Corrosion resistant materials

AH columns, distributors, and ancHlary hardware such as piping, valves, and pumps must be constmcted of corrosion-resistant materials, or coated with an appropriate substance. AH streams that contact the hardware during each step of the cycHc operation need to be considered in this selection. 

Liquids. Approximately 170,000 railroad tank cars are used in the United States. The interior surfaces of these cars are tailored to carry a wide variety of products and are constmcted of steel which is either unlined or lined with materials to enhance the chemical compatibiUty with a specific product these lining materials include synthetic mbber, phenoHc or modified epoxy resins, or corrosion-resistant materials such as aluminum, nickel-bearing steel, or stainless steel. 

Corrosiveness. The catalyst solutions are corrosive, and the reactors, separation devices, etc that come in contact with them must be made of expensive corrosion-resistant materials. 

Polycarbonates. Polyarjiates are aromatic polyesters commonly prepared from aromatic dicarboxylic acids and diphenols. One of the most important polyarylates is polycarbonate, a polyester of carbonic acid. Polycarbonate composite is extensively used in the automotive industry because the resin is a tough, corrosion-resistant material. Polycarbonates (qv) can be prepared from aUphatic or aromatic materials by two routes reaction of a dihydroxy compound with phosgene accompanied by Hberation ofHCl(eq. 5) ... 

Packed vs Plate Columns. Relative to plate towers, packed towers are more useful for multipurpose distillations, usually in small (under 0.5 m) towers or for the following specific appHcations severe corrosion environment where some corrosion-resistant materials, such as plastics, ceramics, and certain metaUics, can easily be fabricated into packing but may be difficult to fabricate into plates vacuum operation where a low pressure drop per theoretical plate is a critical requirement high (eg, above 49,000 kg/(hm ) (- 10, 000 lb/(hft )) Hquid rates foaming systems or debottlenecking plate towers having plate spacings that are relatively close, under 0.3 m. 

Corrosivity. Corrosivity is an important factor in the economics of distillation. Corrosion rates increase rapidly with temperature, and in distillation the separation is made at boiling temperatures. The boiling temperatures may require distillation equipment of expensive materials of constmction however, some of these corrosion-resistant materials are difficult to fabricate. For some materials, eg, ceramics (qv), random packings may be specified, and this has been a classical appHcation of packings for highly corrosive services. On the other hand, the extensive surface areas of metal packings may make these more susceptible to corrosion than plates. Again, cost may be the final arbiter (see Corrosion and corrosion control). 

The gas distribution system can be composed of a network of perforated pipe, slotted or vented concrete block, or metal grating. When there are no space hmitations, single-level filters are used. In regions where footprint space is hmited, hke Japan, multiple-deck filter beds have become commonplace. If inorganic compounds are being treated, corrosion-resistant materials of construc tion are used due to the acidic by-products of the bioreaction. 

Eveiy effort should be made to eliminate direct (Bourdon-type) pressure gauges. Diaphragm pressure gauges constructed of appropriate corrosion-resistant materials are preferred. Flow limiters should be used to limit flow in case of loss of integrity... 

Sometimes there is no practical, economical way to reduce deposition, protect surfaces cathodically, change design and operation, or treat existing systems chemically. A material change is required. The most economical solution usually is to coat existing structures with water-impermeable, sacrificial, or corrosion-resistant materials. 

Substituting one alloy for another may be the only viable solution to a specific corrosion problem. However, caution should be exercised this is especially true in a cooling water environment containing deposits. Concentration cell corrosion is insidious. Corrosion-resistant materials in oxidizing environments such as stainless steels can be severely pitted when surfaces are shielded by deposits. Each deposit is unique, and nature can be perverse. Thus, replacement materials ideally should be tested in the specific service environment before substitution is accepted. 

Use corrosion resistant material of construction Implement mechanical integrity program to prevent leaks of corrosive material Use multiple voting with plausibility analysis... 

Recently in some types of refuelling stations, corrosion-resistant materials have been used between the filter-water separator and the outlet pipeline and valves, usually stainless steel, rarely aluminum. If these are buried, they must have good insulating coating and be electrically separated from other tank installations by insulating couplings. 

In the tidal zone and the spray zone (known as the splash zone), cathodic protection is generally not very effective. Here thick coatings or sheathing with corrosion-resistance materials (e.g., based on NiCu) are necessary to prevent corrosion attack [4]. The coatings are severely mechanically stressed and must be so formed that repair is possible even under spray conditions. Their stability against cathodic polarization (see Section 17.2), marine growths, UV rays and seawater must be ensured [4,5]. 

The use of electrochemical protection in the chemical industry started about 20 years ago, which is somewhat recent, compared with its use for buried pipelines 40 years ago. Adoption was slow because the internal protection has to be tailored to the individual plant, which is not the case with the external protection of buried objects. Interest in internal protection came from the increasing need for greater safety for operating plants, increased demands for corrosion resistance, and larger plant components. While questions of its economy cannot generally be answered (see Section 22.6), the costs of electrochemical protection are generally less than the cost of equivalent and reliable coatings or corrosion-resistant materials. 

The use of corrosion-resistant materials and the application of corrosion protection measures are in many cases the reason that industrial plants and structures can be built at all. This is particularly so in pipeline technology. Without cathodic protection and without suitable coating as a precondition for the efficiency of cathodic protection, long-distance transport of oil and gas under high pressures would not be possible. Furthermore, anodic protection was the only protective measure to make possible the safe operation of alkali solution evaporators (see Section 21.5). 

The flexible element coupling requires no lubrication, which is a distinct advantage. The need for lubrication is always a problem with gear couplings. This advantage is partially offset in the flexible element by the need for corrosion-resistant materials for the normal chemical plant atmosphere. Inconel 718 and 15-5 PH have been used and have been rea-... 

Some corrosion-resistant materials for concentrated aqueous solutions and acids are given in Tables 4.10 and 4.11. The resistance of some common polymers to organic solvents is summarized in Table 4.12. The attack process is accelerated by an increase in temperature. The chemical resistance of a range of common plastics is summarized in Table 4.13. 

Table 4.10 Corrosion-resistant materials for concentrated aqueous solutions ...

The use of fully corrosion-resistant materials is not always the best choice. One must optimize the relation between capital investment and cost of subsequent maintenance over the entire estimated life of the equipment. 

No materials have properties that fulfill all requirements. For example, good heat conductivity is a desirable property for the fabrication of heat exchanger surfaces, but not for insulation purposes. Obviously, both positive and negative properties can coexist in a single material. A corrosion resistant material may be insufficient for heat resistance or mechanical strength. Strong materials may be too brittle, e.g., ferrosilicon. Also, materials that have good mechanical and chemical properties may be too expensive. 

These are used as corrosion-resistant materials. Examples are given in Table 3.32. Some can be strengthened by heat treatment. The alloys containing substantial amounts of silicon have the best foundry characteristics and a high resistance to corrosion, but are not readily machined. 

Although transformers suitable for other industrial installations are generally suitable for producing applications, certain options may be desirable— primarily due to environmental considerations. At locations subject to harsh environmental conditions, and particularly at locations subject to washdown with high-pressure hoses, non-ventilated enclosures are desirable, if not necessary. Likewise, at locations subjected to salt water and salt-laden air, it often is desirable to specify copper windings and lead wires. Most manufacturers provide standard units with aluminum windings and lead wires. Even if aluminum coils are used, it is almost always desirable to require stranded copper lead wires. This will lessen corrosion and loose terminal problems when transformers arc interconnected to the facility electrical system with copper conductors. If the transformers are to be installed outdoors in corrosive environments, cases should be of corrosion-resistant material (e.g., stainless steel) or be provided with an exterior coating suitable for the location. 

Designs and/or specifies items of equipment required to define the process flowsheet or flow system specifies corrosion resistant materials of construction. 

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