Proper material selection is important in process industries to minimize corrosion and its economic and safety impacts. The document discusses key factors in material selection such as environmental conditions, corrosion resistance, life cycle costs, and information resources. It also provides an overview of material selection challenges within the Indian context.
The main objective of this review is to describe some of the important topics related to the use of marine and protective coatings for anti-corrosive purposes. In this context, "protective" refers to coatings for containers, off shore construction, pipe lines, pumps, steel structures, chemical equipment, bridged, storage tanks and petrochemical plants. The review aims at providing a thorough picture of state-of-the-art in anti-corrosive coatings systems. International and national legislation aiming at reducing the emission of volatile organic compounds (VOCs) have caused significant changes in the anti-corrosive coating industries. An important aspect in the development of new VOC -compliant, high performance anti-corrosive coating system is a thorough knowledge of the components in anti-corrosive coatings, their interaction, their advantages and limitations as well as detailed knowledge on the failure modes of anticorrosive coatings. The different types of anticorrosive coatings are presented, and the most widely applied generic types of binders and pigments in anticorrosive coatings.
Degradation and Microbiological Validation of Meropenem Antibiotic in Aqueous...IJERA Editor
Aqueous UV, UV/H2O2, UV/TiO2 and UV/TiO2/H2O2mediateddegradation/oxidation of the carbapenem antibiotic, meropenem (MERO) was experimentally studied. Degussa P-25 titanium dioxide was used as photocatalyst and UV-light source was used for activation of TiO2.The nanosized titanium dioxide was immobilized on the glass support for improving the efficiency and economics of the photocatalytic processes. The immobilized film of titanium dioxide has been characterized, using X-ray diffraction (XRD) andscanning electron microscopy (SEM).The study of antibiotic degradation was conducted in the specific Batch Photocatalytic Reactor. MERO standard solution was used at 500 μg/ml concentration, which degraded up to 99% of antibiotics. Microbiological assay showed that the loss of antibacterial activity is directly proportional to the time of UV-irradiation. The experiment also showed that the UV-irradiation itself causes the degradation of antibiotics, but in very slow manner in comparison to the photocatalysis process. The experimental study showed that UV/TiO2/H2O2 system is effective and efficient for the treatment of antibiotic waste.
The main objective of this review is to describe some of the important topics related to the use of marine and protective coatings for anti-corrosive purposes. In this context, "protective" refers to coatings for containers, off shore construction, pipe lines, pumps, steel structures, chemical equipment, bridged, storage tanks and petrochemical plants. The review aims at providing a thorough picture of state-of-the-art in anti-corrosive coatings systems. International and national legislation aiming at reducing the emission of volatile organic compounds (VOCs) have caused significant changes in the anti-corrosive coating industries. An important aspect in the development of new VOC -compliant, high performance anti-corrosive coating system is a thorough knowledge of the components in anti-corrosive coatings, their interaction, their advantages and limitations as well as detailed knowledge on the failure modes of anticorrosive coatings. The different types of anticorrosive coatings are presented, and the most widely applied generic types of binders and pigments in anticorrosive coatings.
Degradation and Microbiological Validation of Meropenem Antibiotic in Aqueous...IJERA Editor
Aqueous UV, UV/H2O2, UV/TiO2 and UV/TiO2/H2O2mediateddegradation/oxidation of the carbapenem antibiotic, meropenem (MERO) was experimentally studied. Degussa P-25 titanium dioxide was used as photocatalyst and UV-light source was used for activation of TiO2.The nanosized titanium dioxide was immobilized on the glass support for improving the efficiency and economics of the photocatalytic processes. The immobilized film of titanium dioxide has been characterized, using X-ray diffraction (XRD) andscanning electron microscopy (SEM).The study of antibiotic degradation was conducted in the specific Batch Photocatalytic Reactor. MERO standard solution was used at 500 μg/ml concentration, which degraded up to 99% of antibiotics. Microbiological assay showed that the loss of antibacterial activity is directly proportional to the time of UV-irradiation. The experiment also showed that the UV-irradiation itself causes the degradation of antibiotics, but in very slow manner in comparison to the photocatalysis process. The experimental study showed that UV/TiO2/H2O2 system is effective and efficient for the treatment of antibiotic waste.
Evaluation Methods for Material Selection with Case StudyAditya Deshpande
Here I have discussed meaning and various material selection methods which can be used effectively.
To elaborate concept of material selection, a case study is provided of table along with mathematical calculations and process steps to reach at final optimum material selection.
Thus case study shows potential of Weighted Property Indices method. The case study serves as a beneficial example for material selection of modern automobiles.
Richard Crawford from Integrated Global Services, a solution provider at the marcus evans Petrochemical & Refining Summit 2012 and Power Plant Management Summit 2012, on asset safety and optimization.
Interview with: Richard Crawford, President, Integrated Global Services
tA composite material can be defined as a combination of two or more materials that gives better properties than those of the individual components used alone. In contrast to metal-lic alloys, each material retains its separate chemical, physical, and mechanical properties.The two constituents are reinforcement and a matrix. The main advantages of compositematerials are their high strength and stiffness combined with low density when comparedto classical materials. Micromechanical approach is found to be more suitable for the anal-ysis of composite materials because it studies the volume proportions of the constituentsfor the desired lamina stiffness and strength.It is found that the manufacturing processes are responsible of many defects which mayarise in fibers, matrix and lamina. These defects, if they exist include misalignment of fibers,cracks in matrix, non uniform distribution of the fibers in the matrix, voids in fibers andmatrix, delaminated regions, and initial stress in the lamina as a result of its manufactureand further treatment.The above mentioned defects tend to propagate as the lamina is loaded causing an accel-erated rate of failure. The experimental and theoretical results in this case tend to differ.Hence, due to the limitations necessary in the idealization of the lamina components, estimated should be proved experimentally.
A polymer is any of a class of natural or synthetic substances composed of very large molecules, called macromolecules, which are multiples of simpler chemical units called monomers. Polymers make up many of the materials in living organisms and are the basis of many minerals and man-made materials.A polymeric structure is often envisaged as an entangled mass of chain molecules. As the Tg values for many commercial polymers are fairly low, one assumes that thermal agitation causes molecules to wriggle at ambient temperatures.
Evaluation Methods for Material Selection with Case StudyAditya Deshpande
Here I have discussed meaning and various material selection methods which can be used effectively.
To elaborate concept of material selection, a case study is provided of table along with mathematical calculations and process steps to reach at final optimum material selection.
Thus case study shows potential of Weighted Property Indices method. The case study serves as a beneficial example for material selection of modern automobiles.
Richard Crawford from Integrated Global Services, a solution provider at the marcus evans Petrochemical & Refining Summit 2012 and Power Plant Management Summit 2012, on asset safety and optimization.
Interview with: Richard Crawford, President, Integrated Global Services
tA composite material can be defined as a combination of two or more materials that gives better properties than those of the individual components used alone. In contrast to metal-lic alloys, each material retains its separate chemical, physical, and mechanical properties.The two constituents are reinforcement and a matrix. The main advantages of compositematerials are their high strength and stiffness combined with low density when comparedto classical materials. Micromechanical approach is found to be more suitable for the anal-ysis of composite materials because it studies the volume proportions of the constituentsfor the desired lamina stiffness and strength.It is found that the manufacturing processes are responsible of many defects which mayarise in fibers, matrix and lamina. These defects, if they exist include misalignment of fibers,cracks in matrix, non uniform distribution of the fibers in the matrix, voids in fibers andmatrix, delaminated regions, and initial stress in the lamina as a result of its manufactureand further treatment.The above mentioned defects tend to propagate as the lamina is loaded causing an accel-erated rate of failure. The experimental and theoretical results in this case tend to differ.Hence, due to the limitations necessary in the idealization of the lamina components, estimated should be proved experimentally.
A polymer is any of a class of natural or synthetic substances composed of very large molecules, called macromolecules, which are multiples of simpler chemical units called monomers. Polymers make up many of the materials in living organisms and are the basis of many minerals and man-made materials.A polymeric structure is often envisaged as an entangled mass of chain molecules. As the Tg values for many commercial polymers are fairly low, one assumes that thermal agitation causes molecules to wriggle at ambient temperatures.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
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This project focuses on MgO-C refractories for teeming ladles in steelmaking. It provides an overview of refractory basics, their significance in steel production, and the specific properties of MgO-C refractories. The presentation delves into the manufacturing process, highlighting key steps such as raw material preparation, shaping, and quality control. It explores the critical performance requirements of teeming ladle linings and discusses how MgO-C refractories meet these demands. Case studies demonstrate the benefits of using MgO-C refractories, including extended lifespan, improved operational efficiency, and cost reduction. The project also addresses challenges in teeming ladle lining and emphasises the importance of proper maintenance and sustainability practices. Finally, it outlines future innovations in refractory technology, highlighting opportunities for enhancing performance and sustainability in the steel industry.
Materials Technology for Engineers pre-test 1 notesmusadoto
Materials are probably more deep-seated in our culture than most of us realize. Transportation, housing, clothing, communication, recreation, and food production virtually every segment of our everyday lives is influenced to one degree or another by materials. Historically, the development and advancement of societies have been intimately tied to the members’ ability to produce and manipulate materials to fill their needs. In fact, early civilizations have been designated by the level of their materials development (i.e., Stone Age, Bronze Age). The earliest humans had access to only a very limited number of materials, those that occur naturally: stone, wood, clay, skins, and so on. With time they
discovered techniques for producing materials that had properties superior to those of the natural ones; these new materials included pottery and various metals. Furthermore, it was discovered that the properties of a material could be altered by heat treatments and by the addition of other substances. At this point, materials utilization was totally a selection process, that is, deciding from a given, rather limited set of materials the one that was best suited for an application by virtue of its characteristics. It was not until relatively recent times that scientists came to understand the relationships between the structural elements of materials and their properties. This knowledge acquired in the past 60 years or so, has empowered them to fashion, to a large degree, the characteristics of materials. Thus, tens of
thousands of different materials have evolved with rather specialized characteristics that meet the needs of our modern and complex society; these include metals, plastics, glasses, and fibers. The development of many technologies that make our existence so comfortable
has been intimately associated with the accessibility of suitable materials. An advancement
in the understanding of a material type is often the forerunner to the stepwise progression of a technology. For example, automobiles would not have been possible without the availability of inexpensive steel or some other comparable substitute. In our contemporary era, sophisticated electronic devices rely on components that are made from what are called semiconducting materials.
Similar to Material Selection - Challenge for Corrosion Management in Process Plants (20)
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Material Selection - Challenge for Corrosion Management in Process Plants
1. Features
Corrosion Management
Material Selection: Challenge
for Corrosion Management in
Process Plants
Proper material selection and material protection, i.e. protection against various
corrosion phenomena in chemical environments, is of prime importance in the chemical,
petrochemical, and other process industries. In the process industries, proper materials
engineering and corrosion control are key issues with respect to production economics,
safety and environmental issues.
C
orrosion is a process rapid attack can occur in the materials from pipes or vessels.
which exerts its influence presence of reactive gases, It can also result in the sudden
in all fields of endeavour, high temperatures, and in catastrophic failure of critical
and its consequences affect combination with abrasion components, particularly
every individual. It is driven by and wear. It is inevitable where corrosion-assisted
thermodynamic considerations, that corrosion can incur cracking takes place, with an
which dictate that metallic huge financial costs, not only associated threat of injury and
materials will tend to return to due to the need to replace loss of life.
their most stable state, often as manufactured components
oxides or other combined forms, and plant, which become Proper materials selection
particularly under aggressive degraded by the process, but and materials protection, i.e.
environmental conditions also due to the consequences protection against various
which accelerate the process. of corrosion for health and corrosion phenomena in
Corrosion can manifest itself in safety, the environment and chemical environments, is
many forms, both general and the quality of life of individuals. of prime importance in the
localised (including cracking Corrosion can be a major cause chemical, petrochemical, and
under conditions of tensile or of pollution where it results other process industries. In
cyclic stressing). Particularly, in the leakage of hazardous the process industries, proper
Chemical Engineering World | 71 | MAY 2011 www.cewindia.com
Feature-Challenge for Corrosion 71 71 5/31/2011 7:49:57 PM
2. Features
materials engineering and corrosion
control are key issues with respect Dixon and Poli suggest a four level approach to materials selection
to production economics, safety and
environmental issues. Level l - Based on critical properties, determine whether the part will be made from metal,
plastic, ceramic, or composite.
Level II - Determine whether metal parts will be produced by a deformation process (wrought)
The selection of correct materials for
or a casting process; for plastics, determine whether they will be thermoplastic or thermo
a design is a key step in the process
setting polymers.
because it is the crucial decision
Level III - Narrow options to a broad category of material. Metals can be subdivided
that links computer calculations into categories such as carbon steel, stainless steel, and copper alloys. Plastics can be
and lines on an engineering drawing subdivided into specific classes of thermoplastics and thermosets such as polycarbonates
with a working design. Materials and polyesters.
and manufacturing processes that Level IV - Select a specific material according to a specific grade or specification.
convert the material into a useful
engineering design. An incorrectly
chosen material can lead not only is dictated by the unique resistant materials. In many cases,
to failure of the part, but also to environmental conditions that this approach is an economical
unnecessary cost. Selecting the pertain to a specific application at alternative to other corrosion control
best material for a part involves all stages in a component lifetime methods. Corrosion resistance is not
more than selecting a material that including procurement, fabrication, the only property to be considered
has the properties to provide the transportation, storage, installation, in making material selections, but
necessary performance in service; commissioning, operation and it is of major importance in the
it is also intimately connected with maintenance. Corrosion failures chemical process industries.
the processing of the material into have occurred because of
the finished part. A poorly chosen unexpected causes that resulted Selection Process - Is it a Material
material can add to manufacturing from a lack of information about or Process Issue?
cost and unnecessarily increase the corrosion, sometimes the direct A materials selection problem
cost of the part. Also, the properties result of poor communication and/ usually involves one of two
of the material can be changed or a lack of appreciation of the true situations: selection of the materials
by processing (beneficially or service conditions. and the processes for a new product
detrimentally), and that may affect or design and materials substitution
the service performance of the part. From a purely technical standpoint, for an existing design.
an obvious answer to corrosion
The type and extent of corrosion problems would be to use more When selecting construction
materials, it is essential to know
how the materials will behave when
exposed to the actual operating
environment. In particular, special
attention must be given to the
following factors; potential for
corrosion, operating temperatures
and pressures, unexpected
operating conditions and startup
and shut-down procedures. A large
share of equipment operation and
maintenance costs in the chemical
processing industries are the result
of materials failure due to abrasive,
corrosive or high temperature
environments. If corrosion is not an
issue, the least expensive material
with the appropriate mechanical
www.cewindia.com Chemical Engineering World | 72 | MAY 2011
Feature-Challenge for Corrosion 72 72 5/31/2011 7:49:59 PM
3. Features
Material Selection Chart
properties is usually selected. areas that are difficult to repair or designed and fabricated, will require
in components that would cause minimum maintenance and will
Costs and Related Aspects of major shutdowns in case of failure. function reliably. Rising labour costs
Materials Selection In these situations, the original cost in most industries, together with the
The decision on materials selection of the material can be insignificant need for high reliability in capital-
ultimately will come down to a compared to the loss of production intensive plants has produced a
trade-off between performance caused by the use of a lower-cost, trend to this type of system.
and cost. There is a spectrum of but less-effective, material. The
applications varying from - those following two extreme alternatives In practice, many systems are a
where performance is paramount describe the consideration given mixture of these extreme options,
(defense-related aerospace) to those to economic factors when selecting resulting in the high initial costs
where cost clearly predominates materials for specific service. One of one and the high maintenance
(household appliances). The total is a low initial cost system largely costs of the other. For example,
cost of a part includes the cost of the based on carbon steel and cast a plant that has experienced
material, the cost of tooling (dyes, iron that will require considerable costly replacement to galvanised
fixtures), and the processing cost. maintenance over the life of the steel piping may replace it with
plant. copper alloy piping, leaving valve
The important criterion should not fittings and other equipment in
be the initial cost of a material, but its Such a system is a reasonable choice carbon steel and cast iron. The
life-cycle cost or cost effectiveness. It in areas where labour costs are low resulting galvanic corrosion effects
usually is much more cost-effective and material is readily available. The result in reduced life for these
to specify a material that will provide second one is a system based mainly parts. Thus, avoidance of higher
an extended life, particularly in on alloy materials that, if correctly initial costs will result in reduced
Chemical Engineering World | 73 | MAY 2011 www.cewindia.com
Feature-Challenge for Corrosion 73 73 5/31/2011 7:50:03 PM
4. Features
reliability and high maintenance specifications, research reports, as it is large, with a number of major
costs. Unfortunately, competitive technical publications, market sectors including manufacturing
bidding and corporate bottom survey reports, materials databases, industries, agriculture, textiles,
lines frequently create barriers expert systems, and process specific handicrafts and services. The
that inhibit realisation of long research studies. Indian chemical industries
equipment life. The enlightened comprise small, medium and large-
company will recognise the value Internet-based systems play a scale units. Development of process
of the life-cycle cost approach on crucial role in assisting the designers specific research studies, material
long-term financial health and not and material selection personnel testing programmes, material
embrace only the low initial cost to fetch the proven experience of databases and corrosion-related
option. materials considered for similar standards for our Indian conditions
process situations elsewhere in the is always a grand challenge for our
In order to prevent corrosion related world. The modern day social and industries. In spite of tremendous
failure modes from occurring they technology networking systems progress in recent times, India
should be considered during the facilitate the researchers, material continues to face challenges
design and material selection stages suppliers, designers, consultants that could derail its ‘science and
of system development. Accounting and industries personnel to technology’ aspirations. There is
for many of the issues that are exchange their views on selection a large gap between the installed
correlated with corrosion, including and find appropriateness of capacity and projected needs in
test, design, and metallurgical selected materials. “We can control basic infrastructure, including
factors facilitates the development corrosion in India” is an example of power, roads, telecommunications,
of an inherently corrosion such a networking group. seaports and airports.
resistant design. For many forms of
corrosion, there are no quantitative This group establishes global level Source
1. ISO TC156 – Corrosion of Metals and Alloys.
measurement techniques, and thus multi-dimensional communication
2. Materials Engineering for the Chemical
materials are only rated based upon pathways (Technology Providers- Process Industries, MTI, 2006.
their relative susceptibilities. Technology Users-Academic and 3. Overview of the Materials Selection Process
Research Institutions-Professional by George E. Dieter, University of Maryland.
4. ASM Handbook Volume 13A, Corrosion:
Information Management for Associations-Legislation Support) Fundamentals, Testing, and Protection, 2003.
Material Selection: Influence and guides professionals from 5. Handbook of Corrosion Engineering by Roberge
of Social and Technology various disciplines and other Pierre.
6. E n g i n e e r i n g D e s i g n a n d D e s i g n f o r
Networking Systems technology groups to network
Manufacturing, Field Stone Publishers, 1995.
A new material cannot be employed with the best material selection 7. Overview of the Materials Selection Process
in a design unless the engineer knowledge source for corrosion by George E Dieter, University of Maryland.
has access to reliable material management. 8. Handbook of Corrosion Engineering by Roberge
Pierre.
properties and, hopefully, costs.
9. NiDI Technical Series 10071, Nickel
This illustrates one reason why the Our Indian Scenario Development Institute, 1992.
tried and trusted materials are used The cost of developing and 10. Corrosion Conscious Design, The AMPTIAC
repeatedly for designs even though incorporating advanced materials is Quarterly, Volume 9, Number 3, 2005.
11. Corrosionmanagementsurvey.in.
better designs could be achieved high. The reliability of new materials 12. Technology Roadmap for Materials of
with newer materials. At the start is unproven in most practical Construction, Materials Technology Institute,
of the design process, low-precision applications, and exploring their USA, 1998.
but all inclusive data are needed. At use in a process environment is risky. 13. S & T Strategies of Six Countries, National
Academy of Sciences, USA, 2010)
the end of the design process, data Significant R&D, from bench scale
are needed for only a single material, experiments to the construction
but they must be accurate and very and testing of prototypes, is usually Author Details
detailed. necessary before a new material M Vallippan
can be implemented in chemical Corrosion Mgmt. Consultant,
Information comes through various processing equipment. Kuwait Oil Company &
channels; handbooks, international/ Corrosion Mgmt. Services
national/company standards and The economy of India is as diverse E-mail: corrosion.management@gmail.com
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