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INDUSTRIAL & FERTILIZER MATERIALS
The document discusses various industrial and fertilizer materials. It covers the classification and properties of ferrous metals including carbon steel, alloy steels, cast iron and stainless steels. It describes the composition, mechanical properties and common uses of different grades of these materials. Specific grades used in fertilizer plants are also mentioned including Cr-Mo steels, austenitic stainless steels, and duplex stainless steels used in urea services and reactors.
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INDUSTRIAL & FERTILIZER MATERIALS
- 1. A REFRESHER ON INDUSTRIAL& FERTILIZER MATERIALS By Waqas CH
- 2. YOUR ASSESSMENT 1 –Iron with temporary magnetic field 2 – Stainless Steel Urea Grade or 25-22-02 5 - a - Austenitic b - Martensitic c - Ferritic d - Duplex 4 - Material which contains by mass more iron than any other material 6 - No 7 – Low Carbon Steel 8 - Copper 9 - Killed Carbon Steel 3 - Yes
- 3. MATERIAL CLASSIFICATION METALS NON -METALS NON - FERROUS FERROUSFERROUS MATERIALS
- 4. FERROUS METALS ORIGINAL DEFINITION -IRON CONTENTS GREATER THAN 50%. REVISED DEFINITION (1993) - MATERIAL WHICH CONTAINS BY MASS MORE IRON THAN ANY OTHER SINGLE ELEMENT. Cr : 26 max. Ni : 22 max. Mn : 02 max. Si : 1.5 max. Total : 51.5 max. SS 310
- 5. CLASSIFICATION FERROUS METALS FERROUSMETALS CARBON STEEL CAST IRON ALLOY STEEL WROUGHT IRON BASED ON “C” ADDITION
- 6. IRON ORE COKE LIME STONE BLASTFURNACE IRON MAKING STEEL MAKING CONTINUOUS CASTING PRODUCTS BASIC OXYGEN FURNACE ELECTRIC ARC FURNACE BILLETS CASTING REHEATING FURNACE PLATES RODS PIPE PIG IRON WROUGHT IRON
- 7. CLASSIFICATION FERROUS METALS FERROUSMETALS CARBON STEEL CAST IRON ALLOY STEEL WROUGHT IRON BASED ON “C” ADDITION
- 8. PROPERTIES OF MATERIALS ELASTICITY -Theproperty of a material due to which it comes to its original shape after the removal of load is called elasticity. - There is a certain limit of every material upto which it can regain its original shape. This limit is called Elastic Limit. PLASTICITY -The property of a material due to which it is permanently deformed (re-shaped) on the application of load, without any rupture is called plasticity.
- 9. PROPERTIES OF MATERIALS HARDNESS -It is the property of a material due to which it resists wear, abrasion and indentation. - Also hardness is the property which enables to cut the other material. TOUGHNESS -Ability of material to resist fracture due to sudden shocks (impact loads) or bending/twisting is called toughness.
- 10. PROPERTIES OF MATERIALS STIFFNESS -Ability of a material to resist deformation due to the external forces is called stiffness. BRITTLENESS - The property of a material to easily break up into pieces without deformation is called brittleness. DUCTILITY - Ability of a material to be drawn into wires or undergo elongation without fracture is called ductility.
- 11. PROPERTIES OF MATERIALS STRENGTH -It is the ability of a material to withstand the external forces of different types before undergoing the permanent deformation or fracture - Tensile strength ….. Maximum tension beared per unit area - Compressive strength ….. Maximum compression beared per unit area - Shear strength ….. Maximum shearing force beared per unit area
- 12. PROPERTIES OF MATERIALS MALLEABILITY -If a material can be rolled or hammered to thin sheet, it's property is called malleability CONDUCTIVITY - Ability of a material to allow the passage of heat or electricity through it, is called its conductivity WELDABILITY - Ability of a material to join by welding
- 13. EFFECT OF CARBONON STEEL Hardness Strength Ductility Weldability Carbon
- 14. WROUGHT IRON COMPOSITION MECHANICAL PROPERTIES -CONTAINS SMALL AMOUNT OF SLAG (SiO2) - CARBON CONTENTS LESS THAN 0.08 % CARBON USES - EASILY WELDABLE - LOW STRENGTH , MALLEABLE AND DUCTILE - CURRENTLY WROUGHT IRON IS NOT PRODUCED DUE TO HIGH MANUFACTURING COST - MODERN WROUGHT IRON PRODUCTS ARE ACTUALLY MADE FROM LOW CARBON STEEL
- 15. CARBON STEEL CARBON STEELIS CLASSIFIED ACCORDING TO: ITS TREATMENT FOR DEOXIDIZATION ITS CARBON CONTENTS TYPE OF STEEL FOR WHICH: - CARBON CONTENTS ARE < 2% - NO ALLOYING ELEMENT IS ADDED EXCEPT CARBON
- 16. CARBON STEEL CLASSIFICATION ACCORDINGTO CARBON CONTENTS CARBON STEEL LOW CARBON STEEL MEDIUM CARBON STEEL HIGH CARBON STEEL CARBON CONTENTS < 0.3 % CARBON CONTENTS BETWEEN 0.3 % AND 0.6% CARBON CONTENTS BETWEEN 0.6 % AND 2.0%
- 17. EFFECT OF CARBONON MICROSTRUCTURE Low Carbon Steel Medium Carbon Steel High Carbon Steel Cast Iron
- 18. LOW CARBON STEEL COMPOSITION MECHANICALPROPERTIES - LESS THAN 0.3 % CARBON GENERAL USES - GRADES HAVING CARBON B/W 0.1 % TO 0.3 % ARE HEAT TREATABLE - EXCELLENT FORMABILITY AND WELDABILITY - SHEETS MANUFACTURING, PIPING AND PRESSURE VESSEL COMPONENTS
- 19. LOW CARBON STEEL USEDAT FERTILIZER PLANT - LOW, MEDIUM AND HIGH PRESSURE STEAM/CONDENSATE - PIPING, VALVES AND VESSELS FOR - COOLING WATER, INSTRUMENT AIR, FUEL GAS, NATURAL GAS - LIQUID AMMONIA (HIGH TEMPERATURE) - LOAD BEARING STRUCTURES AND SHEETS LOW CARBON STEEL GRADES API 5L GRADE B ASTM A - 105 ASTM A - 234
- 20. MEDIUM CARBON STEEL COMPOSITION MECHANICALPROPERTIES - CARBON CONTENTS BETWEEN 0.3% TO 0.6% GENERAL USES - HEAT TREATABLE - GOOD BALANCE BETWEEN STRENGTH AND DUCTILITY - MANUFACTURING OF GEARS, CRANKSHAFT ETC.
- 21. HIGH CARBON STEEL COMPOSITION MECHANICALPROPERTIES - CARBON CONTENTS BETWEEN 0.6% TO 2.0% GENERAL USES - LOW DUCTILITY - HIGH STRENGTH - HIGH STRENGTH WIRES AND SPRINGS - POOR WELDABILITY AND FORMABILITY
- 22. CARBON STEEL CLASSIFICATION ACCORDINGTO DEOXIDIZATION TREATMENT CARBON STEEL CAPPED STEEL SEMI KILLED STEEL KILLED STEEL NO DEOXIDIZER IS ADDED DEOXIDIZERS ARE ADDED IN SMALL QUANTITY DEOXIDIZERS ARE ADDED IN SUFFICIENT QUANTITY RIMMED STEEL MOLTEN STEEL IS CAPPED TO STOP RIMMING ACTION
- 23. KILLED CARBON STEEL COMPOSITION MECHANICALPROPERTIES - CARBON STEEL WITH INCLUSION OF SILICON OR ALUMINUM GENERAL USES - INCREASED STRENGTH DUE TO HOMOGENOUS MICRO STRUCTURE - PRESSURE VESSEL, PIPING ETC. USES AT FERTILIZER PLANT - PIPING, VALVES AND VESSELS FOR LOW TEMPERATURE LIQUID AMMONIA - DIFFICULT WELDING AS HEAT TREATMENT IS INVOLVED
- 24. CAST IRON COMPOSITION MECHANICAL PROPERTIES -CARBON CONTENTS BETWEEN 2% AND 5% GENERAL USES - MELTING TEMPERATURE BELOW CARBON STEEL - POOR WELDABILITY AND DUCTILITY - EXCELLENT FLUIDITY (REQUIRED FOR CASTING PURPOSE) - SILICON INCLUSION BETWEEN 1% AND 3% - MANUFACTURING OF PUMPS, TURBINES, COMPRESSORS AND GEAR BOX CASINGS
- 25. CLASSIFICATION FERROUS METALS FERROUSMETALS CARBON STEEL CAST IRON ALLOY STEEL WROUGHT IRON BASED ON “C” ADDITION
- 26. ALLOY STEELS ALLOY STEEL LOWALLOY STEEL HIGH ALLOY STEEL ALLOYING ELEMENT UP TO 8.0% ALLOYING ELEMENT GREATER THAN 8.0% CORROSION RESISTANT HEAT RESISTANT WEAR RESISTANT Cr-Mo Alloy
- 27. Cr – MoSTEELS GENERAL USES - PRESSURE VESSEL, PIPING AT HIGH TEMPERATURE COMPOSITION - Cr UPTO 2.25% AND Mo UP TO 1.25% MECHANICAL PROPERTIES - HIGH STRENGTH AT TEMPERATURES UP TO 650 0 C - DIFFICULT WELDING AS HEAT TREATMENT IS INVOLVED ALLOYING EFFECT - Cr INCREASES CORROSION RESISTANCE - Mo ADDS ELEVATED TEMPERATURE STRENGTH
- 28. Cr - MoSTEEL GRADES A-335 GRADE P11 (PLANT-I KS) Cr – Mo STEELS A-335 GRADE P22 (PLANT-I KS) USES AT FERTILIZER PLANT - PIPING, VALVES AND VESSELS FOR VER HIGH PRESSURE STEAM (KS)
- 29. STAINLESS STEEL WHEN CrCONTENTS ARE GREATER THAN 11.5 %, Cr REACTS WITH ATMOSPHERIC O2 AND FORM THIN PASSIVE Cr-O2 LAYER ON STEEL SURFACE PREVENTING OXIDATION OF Fe CONTENTS Cr–O2 LAYER STEEL
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- 33. COMPOSITION MECHANICAL PROPERTIES GENERAL USES -GOOD WELDABILITY - EXCELLENT CORROSION RESISTANT - FOOD PROCESSING, CORROSIVE SERVICES e.g. UREA, ACID etc. - CAN BE USED AT LOW AND HIGH TEMPERATURE (UP TO 900 0 C) Ni UP TO 30% Cr UP TO 30% C 0.3% AUSTENITIC STAINLESS STEEL - CANNOT BE HARDENED BY HEAT TREATMENT
- 34. USED AT FERTILIZERPLANT - ALL PRESSURE UREA SERVICE AND UREA FLUSHING CIRCUIT - PIPING, VALVES AND VESSELS FOR - MDEA, PROCESS GAS, DEMIN WATER AUSTENITIC STAINLESS STEEL AUSTENITIC GRADES SS- 304 SS- 316 SS- 316L Modified 25 Cr – 22Ni – 02 Mo SS- 321
- 35. CONCEPT OF SENSITIZATIONIN STAINLESS STEEL CHROMIUMCARBIDE (Cr23 C6) GRAIN BOUNDARIES CHROMIUM AT HIGH TEMPERATURE (> 750 0 C) Cr REACTS WITH C AND FORMS CrC TO PREVENT SENSITIZATION Ti OR Nb IS ADDED TO FORM TiC OR NbC
- 36. COMPOSITION MECHANICAL PROPERTIES GENERAL USES -POOR WELDABILITY - MODERATE CORROSION RESISTANT - SHAFTS, SURGICAL INSTRUMENTS, FASTENERS - CAN BE HARDENED BY HEAT TREATMENT MARTENSITIC STAINLESS STEEL C 1.2% Cr UP TO 17% Ni 0%
- 37. USED AT FERTILIZERPLANT - PUMP SHAFTS, IMPELLERS FOR CORROSIVE SERVICE MARTENSITIC GRADES SS- 416 SS- 420 MARTENSITIC STAINLESS STEEL SS- 440 SS- 410
- 38. COMPOSITION MECHANICAL PROPERTIES GENERAL USES -POOR WELDABILITY - MODERATE TO GOOD CORROSION RESISTANT - DOMESTIC EQUIPMENTS FERRITIC STAINLESS STEEL - CANNOT BE HARDENED BY HEAT TREATMENT C .3% Cr UP TO 30% Ni 0%
- 39. COMPOSITION MECHANICAL PROPERTIES GENERAL USES -GOOD STRENGTH : GREATER THAN AUSTENITIC AND OTHER GRADES - GOOD CORROSION RESISTANCE - OFF-SHORE APPLICATIONS, HIGH PRESSURE UREA DUPLEX STAINLESS STEEL - GOOD WELDABILITY C .3% Cr UP TO 30% Ni UP TO 8%
- 40. USED AT FERTILIZERPLANT - UREA REACTOR (STAMI CARBON PLANTS) DUPLEX STAINLESS STEEL - STEMS FOR HIGH PRESSURE UREA VALVES DUPLEX GRADES HVD-1 FERRALIUM ALLOY
- 41. SS – 304 18Cr – 8 Ni SS - 316 SS - 317 ADD Mo (2%) FOR PITTING RESISTANCE ADD MORE Mo (4%) FOR PITTING RESISTANCE ADD Nb + Ta TO REDUCE SENSITIZATION SS - 347 ADD Ti TO REDUCE SENSITIZATION SS - 321 LOWER C SS - 317L SS - 316L SS - 304L ADD Cr & Ni STRENGTH & CORROSION RESIST. SS – 310 SS - 309 REDUCE Ni TO REDUCE AUSTENITIC STRUCTURE DUPLEX STEEL NO Ni FERRITIC STEEL INCREASE C LOWER Cr MARTENSITIC STEEL
- 42. MATERIAL DESIGNATION SYSTEM -American Society for Testing MaterialsASTM - American Iron and Steel InstituteAISI - Society of Automotive EngineersSAE - Unified Numbering SystemUNS - German StandardsDIN - British StandardsBS - Japanese StandardsJS
- 43. AISI/SAE DESIGNATION SYSTEM CLASSIFYMATERIAL ON THE BASIS OF COMPOSITION CARBON AND ALLOY STEEL (EXCEPT STAINLESS STEEL) 13 Y 12X CARBON %AGE MATERIAL TYPE PREFIX M OR E Z ADDITION OF ELEMENTS SUFFIX H - Carbon Steel10 - 1% Cr & 0.3% Mo Steel41 - Merchant Quality SteelM - Electric Furnace SteelE - BoronB - LeadL - HardenabilityH
- 44. AISI/SAE DESIGNATION SYSTEM STAINLESSSTEEL 3 16 No Specific Interpretation MATERIAL TYPE Z Element addition - Austenitic Stainless Steel2 - Austenitic Stainless Steel3 - Low Carbon (<0.03%)L - High Carbon ContentsH - Added NitrogenN - Added CopperCu - Martensitic & Ferritic4
- 45. ASTM STANDARDS Ferrous Metals DESIGNATIONSYSTEM ASTM A 182 / 182 M - 93b F 304LASTM A 182 / 182 M - 93b F 304L Arbitrary Number Metric System Year of Revision AISI NO CLASSIFY PRODUCTS ON THE BASIS OF MANUFACTURING METHOD MOST WIDELY USED SYSTEM – COVERS ALL DETAILS REQUIRED FOR MATERIAL PROCUREMENT Grade
- 46. ASTM STANDARDS DESIGNATION SYSTEM -Corrosion ResistantC - Heat ResistantH - Addition of MolybdenumM - Carbon PercentageDigital No. - PipeP - TubeT - Tube and PipeTP - ForgingF EXAMPLES A 403/A 403M -93 WP304L A 351 Grade HK40 A 336/A 336M-89 Class F22 A 351 Grade CF8M - WroughtW
- 47. UNIFIED NUMBERING SYSTEM(UNS) JOINT VENTURE AS ASTM AND SAE TO GENERATE UNIFIED COMPUTER FRIENDLY SYSTEM 1040 1X ELEMENT ADDITION TYPE OF STEEL AISI/SAE NUMBER - Carbon and Alloy steelsG - Cast IronsF - Heat and Corrosion Resistant Steels H - Boron1 - Lead4 - Electric Furnace Steel6
- 48. MATERIAL COMPOSITION WHERE TOFIND BLACK BOOK BY CASTII PUBLISHING (PDF FORMAT) KEY TO STEEL (SOFTWARE) ASTM STANDARDS
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- 50. Cr – MoSTEELS
- 51. C .3% Cr UPTO 30% Ni UP TO 8% C 0.3% Cr UP TO 30% Ni 0% Ni UP TO 30% Cr UP TO 30% C 0.3% C 1.2% Cr UP TO 17% Ni 0%
- 52. STAINLESS STEEL CONCEPT OFSENSITIZATION CHROMIUM CARBIDE (Cr23 C6) CHROMIUM DEPLETED LAYER
- 53. MATERIAL CLASSIFICATION FERROUS METALS CASTIRON LOW ALLOY STEEL HIGH ALLOY STEEL CARBON STEEL LOW CARBON HIGH CARBON MEDIUM CARBON
- 54. STAINLESS STEEL Ni UPTO 30% Cr UP TO 30% C .3% AUSTENITIC STAINLESS STEEL C 1.2% MARTENSITIC STAINLESS STEEL Cr UP TO 17% Ni 0% C .3% DUPLEX STAINLESS STEEL Cr UP TO 30% Ni UP TO 8% C .3% FERRITIC STAINLESS STEEL Cr UP TO 30% Ni 0%
- 55. AUSTENITIC STAINLESS STEEL UN-STABILIZEDGRADE - SS 304 - SS 316 - 25 Cr – 22 Ni – 2 Mo - 316L + G510 STABILIZED GRADE - SS 321 - SS 347 Cannot Be Used for High Temperature Can Be Used for High Temperature
- 56. SS – 304 18Cr – 8 Ni SS - 316 SS - 317 ADD Mo (2%) FOR PITTING RESISTANCE ADD MORE Mo (4%) FOR PITTING RESISTANCE ADD Nb TO REDUCE SENSITIZATION SS - 347 ADD Ti TO REDUCE SENSITIZATION SS - 321 LOWER C SS - 317L SS - 316L SS - 304L ADD Cr & Ni STRENGTH & CORROSION RESIST. SS – 310 SS - 309 AUSTENITIC STAINLESS STEEL
- 57. CARBON STEEL CARBON STEEL MEDIUMCARBON STEEL HIGH CARBON STEEL LOW CARBON STEEL CARBON CONTENTS < 0.3 % CARBON CONTENTS BETWEEN 0.3 % AND 0.6% CARBON CONTENTS BETWEEN 0.6 % AND 2.0%
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- 59. CARBON STEEL CLASSIFICATION ACCORDINGTO CARBON CONTENTS
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