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ABSTRACT
The application of stainless steel is dealt with, including the general
properties of the material .with regard t o wear resistance and corrosion
resistance in the sugar industry. It covers the various grades of stainless steel
including AlSl 41 0, 430, 304 and 31 6 and also the form or shape including
rod, plate, sheet and tubing.
Discussed also are some of the failures that can occur with this material
and some of the new applications which have been found to be successful,
and also areas where it is considered the use of stainless steel will not be
advantageous. A detailed investigation is given on the use of stainless steel
i n scrubbers on smut arrestors for bagasse and coal fired boilers. Finally, the
cost of using stainless steel, as against other conventional materials is
discussed, using as an example a new mill to crush a million tons of cane,
and this shows the investment in stainless steel would only be approximately
0,5% extra on the whole project.
General
<<
Stainless steel" is not a single metal - it is the name given to a group of
iron based alloys containing a minimum of 11% chromium.. .Most stainless
steels also contain nickel, often in association with more exotic elements such
as molybdenum, titanium, niobium - used to confer specific properties. These
stainless steels are divided into other categories according to their metallurgical
structures. Table 1 details these basic metallurgical structures and properties
in the AISI series; Appendices A and B give the basic analyses and world wide
specifications of the stainless steels referred to in this paper.
Wear resistance
Martensitic grades -A I S I 400 Series (see Appendix A)
Fatigue and wear resistance increase with higher strength values.
The martensitic grades can be hardened to Rc 60 and UTS values of
135 kg/mm. They find extensive use where abrasion, or torque and fatigue
loading, is required. Typical examples are AISI 410, 420, 440, 431.
These stainless steels can also be nitrided or hard chromed to give ex-
cellent shaft bearing surfaces.
Ferritic grades - A I S I 400 Series
These grades cannot be hardened and are not normally employed for
heavy wear or abrasion-resistant applications. However, they are
used extensively where mild abrasion is combined with mild corrosion,
which is normally sufficient to attack mild steel. Typical examples are
AISI 405 and 430.
C . G. W. ROFFEY AND I. A. ELSDON-DEW 1697
FIGURE 3a. Typical example of stress FIGURE 3b. Stress corrosion and cracking.
corrosion cracking.
The correct specification of the "L" grades to ensure full corrosion resistance
of the weld joint is completely useless if the fabricator re-introduces
the problem as outlined above.
Stress corrosion cracking
This is catastrophic failure due to the combination of stresses (from
operation and/or fabricating) and a corrosive environment, normally
chlorides (Fig. 3). Failure would not normally occur if the stress or
corrosion were present singly. The operating temperature is normally
above 50 C before failure occurs. Whilst the austenitic grades are sus-
ceptible to this form of failure, the ferritic ones are not.
Crevice corrosion
This is due to the deposition of a porous film, wet sludge or bad
design creating tight crevices. The area of stainless steel under the film
or in the crevice, where the solution is not easily replenished, sets up a
corrosion cell with the area in free contact with the solution. Rapid
pitting attack occurs under the covered area. Fig. 4 shows the crevice
attack caused by wet smuts or burnt bagasse lying on a new stainless
steel tube.
APPLICATIONS
B a r stock
Abrasion/ W e a r resistance
These applications have been limited to the heat treatable martensitic
grades. Cane shredder bars in AISI 420 and 43l'hardened to Rc 60
are giving a life of approximately 3 times that of alloy steels of the 40 - 60
ton types. Pins and bushes for intercarrier chains in these alloy steels were
1700 MANUFACTURING - ENGINEERING I
Left:
FIGURE 4. Typical example of crevice
corrosion on stainless steel tube.
Bottom Left:
FIGURE 5 (a). Comparison of maceration
tanks in mild steel AISI 430.
~ o f i o r nRight:
FIGURE 5 (b). Mild steel maceration
tank after 3 seasons operation.
failing prematurely due to corrosion from the bagasse; AISI 410 and 420
have solved this problem, giving a t least 3 times the life, ensuring that
the chains will last the whole season without unscheduled stoppages.
O n average the stainless steel components used have cost double that of
the alloy steel.
Problems encountered
The martensitic steels in the hardened condition are very difficult
to weld, and heat treatment before and after welding is essential. The
C. G. W. ROFFEY AND I. A. ELSDON-DEW 1701
Corrosion
There is always an inherent corrosion problem for mild steel in a
sugar mill due to the chloride content of the juice. The lives of many steel
parts appear to be satisfactory, for example 5 seasons. However the use of
stainless steels has completely eliminated replacements, allowed main-
tenance labour to be used for other purposes, and has considerably re-
duced erection and structural support costs.
Table 3 details several areas where stainless steels are being success-
fully applied. Note should be taken of the drastic reduction of many
metal thicknesses compared with cast iron and steel. I n many cases the
stainless steel was installed for the same price as the steel component.
Apart from these applications there are many others such as Donnelly
chutes, juice gutters, servo bajances, juice scale tanks, etcetera.
Combined abrasion and corrosion
The stainless steels are ideal materials to combat the combined effects
of wear and corrosion which completely destroy other materials and
Table 4 details current experience in solving this problem. I t should be
noted that lives of between 5 and 10 times more than mild steel are
anticipated although in many cases the stainless steel thicknesses are
drastically reduced.
1702 MANUFACTURING - ENGINEERING
costs
Spiralling copper prices, combined with an uncertain supply position,
made stainless steel a decidedly cheaper material, particularly when
tube wall thickness is reduced from 2 mm or 1,5 mm to 1,2 mm. The
Vallinox 430 tube offers a further 10% saving over AISI 304 tubes.
Fabrication
As both Vallinox 430 and AISI 304 tubes are supplied in the fully
annealed condition, there are no problems in expanding the tube ends.
I t is not necessary to attempt to anneal the tube ends on site - in fact
any heating of the Vallinox 430 will destroy the ductility.
MANUFACTURING - ENGINEERING
Heat transfer
Lengthy discussions of the relative merits of stainless steel and brass
heat transfer rates are irrelevant since the film formation and thinner wall
of the stainless steel even out any original advantages claimed for brass.
Scale remoual
Where scale is soft, a brush is usually employed, but on harder scales
a skatoskalo is used. As the stainless steel has a harder surface than brass,
the scoring of the tube is reduced and thus there is less "key" for the scale
to adhere to. Acid cleaning is being investigated, but results are not avail-
<>
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able a t this stage. ?, +
Corrosion
The increasing use of nitrogenous fertilizers has resulted in a n in-
creasing amount of ammonia being evolved in the effect system and
whereas the stainless steels are fully resistant, the brasses (particularly
in the hard drawn condition) are very susceptible to season cracking.
There, have been some failures of AISI 304 tubing in South Africa
due to stress corrosion cracking. This has normally occurred adjacent to
the tube plate, ,ahd in one instance was induced by heavy fatigue stresses
due to the tube not being supported over a 7 m length.
One of the major factors (apart from the price) for the swing to
Vallinox 430 tubing in South Africa is that this ferritic stainless steel is not
susceptible to stress corrosion cracking. There has been no evidence of
pitting attack in either Vallinox 430 or AISI 304 tubes in evaporator
effects even though chlorides of up to 6 000 ppm are common.
POLLUTION CONTROL
TABLE 6. Typical corrosion problems encountered in wet scrubbing coal and bagasse fired
boilers.
Corrosive products
Fuel stock in wet scrubbers Corrosion problems
Bagasse only Hot chlorides 1) Pitting attack
(Probably 100-500 ppm) 2) Crevice corrosion under flue dust deposits
3) Possibility of stress corrosion at higher chloride
levels
Coal only Hot sulphuric acid 1) Heavy general corrosion
2) Crevice corrosion
3) Weld decay
Mixed or Hot chlorides 1) Heavy pitting attack
alternating (Up to 6 000 ppm) 2) Heavy general corrosion
coal and and 3) Heavy crevice corrosion
bagasse Hot sulphuric acid 4) Possibility of stress corrosion
5) Weld decay
I
b) p H and chloride analysis of the water to be used for scrubbing;
c) continuous chloride and p H checks on the recycling water;
d) p H and chloride analysis of the make-up water;
e) fuel analysis of the flue gases, with particular attention to chlorides,
sulphates and solids content.
This information is required for every boiler, and it is dangerous to take
one set of results and apply it to another boiler system or mill. We have found
that AISI 430 has given satisfactory service as scrubber shells, vanes, droplet ,I
eliminators when operating on bagasse fired boilers where there is no sand con-
tent in the flue gas, the pH does not fall below 5,5, and the chloride content of
the water does not exceed 500 ppm. None of the stainless steels will give a
guaranteed long life in wet scrubbers handling gases from coal or mixed flue
fired boilers - particularly if the scrubbing water contains chlorides and oper- I
ates on a closed cycle system allowing heavy build-up of the corrosive elements.
MARKET STATISTICS
Approximately 400 tons per annum of stainless steel plate - 95% of
which is AISI 430 - is being used in the South African sugar industry. The
tube market is very variable, but averages approximately 450 tons per annum.
Although stainless steel tubes have traditionally had the major portion of the
total stainless steel market, we estimate that the rapidly increasing plate
tonnage will outstrip the tube tonnage by 1976. Most applications for stainless
steel are replacements for other materials when they fail. Approximately
1706 IvIANUFACTURING - ENGINEERING
18 million tons of cane is crushed per annum in South Africa, giving an approxi-
mate figure of 45 tons of stainless steel plate per million tons of crushed cane.
However, if a new mill were erected to crush a million tons of cane per
annum. we antici~atethat 350 -400 tons of stainless steel would be reauired-
solely for proven applications. The additional capital expenditure involved on
the project when using stainless steel instead of other materials would result in
a n overall increase of less than 0,5 %.
ACKNOWLEDGEMENT
We would like to express our sincere thanks to the South African sugar
industry. I t is only through their'iwholehearted co-operation and helpfulness
that this development of stainless steels in the sugar industry has been achieved.
APPENDIX "Ayy
BASIC ANALYSES OF THE STAINLESS STEELS REFERRED T O I N THE PAPER
,
Ferritic
Austenitic
9,
APPENDIX "B"
WORLDWIDE SPECIFICATIONS OF STAINLESS STEELS REFERRED TO IN THE PAPER
Germany
AISI French Italian Werkstoff UK Japan Swedish
no. no.
ZlO.Cl3 sus 2 1 SIS 2301
ZlO.Cl3 sus 22 SIS 2302
Z2O.Cl3
Z3O.Cl3 SUS 23 SIS 2303
- - -
Z15.CN16.2 SIS 2321
Z 8.C17 SUS 24 SIS 2320
Z6.CN18.10 SUS 27 SIS 2332
Z2.CN18.10 SUS 28 SIS 2352
Z1O.CNT 18.10 SUS 29 SIS 2337
Z10 CNN6 18.10 sus 43 SIS 2338
2 5 CND 18:12 SUS 32 SIS 2343
22 CND 18.12 sus 33 SIS 2353
28 CNDT 18.12 - SIS 2344
C . G. W. ROFFEY AND I. A. ELSDON-DEW
RESUMEN
Este folleto trata sobre la utilizacidn del acero inoxidable, incluyendo las
propiedades del material, con relacidn a su resistencia al desgaste y a su
resistencia a la corrosidn, en la industria de la caAa de azlicar. Cubre diferentes
tipos de aceros inoxidables incluyendo 10s AlSl 41 0, 430, 304, y 316 en
secciones redondas, en Isminas y en tuberias.
TambiBn se discuten algunas fallas que ocurren con este material y
algunos de 10s nuevos usos en 10s cuales ha tenido Bxito; Asi como tambien
fireas donde se Cree que el uso del acero inoxidable podria ser ventajoso.
Se incluye una investigacidn detallada referente al uso de acero inoxidable
en lavadoras de gases y eliminadores de hollin en calderas de bagazo o
carbdn.
Finalmente se comparan 10s costos entre utilizar acero inoxidable y usar
materiales convencionales llegando a la conclusidn de que en una ftibrica
nueva, para moler un milldn de toneladas de cafia la inversidn en acero
inoxidable incrementaria en un 0.5% el valor del proyecto.