LECTURE ON MATERIAL OF CONSTRUCTION OF UREA

PLANTS AND ADVANCEMENT OF MATERIAL

Prepared by: ALI ZAMA KHAN

Sr. A.M. (PROD. -
UREA)
DATE - 29/02/2016

INTRODUCTION :-
Materials plays very important role in any industry.
wrong selection of material may lead to catastrophic failures and outrage of plants and
even loss of human lives.
Right selection of material leads to long life of plant.
there is a wide vareity of materials use to construct process equipment . The types of
material selected depends on its compability with process conditions and cost.

METALS

All metals except gold are generally found chemically

combined with other elements in the form of
oxides and sulphates. Commonly known as ores.

Metal that are not mixed with any other materials are known
as pure metals. Metals listed in the Periodic Table are pure
metals
E.g. Iron (Fe), Copper (Cu) and Zinc (Zn)

Alloys are mixtures of two or more metals formed together

with other elements/materials to create new metals with
improved Mechanical Properties and other properties
of the base metal.

E.g. Brass (Copper and Zinc),

Stainless steel (steel and chromium)
Alloy = metal A + metal B + … + other elements
 CLASSIFICATION OF MATERIALS

METALS NON-METALS

TEFLON

RUBBER

FERROUS NON-FERROUS WOOD

CAST IRON ALUMINIUM

CARBON STEEL ZIRCONIUM

ALLOY STEEL COPPER

WHITE METAL
STAINLESS STEEL
TITANIUM

FERROUS METALS :- ferrous metals are metals that consist mostly of iron(greater
than 50%) and small amount of other metals ferrous metals are prone to rusting if
exposed to moisture. It can also be picked by a magnet. The rusting and magnetic
properties in ferrous metals are both down due to the iron.
 1.) CAST IRON :- it is a very strong metal when it is in compression and is also
very brittle . It consist of 93% iron and carbon contents between 2 and 5%.
Silica inclusion between 1 and 3%.
Mechanical properties:- melting point below carbon steel
Excellent fluidity (required for casting purpose)
Poor weldability and ductility

Uses:-manufacturing of pumps, turbines, compressor and gear box casing.

melting point :- 1200 c

2.) CARBON STEEL:-carbon steel has less than 2.0 % carbon. No alIoying
elements is added excep carbon is easy to fabricate , has better strength and
easier to weld than cast iron. The main disadvantages in using carbon steel is
its susceptibility to corrosion.

TYPES OF CARBON STEEL

a.) MILD STEEL OR LOW CARBON STEEL :- it contain upto 0.3% carbon .

Mechanical properties. A ductile and malleable metal , excellent weldability.

Mild steel will rust quickly if it is frequent contact with water.

Uses:- steam condensate line, cooling water line, inst. Air line and load bearing
structure and sheets
Grades -API 5L GR.B.
melting point – 1600 C

b.) MEDIUM CARBON STEEL :- it contain upto 0.3 to 0.6% carbon.

Mechanical prop. Harder and more tensile strength then low carbon steel and better
machine qualities and more reposive to heat treatment
use:- shafts, connecting rods, spindles and machine parts.
c.) HIGH CARBON STEEL:- contains upto 0.6 to 1.7% carbon.

Mechanical prop. Low ductility, poor weldability,Higher tensile strength and

very hard steel that has a high resistance to abrasion. Readily respond to heat
treatment.

Uses :- hand tools such as screw drivers, chisels, punches, hammers, saws, garden
tools and rail road wheels etc
melting point – 1800 C
 d.). KILLED CARBON STEEL :- deoxidizer are added in sufficient
quantity, carbon steel with inclusion of Al orSi. A steel deoxdized to such a
level that essentially no reaction occurred between carbon and oxygen during
solidification. The purpose of deoxidizing is to avoid gas bubble in the material
in order to fulfil the quality requirement given in material standards.

Mech. Prop.:- Increase strength, difficult welding as heat treatment is involved

Uses:- piping, valves and vessels for low temp. liquid ammonia.

CARBON EQUIVALENT AND WELDABILITY :-

The carbon equivalent is used for rating of weldability of ferritic low alloy steels. A
commonly used formula to calculate the carbon equivalent.

CE = C + Mn/6 + (Cr + Mo + V)/5 + (CU + Ni)/15

For this equation the weldability based on a range of CE values can be defibed as follows:-
CARBON EQUIVALENT WELDABILITY
UPTO .35 % EXCELLENT
.36 -.40 % VERY GOOD
.41 - .45 % GOOD
.46 - .50 % FAIR
ABOVE .50 % POOR

ALLOY STEEL:- So, there was a need to create better types of steels, which are
alloy steels, ie., additions of alloys (low amounts of Mn, Ni, Cr, Ti, Si, etc) to improve
its properties.
low alloy steel alloying element upto 8.0%
chemical composition:- cr upto 2.25%, mo upto 1.25%
alloying effects Cr increases corrosion resistance, Mo adds elevated temp.
strength
Mech Properties:- high strength at high temp. upto 650C.
Uses:- piping , valves, and vessels for very high pressure steam
Alloying increases the cost of the steel, but the enhanced properties are essential in
many applications.Alloying improves corrosion resistance (particularly with the
addition of Chromium), producing the stainless steels.
Alloys are mixtures of two or more metals formed together
with other elements/materials to create new metals with improved Mechanical
Properties and other properties of the base metal.

E.g. Brass (Copper and Zinc),

Stainless steel (steel and chromium)
Alloy = metal A + metal B + … + other elements
STAINLESS STEEL:- stainless steel are another class of ferrous alloys, which
have been made for and are used because of their excellent corrosion resistance.
A true stainless steel that has at least 12% cr. In the steel. This steel is exposed to
oxygen, which forms a thin, stable CR2O3 coating on the surface, which is very
corrosion resistant.
Insoluble chromium oxide film on the surface of the metal - (Cr O ) . Layer is too
2 3
thin to be visible
Quickly reforms when damaged
Susceptible to sensitization, pitting, crevice corrosion and acidic environments.
Passivation can be improved by adding nickel, molybdenum and vanadium.
Another criterion defining a stainless steel is its passivity
passivity:- passivity is the ability of a metal to form an imprevious surface coating
which inhibits corrosion resulting from the electrochemical reaction of the metal with
the surrounding environment.
Passivity occurs when an oxidizer layer form a contious film on a metal surface that
prevents further oxidation (corrosion).
Stainles steel exhibit passivity in oxidizing environment.
Uses:- kitchen sinks, industrial equipment , surgical instrument , cookware etc
melting point – 1400 C.

TYPES OF STAINLESS STEEL

THERE are three general types of stainless steel
a.) Ferritic stainless steel
b.) Austenitic stainless steel
C.) Martensitic stainless steel
d. ) Duplex steel
Best corrosion resistance (CR): Austenitic (25% Cr)

Middle CR : Ferritic (15% Cr),

Least CR: Martensitic (12% Cr), but strongest

Over 150 grades of SS available, usually categorized into 4 series containing alloys
w/ similar properties.
AISI classes for SS:
200 series = chromium, nickel,manganese (austenitic)
300 series = chromium, nickel (austenitic)
400 series = chromium only (ferritic)
500 series = low chromium <12% (martensitic)

a.) FERRITIC STAINLESS STEEL:-

Carbon content of 0.2% or less.
Chromium content : 11-18%, nickel 0%
although it can not be heat treated and has poor tensile and impact strength, poor
weldability it better corrosion resistance than martensitic stainless steel.
It is suitable for use with strong oxidizing acids such as nitric acid.
Cheaper than austenitic steel
used in architectural trim, kitchen range hoods, jewelry, decorations, utensils Grades

The standard ferritic grades are alloyed with chromium (11.2–19 %), but with no, or
very small addition of nickel.

AISI %C % MN %P % SI % CR
430 .12 .04 .03 1.0 14 TO 18

b.)Austenitic stainless steel

it is a more complex material because the addition of nickel (3.5 to 22%) allows it to
retain its austenitic microstructure at all temperature.
It has a high tensile strength and best impact strength, ductility and corosion
resistance of all the stainless steel over a wide range of temperatures.
However, austanitic steel with high molybdenum content (1 to 3 %) have improve
resistance to pitting.
Austenitic steels in high temperature service.
These alloys are basically chromium nickel steels.
series. Grades 301, 302, 303, 304, 316, and other 300 series.

c.) MARTENSITE STAINLESS STEEL:-

CARBON – 1.2% or less
chromium – 12 to 18%
it has better hardenaBILITY AND STRENGTH THAN DOES ferritic stainless steel
it is used as cladding to carbon steel for some process vessels.

High strength, hardness, resistance to abrasion; used in turbine parts, bearings, pump
shafts, impeller for corrosion service knives, cutlery and generally Magnetic. Grades 17-4, 410, 416,
420, 440 and other 400 series.
AISI %C % MN %P % SI % CR
410 .15 1.0 .04 1.0 11.5 to TO
13.5
420 .15 1.0 .04 1.0 12 to 14
 d.) DUPLEX STAINLESS STEEL

Duplex grades have a ferritic-austenitic microstructure, with a phase balance of

approximately 50 % ferrite and 50 % austenite. Duplex grades combine many of the
beneficial properties of ferritic and austenitic stainless steels. The duplex
microstructure also contributes to the high strength and high resistance to stress
corrosion cracking. Characteristic for the duplex stainless steels is high chromium
content (20.1–25.4 %), but rather low nickel content (1.4–7 %) compared to the
austenitic grades. The low nickel content of the duplex grades makes them more
price stable. Molybdenum (0.3–4 %) and nitrogen are added to improve the
corrosion resistance and balance the microstructure.
Uses :-Urea Reactor (stami carbon plant)
Stems for high pressure urea valves

Duplex grades
HVD 1
SAFUREX(STAMI CARBON)
DP28W(TOYO PLANT )

NON FERROUS ALLOYS

NON-FERROUS metals are metals that do not have any iron in themat all. This
means that non-ferrous metals are not attracted to a magnet and they also do not
rust in the same way when exposed to moisture
 WHY NON FERROUS ?

Light weight

STIFFNESS – STRENGTH TO WEIGHT RATIO

High temperatureproperties

Non Ferrous
Oxidation resistance

Corrosion resistance
High Cost
Thermal / electrical conductivity

Biocompatibility
PROFESSIONAL ORGANIZATION AND THEIR SCOPE OF CONCERN

ABBREVIATION ORGANIZATION SCOPE OF CONCERN

ASTM AMERICA SOCIETY OF PROVIDES TESTING
TESTING AND MATERIAL PROCEDURES FOR A
WIDE VARIETY OF
MATERIAL
ASME AMERICAN SOCIETY OF PROVIDES A LIST OF
MECHANCIAL RECOMMENDED METAL
ENGINEERS & WELDING MATERIAL
AISI AMERICAN IRON & PROVIDES STANDARD
STEEL INSTITUTE DESCRIPTIONS FOR CS
& ALLOYS
ANSI AMERICAN NATIONAL PROVIDES SAFETY &
STANDARD INSTITUTE DESIGN CRITERIA

MATERIALS FOR VARIOUS NETWORKS

NETWORK MATERIAL GRADE COMPOSITION OF

ELEMENTS
COOLIG WATER, CARBON STEEL API 5L GR.B C- .30%, Mn- .95%,
STEAM P- .05% , S- .06%.
CONDENSATE
STEAM UPTO 375C CARBON STEEL ASTM A106 GR.B C- .30%, Mn- .29
-1.06%, P- .25% ,S- .
25%, Si- .10%.

STEAM MORE ALLOY STEEL ASTM A335 GR.P11 C- .15%, Mn- .60%, P- .
THAN 400 C & P22 025% ,S- .025%, Si- .
50%,
Cr- 1.9-2.6%, Mo - .87-
1.13%
 AUSTENETIC STAINLESS STEEL

AISI USES
304 DM WATER, LUBE OIL, WASTE WATER, CO2
304L VACUUM SECTION
309 ITS FILLER WIRE & ELECTRODES ARE USED TO WELD CARBON
STEEL WITH AUSTENITIC STAINLESS STEEL
316L M.P. SECTION, L.P. SECTIONS AND HYDROLYZER SECTION

MATERIAL OF CONSTRUCTION (COMPOSITION IN WT%)

ALLOY C P S SI MN Cr Ni MO N
304 .08 .045 .030 1.0 2.0 18-20 8-10.5 - -
304L .03 .045 .030 1.0 2.0 18-20 8-12 - -
316 .08 .045 .030 1.0 2.0 16-18 10-14 2-3 -
316L .03 .045 .030 1.0 2.0 16-18 10-14 2-3 -
316LM .02 .015 .010 .40 1.70 17.5 14 2.6 .18
2RE-69 .02 .015 .010 .40 1.70 25 22 2.1 .12
(snam.)
HVD-1 .05 CU-1.5 .02 .038 1.25 25 8.5 2.5 -
SAFUREX .03 .03 .03 .50 .8-1.25 28-30 5.8-7.5 1.5-2.6 .3-.4
(STAMI
CARBON) CU<.8
DP28W .03 W- 2.1- 27-28 7-8.2 .8-1.2 .3-.4
(TOYO) 2.5
S.NO. MOC ADVANTAGES DISADVANTAGES
1. TITANIUM Good passivation properties 1. Susceptible to
with less air Erosion
2. Difficult to Weld
3. Costly
2. STAINLESS STEEL 1. Immune to Erosion 1. Large amount of
2. Good Weldability passivation air
3. 316LM 1. Excellent Weldability 1. Large amount of
2. Fair corrosion Passivation air
3. Relatively less cost
4. 2RE69(SAIPEM) 1. Excellent weldability Susceptible to SCC
2. Better Corrosion resistance by chloride
than 316LUG 2. Costly
5. SAFUREX(STAMICARBON) 1. Good Weldability 1. Costly
2. Excellent Corrosion
Resistance
3. Passivation air is not
required
6. DP28W(TOYO) Excellent corrosion resistance 1.) costly
very high mechanical strength
good weldability and
formability
corrosion rate lower than
titanium

ROLE OF DIFFERENT ELEMENTS USED IN STEEL ALLOYS

Chromium (Cr)
This is the most important alloying element and it gives stainless steels their basic
corrosion resistance. All stainless steels have a Cr-content of at least 12.0 % and the
corrosion resistance increases with increasing chromium content. Chromium also
increases the resistance to oxidation at high temperatures .
It is essential for formation of passive film to resist corrosion.
It improves hardness and wear to resistance .

Nickel (Ni)
The main reason for the nickel addition is to promote an austenitic microstructure.
Nickel generally increases ductility and toughness and ease to welding. It also
reduces the corrosion rate in the active state and is thus advantageous in acid
environments. it improves resistance to fatigue failure
Molybdenum (Mo)
Molybdenum significantly increases the resistance to both crevice and pitting
corrosion.

Copper (Cu)
Copper enhances the corrosion resistance in certain acids and promotes an
austenitic microstructure. It can also be added to decrease work hardening in grades
for improved machinability. It may also be added to improve formability. Used in
concentration of about 0.5 % or less. Produces a tenacious self sealinG oxide film on
a metal surface .

Manganese (Mn)
it prevents to form iron sulphide which is harmful to steels.
Manganese is generally used in stainless steels in order to improve hot ductility.

Silicon (Si)
Silicon increases the resistance to oxidation, both at high temperatures and in
strongly oxidising solutions at lower temperatures.
Carbon (C)
Carbon is a strong austenite former that also significantly increases the mechanical
strength.

Nitrogen (N)
Nitrogen is a very strong austenite former that also significantly increases the
mechanical strength. Nitrogen increases the resistance to localised corrosion,
especially in combination with molybdenum.
It enhances pitting resistance.

Sulphur (S)
Sulphur is added to certain stainless steels, the free-machining grades, in order to
increase the machinability.

Phosphorous :- it is added in low carbon steels upto 0.12% . it dissolves in ferrite

and increases strength and hardness.
It improves the machinability.
MATERIAL FOR CARBAMATE SERVICES
carbamate is highly corrosive in nature at high pressure and temperatures
all over the world licensers of urea plants are searching or cost effective and bettter
corrosion resistant materials.

Following materials are being used in urea plant

 TITANIUM
 ZIRCONIUM
 2RE69
 AISI316LM
 DUPLEX STEEL
2RE69 is a fully austenitic stainless steel with extra low carbon and impurity
contents. The grade is characterized by:
 Excellent resistance to corrosion in ammonium carbamate and nitric acid.
 High resistance to pitting and crevice corrosion.
 Good weldability.
Alloy 316/316L is a chromium-nickel molybdenum austenitic stainless steel
developed to provide improved corrosion resistance to Alloy 304/304L in moderately
corrosive environments.
 It also provides higher creep, stress-to-rupture and tensile strength at elevated
temperatures.
 Alloy 316/316L has excellent strength and toughness at cryogenic
temperatures.

TITANIUM:- high strength to weight ratio

moderate- high temperature properties
corrosion resistance
biocompatibility
passiviation air is not required
stripper bottom temperature can be kept upto 210 C.

Disadvantage:- It is not maintenace friendly

erosion of tubes ends resulting bypassing

Uses:- it is used for lining and tube material of ammonia stripper in snamprogetti's
urea plants.
Used for lining of urea reactors of toyo plants at panipat and bhatinda

structure of high speed aircrafts

turbine blades
 chemical industry

ZIRCONIUM :- Zr is a very strong,malleable, ductile, lustrous silver-gray metal.its

chemical and physical properties are similar to those of titanium. Zr id extremely
resistant to heat and corrosion.Zr is lighter than steel and its hardness is similar to
copper.
Melting point:- 1852 C
USES:- It is mainly used in chemical industry where highly corrosive fluid like
carbamate .
The metal is used in the nuclear industry for cladding fuel elements since it has a low
absorption cross section for neutrons.
The metal is also used as an alloying agent in steel and for making surgical
appliances
Advantages:- excellent corrosion and erosion resistant
cost effective
disadvantages :- temperature is limited to 207 c
poor weldability with other alloys.

SAFUREX (DUPLEX STEEL):-safurex is a duplex material patented by stami

carbon, this material developed by sandvik material technology .
The new ss developed for service in the stamicarbon. For high strength compare to
2RE69, similar thermal expansion to cs , improved corrosion resistance in oxygen
free urea solution. No need of passivation air .

DP28W (DUPLEX STEEL):-

Another new duplex, ferrite-austensite stainless steel DP28W has been developed
by sumitomo metal industries ltd. And toyo engg. Corporation. Specifically for use in
urea plants.
DP28W is shown to have excellent corrosion resistance the urea-carbamate
solution, which is achieved by its two phase structure and high Cr and W contents.
Tungsten is selected as an additive to improve corrosion resistance and to prevent
alfa phase equiliburium after welding as substitution of Mo.
The excellent re passivation properties of DP28W contributes to minimize the risk of
active corrosion. Corrosion rate lower than titanium

RATE OF CORROSION RATE (AS PER HUEY TEST)

 Material Corrosion rate MM/YEAR
zirconium 0.005
titanium 0.06
2RE-69 0.3
AISI-316LM 0.6
HUEY TEST- METAL SAMPLE IS BOILED IN 65% HNO3 FOR 48 HRS(5 TIMES)
TO ESTIMATE CORROSION RATE

MATERIAL OF CONSTRUCTION FOR MAJOR EQUIPMENT IN UREA

PLANT

REACTOR (R-1)

A.) SHELL ------------------------------- CS

B.) CLADDING ------------------------------ AISI-
316L
C.) LINER ---------------------------------- AISI-
316LM
D.) TRAYS------------------------------------ AISI
-316LM
E.) INTERNALS BOLTS/NUTS/WASHERS -
2RE-69

Cladding:- the process of bonding one metal to another usually to protect the inner
metal from corrosion .
Liner:- carbon steel -1000 mm/year(if carbamate is high).
A protective layer is needed to protect the carbon steel. The thickness of the liner
varies between 4 & 10 mm and depend on licenser.

STRIPPER (E-1)
A.) TOP & BOTTOM DOMES - 2RE-69
B.) TUBES – BIMETALLIC (OUTER SIDE -2RE-
69{2.0MM})
(INNER SIDE – Zr{0.7MM})
C.)FERRULES –---------------------------------- 2RE-69
D.) SHELL –---------------------------------- CS
E.) INTERNALS –-------------------------------- 2RE-69

BRIEF HISTROY OF STRIPPER TUBES :-

CARBAMATE CONDENSER (E-5):-

A.) SHELL – -----------------------CS
B.) TUBES – -----------------------2RE-69
C.) CHANNEL – ------------------CS + LINNER 2RE-
69(5MM)
D.) DOME LINER –--------------- 2RE-69
E.) TUBE SHEET ----------------- CS + LINNER 2RE-69
(10MM)
F.) PARTITION PLATE –--------- AISI 316LM

CARBAMATE CONDENSER (MV-01):-

SHELL –------------------------------- CS
LINER – ----------------------------AISI- 316LM(05 MM)

LV-02 – SEAT PLUG AND SPINDLE:----- --------HVD-01

EJ-01- SEAT PLUG AND SPINDLE :- ------------HVD-01
PV-12 – SEAT PLUG AND SPINDLE :------------ HVD-01
HV-03 AND HV-01 ETC
EQUIPMENT MATERIAL OF CONSTRUCTION
MV-02, E-02, ME-02 AISI- 316L
C-01 AISI- 316L
E-07:- SHELL AISI-316L
TUBE & TUBESHEET
E-09 :- SHELL AISI-304L
TUBE & TUBESHEET
V-1:- SHELL & HEADS CLADDING AISI-304(3MM)
INTERNALS AISI-304
MV-03, E-03, ME-03 AISI-316L
E-08:- SHELL AISI-316L
TUBE & TUBESHEET
V-03 AISI-304L
V-05 AISI-304L
VACUUM SECTION AISI-304L
W.W.T SECTION AISI-304

DISTILLATION TOWER (C-2) AISI-304L

HYDROLYSER(R-2):- SHELL & AISI-316L(3MM)
HEADCLADDING AISI-316L
INTERNALS
P-1:- CASING CS
INNER CASING SS 13% Cr
IMPELLER SS 11-13% Cr
SLEEVE SS-304
SHAFT SS 11-13% Cr
THRUST DISC AISI-4135(cr-1.110%,fe-97.0%,
mn-.90,mo-.25%, c-.38%)
ALL INTERNALS SS 13% Cr
P-2:- SHAFT SCS16
IMPELLER AISI-316L
M-SEAL SLLEVE AISI-316L
SEAL END PLATE AISI-316L
CASING AISI-316L
PHYSICAL PROPERTIES :-

PROPERTIES OF MATERIAL
HARDNESS:- hardness is resistant offered by material to identation , resistance to
bending , scratching, abrasion or cutting.

STRENGTH:- the strength of a material is its ability to withstand an applied load of

different types before undergoing the permanent deformation or fracture.

ELASTICITY :-the property of material due to which it comes to its original shape
after the removal of load is called elasticity.

PLASTICITY :-the property of a material due to which it is permanently deformed

on the application of load . without any rupture is called plasticity.

TOUGHNESS :-ability of material to resist fracture due to sudden shocks impact

load( or bending is called toughness

STIFFNESS ability of material to resist deformation due to the external forces is

called stiffness

MALLEABILITY :- if a material can be rolled or hammered to thin sheet, its

property is called malleability

DUCTILITY:- it is a measure of the amount of plastic deformation a material can

take under tensile force withot fracture. Ratio of elongation of material at fructure to
original strength.

BRITTLENESS the property of a material to easily break up into pieces without

deformation is called brittleness.

WELDABILITY :-the ability of a material to be welded well , using simple

procedures.

MACHINABILITY :- the ability to make parts using machining cutting tools.

CREEP :- creep may be defined as a time dependent deformation at elevated

temperature and constant stress.

FATIGUE :- it is the weakening of a material caused by repeatedly applied loads. It

is the progressive and localized structural damage that occurs when a material is
subjected to cyclic load.