Part 3 of the seven-part series on material selection for chemical process equipment focuses on select other materials beyond Metals (Part 1) and Plastics (Part 2). This summary of other materials includes Fiberglass Reinforced Plastics (FRP), Rubbers and Specialty Elastomers, Advanced Composites, and Technical Ceramics. Materials not in this Part 3 include products more applicable to project facility/area construction (e.g., concrete and wood), lightweight minor components (e.g., polymer foams and various material honeycombs), and more advanced/specialty materials not yet fully commercialized.

Fiberglass Reinforced Plastics (FRP)

FRP is a composite material using thermoset polymer resins and two- or three-dimensional fiber reinforcements with product-specific curing compounds, additives, and fillers to provide individual product properties. FRP composites have been used in chemical process equipment applications for more than 70 years and continue to develop with new resin and filler/additive materials and manufacturing techniques and technologies. FRP materials are used for tanks, tank shells, piping systems, ventilation hoods and ducting and blowers/fans and scrubbers, grating/stairs/ladders, structural shapes, and many custom wet process components. Similar to thermoplastics, application-appropriate, relatively lightweight FRP materials offer chemical resistance advantages over steels and stainless steels and for many cases over higher cost metals and alloys.  Depending on material market pricing and application specifics, FRP can be higher or lower installed cost* than stainless steels. FRP is an electrical insulator and does not present contact or galvanic corrosion  issues. FRP materials offer application-specific strength and temperature advantages over many thermoplastics.

FRP chemical process equipment can be manufactured through a range of processes, including molding, pultrusion molding, and several types of hand or automated lay-up processes. Different thermoset curing processes are also used, including combinations of catalysts or additives, heat, pressure, vacuum, or ultraviolet or other electromagnetic curing. FRP fabrication workmanship and process quality control are very important to production of quality, long-life FRP products.

FRP formulations using different resins provide for a broad range of excellent chemical resistance with some higher strength and temperature properties over commodity thermoplastics. Resin types range from more common polyester to more robust vinyl ester to higher strength epoxy resins. Other resin types include polyurethane, phenolics, and furans.  Fiber reinforcements, including fiberglass, carbon fiber, or aramid (e.g., Kevlar) fiber, give different strength properties. In favorable application conditions, vinyl ester or furan resin FRP pipe can be suitable for up to 200°F, and epoxy or phenolic resin FRP pipe can be suitable for up to 300°F.

FRP laminate products typically consist of layers of resin and fibers (glass or other materials) with layer-specific relative compositions; for example:

• Inner Laminate, or Chemical Barrier Layer (CBL): This layer is in contact with the process chemistry

(e.g., inside surface of a tank or pipe or duct) and protects the Structural Layer from chemical exposure. The Inner Laminate typically has a higher resin to fiber ratio (e.g., 70%|30%).

• Structural Layer: This layer provides load-carrying mechanical support and typically has a lower resin to fiber ratio (e.g. 30%|70%). FRP composite layers can also be built around metal or other material stiffeners or frames to provide additional strength.
• Top Layer: This layer, such as the CBL, has a relatively higher resin to fiber ratio to protect the Structural Layer from process chemistry splashes and spills.
• Gel Coat: This layer is prepared from the base resin and additives to provide a chemical resistant, high quality color finish.

FRP with glass-fiber reinforcing is lightweight (approximately 25% of steel) and typically provides approximately 50% of lengthwise tensile and flexural strength of steel. FRP strength in cross-wise direction is typically much lower than lengthwise strength (e.g., 25% to 30% of lengthwise strength), unless the specific FRP product is reinforced in the cross-wise direction.

In addition to catalysts and curing compounds, FRP additives can include fire retardants; UV protection; and surface enhancements, including abrasion resistance, traction enhancement, and static reduction.

FRP systems can be repaired in place without arc welding (an issue for some metal equipment in hazardous areas).  Coating, liner, and dual laminate applications for FRP and other materials are discussed in Part 4.

Rubbers and Specialty Elastomers

Rubbers and specialty elastomers are any of a wide range of polymer materials that differ from polymer plastics, as they are joined by chemical bonds to yield a cross-linked structure that provides for levels of elasticity where the materials can repeatedly deform under stress and return to original shape when the stress is removed.  Elasticity provides for good sealing performance over pressure and temperature variations.  Typical uses in process systems include gaskets and seals, belts and hoses, anti-vibration pads, and mounts. These materials have a broad range of chemical resistance, minimum service temperature (e.g., -10°F to -60°F) maximum service temperature (e.g., 175°F to 450°F), physical properties, and cost.

Rubbers

Rubbers are commonly grouped into oil resistant and non-oil resistant. Oil resistant rubbers include Nitrile rubber (NBR or Buna-N), Neoprene, Hypalon, Urethane, and Polysulfide.  Non-oil resistant rubbers include Natural Rubber, styrene-butadiene (SBR), and ethylene propylene diene terpolymer (EPDM). Various rubber compounds exhibit a broad range of chemical resistance and also vary with application range of temperature and physical properties such as hardness, compression resistance, and abrasion resistance.

Specialty Elastomers

There are  hundreds of specialty elastomers with a broad range in performance and price. Examples include silicone rubber, fluoroelastomer, FKM (e.g., Viton), and perfluoroelastomer, FFKM (e.g., Kalrez). Temperature and chemical resistance performance generally increase from standard silicone rubber to FKM to FFKM, and cost correspondingly increases significantly.

Technical Ceramics

Technical (i.e., Engineering or Advanced) ceramics include more conventional silicate ceramics used as electrical insulators (e.g., porcelains, magnesium silicates, and alkaline earth – silicon silicates), oxide ceramics (e.g., aluminum oxide, zirconium oxide, and mixed-oxide ceramics), and non-oxide ceramics (e.g., silicon carbide, silicon nitride, and aluminum nitride).

Technical ceramics are relatively chemically inert and can provide specialized high temperature service (e.g., above 1800°F) and mechanical property requirements (e.g., compressive strength, hardness, and abrasion resistance) for very challenging applications. Tensile strength for technical ceramics is typically a fraction of the material specific compressive strength. Technical ceramics are not widely used in surface finishing chemical process equipment but are important to some advanced manufacturing industry applications, including specialty pump and valve components, specialty tubing and piping, burner nozzles and refractory components, electrical components, and other custom process components. Specialty ultra-high temperature ceramics (UHTC) developed for NASA and aerospace applications have some of the highest known melting points of any materials and are used beyond application temperatures of nickel-based superalloys.

Advanced Composites

Advanced composites include polymer matrix composites (PMC), ceramic matrix composites (CMC), metal matrix composites (MMC), and carbon matrix composites. Advanced composites can contain fibers similar to FRP (e.g., glass, aramid, or carbon), and can use manufacturing techniques similar to FRP products. These materials can be relatively lightweight compared to metals (even significantly lighter than aluminum) and can be formulated to provide high axial and longitudinal strength properties similar to metals and metal alloys.  Advanced composites can provide relatively high range of application temperature (e.g., up to almost 500°F), chemical resistance, and fire retardance. Advanced composites can be very high initial cost, typically in the range of exotic metals and alloys, but can offer life-cycle cost advantages over lower performance materials. Advanced composites are used in newer aerospace, automotive (e.g., brakes, cylinder sleeves, bearings) military, and sporting goods applications. Applications are limited in surface finishing process equipment uses  and can require a very high level of up-front applications and design engineering.  Advanced composite materials, such as carbon + fiberglass or carbon + Kevlar, are commercially available as tubing, shaped tubing, and also as panels, plates, and angles. Metals can be deposited onto composite surfaces, an important application in the surface finishing industry, providing desired enhanced surface properties (see Part 4).

Next week, watch for Part 4: Material Selection for Chemical Process Equipment – Liner and Coating Systems. Part 4 provides information on a broad range of materials used for liners (plastics, metals, glass, ceramics, composites, etc.) and coating systems (plastics, epoxies, composites, etc.) to extend the application range of base materials.

* Specific metal alloy and FRP prices can vary significantly with market conditions.  Application specifics can result in a broad range of FRP resin and fiber/additive requirements that vary the FRP total installed cost.

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Integrated Technologies, Inc. is an industry-leading engineering, design, and consulting solutions firm based in Burlington, VT. We offer project planning and development, full-service engineering and design, project and construction management, and services during construction to the surfacing finishing and industrial manufacturing industries. 

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Part 2 of the seven-part series on material selection for chemical process equipment focuses on plastics. Plastics include a range of organic polymer structures that can include chlorine or fluorine and other functional groups. Plastics are commonly used in applications for tanks, pumps, piping and valving, ventilation systems, and miscellaneous equipment and components. Various plastics provide good to excellent chemical resistance for caustics, acids and some solvents that can be superior to even higher cost metals. In some applications with very aggressive process chemistries, fluoropolymer plastic heat exchangers are used instead of metal heat exchangers (although plastics require significantly larger heat transfer surfaces compared to metals). Factors including temperature, concentrations and combinations of chemistries, and mechanical stresses/loads  including fluid pressures, are important considerations for selecting specific plastics for chemical process equipment applications. Different proprietary and non-proprietary plastic formulations for a specific plastic type can provide significant variations in product purity, structure, temperature application range, and chemical resistance. Plastics are very light weight compared to metals, provide thermal and electrical insulation, and can be simple to form and machine. Plastic material prices can vary by more than an order of magnitude from commodity plastics up to more exotic fluoropolymer and imidized plastics. Individual plastic prices* can vary significantly with market demand and raw material supply. Some plastics used in surface finishing process applications include the following types:

Polyvinyl Chloride (PVC) and Chlorinated Polyvinyl Chloride (CPVC)

PVC and CPVC are relatively low cost and provide good chemical resistance for a range of acids, bases, and salt solutions. PVC is attacked by polar solvents. CPVC (modified PVC with chlorine content increased from ~57% to ~67%-74%) is higher in cost but provides added chemical resistance over PVC in many applications. CPVC is also suitable for higher temperatures up to 180°F to 210°F for some products and applications, compared to 140°F for PVC under favorable pressure and chemical exposure. CPVC also provides superior fire-resistance over PVC. PVC and CPVC are common materials for ventilation hoods and ducting up to application specific temperature and chemistry limits.  Metals, such as stainless steel (SS), or fiberglass reinforced plastic (FRP) composites with appropriate materials and reinforcement are needed for some higher temperature applications. The density of PVC is ~50% more than PP and HDPE, and PVC has some strength advantages over other common plastics. HDPE pipe walls must be 2.5 times thicker than PVC to achieve the same pressure rating for room temperature water applications, and the tensile and flexural strength of PVC are significantly higher than PP or HDPE.

Polypropylene (PP)

PP is used as a cost-effective material for tanks, including seamless tanks, and other process system equipment and components in a wide range of surface finishing applications. PP is also preferred over PVC and CPVC for piping and ventilation in many parts of the world. PP provides superior chemical resistance and high temperature resistance in many applications beyond PVC and is superior in chemical resistance over PVDF in some applications with strong bases and with some solvent and mixed chemical applications. PP has superior bending stiffness and tensile strength as compared to HDPE. PP has a Vicat heat distortion (softening) temperature in the range of ~289-305°F, compared to ~ 176°F for rigid PVC.  Different PP polymer formulations (e.g., homopolymer vs. copolymer) provide different properties, such as low temperature application range, impact strength, hardness, malleability, melting and softening points, and translucence. PP brittleness increases substantially more than HDPE or PVC or PVDF at temperatures approaching and below freezing.

Polyethylene (PE)

PE is available in a range of densities/molecular weights, providing different physical properties in addition to broad chemical resistance. PE can provide similar temperature and chemical resistance for many applications compared to PP (both are polyolefins).  PE has superior abrasion resistance to PP and PVC, with a sand-slurry method seven times higher than PP and over 50% more than steel.  Some common PE types include the following:

• Low-Density Polyethylene (LDPE) and Medium-Density Polyethylene (MDPE): LDPE is very flexible but relatively low in strength – it is commonly used for plastic sheeting. MDPE is stronger than LDPE and provides some additional chemical resistance.
• Cross-Linked Polyethylene (PEX or XLPE): The cross-link polymer bonds in this medium-to-high-density PE improve high temperature properties and enhance chemical resistance for some applications.
• High-Density Polyethylene (HDPE): HDPE provides significantly more strength and stiffness and higher temperature resistance than LDPE and MDPE and is easy to fabricate and weld. HDPE is available in sheet and pipe form and is molded into complex shapes.
• Ultrahigh Molecular Weight Polyethylene (UHMW): Due to a less-efficient molecular packing structure, the density of UHMW is slightly lower than HDPE. UHMW is less rigid and has ~78% tensile strength and ~55% flexural modulus of HDPE but provides superior impact resistance over HDPE. UHMW has a low coefficient of friction and is self-lubricating, making it excellent for parts exposed to friction and wear.

Polyvinylidene (PVDF)

PVDF is a relatively higher cost fluoropolymer thermoplastic that provides superior chemical resistance in many applications (strong bases are one exception) and has a significantly higher service temperature, ranging up to 250°F to 300°F in favorable conditions, compared to CPVC, PP, and HDPE. PVDF is almost twice as dense as PP. PVDF is available in piping, sheet, tubing, film, and plate form. Kynar® (one common group of PVDF plastics) can be homopolymer or copolymer and may also contain application specific additives (e.g., Red Kynar® has pigment added for ultraviolet (UV) protection). High purity 100% homopolymer PVDF is non-leaching and does not support growth of biological impurities, making it suitable for high and ultrapure applications.

Other Fluoropolymer Plastics

Polytetrafluoroethylene (PTFE) is a fluoropolymer plastic with excellent chemical resistance and high temperature resistance extending well beyond PVDF and other commodity plastics. A common brand name is Teflon. PTFE is not melt-processable. PTFE is primarily used as a high-performance coating and is featured more in Part 4 of this series. Perfluoroalkoxy (PFA) is a melt-processable fluorinated copolymer that provides chemical resistance and temperature performance similar to PTFE but at higher cost. Fluorinated ethylene propylene (FEP) copolymer has a slightly different structure than PTFE and is melt-processable but has reduced chemical resistance and temperature performance. FEP is lower cost than PTFE. Ethylene Tetrafluoroethylene Copolymer (ETFE) provides chemical inertness approaching PTFE and with superior melt-processability and mechanical properties beyond FEP and PFA. In addition to coating applications, various fluoropolymers are used in tubing for heat exchangers and other fluid applications with a combination of aggressive chemistries and elevated temperatures, including seals and gaskets and valve components. PTFE, FEP, and PFA are non-combustible, and PVDF and ETFE are self-extinguishing.

Imidized Plastics

These high cost, highest performance plastics include polyamide-imides and polyimides. Imidized plastics provide good to excellent chemical resistance and are superior to other plastics in combined high-temperature application range (up to 500°F) with high load bearing and wear performance. Imidized plastics are available as sheet, rod, or fabricated parts and are also used as a coating material. Example applications include bearings and bushings, pump and valve parts, and seals and specialty components in aerospace, electronics, and semiconductor industries.

Acrylics and Polycarbonates

Acrylic and polycarbonate plastics are used where clear, impact-resistant materials are needed for viewing ports, equipment enclosures/barriers, and other specialized applications. One common acrylic is Plexiglas. One common polycarbonate is Lexan. In addition to having different chemical resistance properties for select applications (e.g., polycarbonates provide superior resistance to chlorine bleach and hydrogen peroxide solutions), these clear plastics differ substantially in physical properties.  Polycarbonates are far superior in impact resistance, and acrylics provide superior resistance to scratching.

Additives and Fillers in Plastics

Plastic compositions vary with manufacturer-specific formulations, including ranging from pure homopolymers to varied copolymer structures, and may include various additives and fillers. For example, while homopolymer polypropylene contains only propylene monomers, copolymer polypropylene has ethylene incorporated into the polypropylene polymer chains either randomly (typically up to 6% ethylene) or in regular block patterns (typically 5% to 15 % ethylene). Some plastics, such as PVDF and PP, are provided in commercial high-purity form, and other plastics contain additives and/or fillers. For example, PVC stabilizers can include various metals or rare earths or metal-free compounds (e.g., newer technologies have moved away from lead and tin stabilizers).

A range of additives are used in various plastic products to aid in the polymer material production processes. These include plasticizers to improve flexibility and slip agents for easier release from molds. Additives are also used in plastics to enhance or modify plastic product properties, including long term stability, mechanical properties, chemical resistance, service temperature range, UV light resistance, resistance to biofouling, degree of opacity, product color, antistatic performance, electrical or thermal conductivity, and fire retardance.

Application Considerations for Plastics

With over 100 different grades of application-specific plastics used for chemical process equipment and systems, it is important to define technical design criteria and project cost and non-cost criteria to focus on candidate plastic materials that can be systematically evaluated vs. metals, other materials, and combinations of materials. Application specifics, including ranges and variation in chemical and temperature exposure and mechanical stresses over the design life, can significantly impact the service life of different plastics and impact life-cycle costs for chemical process equipment and process systems. Environmental sustainability is another consideration for evaluating different plastic options for chemical process equipment and components and for evaluating plastics vs. other materials.

Next week, watch for Part 3: Material Selection for Chemical Process Equipment – Other Materials. Part 3 provides information on fiberglass reinforced plastics (FRP), rubbers and specialty elastomers, and advanced composites. 

* For example, the polypropylene price increased ~65% between December and March 2017 and decreased ~ 26% between March and May 2017.

__________________________________________________

Integrated Technologies, Inc. is an industry-leading engineering, design, and consulting solutions firm based in Burlington, VT. We offer project planning and development, full-service engineering and design, project and construction management, and services during construction to the surfacing finishing and industrial manufacturing industries. 

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Part 1 of the seven-part series on material selection for chemical process equipment focuses on metals and alloys. Metals and alloys can be selected as materials ranging from larger structural systems to specialty small components for surface finishing process systems. Examples include:

• Structural frameworks, including hoist superstructures, catwalks, and tank supports, to extend beyond base floor elevation and also to suspend equipment from a structure above a process line.
• Material handling equipment, including hoists, shuttles, and carts.
• Process tanks and accessories (e.g., baffles, weirs, equipment mounts, and load saddles).
• Shells and internals of process equipment, including pumps, heat exchangers, and filters.
• Exhaust ventilation collection and air pollution control systems.
• Piping and valving systems for process fluids and process utility fluids.
• Electrical and Instrumentation and Control (I&C) cabinets and electrical conduit.
• Process accessories, including electrodes, mounts, fixtures, flight bars, and sensor probes.
• Grating, platforms, and ladders.

Different metals and alloys provide widely varying chemical resistance. There are also several orders of magnitude in raw metal or alloy cost, ranging from the more common metals and alloys to specialty high performance superalloys to precious metals.  Various metals also range in important physical properties (e.g., density, yield strength, temperature range, formability, stiffness, weldability, electrical conductivity, ferromagnetism, and application-specific durability) that can impact material selection.

ASTM Structural Carbon Steel

These relatively low-cost steels are available in standard grades for structural shapes and plate and for structural pipe and tubing. Chemical resistance is limited for many chemical process applications. Liners and/or coating/paint systems are required for most applications of steel components in process plants for chemical exposure applications. Proper surface preparation using abrasive blasting and/or chemical pretreatments of steel components is critical with for successful application of liners and/or coating/paint systems. Primary applications for coating systems include superstructures, tanks support systems, and platforms. Primary applications for liners are process tanks.

Stainless Steel (SS) Alloys

Stainless steels (e.g., 304, 304L, 316, & 316L) are common in surface finishing applications. The alloy mix for 316SS alloys (~16% chromium (Cr), ~10% nickel (Ni), ~2% molybdenum (Mo) provides for superior chemical resistance, including many solutions containing chlorides and some acids, over 304SS alloys (~18% Cr, 8% Ni). However, there are applications where 304SS provides superior chemical resistance to 316SS. 304LSS and 316LSS are lower carbon alloys that are better for welding. Stainless steel alloys provide superior chemical resistance over carbon steel for a broad range of applications. Steel alloy prices vary with market conditions and alloy metal price variances. Relative prices also vary with form and quantity purchased. 316LSS plate is almost 30% higher in price* over 304LSS plate, and 304SS plate is roughly four times the price* of A36 grade carbon steel plate.

High Nickel Content Alloys

These higher cost alloys, such as Hastelloy C, provide superior corrosion resistance beyond SS alloys for some applications. However, some SS alloys provide superior corrosion resistance for some applications over high nickel alloys (e.g. – some phosphoric acid solutions). The nickel content of Hastelloy C276 is typically up to 56%. Hastelloy C276 is more than five times the price* of 316LSS and has approximately 10% higher density. The yield strength of C276 is similar to titanium.

Titanium (Ti) and Alloys

These metals and alloys range significantly in cost and provide superior chemical resistance for many applications. Titanium is lower density than 316LSS  (~56%) and higher yield strength (~160%). Grade 2 (commercially pure) Ti has good weldability, strength, ductility, and formability and is the most common bar and sheet form for chemical process applications including tanks. While Grade 2 Ti is over four times the price* of 316LSS on a per weight basis, it can be only an approximate 50% price* premium over 316LSS for structural applications where Ti higher strength and lower weight factor into the equipment (e.g., tanks). Grade 5 Ti (aircraft grade) is the most common Ti alloy and accounts for ~50% of Titanium global use. Grade 7 Ti is similar in properties to Grade 2 but has interstitial palladium (Pd), making it the most corrosion resistant of all Ti alloys. Grade 7 Ti is almost five times the material price* of Grade 2 Ti. Some nitric acid applications are one example where stainless steels (304LSS in particular) provide superior corrosion resistance over pure Ti. Titanium provides superior chemical resistance for some chromic acid solutions, compared to 316LSS and Alloy 276.

Copper (Cu) and Alloys

In surface finishing, copper bussing (typically C11000 Electronic Tough Pitch – 99.9% Cu) is widely used above tanks for electrified processes. Copper is typically not recommended as a primary material for a range of acid and caustic solutions. A combination of good design for bussing routing, ventilation design, design to minimize dripping and splashing on bussing, and good process maintenance and housekeeping practices are needed to minimize copper bussing corrosion. In some cases, copper is plated or coated to control corrosion.

Other Metals

Many other metals and alloys are important for select process chemistry applications in surface finishing. Precious metals, such as gold (Au), palladium (Pd), and platinum (Pt), provide some of the highest levels of chemical resistance and are important metals for some process chemistry applications. These are extremely high in price and used only when essential. For some specialized applications, other noble metals, such as rhodium (Rh), ruthenium (Ru), rhenium (Re), and iridium (Ir), are used in pure form or in alloys (e.g., Ru is alloyed with Pt or Pd to increase wear resistance) for their differing physical and chemical resistance properties. Iridium is generally the most corrosion-resistant metal. Some other metals and applications are as follows:

• Tantalum (Ta), Zirconium (Zr), and Niobium (Nb) are significantly higher cost than titanium and provide superior chemical resistance in select applications (e.g., heat exchanger internal metals for aggressive process chemistries).
• A range of electrode metals are used for chemical processes application. In some cases, soluble metal anodes are used to make up solution chemistries. In other cases, metals are selected to provide more stable, inert electrodes. Electrode metals and alloys include copper, gold, iron, nickel, lead, platinum, silver, tin, titanium, and zinc and metal alloys, such as brass and tin-nickel.
• Life-cycle, cost-effective, insoluble anodes include more noble metal and metal oxide coatings comprised of Ir, Pt, Rh, Ru, and/or Ta over a lower-cost base metal (e.g., titanium).

Various metals and alloys are suitable for a wide range of surface finishing chemical process equipment applications. The process chemistry application range of lower cost metals can be extended with liners and with coating and paint systems (see Part 4). A diversity of plastics (see Part 2) and other materials, such as fiberglass (see Part 3), provide alternatives to metals for many surface finishing process chemistry applications.  Life-cycle costs should be carefully evaluated for different material options for chemical process equipment.

Next week, watch for Part 2: Material Selection for Chemical Process Equipment – Plastics. Part 2 provides information on PVC and CPVC, PE (various densities), PP, PVDF, PTFE, and other plastics. 

*- Early 2019 pricing. Metal and alloy prices vary with market conditions (e.g. – between late 2005 and late 2008 Ni metal price increased by more than 330% and then dropped to less than 20% of peak price.)

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Integrated Technologies, Inc. is an industry-leading engineering, design, and consulting solutions firm based in Burlington, VT. We offer project planning and development, full-service engineering and design, project and construction management, and services during construction to the surfacing finishing and industrial manufacturing industries. 

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Is your surface finishing line well-designed? Material selection for chemical process equipment is critical to the design and implementation of high-quality and cost-effective surface finishing systems. The goal of this seven-part series is to discuss some basic information to help identify and plan for the complex array of design and life cycle project considerations for material selection for process systems. This series will lay out the major material groupings; discuss the factors that impact material selection in practical application; and, finally, tie everything together by exploring the economic and operational benefits of proper material selection. To kickoff, the following is an overview of the topic of material selection for chemical process equipment.

Overview

Whether planning new or renovated wet process systems, material selection for chemical process equipment should be carefully evaluated and documented for all process systems that will or could be exposed to the planned process chemistries. Critical systems to consider include, but not limited to:

• Primary and ancillary process systems/equipment, and all subcomponents, that store, transfer, or process the wet process fluids, including fluid tanks and attachments, pumps, piping/valving systems, filters, heat exchangers, treatment vessels and reactors, and sumps.
• Hoists, cranes, and transport systems.
• Exhaust ventilation collection and air pollution control systems.
• Exteriors of process systems/equipment, and all subcomponents, as well as all related/other systems and structures (e.g. – grating, platforms, ladders) that will be or potentially could be exposed to spills, splashes, or vapors from the process fluids and associated process chemistries.
• Electrodes, eductors, sensors, fixtures, and other devices immersed in process solutions.
• Instrumentation and control systems, including panel enclosures.
• Conduit and enclosures for electrical power and distribution systems.
• Spill containment systems and wastewater treatment systems.

For each application, a full material selection must include all components, including wetted and non-wetted surfaces, motors, gaskets and seals, miscellaneous mechanical, electrical, and I&C devices and parts/components. Material selection for chemical process equipment impacts systems designed and selected across process, mechanical, electrical, I&C, civil, and architectural disciplines.

About Material Selection

Complete material selection for even a single piece of equipment, like a process solution pump, can include a combination of several materials needed to provide long life for all subcomponents. Commercial material variations in purities, compositions, densities, and other properties are available for different applications and can provide varying chemical resistance and different physical properties. Even though some materials have generally superior chemical resistance across a range of chemistries, there are specific chemistries and applications where a typically superior, higher cost material will underperform a lower cost material with typically lower resistance to chemical attack.  Chemical resistance can be highly application-specific and must be carefully evaluated.

Next week, watch for Part 1: Material Selection for Chemical Process Equipment – Metals. Part 1 provides information on steel and stainless steels (e.g. 304LSS & 316SS), copper, zinc, and nickel, high content nickel alloys like Hastelloy C-type, high performance metals like titanium, tantalum and zirconium, and selected uses of precious metals like silver, gold, and platinum.

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Integrated Technologies, Inc. is an industry-leading engineering, design, and consulting solutions firm based in Burlington, VT. We offer project planning and development, full-service engineering and design, project and construction management, and services during construction to the surfacing finishing and industrial manufacturing industries. 

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Creating Roadmaps for Successful Transformation

21st Century surface finishing manufacturers face challenges to be profitable while improving quality and efficiency. Other challenges include responding to changing production and health/safety/environmental requirements. There are substantial opportunities for process improvement to meet and rise above these challenges – success depends on seeing the opportunities and moving forward with successful projects for renovating or implementing new process and operations systems. Advanced planning enhances visualizing opportunities and creates roadmaps for successful projects.

Advanced planning provides strong benefits at relatively low investment for almost any surface finishing project. Advanced planning improves project vision and encourages strategic thinking. Advanced planning can range from focused and fast-track conceptual/strategic planning to comprehensive master planning. Advanced planning is tailored to specific project needs and opportunities, providing a range of ongoing benefits, including:

• Avoid costly rework
• Discover and plan synergistic approaches
• Provide a framework for more efficient communication and decision-making
• Provide a framework for more efficient design and implementation
• Prepare for uncertainties and changes

Plan to Plan

Advanced planning starts with recognizing its value for a surface finishing project or series of projects and allocating appropriate time and resources. Key elements to consider for the advanced planning process include:

• Background/orientation – What is the current and desired surface finishing situation? What are the goals and constraints? What information and resources are available?
• Assessment/analysis – Consider the current situation and potential approaches to achieve the desired situation. Consider interrelated elements and influences/impacts.
• Approaches – Strategize solution outcomes to achieve desired results and alternate solutions that may provide additional value through encompassing other opportunities and benefits.
• Conceptualization/Visualization – Develop concepts, description and examples (graphics, models, pictures and/or visit facilities) that enhance visualization of alternate solutions.
• Decision Framework – Define decisions to be made and a decision methodology that will keep the project moving forward with maximum efficiency.
• Change Management Strategy – Define potential changes and establish approaches for responding to and managing/minimizing impact to the overall project.
• Documentation – Advanced planning must be well documented to provide for an easy and useful reference to guide future decision-making.
• Successful process troubleshooting involves planning for and commitment of adequate resources – including people, time, and access to processes/information and funding.

A manufacturer’s decision to seek guidance early from surface finishing advanced planning experts (planning to plan) provides an opportunity to achieve significant benefits and cost savings that would otherwise be missed or will cost significantly more to achieve later.

Strong Payback for Advanced Planning

Expert advanced planning achieves strong short-term paybacks and sets the stage for enhanced life cycle project benefits and cost savings. Advanced planning can reduce the design cost for surface finishing projects by anticipating and avoiding costly changes and by providing a basis for a more efficient design process (see Figure 1, line A compared to B). Advanced planning can reduce implementation costs for surface finishing projects by anticipating and avoiding costly changes and by providing a basis for more efficient construction/ implementation (see Figure 1, line A compared to C or D). Advanced planning typically pays for itself during the design phase. Construction and life cycle O&M cost savings for advanced planning are typically orders-of magnitude greater than the initial advanced planning investment.

Figure 1

Capital cost range and scenarios for surface finishing project

Figure 2

Capital and O&M costs for new surface finishing lines

Figure 3

Capital and O&M costs for complex surface finishing facility renovation

Figure 2 shows a comparison of capital and combined capital plus five year operating and maintenance (O&M) costs for three project scenarios for new surface finishing lines and related process systems: design/implementation without advanced planning (A), design/implementation with advanced planning (B) (allowing for design, implementation and O&M efficiencies for a project scope similar to A), and design/implementation with advanced planning and additional capital expenditures to achieve additional O&M efficiency identified in advanced planning (C). One of the biggest paybacks with advanced planning utilizing surface finishing experts is to foresee and have the opportunity to implement changes that would be cost effective even as retrofits after a project is complete. These changes may be implemented at no or little incremental cost if integrated into the original project.

Benefits of Expert Surface Finishing Support

Advanced planning sets the stage for successful surface finishing design, implementation, operations and maintenance, and also allows preparation for efficiently managing change and uncertainty. Surface finishing advanced planning experts enhance the overall effectiveness of projects for new/renovated processes and systems/practices by augmenting client resources, providing:

● Expertise – The combination of broad range and depth of expertise with surface finishing processes (setup areas, racking and fixturing, hoists, process mechanical, ventilation and air pollution control systems, building interfaces, water and wastewater treatment, automation and information systems, heating and cooling systems, agitation and pumping systems, rectifiers, safety systems, process solution maintenance and control, workflow, etc.) enhances integrated advanced planning that considers interrelated systems. Expert surface finishing process input can provide essential insight for developing both short term fixes and systematically working through more complex issues.

● Perspective – Expert perspective based on successes and failures/shortcomings from a large number of diverse surface finishing manufacturing facilities provides compelling input early in the project to make decisions resulting in some significant cost-saving and/or project enhancing changes. These changes would not otherwise happen or would be realized much later when costs for making changes are significantly higher. Knowledge of previous similar process improvement situations and results, of best management practices, and of the full range of relevant process steps and issues can help to avoid rounds of costly trial and error problem-solving and can lead to better overall process improvement solutions that are more robust, flexible and cost-effective.

● Visualization – Significant past experience with mapping, schematics, diagrams and even process models and early 3-D visuals provides a strong basis to visualize new or renovated facilities and processes. Visualization helps with anticipating issues and opportunities and overall integrated systems. Visuals are key to providing clients with better understanding of alternatives and opportunities earlier in projects. This leads to better decision-making.

● Tools/Methods – Significant experience with advanced planning tools and methods, decision processes and outcomes, and quantities and costs, facilitates and enhances the effectiveness of this critical early project phase.

● Standard and Custom Solutions – Client needs are met and exceeded at minimal cost and risk when customized solutions are developed from proven approaches based on expert consideration of site-specific, application-specific factors.

Surface Finishing Master Planning

Surface finishing master planning is advanced planning dealing with integration of relatively complex series of projects, renovations or new surface finishing systems that are large and diverse and/or have significant interface and/or phasing issues. The master plan helps ensure that projects are done right the first time and that future projects follow a logical and systematic development plan. The master plan is a tool for management decision support regarding surface finishing and related systems and facilities and resources supporting interrelated projects that work well together to most efficiently and effectively achieve desired outcomes. Master planning provides a comprehensive approach to decision-making and to change management. The benefits and cost paybacks for master planning increase dramatically as the complexity of a project or interrelated projects increases. Figure 3 provides the same comparison for planning/design/implementation as Figure 2, but showing even stronger initial and longer term cost savings for a complex, multi-phased surface finishing renovation project.

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Integrated Technologies, Inc. is an industry-leading engineering, design, and consulting solutions firm based in Burlington, VT. We offer project planning and development, full-service engineering and design, project and construction management, and services during construction to the surfacing finishing and industrial manufacturing industries. 

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