Correct selection of the materials of construction is of
great importance for two reasons: First, the material selected must be able to withstand corrosion by the reagents and products involved in the reaction. Secondly, materials selection can have a major influence on the capital cost of the plant.
The most common materials used in chemical plant
construction are carbon steel (CS) and various grades of stainless steel (SS, see below). Equipment fabricated from CS is significantly cheaper than that fabricated from SS. Not only is the purchase cost of CS lower than that of SS ($800 versus $2500 per tonne) but fabrication is easier and therefore cheaper.
A number of heuristics (rules of thumb) have been
developed to aid in materials specification. Note that this is not an exact science though and the assistance of a specialist is highly recommended.
ChE 491 Plant Design Materials of Construction Slide 1
Heuristic 1: For industrial-scale processes, start by assuming that all equipment is constructed of CS. Check for corrosion properties by reviewing the properties of chemicals in the process. Adjust to more expensive materials of construction as problems are encountered.
Heuristic 2: Carbon steel may be acceptable if the process
is essentially free of water and doesn’t involve halogens. (But see below)
Heuristic 3: Stainless steel (316) may be acceptable if the
process involves water, nitric or sulfuric acids, and is free from halogens.
Heuristic 4: Hastelloy or titanium may be required if the
process involves the use of halogenated species.
Heuristic 5: Don’t rely entirely on lab results. Conditions
are always more difficult to control in industrial processes.
Heuristic 6: High operating temperatures always increase
corrosion rates. Work at temperatures close to ambient wherever possible. Ceramics may be required for high temperature operations. Recognize that such materials are often brittle and much more fragile than CS equipment.
Heuristic 7: Corrosion problems can be controlled by
using lined equipment. However, linings are subject to tears and wear out.
ChE 491 Plant Design Materials of Construction Slide 2
Types of Steel
Carbon Steel. This is used with most organic chemicals
and neutral or basic solutions at moderate temperatures.
resistant properties. They may contain one or more of the following elements: Ni, Cr, Si, Mo, C. There are more than 70 types of stainless steel, which may be classified as Martensitic, Ferritic, or Austenitic.
Martensitic Steels. These steels contain 12-20 % Cr plus C
and other alloys. They are hardened by heat treatment and have relatively poor corrosion resistance.
Ferritic Steels. These contain 15-30 % Cr plus <0.1 % C.
Their strength is increased by cold working. They have good corrosion resistance.
Austinitic. These steels contain 16-26 % Cr plus 6-22 %
Ni; C<0.08 %. Mo is added in e.g 316 SS to increase corrosion resistance. Can be work-hardened.
Machinability is improved by adding a small quantity of P
as in the following grades of SS: 303, 309, 310, 410, 416, 430F.
ChE 491 Plant Design Materials of Construction Slide 3
Medium and high alloys give improved corrosion protection. Medium allots include Incoloy 825 and Hastelloy G-3 and G-30. High alloys all contain large percentages of Nickel. For example, Hastelloy B contains 61 % Ni and 28 % Mo. This provides excellent resistance to hydrochloric acid at all concentrations in the absence of oxidizing agents.
ChE 491 Plant Design Materials of Construction Slide 4
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Oxy-Acetylene Welding and Cutting
Electric, Forge and Thermit Welding together with related methods and materials used in metal working and the oxygen process for removal of carbon
Oxy-Acetylene Welding and Cutting: Electric, Forge and Thermit Welding together with related methods and materials used in metal working and the oxygen process for removal of carbon