CHEN3000 Process Plant Engineering Sem 2 2016 Miri

Summary Selection Materials

Purpose to select materials for equipment & piping

Criteria to look:
1) Material ability to resist corrosion, acid, base, oxidative
2) Suitable for process condition (T, P) e.g. high T increases corrosion
3) Should meet requirements from mechanical design engineer (sufficient strength, easy
to work with)
4) Other factors product contamination & safety
Objectives of this lecture:
1) To know some major forms and types of material available
2) Specification of materials, how they work
3) After knowing the specification/properties/background of the material, then we can
consult & communicate with a material specialist during the early stage of design
4) To identify & establish materials that meet the process conditions
Properties of Material to look at:
1) Mechanical properties tensile strength, stiffness, toughness, hardness, fatigue (esp.
for rotating equipment), creep (gradual extension or elongation of material)
2) Effect of temperature on mechanical properties
3) Corrosion resistance
4) Any special properties thermal conductivity, electrical resistance, magnetic
properties
5) Ease of fabrication forming, welding, casting
6) Availability in standard sizes, plates, sections, tubes etc
7) COST the most important consideration

Dr Jibrail Kansedo | CURTIN DEPARTMENT OF CHEMICAL ENGINEERING 2016

Influencing Parameters:
1) Temperature (can affect the corrosion rate & mechanical properties)
2) Pressure
3) pH acid vs base
4) Presence of impurities (can cause stress corrosion 5) The amount of aeration (can cause differential oxidation 6) Stream velocity & agitation (can cause erosion corrosion
7) Heat transfer rates either conducting or resisting heat
Refer to Tables for the Properties of Many Materials (Further read Textbooks)
Corrosion

Definition gradual degradation/destruction of materials due to its reaction with

environment

Factors contributing to corrosion

Chemical or electrochemical attack (often confined to metal surface, sometimes can

occur along grain boundaries or other metal weaknesses)

Types of Corrosion

Localized (one spot) crevices, intergranular boundaries, oxygen-deficient cells, or

stress-activated surface

Structural (the whole equipment itself) graphitic, dezincification, biological corrosion

Specific types of corrosion galvanic, impingement, cavitation, hydrogen attack

To prevent galvanic corrosion, need to select combination of metals that are close to
each other in the galvanic series (refer table in lecture slides)

Oxidation

Can be affected by pH, different types of materials, oxidizing agents, temperature

Prevention protective layer (protective oxide) on the surface, use suitable pH (if
applicable), lower the temperature

Dr Jibrail Kansedo | CURTIN DEPARTMENT OF CHEMICAL ENGINEERING 2016

How to combat/prevent corrosion?

Select appropriate/ suitable material (carbon steel, stainless steel, plastic, glass,
ceramics etc)

Change the environment (lower temperature or pressure)

Use inhibitor (to inhibit oxidation agents)

Cathodic or anodic protection (galvanic corrosion)

Substitution of less corrosive materials (weak acid to replace strong acid)

Use non-metallic castings and lining materials in combination with steel (to prevent
structural corrosion)

Use organic coatings, glass etc

Classifications of materials

Refer to tables in lecture slides

Different materials have different properties at certain temperature

Alloys are generally divided into two types according to their composition and how
they made (casting (use molten metal poured into mould), wrought (bending,
hammering, welding, bending, etc)

Brief plan for studying materials of construction (remember 5 steps)

Preliminary selection

Laboratory testing

Interpretation of laboratory results and other data

Economic comparison

Final selection

Dr Jibrail Kansedo | CURTIN DEPARTMENT OF CHEMICAL ENGINEERING 2016

Final Thoughts

Service requirement (function or use of the equipment)

Fabrication requirement (how easy can it be made)

Economic requirement (cost)

Selection Criteria

Operating temperature

Thermal stability

Strength

Oxidation

Carburization

Other sulfidation, fabricability, design, thermal expansion, molten metal, galling

(when they slide against each other), cast versus wrought heat resistant allow (refer
table in lecture slides)

Industrial Applications
Chlorine

Flow must be restricted to avoid removal of ferric chloride on the surface (protection
layer)

Most suitable PVDF (refer lecture slide), ebonite or rubber lined steel

Zinc can be used, only for low temperature

Bromine

Need to be tested before use

Most suitable steel lined with lead, PVDF, or glass

Sulfuric acid

Protection layer (iron sulphate coating), similar to chlorine

Most suitable chemical lead, PVC or fluorocarbon plastics

Dr Jibrail Kansedo | CURTIN DEPARTMENT OF CHEMICAL ENGINEERING 2016

Most suitable specially developed stainless steel for high temperature duties

Hydrochloric acid

Very corrosive especially towards copper

Most suitable plastic and rubber lined steel for pipelines and small vessels

Ammonia

Types of suitable material dependent on operating temperature

Most suitable ambient temperature use mild steel (regular steel)

Most suitable low temperature use special steel

Highly corrosive towards copper and zinc

Most Commonly Used Metals

Carbon steel (most commonly used) refer lecture notes (tables) for the types of
carbon steel, not suitable for dilute acids or alkaline solutions, brine or salt solutions,
high or cryogenic (very low) temperature

Stainless steel or ferrous alloys (refer lecture slides for the types) most commonly
used SS type 302, 304, 316, resistant to corrosion, high temperature strength

Recommendation

Copper alkali

Nickel clad steel caustic (alkaline) materials

Glass lined steel caustic materials

Plastic moderate temperature

Low temperatures (refer lecture notes, last page)

Dr Jibrail Kansedo | CURTIN DEPARTMENT OF CHEMICAL ENGINEERING 2016