MATERIALS OF CONSTRUCTION

Correct selection of the materials of construction is of

great importance for two reasons:
ƒ First, the material selected must be able to
withstand corrosion by the reagents and products
involved in the reaction.
ƒ 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.

Low-alloy steels offer improved mechanical/corrosion-

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.

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