A Game-Changer in Corrosion-Resistant Alloys
In the world of industrial manufacturing, where reliability and longevity are paramount, the development of materials that can withstand extreme conditions is crucial. Among these advancements, Sanicro® 35 stands out as a significant breakthrough. Launched by Alleima (formerly Sandvik Materials Technology) five years ago, this advanced alloy has quickly gained recognition for its superior corrosion resistance. It has been deployed across various industries, ranging from chemical processing to biorefineries and petroleum refineries, where harsh and corrosive environments are the norm.
Sanicro® 35 bridges the performance gap between traditional stainless steels and high-cost nickel-based alloys, offering a solution that is both cost-competitive and highly reliable in environments exposed to corrosive chemicals, seawater, and high-temperature conditions.
The Evolution of Sanicro® 35: A Historical Perspective
Sanicro® 35 was first introduced in 2020 at the AMPP (Association for Materials Protection and Performance) Annual Conference and Expo in Texas, USA. Since its global market debut, it has quickly emerged as a best-seller in the world of high-performance alloys, proving to be a game-changer for industries needing high resistance to corrosion.
One of the alloy’s first major applications was at a US Gulf Coast refinery, where it was chosen for the construction of heat exchangers in the refinery's crude unit overhead. The results were promising, as the alloy proved its value by offering a level of resistance that was traditionally only achievable with more expensive nickel alloys.
Sanicro® 35: Exceptional Corrosion Resistance
Sanicro® 35 has earned its reputation due to its impressive performance in some of the most corrosive environments encountered in industrial processes. Here's a breakdown of the key characteristics that make it stand out:
• Superior Corrosion Resistance:
Sanicro® 35 is designed to withstand severe corrosive conditions, including exposure to seawater, ammonium chloride salts, acidic and alkaline environments, and other harsh chemicals. It is especially effective in industries where corrosive materials are the norm, such as in the chemical processing and petroleum refining sectors.
• Stress Corrosion Cracking (SCC) Resistance:
In addition to resisting basic corrosion, Sanicro® 35 is highly resistant to stress corrosion cracking (SCC), a phenomenon that can cause catastrophic failure in materials exposed to tensile stress in corrosive environments. This makes it ideal for critical applications where reliability is non-negotiable.
• Outstanding Mechanical Strength and Formability:
The alloy’s high mechanical strength ensures that it can withstand the mechanical stresses found in challenging industrial processes. Additionally, it offers excellent formability, weldability, and machinability, making it easier to work with during the fabrication process.
Sanicro® 35 in Industrial Applications
The diverse applications of Sanicro® 35 underscore its versatility and suitability across multiple industries. Here are some of the areas where the alloy has been successfully deployed:
• Heat Exchangers and Process Piping:
Sanicro® 35 is widely used in the construction of heat exchangers and process piping. These components are critical in industries such as oil refining, chemical production, and biorefining, where exposure to corrosive substances is constant. The alloy’s resistance to corrosion in high-temperature environments, such as those found in seawater applications or sour gas environments, makes it indispensable.
• Petroleum Refineries:
In refining applications, such as crude overhead condensers and air coolers, Sanicro® 35 has proven its worth. Its ability to withstand corrosive substances like ammonium chloride salts has led to its use in upgrading key refinery components. The recent order from a major refinery on the US Gulf Coast, which upgraded seven crude unit air coolers, is a prime example of Sanicro® 35’s growing importance in the sector.
• Renewable Feedstock Pre-Treatment:
With the rising demand for sustainable energy, Sanicro® 35 has found a niche in renewable feedstock pre-treatment applications. Its resistance to corrosion ensures it performs well in the processing of renewable diesel and other biofuels, where chemical reactions often involve harsh conditions.
A Cost-Effective Alternative to Nickel Alloys
Historically, nickel-based alloys, like Alloy 625, were considered the benchmark for corrosion-resistant materials in critical applications. However, their high and fluctuating price, driven by the cost of nickel (which can account for up to 58% of the alloy), made them less appealing for cost-conscious manufacturers.
Sanicro® 35 offers similar performance to nickel-based alloys but at a more affordable price point. This makes it a cost-effective alternative for industries that require high-performance materials but need to keep costs under control.
Sanicro® 35's Success Stories: From Refinery Upgrades to Large-Scale Orders
Sanicro® 35’s success can be seen in its growing list of global references. The product has earned millions in annual orders across industries such as fertilizer production, chemical processing, and renewable feedstock pre-treatment. Some of the notable success stories include:
• Crude Unit Air Coolers Upgrades:
In one of the largest orders, Sanicro® 35 was selected for upgrading the air coolers in a major US Gulf Coast refinery, where its superior corrosion resistance in ammonium chloride salt environments made it the perfect choice.
• Collaborations with Leading Fabricators:
Brask Inc., a prominent tube & shell heat exchanger manufacturer, became one of the first fabricators to work with Sanicro® 35. Brask praised Alleima’s support in ensuring successful fabrication, which helped meet an expedited delivery deadline for a refinery project.
• Global Adoption in Chemical and Biorefineries:
The alloy has been widely adopted in chemical processing plants and biorefineries, where its ability to withstand sour environments and seawater makes it a crucial component for infrastructure that deals with harsh chemicals and extreme conditions.
The Future of Sanicro® 35: Continued Innovation and Expansion
Despite being a relatively new product, Sanicro® 35 has already established itself as a market leader in corrosion-resistant alloys. As industries increasingly seek sustainable, cost-effective, and reliable materials, the demand for Sanicro® 35 is expected to continue growing.
Alleima continues to focus on developing innovative alloy solutions, expanding its capabilities to meet the growing challenges of industrial environments. The AMPP 2025 Conference in Nashville, where Alleima will showcase its alloys and technical expertise, is just one example of the company’s commitment to pushing the boundaries of metallurgical science.
Key Takeaways:
• Sanicro® 35 is a corrosion-resistant alloy developed by Alleima that has become crucial in industries like petroleum refining, chemical processing, and biorefining.
• Introduced in 2020, Sanicro® 35 offers a cost-effective alternative to nickel alloys, while delivering similar performance in demanding environments.
• The alloy’s superior corrosion resistance makes it ideal for heat exchangers, process piping, and applications exposed to ammonium chloride salts, sour environments, and seawater.
• Sanicro® 35 is noted for its high mechanical strength, weldability, and formability, making it an excellent choice for various fabrication needs.
• Since its launch, Sanicro® 35 has secured millions in orders annually and has been widely adopted by industries that require reliable, high-performance materials in extreme conditions.
Sanicro® 35’s development is a testament to Alleima’s commitment to providing innovative solutions for industries that rely on materials capable of withstanding some of the most demanding environments in the world.
