightly accelerated rate of corrosion
due to galvanic contact with stainless steel, but should survive until 2012. The
non-galvanic corrosion rate should not change appreciably after the 2011
shutdown when this effect is converted to E-4.
Significant corrosion of the carbon steel in the bottom liquor zone was observed.
A stainless steel lining installed during the 2011 shutdown was incomplete
(covering the cylindrical section and the conical section except for the lower cap).
The remaining carbon steel may experience an accelerated rate of corrosion due
to galvanic contact with stainless steel, but should survive until 2012. The non-
4
galvanic corrosion rate should not change appreciably after the 2011 shutdown
when this effect is converted to E-5.
Significant corrosion of the carbon steel in the bottom liquor zone was observed.
A stainless steel lining installed during the 2011 shutdown was incomplete
(covering the cylindrical section and the conical section except for the lower cap).
The remaining carbon steel may experience an accelerated rate of corrosion due
to galvanic contact with stainless steel, but should survive until 2012 without
leaking.
Surface Condenser
The internal carbon steel surfaces were covered with a thick oxide scale that had
pitting corrosion underneath, characteristic of oxygen corrosion. If this situation
is unacceptable for operational purposes, consideration should be given to
replacement of the surface condenser using 304L stainless steel.
Line 1 (Pine) Continuous Digester
Some erosion thinning was observed on the uppermost flight of the top separator
screw. The screw was replaced during the 2011 shutdown.
Repairs made to the "half-pipe" header in 2010 had survived. No new leaks were
observed.
Visual inspection of the arms for the bottom scraper did not reveal any cracking.
5
The 304L stainless steel China hat had experienced severe erosion thinning that
resulted in a failure of one segment. Weld repairs made using E309L stainless
steel in 2010 had not survived as they were too soft. It was recommended that
the China hat the replaced using duplex stainless steel. At least, the weld repairs
should be done using 312 stainless steel which is harder than 308L or 309L and
more resistant to erosion.
Numerous cracked 309L stainless steel stitch welds were observed at screens and
blank plates in the wash zone. Repair welds should be made using 312 stainless
steel which resists cracking better than 309L stainless steel.
Visual inspection of the two steam injectors in the top did not reveal any
problems. Experience in other digesters has been that the inserts corrode inside
the nozzles and this can only be inspected by removal of the inserts.
Line 2 (Eucalyptus) Continuous Digester
No significant erosion was observed of the 3040 China hat.
Repairs made to the "half-pipe" header in 2010 were intact. No new leaks were
observed.
Cursory visual inspection of the bottom scraper arms revealed no cracking.
Visual inspection of the two steam injectors in the top did not reveal any
problems.
6
Bleach Plant Presses
Nickel-base welds in D-stage service are experiencing transpassive corrosion at a

greater rate than the 6% Mo stainless steel used for construction of the bleach
presses. Preferential corrosion of the nickel base welds is most obvious on the
flaps, vats, and rolls of the D-stage presses. This corrosion should be monitored
over the next several years as it may become necessary to make repairs.
Pitting corrosion of 6% Mo stainless steel components of the D-stage presses is

continuing. Diligent monitoring is required.
Weld repairs made in 2010 to mechanical damage of the roll in the second press
of Line 1 had survived, suggesting that weld repairs may be made to other
locations of damage on the rolls.
Bleach Plant Piping
A long run of corroded 2205 duplex stainless steel piping below the Line 1
presses had been replaced after the 2010 shutdown using fibreglass reinforced
plastic (FRP) piping. The FRP piping should resist corrosion in D-stage filtrate
service. Some 2205 duplex stainless steel piping remains in both Line 1 and Line
2. Leaks due to corrosion were observed in ring headers around the bottom of
the drop legs for the Line 1 presses 5 and 6. The D-stage filtrate in the ring
headers is too corrosive for duplex stainless steel to resist corrosion and leaking.
All duplex stainless steel piping in D-stage filtrate service in Line 1 should be
replaced using FRP, 6% Mo stainless steel, or titanium.
7
Corrosion has not yet been observed in Line 2 piping. The residual chlorine
dioxide level in Line 2 may be lower than that of Line 1 and this may account for
the lack of corrosion. Corrosion may have initiated, however, on the inside of
duplex stainless steel pipes that may progress to leaking in the future. Diligent
monitoring is required.
Pulp Machines
Corrosion of 316L stainless steel components in Line 1 is becoming widespread,

and now includes white water tanks, the Fourdrinier section (both above and
below the pan), white water piping, the slice and apron lips of the headbox, and
the baskets within screens. All of the corrosion may be microbiological in origin.
It is important that the microorganisms responsible for the microbiologically
influenced corrosion (MIC) be identified and that measures be taken to eliminate
the microorganisms from the white water system.
Comparable corrosion has yet to be observed in the Line 2 pulp machine white
water tanks. This would normally suggest that the carryover of residual chlorine
dioxide from the bleach plant to the pulp machine is less in Line 2; however, it
may be the case that eucalyptus pulp has an antibacterial function that inhibits
MIC. If this is the case, the MIC in Line 1 may be treated by adding some white
water from Line 2 into the Line 1 system.
8
RECOMMENDATIONS
I recommend that:
For the Superconcentrator:
S1. Repairs made to the tubes and condensate headers should be carefully
inspected during all general plant shutdowns.
S2. If it is necessary to replace tube panels, diligent quality assurance by an

independent contractor should be done during manufacture.
For the Concentrator:
C1. Ongoing efforts should be made to eliminate all cracks from the 304L shell,
with the priority being (in order) sections A, B, C, and D.
C2. Reference areas of existing cracks in the dividers (non-pressure parts) should
be re-examined to determine whether the cracking is growing in extent.
For the Evaporators:
E1. The stainless steel linings in effects E-5, E-6, and E-7 should be completed as
soon as is practical. Before the linings are completed, the thickness of the
stainless steel shell must be verified.
E2. The absence of carbon steel in the bottom zone of the original effects E-2 and
E-3 should be verified by consulting the relevant drawings for these
evaporators.
9
For the Digesters:
D1. The China hat for the Line 1 digester should be replaced. The new China hat
should be constructed using 2205 or 2304 duplex stainless steel.
D2. In locations where erosion or weld cracking is observed, weld repairs should
be done using 312 duplex stainless steel that is harder and also resists
cracking better than the austenitic stainless steel that is currently used.
D3. The bottom scraper arms should be cleaned and inspected using penetrant
testing (PT) during each general plant shutdown. The thickness of the arms
should also be monitored using ultrasonic testing (UT).
D4. Consideration should be given to removing at least one of the inserts from
the steam injectors in the Line 1 and Line 2 digesters, so they can be
inspected for corrosion occurring in the annulus between the insert and the
oblique steam nozzle.
For the Bleach Plant:
B1. All nickel base welds in D-stage service should be diligently monitored for
transpassive corrosion.
B2. All 2205 duplex stainless steel piping in Line 1 D-stage filtrate service should
be replaced. Suitable materials are: FRP, 6% Mo stainless steel, and titanium.
B3. The 2205 duplex stainless steel piping in Line 2 should be carefully
monitored for signs of corrosion from the inside (leaking).
10
B4. Weld repairs of mechanical damage on the twin roll presses may be made.
For the Pulp Machines:
P1. The hypothesis that the corrosion is due to MIC should be tested. Samples
should be sent for DNA testing to determine which bacteria are present.
P2. Where suspected MIC is observed, the tubercles should be removed and the
surface cleaned so that a weld repair can be done using an over-matched
filler metal. Type 309L stainless steel is slightly overmatched and is
preferable to using 316L stainless steel. Welds made using Alloy 625 may
offer even better resistance to corrosion.
P3. Consideration should be given to upgrading the metallurgy of tanks and

piping in critical service. For example, 316L stainless steel may be replaced
using 2205 stainless steel or (even better) 6% Mo stainless steel.
P4. The slice and apron lips for the headboxes should be upgraded to at least 6%
Mo stainless steel.
P5. Addition of Line 2 (Eucalyptus) white water into the Line 1 (Pine) white
water system may help control the corrosion if it can be established that
Eucalyptus inhibits microbiological activity.
P6. The lining on the concrete under the Fourdrinier of the Line 2 pulp machine
should be repaired to prevent contact between the white water and the
underlying concrete.
11
1.0 INTRODUCTION
I was at the Nueva Aldea mill from 12 August through 19 August 2011
during the annual general plant shutdown (I gave my exit presentation
during the morning of 20 August). I previously attended the general plant
shutdowns in November 2007 [Ref. 1], January 2009 [Ref. 2], and April
2010 [Ref. 3]. The mill started up in 2006.
I was based in the contractor's room on the second floor of the main office
building. Most of my inspections were made in the evaporators and
concentrators. I also made inspections in the digesters, bleach plant
presses, and the wet ends of the pulp machines. I was assisted by
Alejandro Soto, a metallurgist hired by Celulosa Arauco y Constitución.
He accompanied me on many of my inspections.
Safety requirements for 2011 mandated the wearing of harnesses for

inspection and other work from scaffolding. Locks were also required
prior to entry into the equipment.
12
2.0 EVAPORATORS
Nueva Aldea has a Kvaerner (Metso) seven-effect falling film evaporator

train with a superconcentrator. The liquor and vapour flows are:
WEAK STRONG
COOL
BLACK BLACK
VAPOUR
LIQUOR LIQUOR
54C
19% 77%
28% 24% 21% 39% 45% 73%
7 6 5 4 3 2 1 S1
65C 74C 83C 91C 102C 114C 142C
34%
HOT
175C
STEAM
After the 2011 shutdown, a new concentrator (F, G) and a new seventh
effect evaporator (E-7) are to be brought on-line. The existing evaporators
will be re-named:
• The existing effect E-2 will become E-2A.

• The existing effect E-3 will become E-2B.
• The existing effect E-4 will become E-3.
13
2.1 Superconcentrator S-1
The cylindrical shell and internals of the

superconcentrator were constructed using type
2304 duplex stainless steel (green colour in the
drawing at left); the top and bottom heads (pink
colour) were type 2205 duplex stainless steel. The
superconcentrator has two sections (A and B)
within a single body.
E-S1 A/B
Massive deposits were found in the top part of the

superconcentrator (Figure 1), resulting in delays
while the deposits were removed by
hydroblasting and physical labour. Dirty water
running down the tubes impeded visual
inspections in the bottom.
Inspections of the condensate drains in the bottom revealed that the elbow
that was replaced in 2010 was in good condition (Figure 2). It had been
determined that the original elbow had failed due to improper heat
treatment. The heat treatment procedure has been corrected, so that any
new elbows should be resistant to SCC.
Plugs installed in 2010 to seal off tubes with leaks at the tube to header
welds had failed (Figure 3). New tapered plugs of 2205 duplex stainless
steel were prepared for installation in 2011 (Figure 4). These plugs were
successfully installed (Figure 5).
14
The reason for the leaking at the tube to header welds had been
determined to be the result of poor quality assurance during the
manufacturing process. Some examples of weld undercut were observed
in tubes that had not (yet) failed (Figure 6). Figure 7 shows a tube to
header weld that was different in appearance from the others, and may be
an example of a successful weld repair carried out in the field.
2.2 Concentrator Effect E-1 A, B, C, D
The concentrator has four sections (A, B, C, and D)

within a single body. The shell of the concentrator
was constructed entirely of type 304L austenitic
stainless steel, including the top and bottom heads
and all of the cylindrical rings (blue colour).
Originally, all the tubes were 304L stainless steel,
with duplex stainless steel being used for only the
E-1 vapour inlets at the top and large-diameter
A, B, C, D
headers and drain tubes in the bottom.
In 2009, SCC was found in the 304L tubes in

bodies A, B, and C. SCC was also found
associated with the circumferential and vertical
welds in the 304L shell.
In 2010, the top head was temporarily removed and the tubes were
removed from sections A, B, and C to gain access to the shell of the
digester. New 2304 duplex stainless steel tube bundles were installed in
sections A, B, and D. All cracks on the process-side of the shell were
removed from ± 25 millimeters of the weld seams. There was not enough
15
time to remove cracks in other locations in the shell or in non-pressure

parts such as the dividers between the four sections.
In 2011, there were massive deposits in the upper part of the concentrator
whose removal by hydroblasting and physical labour resulted in delays in
the work that could be done below.
In the past, cracking and corrosion thinning had been the most severe in
section A. Visual inspection of the tubes in section A revealed no cracking
or thinning (Figure 8). One of the supports for a header in section A had
been deflected below the header (Figure 9).
The only circumferential weld accessible for visual inspection in section A

was the weld between the lowest cylindrical section and the top of the
bottom cone. No re-initiation of cracks was observed in the area within ±
25 millimeters of the accessible weld seams. The cracks that were
removed in 2010 did not reappear in 2011. Outside the ± 25 millimeter
zone, however, there were numerous locations of pre-existing cracks that
were not removed in 2010. Figure 10 is an example. Also, an
unauthorized weld (it is not known when this weld was made) was found
across a longitudinal weld in the conical section (Figure 11). Closer
inspection revealed SCC around the unauthorized weld, in both the
parent metal of the shell and the longitudinal weld (Figure 12).
Cracking was also observed on the dividers in section A. Figure 13 shows

the divider between sections A and D. A location of SCC was selected as a
reference for future monitoring (Figure 14). Re-examination of this
location in 2012 and subsequent years will reveal whether the cracking is
increasing in extent.
16
The next-highest risk of SCC in the concentrator is section B. No tube

cracking was observed (Figure 15). No cracking was observed within the
± 25 millimeter so of the assessable weld seams in section B (Figure 16).
Cracking was observed on the divider. Figures 17-20 document reference
locations on the dividers between sections B and C, and sections B and D.
Visual inspection of the tubes in section C revealed no cracking (Figure

21). These tubes may be the 304L austenitic stainless steel tubes that were
moved from section D in 2010. If so, they may be susceptible to SCC in
the future.
Figure 22 shows cracking of stitch welds on the divider between section C

and section B. This cracking may be mechanical in origin. Again, no
cracking was found on the shell within ± 25 millimeters of the accessible
weld seams (Figure 23). Cracking of the shell was found outside the ± 25
millimeters from the accessible welds (Figure 24). All cracking of the shell
was associated with temporary welds that had been removed and ground
flat. Obviously, grinding does not remove the residual stresses associated
with the temporary welds.
Section D is at the lowest risk of cracking and corrosion in the

concentrator, due to its having the lowest percent solids of black liquor
and the lowest temperature. No SCC was observed in section D. A
support that was cut in 2010 had not been re-installed (Figures 25 and 26).
Figure 27 is a view of the circumferential welds at the top of the

concentrator, including original weld 12 between the cylindrical section
and the top head and a new weld 11A that was made when the head was
17
reattached after the shutdown in 2010. Figures 28 and 29 are closer views
of weld 11A and 12, respectively. There was no cracking within ± 25
millimeters of either weld. There were locations of SCC in the top head
outside the ± 25 millimeter zone (Figure 30). This SCC appeared to be the
same visually as in 2010.
Overall, it appears that no new cracking had initiated in the shell of the
concentrator. Further, the existing cracking does not appear to have
grown in extent. This means that it may be possible to eliminate the
cracking from the concentrator. It was recommended that all accessible
cracks in the shell be removed by polishing using flap discs. I had left the
mill before any work was done. No scaffolding had yet been constructed.
2.3 New Concentrator Effect E-1 F, G
A new concentrator was being installed during the 2011 general plant
shutdown (Figure 31). The material of construction was reportedly
duplex stainless steel. The name tag revealed that the new concentrator
had been built in the People's Republic of China (Figure 32). Large duplex
stainless steel pressure vessels require diligent quality assurance during
manufacture to prevent corrosion and cracking problems during
operation. It is not known whether any quality assurance was done. I do
not have great confidence in the capabilities of Chinese manufacturers to
follow specifications. I have provided quality assurance guidelines for
duplex stainless steel pressure vessels to Nueva Aldea. These should be
followed.
18
2.4 Evaporator Effect E-2
The body of the second effect evaporator E-2 was

constructed using a mixture of SA516-Grade 70
carbon steel (yellow) in the vapour zone and type
304L stainless steel (blue) in the upper liquor zone,
the lower liquor zone, and the top of the steam
chest in the vapour zone.
E-2 In August 2007 there was a leak at the entrance of

the recirculation line at the top of E-2 due to
galvanic corrosion. The inlet of the recirculation
line was replaced using type 304L stainless steel.
In November 2007, rapid corrosion thinning of the
carbon steel top cone in the vapour zone above the
top stainless steel ring was observed. In 2009, the
carbon steel top head was replaced with a new
head of type 304L stainless steel.
Figure 33 is a view inside the top of effect E-2 showing the stainless steel
upper tubesheet, the upper stainless steel cylindrical ring, and the new
(2009) stainless steel top head. Visually, no problems were observed.
Figure 34 is a view of the bottom of effect E-2. The shell in this location is
solid 304L stainless steel and appears to have completely resisted
corrosion. A detailed drawing should be consulted to confirm that no
carbon steel is exposed below the elevation of the bottom tubesheet, as
carbon steel has poorer corrosion resistance in this effect.
19
The body of the third effect evaporator E-3 was

constructed using a mixture of SA516-Grade 70
carbon steel (yellow) for the top head and in the
vapour zone, and type 304L stainless steel (blue)
in the bottom of the upper liquor zone, the lower
liquor zone, and the upper part of the steam chest
E-3 in the vapour zone.
Inspection of the top head in 2009 revealed slight

galvanic corrosion of the carbon steel top head
above the upper stainless steel ring in the upper
liquor zone. In 2011, a new ellipsoidal top head of
304L stainless steel was installed (Figure 35). The
external surface of the new head had a paint
coating. This coating is desirable for protection
against external SCC beneath wet thermal
insulation.
Figure 36 is a view of the bottom of effect E-3. The shell and internals in
the bottom of effect E-3 are all 304L stainless steel and have completely
resisted corrosion. A detailed drawing should be consulted to confirm
that no carbon steel is exposed below the level of the lower tubesheet, as
carbon steel has poor resistance to corrosion in this effect..
20
The body of the fourth effect evaporator E-4 was

constructed predominantly using SA516-Grade 70
carbon steel (yellow) with type 304L stainless steel
(blue) rings in the bottom of the upper liquor zone
and at the top and bottom of the steam chest in the
E-4 vapour zone. Evaporator effect E-4 sees the
weakest black liquor of any of the evaporators, so
is expected to have the fewest corrosion problems
with the carbon steel components.
There was no galvanic corrosion of the carbon

steel top head above the upper cylindrical
stainless steel ring in the vapour zone (Figure 37).
Figure 38 is a view of the bottom of effect E-4. The shell and internal
components in this zone are all carbon steel and apparently without
appreciable corrosion.
Figure 39 shows the divider and the roof around and above the liquor
inlet in effect E-4. The stiffeners around the divider appear to the original
thickness (Figure 40). The roof above the liquor inlet is of the same design
as that in effect E-5 that failed in 2010.
21
The body of the fifth effect evaporator E-5 was

and at the top and bottom of the steam chest in the
vapour zone.
E-5
In 2010, the roof of the divider above the liquor
inlet had failed and was found in the bottom of the
evaporator. The failure was likely the result of the
combination of corrosion and cracking.
There was no galvanic corrosion of the carbon steel top head in the vapour
zone (Figures 41 and 42).
The bottom of effect E-5 was scaffolded in 2011. This permitted access to
the transition between the single stainless steel ring in the carbon steel
cylindrical ring below (Figure 43). Some galvanic corrosion
("fingernailing") was observed (Figure 44). The carbon steel internals in
effect E-5 were corroded (Figures 45 and 46). Carbon steel welds were
preferentially corroded. Carbon steel welds have a higher silicon content
than the A516 grade 70 plate. Higher silicon content impairs corrosion
resistance.
22
A stainless steel lining was to be installed in the bottom of effect E-5

during the 2011 shutdown. The lining was completed in the cylindrical
section but only in one ring of the conical section.
The body of the sixth effect evaporator E-6 was

and in the bottom and top of the steam chest in the
E-6 vapour zone.
There was no galvanic corrosion of the carbon

steel above the upper stainless steel ring in the
upper liquor zone (Figures 47 and 48).
The bottom liquor zone of E-6 was scaffolded in

2011.
Figures 49 and 50 show the transition between the single stainless steel
ring in the lower cylindrical section, and the carbon steel cylindrical rings
below. Galvanic corrosion ("fingernailing") of the carbon steel was
observed.
The carbon steel wall and internals were extensively corroded (Figures 51
through 54). A stainless steel lining was to be installed in the bottom of
effect E-6 during the 2011 shutdown. The lining was completed in the
cylindrical section and part of the conical section (except the bottom).
23
The body of the seventh effect evaporator E-7 was

and in the top and bottom of the steam chest in the
vapour zone.
E-7
There was no appreciable galvanic corrosion of the
carbon steel top head above the upper stainless
steel ring (Figures 55 and 56).
The bottom of effect E-7 was scaffolded during the

2011 shutdown but I had no opportunity to
inspect from the scaffold.
Figures 57 and 58 are views inside the bottom of effect E-7. The corrosion
of the carbon steel was the most severe in this effect. A stainless steel
lining was to be installed in the bottom of effect E-7 during the 2011
shutdown. The lining was completed in the cylindrical section and part of
the conical section (except the bottom).
2.10 New Evaporator Effect E-7
A new seventh effect evaporator was being installed during the 2011
general plant shutdown (Figures 59 and 60). Reportedly, the material of
construction was 304L stainless steel. It was constructed in the People's
Republic of China.
24
2.11 Surface Condenser
Figure 61 is a view through the upper manway. The carbon steel wall was
covered with an oxide scale that appeared to be from oxygen corrosion.
The carbon steel underneath was pitted (Figure 62).
Since there is no practical way to stop the corrosion of the carbon steel,
replacement of the surface condenser in 304L stainless steel should be
considered.
3.0 DIGESTERS
The shells of the two continuous digesters were constructed using type
2205 duplex stainless steel. The non-pressure parts (screens, blank plates,
central pipes, China hats) are mostly constructed of 304L stainless steel.
My internal inspections of the digesters in 2011 were confined to the

bottoms that were accessed through the bottom manways. I made only
cursory inspections inside the impbins.
3.1 Line 1 (Pine) Digester
The top separator screw was removed from the Line 1 digester in 2011
(Figure 63) and replaced with a new top separator screw. Inspection of
the removed screw revealed erosion thinning of the uppermost flight
(Figure 64). The lower flights had not experienced appreciable erosion
(Figure 65).
25
In 2010, extensive repairs were made to the "half-pipe" header on the

outside of the Line 1 digester. In 2011, the insulation was removed to
permit visual inspection of the "half-pipe" header (Figure 66). No
problems or leaks were observed.
In 2008, there were two failures of the bottom scraper in the Line 1 (pine)
digester. The origins of the failures were small cracks in martensitic
carbon steel that formed when the stainless steel filtrate pipes were
welded onto the trailing edges of the scraper arms without preheat. The
small cracks grew across the arms by a fatigue mechanism. A new bottom
scraper, reportedly built using proper preheat, was installed in the Line 1
(pine) digester during the shutdown in 2009. In 2011, visual inspection of
both scraper arms revealed no cracking (Figures 67 and 68). The arms
need to be inspected annually using PT. The thickness of the arms should
also be monitored annually using UT.
In 2010, erosion of the welds on the 304L China hat was observed. Repairs
were made using E309L stainless steel, but this weld metal is too soft to
resist erosion in digester service. In 2011, severe erosion had produced a
failure of the China hat (Figures 69 and 70). In locations that have not
failed, the weld caps had corroded completely away exposing the
underlying carbon steel supports (Figure 71). The China hat was filled
with pulp (Figure 72).
There were numerous cracked stitch welds in the screens (Figures 73 and
74). These welds were probably originally made using type 308L stainless
steel which has low-strength and is prone to hot cracking. I recommended
using type 312 stainless steel welding consumables to repair the stitch
26
welds. Type 312 stainless steel is much stronger and more resistant to
cracking than either 308L or 309L.
There are two vapour injectors in the top of the Line 1 (pine) digester. The
nozzles for the injectors are type 2205 duplex stainless steel. The inserts
are also reportedly of type 2205 duplex stainless steel. In other digesters
the inserts experience corrosion in the annular space between the nozzles
and the inserts. In 2011, visual inspection of the vapour injectors did not
reveal any problems (Figures 75 and 76) but there was no access to the
locations where corrosion could occur.
At least one of the injectors should be removed for visual inspection

during the 2012 general plant shutdown.
3.2 Line 2 (Eucalyptus) Digester
No problems of note were observed in the Line 2 digester in 2011. Visual

inspection of the top separator screw (in-situ) revealed normal wear
(Figure 77). The vapour injectors were intact (Figure 78), although there
was no direct visual access to the locations where corrosion may occur.
The "half-pipe" header around the bottom of the digester that was
repaired in 2010 appeared to be in good condition with no leaks (Figure
79).
The China hat in the Line 2 digester did not appear to have experienced
appreciable erosion (Figures 80 and 81). The bottom scraper in the Line 2
digester visually appeared to be without problems, but conditions were
too wet to permit inspection (Figure 82).
27
4.0 BLEACH PLANT
There are seven Aker Kvaerner (now GL&V) twin-roll "Compact Presses"
in the Line 1 (pine) bleach plant and seven presses in the Line 2
(eucalyptus) bleach plant.
PULP
OUT
DISTRIBUTION SCREW
PULP IN
SHREDDER
FLAP
ROLL ROLL DEWATERING
ZONE
WASH
LIQUOR
IN FILTRATE OUT
Both the pine and eucalyptus lines have three pre-bleach presses, followed
by a D0-stage (press 4), an EOP-stage (press 5), a D1-stage (press 6), and a
D2-stage (press 7). The principal material of construction for presses 1, 2,
3, and 5 is type 316L stainless steel. The principal material of construction
for the D-stage presses 4, 6, and 7 is 6% Mo stainless steel. Most of the
piping is either FRP or 6% Mo stainless steel, but some piping is type 2205
duplex stainless steel.
In 2009 and 2010, corrosion problems were found in the D-stage presses
and piping where significant residual ClO2 existed. The Line 1 (pine) D-
28
stage presses were more corroded than their counterparts in Line 2

(eucalyptus). The most severe corrosion was found in type 2205 duplex
stainless steel piping carrying Line 1 (pine) D-stage filtrate.
4.1 Line 1 (Pine)
Figure 83 shows one of the flaps for the Line 1 press 7. This flap was
modified in 2010 when a 6% Mo stainless steel liner was installed. The
welding consumable used was ERNiCrMo-3 (Alloy 625). Nickel base
alloys such as Alloy 625 are not suitable for service in D-stage filtrates
where an appreciable amount of residual chlorine dioxide exists, as they
are susceptible to transpassive corrosion. The Alloy 625 plug welds in the
liner have appreciable corrosion (Figure 84).
At other locations in the vat, corroded plug welds of Alloy 625 can also be
observed (Figure 85). Preferential weld corrosion can also be observed on
the rolls (Figure 86).
In 2010, considerable mechanical damage was found in the rolls, evidently

a consequence of the earthquake. There was some discussion as to
whether the damage could be weld repaired (would the weld repairs
promote fatigue cracking?), but ultimately most of the mechanical damage
was left unrepaired. A weld repair carried out on one of the rolls in Line 1
press 2 had survived intact (Figures 87 and 88). This confirms that weld
repairing can be done without cracking. Figure 89 shows another location
of mechanical damage on the same roll where cracking has developed in
the absence of a weld repair.
29
Figure 90 shows an opened flap in the Line 1 press 7. Part of the flap was
identified as a duplex stainless steel (magnetic). It is my understanding
that the material of construction is supposed to be 6% Mo stainless steel.
In previous years, severe corrosion of a 2205 duplex stainless steel

pipeline carrying D-stage filtrate had resulted in numerous leaks. Repairs
of the leaks only resulted in new leaks appearing at the repairs. After the
2010 shutdown, the corroded 2205 pipeline was replaced using FRP.
Figure 91 shows one end of the FRP pipeline where it was connected to a
heat exchanger. Provided that the correct vinyl ester resin was selected
for the pipeline, FRP should give better service than duplex stainless steel.
Figure 92 shows a leaking 2205 duplex stainless steel pipe below the Line
1 press 5. Figures 93 through 96 show leaks in duplex stainless steel ring
headers at the bottom of drop legs for Line 1 presses 5 and 6. It was
recommended that these ring headers be replaced. Appropriate materials
of construction include: FRP, 6% Mo stainless steel, and titanium.
4.2 Line 2 (Eucalyptus)
The D-stage presses in Line 2 have experienced less corrosion than their
counterparts in Line 1. This may be due to the concentration of residual
chlorine dioxide being lower in the Line 2 presses.
Figures 97 and 98 show an interesting corrosion phenomenon in the

housing for the shredder above the Line 2 press 5. Although EOP presses
are not normally corrosive to 316L stainless steel, in this case, residual
chlorine dioxide evidently travels up the drop leg and enters the shredder.
So far, the damage is merely cosmetic.
30
The piping for Line 2 is comparable with that in Line 1, that is, it is mostly
6% Mo stainless steel, with some 2205 duplex stainless steel. Visual
inspection did not reveal any leaks of the duplex stainless steel piping in
Line 2. This may be because there is no corrosion (very low residual
chlorine dioxide) or, it may be that the corrosion has yet to perforate
through the wall of the 2205 piping to result in a leak. Diligent
monitoring of the piping in the future should be done.
5.0 PULP MACHINES
The wet ends of both pulp machines were constructed using 316L stainless
steel. This includes the Fourdrinier, the headbox, tanks, piping, and
screens. In the past, corrosion has been observed inside white water tanks
in Line 1. The corrosion has the appearance of MIC.
5.1 Line 1 (Pine)
Figure 99 is a view of the wet end of the Line 1 pulp machine. The
headbox is on the right in the picture. Figure 100 is a view inside the
Fourdrinier pan. The yellow discoloration is some sort of surface film and
is not due to corrosion; however, numerous "tubercles" were observed,
mostly at weld seams in the pan. The "tubercles" appeared to be mostly
iron oxide and were the result of pitting corrosion of the 316L stainless
steel. The corrosion mechanism may be MIC.
Figures 101 and 102 are views underneath the Line 1 Fourdrinier pan
showing numerous locations of corrosion. Much of the corrosion was
31
associated with "tubercles" of iron oxide that covered the locations of

pitting corrosion. The corrosion mechanism may be MIC.
Figures 103 and 104 are views of a stainless steel pipeline beside the
Fourdrinier section of the Line 1 pulp machine. The pipe is experiencing
leaking from corrosion on the inside. The appearance of the leaks
resembles that in the white water tanks in the basement of the pulp
machine. Again, the corrosion mechanism may be MIC. Mechanical
damage due to the earthquake can also be seen in Figure 103.
Figure 105 shows the slice lip and apron lip for the headbox of the Line 1
pulp machine. There was no closer access to determine whether the lips
were corroded, but visual inspection suggests that they are corroding.
Corrosion of slice and apron lips can be highly detrimental to the quality
of the sheet. I do not know the material of construction, but it may be
316L stainless steel. In my experience, it is preferable to use a higher alloy
such as 6% Mo stainless steel for slice and apron lips.
Visual inspection also revealed several examples of carbon steel in wet

end surface (Figure 106). Where feasible, the carbon steel should all be
removed.
Extensive corrosion was found in the stainless steel white water tanks for
the Line 1 pulp machine. The most extensive corrosion was found in tank
572-22-1155 (Figure 107). There were well-developed "tubercles" inside
this tank (Figure 108). There was leaking in the weld below a 316L
stainless steel plate that was installed in 2010 (Figures 109 and 110). The
appearance of the corrosion is consistent with MIC.
32
Corrosion was also observed in some of the screens. Figures 111 through
113 show the basket from an Optiscreen for the Line 1 pulp machine. The
iron oxide had already been removed by polishing before I could
photograph it, but the pitting corrosion damage closely resembled that
observed in the white water tanks and in the Fourdrinier section of the
pulp machine. The corrosion mechanism may be MIC. The impeller for
the Optiscreen had cavitation erosion damage (Figure 114).
5.2 Line 2 (Eucalyptus)
Figure 115 shows the Fourdrinier of the Line 2 pulp machine. The wet
end of the Line 2 pulp machine had relatively few corrosion problems
compared with the wet end of the Line 1 pulp machine. On the headbox,
the slice and apron lips did not have a heavy coating of brown coloured
oxide has was seen in Line 1, but it was not possible to make a close
inspection (Figure 116).
The stainless steel underneath the Fourdrinier was relatively uncorroded

compared with the equivalent locations in Line 1 (compare Figure 117
with Figure 101). There were a few rust stains that could have been initial
stages of corrosion of the Fourdrinier (Figure 118).
There was reportedly no corrosion in the Line 2 white water tanks.
The coating on the concrete below the Fourdrinier section had failed
(Figures 119 and 120).
33
6.0 DISCUSSION
Most of the corrosion problems encountered during the 2011 general plant
shutdown were on the pine side (Line 1).
6.1 Corrosion and Cracking in the Superconcentrator
Many researchers have found that duplex stainless steels such as 2205 and
2304 resist corrosion and cracking in the high solids content black liquors
in superconcentrators. In 2010, examples of apparent corrosion and
cracking were found in the superconcentrator S-1. It has since been
learned that the corrosion was actually the result of poor quality welds
between the tubes and the bottom headers. The necessity for diligent
quality assurance by an independent third-party was discussed in my
2010 report [Ref. 3].
The cause of the cracking found in an elbow in the condensate drain in

2010 has also been determined. In October 2010, I attended a Duplex
Stainless Steel Conference in Beaune, France, where I learned that cracking
of duplex stainless steel elbows was a widespread problem in other
industries, particularly the chemical and petrochemical industries. It
turned out that the elbows were being heat treated in large batches
without proper thermocouple measurements (the thermocouples should
be on the parts in the middle and not just in the furnace). The innermost
elbows in the batches were never properly annealed and thus were highly
susceptible to SCC in service. This problem has since been corrected by
the suppliers of heat treated elbows and other piping components.
34
6.2 Corrosion and Cracking in the Concentrator
It was a considerable relief to find that no new SCC had initiated in the
concentrator effect E-1 A, B, C, D. No cracking was observed within ± 25
millimeters of the welds where all cracking was removed in 2010. There
were, however, numerous locations of SCC in the shell at locations away
from the weld seams. Fortunately, these locations of SCC did not appear
to have grown in extent since 2010. I recommended that as much of this
cracking be removed as possible by flap disc polishing, but I had left the
mill before any work had started.
SCC in the non-pressure parts, especially the dividers between the four
bodies, does not appear to impair the structural integrity of these parts at
this time. Reference locations were selected for future monitoring.
The good news is that the new concentrator effect E-1 F, G was reportedly
constructed entirely using duplex stainless steel. The bad news is that the
new concentrator was built in the People's Republic of China. The quality
of the workmanship is unknown since apparently no independent third-
party inspections were made during construction. I have written two
papers on the subject [Refs. 4 and 5]. These papers contain much useful
information that could have saved Nueva Aldea considerable money. It is
much preferable to find and repair problems in the construction stage
instead of after the vessel has already entered service.
35
6.3 Corrosion in the Evaporators
The reader is referred to the extensive discussion of evaporator corrosion

in my 2009 report {Ref. 2]. It is now understood that carbon steel in black
liquors of intermediate solids content has unstable passivation and is
liable to suddenly change from a passive corrosion state (low corrosion
rate) to an active corrosion state (high corrosion rate). This is what has
occurred in effects E-5, E-6, and E-7, in increasing order of severity of
corrosion.
Stainless steel lining (304L) was selected as the most practical method for
protection of the bottom zones in effects E-5, E-6, and E-7 from corrosion.
Unfortunately, it was not possible to complete the linings in these three
evaporators. The exposed carbon steel in the bottoms of these evaporators
is at risk for continued corrosion. Although the rate of corrosion will
likely be similar to that experienced in the past few years, some
acceleration of the corrosion rate due to galvanic contact with the stainless
steel may occur. Galvanic corrosion may be most severe immediately
adjacent to the stainless steel, and in the worst case may create a corrosion
"groove" in the carbon steel. Nonetheless, there is likely enough thickness
of the existing carbon steel shells that no leaking should occur during the
next year of operation. The linings should be completed during the 2012
general plant shutdown.
Carbon steel is unsuitable as a material of construction in evaporator

effects handling more concentrated liquor (existing E-3 and E-2).
Although the bottoms of both of these effects are 304L stainless steel, there
are some rings that are carbon steel, parts of which may be exposed in the
36
vicinity of the bottom tubesheets. This should be indicated on the

drawings.
The existing evaporator arrangement will soon be changed with the

addition of a new seventh effect E-7. This will result in changes in the
environments seen by the other evaporators. At this time, the changes in
black liquor solids and temperature should be small and not result in
significantly different corrosion situations in the existing evaporators.
6.4 Erosion in the Digesters
The rapid erosion thinning of the China hat in the Line 1 suggests that
conditions in the bottom of the Line 1 digester are significantly more
erosive than those in the bottom of the Line 2 digester. It may be that pine
pulp is inherently more erosive then eucalyptus pulp. Or, there may be
more sand entrained with the pine than with the eucalyptus. I do not
know if there is a "sand separator" for Line 1 as is common in other
digester systems worldwide. The China hat should be replaced (at least
the external parts) using 2205 duplex stainless steel. The hardness and
thus the erosion resistance of 2205 duplex stainless steel is significantly
higher than that of 304L stainless steel.
The carbon steel scraper arms may also be susceptible to erosion thinning.
The thickness of these arms should be monitored using UT.
The shell and bottom head of the digesters is 2205 duplex stainless steel
and should effectively resist erosion.
37
6.5 Corrosion in the Bleach Plant
The reader is referred to my 2010 report [Ref. 3] for a thorough discussion

of the phenomenon of transpassive corrosion of nickel base welds in D-
stage environments. In summary, nickel base materials such as Alloy 625
are highly susceptible to corrosion in highly oxidizing environments.
Unfortunately, nickel base welding consumables have already been
extensively used for welding of 6% Mo stainless steel components,
including the D-stage presses 4, 6, and 7. Alloy 625 was also used for
welding during modifications (linings) of the flaps. At this time, the only
option is to monitor the corrosion of the welds and make repairs when
necessary. The proper welding consumable (such as Avesta P54) cannot
be used to weld over existing nickel-base welds, as there is a risk of
cracking.
Corrosion in D-stage service in Line 1 is appreciably more severe than in

Line 2. The most likely explanation for this is that the concentration of
residual chlorine dioxide is higher on the pine side than on the eucalyptus
side. Perhaps a greater amount of bleaching chemical is required to obtain
the necessary brightness with pine pulp than is the case with eucalyptus
pulp. Efforts should be made to keep the residuals as low as possible.
The 2205 duplex stainless steel piping in D-stage service in Line 1

continues to experience corrosion and leaking. One particularly bad
pipeline was replaced using FRP after the 2010 shutdown. It is not known
which vinyl ester resin was selected, but there are a number of good FRP
resins suitable for D-stage service, including Derakane 470-300. The
duplex stainless steel piping in Line 1 is mirrored in Line 2. Although no
corrosion problems have (yet) been observed in the Line 2 piping, this
38
could be because the corrosion has not yet perforated the walls of the
pipes. Diligent inspection of all duplex stainless steel piping in the bleach
plant is required.
6.6 Corrosion in the Pulp Machines
The corrosion situation in the wet end of Line 1 is much worse than that in
Line 2. Although the corrosion takes the form of pitting attack (that is
normally attributed to the presence of chloride ions and appreciable
residual chlorine dioxide carryover from the bleach plant), there appears
to be a significant microbiological aspect (MIC) to all of the corrosion
observed. Most obvious is the presence of "tubercles" of brown iron oxide.
In MIC, tubercles are created by the bacteria so that they can live in an
environment that favours their growth. Corrosion occurs underneath the
tubercles regardless of what is happening in the outside environment,
possibly negating the effects of any biocides. There are many different
species of bacteria that can cause MIC of stainless steels in waters. It is
likely that either iron oxidizing bacteria or sulfate-reducing bacteria (SRB)
are involved at Nueva Aldea. SRB is evidenced by the black colour (iron
sulfide?) found under many of the tubercles.
I provided three excellent papers from NACE on the subject of MIC [Refs.
6, 7, and 8]. There is also an excellent book on the subject [Ref. 9]. These
papers and book suggest that the first step is to confirm that bacteria
capable of MIC are present in the white water system. This can be done
by culturing bacteria (only successful if done carefully and consistently) or
by using DNA hybridization probes.
39
Cleanliness is essential to prevent the initiation of MIC. Since MIC has

already initiated in the white water tanks for Line 1, the cleaning must
also involve removal of all existing tubercles followed by weld repair of
the pitted stainless steel underneath. For weld repairs to resist corrosion,
they should be made using overmatched filler metals such as Alloy 625.
At a minimum, 309L stainless steel welding consumables would be an
improvement over 316L stainless steel. If it is not possible to stop the
corrosion of existing 316L equipment, an upgrade in the metallurgy
should be considered. Type 2205 duplex stainless steel would be an
improvement over 316L.
Biocide addition is second to cleanliness in the defense against MIC.

There are experts in the field of water treatment who have experience with
the proper application of biocides.
It is interesting that there are comparatively few problems on the Line 2

(eucalyptus) side. Since eucalyptus oil is often used for its anti-bacterial
properties, one may wonder whether eucalyptus pulp has a comparable
inhibitory effect against microorganisms responsible for MIC. If this
could be established, it suggests that one possible method to control the
MIC in Line 1 would be to blend in some of the white water from Line 2.
40
7 .0 REFERENCES
1. Wensley, Angela, Inspections of the Digesters and the Evaporators

at Nueva Aldea, Angela Wensley Engineering Report AWE7032, 17
December, 2007.
2. Wensley, Angela, Inspections during the Shutdown at Nueva Aldea,
Angela Wensley Engineering Report AWE8025, 15 February, 2009.
3. Wensley, Angela, Corrosion Inspections during the General Plant
Shutdown at Nueva Aldea, Angela Wensley Engineering Report
AWE10005, 22 April, 2010.
4. Wensley, Angela, Developments in the quality assurance of duplex
stainless steel pressure vessels for the pulp and paper industry,
Stainless Steel World (2001).
5. Wensley, Angela, Experience with Duplex Stainless Steel Kraft
Digesters, Paper No. 04249 presented at the NACE Corrosion
Conference (2004).
6. Gibbon, Donald, DNA Sequencing Pinpoints Corrosion-causing
Bacteria, Materials Performance, pp. 42-43, March 2004.
7. Scott, P. J. B., Expert Consensus on MIC: Prevention and
Monitoring, Materials Performance, pp. 50-54, March 2004.
8. Scott, P. J. B., Expert Consensus on MIC: Failure Analysis and
Control, Materials Performance, pp. 46-50, April 2004.
9. Borenstein, Susan Watkins, Microbiologically Influenced Corrosion
Handbook, Industrial Press Inc., ISBN 0-8311-3056-3 (1994).
41

Corrosion Inspections at Nueva Aldea Pulp Mill During 2011 Shutdown

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Corrosion Inspections at Nueva Aldea Pulp Mill During 2011 Shutdown

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15397 COLUMBIA AVENUE Tel.

Celulosa Arauco y Constitución S.A.

Attention: Mario Ávila G.

Date: 9 October 2011 Dr. Angela Wensley, P.Eng.

G:\ALL WORK FILES\Neuva Aldea\2011\Report Text Nueva Aldea 2011.doc

4.0 BLEACH PLANT . . . . . . . . 28

5.0 PULP MACHINES . . . . . . . . 31

Evaporator Effect S-1 (Superconcentrator)

Evaporator Effect E-1 A, B, C, D (Concentrator)

Evaporator Effect E-2

Evaporator Effect E-3

Evaporator Effect E-4

Evaporator Effect E-5

Evaporator Effect E-6

Evaporator Effect E-7

Line 1 (Pine) Continuous Digester

Line 2 (Eucalyptus) Continuous Digester

No significant erosion was observed of the 3040 China hat.

Cursory visual inspection of the bottom scraper arms revealed no cracking.

Bleach Plant Presses

Nickel-base welds in D-stage service are experiencing transpassive corrosion at a

Pitting corrosion of 6% Mo stainless steel components of the D-stage presses is

Bleach Plant Piping

Corrosion of 316L stainless steel components in Line 1 is becoming widespread,

For the Superconcentrator:

S2. If it is necessary to replace tube panels, diligent quality assurance by an

For the Concentrator:

For the Evaporators:

For the Digesters:

For the Bleach Plant:

For the Pulp Machines:

P3. Consideration should be given to upgrading the metallurgy of tanks and

Safety requirements for 2011 mandated the wearing of harnesses for

Nueva Aldea has a Kvaerner (Metso) seven-effect falling film evaporator

28% 24% 21% 39% 45% 73%

65C 74C 83C 91C 102C 114C 142C

• The existing effect E-2 will become E-2A.

2.1 Superconcentrator S-1

The cylindrical shell and internals of the

Massive deposits were found in the top part of the

2.2 Concentrator Effect E-1 A, B, C, D

The concentrator has four sections (A, B, C, and D)

In 2009, SCC was found in the 304L tubes in

time to remove cracks in other locations in the shell or in non-pressure

The only circumferential weld accessible for visual inspection in section A

Cracking was also observed on the dividers in section A. Figure 13 shows

The next-highest risk of SCC in the concentrator is section B. No tube

Visual inspection of the tubes in section C revealed no cracking (Figure

Figure 22 shows cracking of stitch welds on the divider between section C

Section D is at the lowest risk of cracking and corrosion in the

Figure 27 is a view of the circumferential welds at the top of the

2.3 New Concentrator Effect E-1 F, G

2.4 Evaporator Effect E-2

The body of the second effect evaporator E-2 was

E-2 In August 2007 there was a leak at the entrance of

2.5 Evaporator Effect E-3

The body of the third effect evaporator E-3 was

Inspection of the top head in 2009 revealed slight

2.6 Evaporator Effect E-4

The body of the fourth effect evaporator E-4 was

There was no galvanic corrosion of the carbon

2.7 Evaporator Effect E-5