MATERIALS OF PLANT CONSTR

Prepared by : Mr. Jitendra L. Patel

FACTORS AFFECTING SELECTION OF

MATERIAL FOR PLANT CONSTRUCTION.
3

Type of factors. 1. Chemical factors 2. Physical factors 3. Economical factors

CHEMICAL FACTORS
1. Contamination of the product by material of plant lead to instability, decomposition and physiological effect. E.g. presence of traces of heavy metal decompose penicillin. Stability of vitamins decrease in presence of metallic ions (Cu++, Co++, Ni++). The color of esters will change to pale yellow in the presence of iron impurities. Esters should be processed in S.S.

CHEMICAL FACTORS
2.The effect on the material of plant by drugs and chemicals. Acids, Alkalis and Oxidizing agent and tannins may affect the material of construction. Allows and Plastic have a corrosion resistant properties.

PHYSICAL FACTORS
1. Adequate Mechanical Strength. 2. Erosion 3. Weight 4. Ease of fabrication 5. Thermal Expansion 6. Thermal Conductivity 7. Cleansing 8. Sterilization 9. Transparency

Strength

The material should have sufficient strength so that it can withstand the stress to which the material is subjected in the production. Iron and Steel satisfy this property. e.g. The packing material should withstand the rigors of handling and transportation.

Mass

The equipment should have a light weight so it is easy to transport. Plastic materials employed for the manufacture of container for use of pharmaceuticals and cosmetics bcz of its light weight.

Wear properties

There is a possibility of friction between the moving parts. During milling and grinding surface wear off and this materials will be incorporated into powder as impurities.
The materials used for evaporators, dryers and heat exchanger should have a good thermal conductivity. Resistant film retard the rate of heat transfer.

Thermal conductivity

If the material has high coefficient of expansion , the temp changes cause increase in stress and risk of fracture. Thermal The material should be able to maintain size and expansion shape of equipment at working temperature.

 It permits the visual observation of the changes during a process. For this reason borosilicate glass has been Transparency used in the construction of reactors, fermentors etc.

Economic factors

Initial costs and maintenance of the plant must be economical. Low wearing qualities and lower maintenance. Higher initial cost is more economical in the long run.

 During fabrication, the materials under go various processes such as casting, welding, forging etc. Glass and plastic can be easily molded into Ease of fabrication containers of diff. size and shape.
Smooth and polished surfaces allow the process of cleansing easy. Stainless steel and glass are easy for cleansing.

Cleansing

In the production of parenterals, ophthalmic products, antibiotics and biologicals, sterilization is an essential step which is obtained by autoclaving . Sterilization The material should be able to withstand the steam pressure.

Material of plant construction

Metals

Non-Ferrous Non-Metals

Aluminum Ferrous

Lead

Inorganic Glass

Organic

Cast Iron

Steel Carbon

Stainless Steel

Rubber

Plastic

FERROUS METALS
Widely used bcz of its mechanical strength, abundant availability and lower cost. Varieties of iron are 1. Cast Iron 2. Carbon Steel 3. Stainless steel

CAST IRON
Cast iron consist of iron with a proportion of carbon (beyond 1.5 %). The properties of iron depends on the amt of carbon present. Cast iron is abundantly available, inexpensive.

Advantages

Cheap Resistant to conc.. H2SO4. HNO3, and dilute alkalis. It has low thermal conductivity so used for construction of outer jackets of steam pans.

Disadvantages

It is very hard and brittle so difficult to machine. It is attacked by dil H2SO4. HNO3 as well as conc. HCl. It has low thermal conductivity so not used for heat transfer in steels.

Uses

Supports for plant. Jackets of steam pans. Lining with enamel, plastic or suitable protective materials

1. Gray Cast iron

2. Malleable Iron

Modifications

3. High Silicon cast Iron

4. Nickel resistant cast iron

GRAY CAST IRON

Composition

Carbon Silicon

Properties

Low cost Easy to cast into intricate shades and linings, Brittle Poor resistant to impact and shock.

Disadvantages

MALLEABLE IRON

Composition

White cast iron Carbon 2-5 % Corrosion resistant Type 1 easy to machine.

Properties

Type 2 less easy to Disadvantages machine.

HIGH SILICON CAST IRON

Composition

Cast iron Silicon 13- 16 %

Properties

Resistant to corrosion, oxidizing and reducing environment. Used in H2SO4 services.

Disadvantages

Not easily machined and welded.

NICKEL RESISTANT CAST IRON

Superior toughness Impact resistant. Easy to weld and machine. Corrosion resistant and heat resistant.

Properties

Disadvantages

Oxidizing agents are highly detrimental. There is a Little attack from neutral or alkaline solution.

CARBON STEEL OR MILD STEEL

CARBON STEEL IS AN IRON ALLOY, WHICH CONTAINS ONLY A SMALL PERCENTAGE OF CARBON.

Advantages

Cheapest Easily weld able and used in fabrication

Carbon steel has limited resistant to corrosion. It can be improved by preparing alloys. It reacts with caustic soda, brine and sea water. Alloying can reduce this properties.

Disadvantages

Uses

Used in construction of bars, pipes and plates. Used to fabricate large storage tanks for water and organic solvents. Also used for supporting structures.

1. Nickel improves toughness, corrosion resistant

2. Chromium increases hardness, abrasive and corrosion resistant

Modifications Alloying it with other metals alter the properties

3. Molybdenum provides strength at elevated temp.

4. Silicon increases hardness, abrasive and corrosion resistant

Different Types & Alloys of Carbon Steel

Variety of Carbon Composition Allow
1.Low Allow Steel

Advantages

High mechanical strength. Low conc. of Iron, carbon, manganese, Corrosive resistant Nickel, Chromium & to environment. molybdenum.

2.Alloying with Nickel

Nickel.

Increase hardness. High corrosion resistant.

Abrasion resistant. Corrosion resistant. Resistant to oxidation.

3.Allowing with Silicon Chromium.

Nickel, Chromium.

It is an allow of iron. It contains chromium and nickel, which makes the steel corrosion resistant. S.S. is stabilized by the addition of titanium, or tantalum. Minor amt of other elements such as copper, molybdenum, & selenium are added. S.S has the advantages of ease of fabrication.

STAINLESS STEEL

Properties

of S.S.

1. Heat resistant 2. Corrosion Resistant 3. Ease of fabrication. 4. Tensile strength 5. Cleaning and Sterilization.

MARTENSITIC

Composition

Chromium : 12- 20 % Carbon : 0.2-.4 % Nickel up to : 2.0 %

Advantages
DisAdvantages Uses

Mildly corrosion resistant atm % organic exposure.

Ductility is poor.

Sinks, bench tops, storage tanks, buckets etc.

AUSTENITIC

Composition

Chromium : 13-20 % Carbon : 0.1 % < 0.25 % Nickel up to : 6-22 %

Highly corrosion resistant. Readily cleaned, sterilizable. Easy to weld.

Advantages
DisAdvantages Uses

Not easy to machine.

Fermentors, storage vessels, evaporators, extraction vessels, buckets, funnels..

FERRITIC

Composition

Chromium : 15-30 % Carbon : 0.1 % Nickel up to : nil

Better corrosion resistant. Easy to machine. Resistant to temp and temp.

Advantages
DisAdvantages Uses

Not good against reducing agents, HCl..

Tower linings, Baffles, Separator, tower, heat exchanger, tubings, condensers, furnace parts, pumps shafts, valve parts..

Non-ferrous metals
1.Aluminium

2.Lead

1.ALUMINIUM
It

is cheap, light in weight and offer good mechanical strength. Al. equipment can be easily fabricated. Al. can be strengthened by cold working. Number of modifications of Al are available. Al is non toxic to micro-organism.

Advantages

High resistant to atm conditions, industrial fumes, vapour and fresh or salt waters. Thermal conductivity of Al. is 60 % that of pure copper.

Disadvantages

Mechanical strength decrease above 150 0 C. Al. can not be used with strong caustic solution. Many mineral acids attack Al. Oxide & hydro-oxide films form rapidly when exposed.

Uses

Preferred for food and pharmaceutical use. Used in heat transfer. Used as storage containers. Used in pdtn of citric acid, gluconic acid and streptomycin. Most useful for construction of drums, barrels, rail tankers.

2.LEAD
It

has the lowest cost. Used as collapsible tube material particularly for non-food products such as adhesives, inks, paints and lubricants. Lead tubes with internal linings are used for fluoride tooth-paste. Lead chamber process is used in the manufacture of sulphuric acid.

Advantages

It has the lowest cost.

Lead has low melting point and hence posses poor structural qualities. It has a high coefficient of expansion. So temp strain result in permanent deformation.

Disadvantages

Uses

Used as collapsible tube material particularly for non-food products such as adhesives, inks, paints and lubricants. Lead tubes with internal linings are used for fluoride tooth-paste. Lead chamber process is used in the manufacture of sulphuric acid. Little use in pharma bcz of risk of contamination even in traces produce toxicity.

LEAD ALLOYA AND MODIFICATIONS Acid lead and copper leads are used in chemical industries. Some metals are added to lead for altering properties. Silver and Copper: Improve corrosion resistant. Improve creep and fatigue resistant. Antimony, Tin, Arsenic: Hardens, steel melting point is low. Lead lined steel structures are used for the constructions of pipes, valves, vessels designed for operations at high temp, fluctuating temp or vacuum.

NON-METAL INORGANIC

1.GLASS

2.GLASSED STEEL

1.GLASS

Composition
Advantages DisAdvantages Uses

Sand : Silica pure (SiO2) : Base material Soda Ash : Na2CO3 : Improves the properties. Lime stone : CaCO3 : Improves the properties. Cullet : Broken glass : Fusion agent

Superior protective qualities, attractive and low cost. Chemically inert to large extent and available in variety of sizes, shapes and colors. Offer excellent barrier against many elements except light.

UV rays and sunlight are harmful to certain ingredients and cause deterioration. Protection against light can be obtained by amber colored bottle and against IR rays by green color glass. Fragility and weight.

Mostly used in pharmaceutical industries as a containers.

1. GLASS
The

glass that is prepared by silicon dioxide alone is the most resistant, but relatively brittle. It can be melted and moulded at high temp. To modify the physicochemical properties cations such as sodium, potassium, calcium, magnesium, aluminum, boron, iron etc are added. Glass containers used in pharmaceutical industries are classified in four groups, class I , class ii, class iii, class iv. Most of the alkali oxides such as Na2O, K2O. Mgo and Cao enter the spaces within the structures and reduce the strength of inter-atomic forces between silicon and oxygen.

1. GLASS
The

oxide decrease the melting point of glass and are comparatively free to migrate. This behavior cause number of problems like: Oxides leach in to the solution, raise the pH, hydrolyze or catalyze chemical reactions. Some times glass flakes are formed in the solution.

Different Types of Glass

Types
I

General Description

Properties
Resistant to alkali leaching, less brittle, low thermal expansion, easy to clean & sterilize. Surface alkali is neutralized by sulphur dioxide vapors. Glass surface is resistant to water. It release comparatively more alkali. It offers moderate hydrolytic resistance

Uses Containers for buffered 7 unbuffered, aqueous solution & injectables. Containers for buffered, aqueous solution with pH below 7.0, dry powders, oleaginous solution. Dry powders, oleaginous solutions. Not for parenterals, used as containers for tablets, oral solutions, suspensions, ointments &liq. For external use.

Highly resistant borosilicate.( Alkali & earth cations are replaced by boron) Treated soda-lime glass

II

III

Soda-lime glass

IV

General purpose soda-lime glass.

2.GLASS STEEL
Glassed steel is an inorganic pdt of fusion, which is cooled to a rigid condition without crystallizing. It requires special consideration in its design & use. Glassed steel combines the corrosion resistance of glass with the working strength of steel.
Excellent resistance to all acids except HF and hot conc.. H2SO4. It can be attacked by hot alkaline solution. Brittle & gets damaged by thermal shock. Hence protected using glass lined with epoxy polyester fiber glass. Glass linings are resistant to All conc. of HCl up to 1200C. All conc. of HNO3 up to boiling point. Dilute conc. of H2SO4 up to boiling point. Acid resistant glass with improved alkali resistance ( up to pH 12)

Advantages

Uses

Used for handling of strong acids, alkalis and saline solutions. For small scale manufacture and pilot plant work glassed steel vessels are used.

NON-METAL ORGANIC

1.RUBBER

2.PLASTIC

RUBBER
Used

as such as a lining material for the construction of plants. Type of rubber 1. Natural Rubber 2. Soft rubber. 3. Hard Rubber 4. Synthetic Rubber.

Natural Rubber

Rubber is naturally occurring polymer obtained as latex from rubber trees. It is common example of an elastomer. Elastomer is a substance that can be stretched readily regains its original form. The naturally occurring polymer is known as soft rubber. It is a polymer of monomeric isoprene (C5H8). It is resistant to dil. Mineral acids, dil. Alkalis and salts. It can be attacked by a oxidizing media, oils & organic solvents. Used lining materials for plants. Addition of carbon black to the soft rubber gives hardened rubber. Used in making tyres, tubes, and conveyor belt.

Soft Rubber

Hard Rubber

When soft rubber is mixed with sulphur, warmed & set into a given, it retains its form. The sulphur combines with the polymeric chains of rubber and cross links between them. This process is known as vulcanization. Soft rubber with 25 % sulphur is known as Hard Rubber. hard Rubber is used for making gloves, bands, tubes, and stoppers.

Synthetic Rubber

Synthetic Rubber is resistant to oxidation, solvents, oils and other chemicals. Synthetic Rubber is thermoplastic. Vulcanization of rubber is possible. Rubber can be hardened by adding carbon black.

SOME VARIETIES OF SYNTHETIC RUBBER.

Five

type of Synthetic Rubber 1. Neoprene 2. Nitrile Rubber 3. Butyl Rubber 4. Silicon Rubber 5. Polyisoprene

1. NEOPRENE (POLYCHLOROPRENE)
Does not burn readily like natural rubber. Properties Stable at high temp.

Uses

Use as insulating material in electric cables, conveyor belts in coal mine, rubber stoppers, cap liners, dropper assembly for eye drops.

2. BUTYL RUBBER.
Resistant to mineral acids and alkalis, concentrated acids (except Properties nitric acid and sulphuric acid).

Uses

Used for closure of freeze dried pdt containers bcz of its low water vapor permeability.

3.Nitrile Rubber Resistant to oil and solvents.

4.Silicone Rubber

Resistant to high and low temp. Resistant to attack to aliphatic solvents, oils and greases.

5.Polyisoprene

Stable at high temp. translucent, flexible.

2. PLASTICS
Light

in wt so transportation is easy and cheap. Available in variety of shape and easily fabricated. Used for storing number of materials. In machines, plastic material is preferred wherever moving parts are present indicating that it offers less resistant. Plastics are synthetic resins containing long chains of atoms linked to form giant or macromolecules (polymer). They have high molecular weight.

 Low thermal and electrical resistance. Excellent resistance to weak mineral acids. Advantages Unaffected by inorganic salts. Resistant to small changes to pH.

Disadvantages Low mechanical strength.

High expansion rates.

TYPE OF PLASTICS
Thermosetting plastics

Thermosetting plastics can be formed under heat and pressure. But this can not be softened or remoulded, once hardened. Some are made of phenolic and urea. They are formed by the application of heat and pressure can be softened and remouled. e.g. of thermoplastic material and their use Polyethene: cables, buckets, pipes. Polypropylene: milk, cartons, ropes. Polyvinyl chloride: gloves, water proof garments. Teflon: gaskets, coatings.

Thermoplastic plastics

BASED ON UTILITY OF PLASTICS Rigid materials Flexible materials Metallic surfaces Plastic cements Special case plastics

Rigid materials

These are phenolic resins with various inert fillers. Used in fabrication of number of items. Light in weight. Used in gears, pipes, fittings, ducts, valves, vessels. Resistant to corrosion except oxidizing substance and strong alkalis.

Flexible materials

These are thermoplastic materials. These materials can be rigid or flexible depending upon the amt of plastcizer added. They are used in fabrication of tanks, pipes, funnel, buckets.

Metallic surfaces

Plastics of polyethelene or polyvinyl chloride types are used along with plasticizer for the coating of metallic surfaces. These are used to protect the metal from corrosion. These linings are applied on tanks, vessels, stirrer and fans.

Plastic cements

Used for spaces between acid resistant tiles and bricks.

Special case

Plastics are used as guards for moving parts of machinery. Nylon and PVC fibers woven into filters cloths and are used for aseptic screening.