Material Selection For Chemical Process Equipment: Engr. Sandino Michael Angelo G. Aguilar, Che Subject Instructor

Material Selection for
Chemical Process
Equipment
Engr. Sandino Michael Angelo G. Aguilar, ChE
Subject Instructor
Introduction
• Any engineering design, i.e for chemical process
plants/industries, is only useful when it can be translated
into reality by using available materials and fabrication
methods.
• Thus, selection of materials of construction combined
with the appropriate techniques of fabrication can play a
vital role in the success or failure of a new chemical plant
or in the improvement of an existing facility
Materials of construction
• As chemical process plants turns to higher temperature and flow rates to
boost yields and throughputs, selection of construction materials takes on
added importance.
• Given with severe operating conditions for the plant, chemical engineers
are forced to search for more dependable, more corrosion-resistant
materials of construction for these process plants.
• Fortunately, a broad range of materials is now available in the market
• However, this apparent abundance of materials also complicates the task of
choosing the “best” material because, in many cases, a number of alloys and
plastics will have sufficient corrosion resistances for a particular
application.
• Final choice cannot be based simply on choosing a suitable material but
must be based on a sound economic analysis of competing materials
CLASSIFICATION OF ENGINEERING
MATERIALS
Materials of construction may be divided into two general classifications:
Metals and Nonmetals.
Note: Pure metals and metallic alloys are included under the first classification
CLASSIFICATION OF
ENGINEERING MATERIALS
METALS
• Polycrystalline bodies which are having number of differentially oriented
fine crystals.
• Mostly solids at normal temperature (except mercury)
• High thermal and electrical conductivity.
• Have positive temperature coefficient of resistance (metal resistance

increases with temperature)
Ex:
Ferrous metals – Cast iron, Wrought Iron, Steel, etc.
Non-ferrous metals – Silver, Copper, Gold, Aluminum, etc.

CLASSIFICATION OF
NON-METAL
• Non-crystalline in nature, exists in amorphic or mesomorphic forms.
• Available in both solid and gaseous forms at normal temperature
• Bad conductor of heat and electricity
• High “resistivity” which makes them suitable for insulation purpose in electrical
machines.
Ex: Plastics, rubber, leathers, Asbestos, etc.
ALLOYS
• Composition of two or more metals or metal and non-metals together
• Produces good mechanical strength, low temperature coefficient of resistance
Ex: Steels, Brass, Bronze, Gunmetal, Invar, Super Alloys, etc.
CLASSIFICATION OF
ORGANIC MATERIALS
• All organic materials are having carbon as a common element
• Chemically combined with oxygen, hydrogen and other non-metallic substances
• Have complex chemical bonding
Ex: Plastics, PVC, Synthetic Rubbers, etc.
CERAMIC MATERIALS
• Non-metallic solids
• Made of Inorganic compounds such as Oxides, Nitrides, Silicates and Carbides.
• Posses exceptional Structural, Electrical, Magnetic, Chemical and Thermal properties
Ex: Silica, glass, Cement, concrete, garnet, MgO, CdS, ZnO, SiC, etc.
COMMONLY USED MATERIALS
OF CONSTRUCTION
A. IRON AND STEEL
- these metals are not resistant to corrosion, except in certain specific
environments such as sulfuric acid and caustic alkalis
- Suitable for use with organic solvents except chlorinated solvents, but traces
of corrosion products may cause discoloration.
A1. Carbon steel

- most commonly used engineering material
- cheap and available in a wide range of standard forms and sizes,
- easily worked and welded.
- characterized by a high carbon content (up to 2.1% wt)
- can work under design temperature of -29 to 427 degC.
OF CONSTRUCTION
A2. High Silicon Irons (14-15% Si)
- High resistance to mineral acids, except hydrofluoric acid.
- Suitable for use with sulfuric acid at all concentrations and

temperatures
- Brittle
OF CONSTRUCTION
B. STAINLESS STEEL
- Most frequently used corrosion-resistant materials in the

chemical industry.
- Chromium content above 12% provides high corrosion

resistance (higher chromium content, more resistant the
alloy to corrosion in oxidizing conditions)
- Nickel is usually added to improve corrosion resistance in

nonoxidizing environment.
- can work under design temperature of -257 to 538 degC.

OF CONSTRUCTION
B. STAINLESS STEEL
Types
1. Ferritic: 13-20% Cr, <0.1% C, with no nickel
2. Austenitic: 18-20% Cr, >7% Ni
3. Martensitic: 12-14% Cr, 0.2-0.4% C, up to 2% Ni.
- Austenitic type is the widely used type of SS in the
chemical industry due to uniform structure (Face-centered
cubic, with carbides in solution)
OF CONSTRUCTION
STAINLESS STEEL STRUCTURES
OF CONSTRUCTION
Common Austenitic Stainless Steel
Type 304 (18/8 SS): most generally used stainless steel. Contains minimum Cr and Ni content
Type 304L (Low carbon type of 304, <0.3% C): used for thicker welded sections, used if carbide
precipitation is present with type 304.
Type 321: Stabilized version of 304 with titanium to prevent carbide precipitation during welding.
Higher strength than 304L, used for high temperature systems.
Type 347: Stabilized SS with niobium
Type 316: Molybdenum is added to improve corrosion resistance in reducing conditions, such as in
dilute sulfuric acid or solutions containing chlorides.
Type 316L: Low-carbon version type 316, specified if welding or heat treatment is liable to cause
carbide precipitation in type 316.
Type 309/310: Alloy with high chromium content, to give higher resistance to oxidation at high
temperatures.
OF CONSTRUCTION
Carbide Precipitation in Stainless Steels
OF CONSTRUCTION
C. NICKEL (<99%)
• Nickel alloy provides good mechanical properties and is easily worked.
• Used for handling caustic alkalis.
• Not subject to corrosion cracking like stainless steel.
D. MONEL (Nickel-Copper, 2:1)
• Most commonly used alloy after stainless steel for chemical plants
which provides good mechanical properties up to 500 oC.
• More expensive than SS but is not susceptible to stress corrosion in
chloride solutions
• Good resistance to dilute mineral acids and can be used in reducing
conditions, where SS would be unstable.
• May be used for equipment handling with alkalis, organic acids, salts
and sea water.
OF CONSTRUCTION
E. INCONEL
• Typically 76% Ni, 7% Fe, and 15% Cr in composition
• Primarily used for acid resistance at high temperatures.
• Maintains high integrity at elevated temperature and is resistant to

furnace gases (if sulfur free)
• Not suitable for sulfidizing environments.
F. INCOLOY
• Nickel alloys with higher chromium content (i.e Incoloy 800, 21% Cr
and RA-33, 25% Cr) are better oxidation resistance at higher
temperature
OF CONSTRUCTION
G. LEAD
• One of the traditional materials of construction for chemical plants
• However due to high cost, it has been replaced by other materials like
plastics.
• Soft, ductile material and mainly used in the form of sheets (i.e linings)
or pipe.
• Good resistance to acids (i.e sulfuric acid)
H. TITANIUM
• Widely used in chemical industry particularly for its resistance to
chloride solutions, including sea water and wet chlorine.
• Can be used for halide services,
• Alloying with palladium (0.15%) significantly improves the corrosion
resistance, particularly to HCl
Materials of
Construction
for Process
Equipment
Materials of
Construction
for Process
Equipment
Selection and Evaluation:
Identification of Process Conditions
Process design is not only on identifying chemical process equipment that will
meet process performance criteria (i.e pump flow rates) but also in
recommending appropriate material for the equipment based on the following:
• Process chemistry and temperature ranges
• Exposure conditions
• Design Life
• Cost
• Operations and Maintenance

Benefits
Selecting and installing appropriate and cost-effective chemical process
equipment and process area materials results in the ff:
• Substantial life cycle cost savings
• Avoiding process shutdowns, fluid removal and replacement and other

production impacts for replacement of equipment and systems that degrade
or fail early
• Avoiding special access and safety measures for equipment/systems removal

and replacement with process solutions in place
• Enhance production performance and reliability
• Reduce waste generation and conserve raw materials.
• Achieve overall energy savings

Material Costs
The quantity of a material used will depend on the material density and
strength (Maximum allowable stress) and these must be taken into account
when comparing material costs.
Materials of Construction
(Towler, Sec. 7 page 397-422)
Corrosion Allowances (Towler,
Sec 13.4.6 page 984-985)
Read more on Steel Pipes used in Process

Industries (Anup Kumar Dey)
Internet: Material Selection for

Chemical Process Equipment
Part 1 to 7 by Integrated
Technologies, Inc.
“Good engineering work for selection and
implementation of materials for chemical process
equipment and systems provides significant life
cycle savings plus a range of other benefits.”
– Nicholas Gallerani, 2019
Integrated Technologies, Inc.
Material Selection for
Chemical Process
Equipment
Engr. Sandino Michael Angelo G. Aguilar, ChE
Subject Instructor

Material Selection For Chemical Process Equipment: Engr. Sandino Michael Angelo G. Aguilar, Che Subject Instructor

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Material Selection for

• Mostly solids at normal temperature (except mercury)

• High thermal and electrical conductivity.

• Have positive temperature coefficient of resistance (metal resistance

Ferrous metals – Cast iron, Wrought Iron, Steel, etc.

Non-ferrous metals – Silver, Copper, Gold, Aluminum, etc.

A1. Carbon steel

- High resistance to mineral acids, except hydrofluoric acid.

- Suitable for use with sulfuric acid at all concentrations and

- Most frequently used corrosion-resistant materials in the

- Chromium content above 12% provides high corrosion

- Nickel is usually added to improve corrosion resistance in

- can work under design temperature of -257 to 538 degC.

• Typically 76% Ni, 7% Fe, and 15% Cr in composition

• Primarily used for acid resistance at high temperatures.

• Maintains high integrity at elevated temperature and is resistant to

• Not suitable for sulfidizing environments.

• Process chemistry and temperature ranges

• Operations and Maintenance

• Substantial life cycle cost savings

• Avoiding process shutdowns, fluid removal and replacement and other

• Avoiding special access and safety measures for equipment/systems removal

• Enhance production performance and reliability

• Reduce waste generation and conserve raw materials.

• Achieve overall energy savings

Read more on Steel Pipes used in Process

Internet: Material Selection for

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