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ChE Design > MATERIALS OF CONSTRUCTION > Flashcards

MATERIALS OF CONSTRUCTION Flashcards

1
Q

T/F: The actual cost of metals and alloys will fluctuate quite widely, depending
on movements in the world metal exchanges

A

T

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2
Q

The quantity of a material used will depend on ___-which must be taken into account
when comparing material costs

A

MATERIAL DENSITY
MATERIAL STRENGTH (MAXIMUM ALLOWABLE STRESS)

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3
Q

Has high maximum allowable stress

A

Austenitic stainless steel
(304 and 316)
Incoloy

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4
Q

How can costs be compared?

A

Calculating cost rating factor

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5
Q

Materials with relatively high maximum allowable stress can be used more efficiently than carbon steel

A

Stainless low alloy steels

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6
Q

The relative cost of equipment made from different materials will depend
on the _____, as well as the basic __-__

A

cost of fabrication
cost of the material

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7
Q

T/F: Unless a particular material requires special fabrication techniques, the
relative cost of the finished equipment will be lower than the relative bare
material cost

A

T

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8
Q
  • If the corrosion rate is uniform, the optimum material can be selected by
    calculating the ___________
A

annual costs

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9
Q

Annual costs will depend on the _____ and ____ of the equipment

A

predicted life
purchased cost

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10
Q

Predicted life is calculated from the?

A

corrosion rate

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11
Q

T/F: * It may prove more economic to install a cheaper material with a high
corrosion rate and replace it frequently, rather than select a more
resistant but more expensive material; but this strategy is only
considered for relatively simple equipment with low fabrication costs and
where premature failure would not cause a serious hazard

A

T

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12
Q

The more expensive, corrosion-resistant, alloys are frequently used as a
_____

A

cladding on carbon steel.

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13
Q
  • If a thick plate is needed for structural strength, as for pressure vessels,
    the use of_____ can substantially reduce the cost.
A

clad materials

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14
Q

t/f: the prevention of the contamination of a process
stream, or a product, by certain metals, or the products of corrosion,
overrides any other considerations when selecting suitable materials

A

T

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15
Q

slight rusting that mark the textiles

A

iron staining

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16
Q

In textile processes, what are used in preference to carbon steel?

A

Stainless steel or aluminum

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17
Q

For equipment handling acetylene, the pure metals, or alloys containing
_____________ must be avoided to prevent the formation of
explosive acetylides.

A

copper, silver, mercury or gold,

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18
Q

The presence of trace quantities of mercury in a process stream can cause the
catastrophic failure of brass heat-exchanger tubes, from the formation of a
_____. Incidents have occurred where the contamination
has come from unsuspected sources, such as the failure of ______

A

mercury-copper amalgam
mercury-in-steel
thermometers

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19
Q

there was evidence that the stress corrosion
cracking of a stainless-steel pipe had been caused by zinc contamination from
galvanized wire supporting lagging

A

Flixborough disaster

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20
Q

Discovery of the vertical crack of Reactor 5

A

March 27, 1974

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21
Q

Prior to explosion during the Flixborough disaster, what was discovered?

A

A vertical crack in Reactor 5 was leaking cyclohexane

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22
Q

When does a 20 inch bypass system ruptured that cause a fire to the nearby 8 inch pipe

A

late afternoon of June 1, 1974

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23
Q

What explosion happened in Flixborough Disaster?

A

Vapor cloud explosion

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24
Q

how many fatalities has occured in the control room

A

18

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25
Q

How many days did the fire still burn?

A

10 days

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26
Q

The _____ rattled the confidence of every
chemical engineer in the country.

A

shock waves

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27
Q
  • In industries such as the ________, the surface finish of the material is as important as the choice
    of material, to avoid contamination.
A

food
pharmaceutical
biochemical
textile

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28
Q

Stainless steel is widely used, and the surfaces, inside and out, are given
a high finish by

A

abrasive blasting and mechanical polishing

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29
Q

Surface finishing is done in the purpose of?

A

hygiene
prevent material from adhering
aid cleaning and sterilization

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30
Q

A good surface finish is important in textile fiber processing to prevent ?

A

fibers snagging

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31
Q

is the most commonly used engineering
material.

A

Low carbon steel (mild steel)

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32
Q

It is cheap, available in a wide range of standard forms and sizes, and
can be easily worked and welded.

A

Low carbon steel (mild steel)

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33
Q

has good tensile strength and ductility.

A

Low carbon steel (mild steel)

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34
Q

are not resistant to corrosion, except in certain
specific environments

A

Carbon steels and iron

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35
Q

Carbon steels and iron are resistant corrosion in specific environments such as ?

A

Concentrated sulphuric acid
caustic alkalis

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36
Q

suitable for use with most organic solvents

A

Carbon steels and iron

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37
Q

Carbon steels and iron are not suitable in ? because traces of corrosion products may cause?

A

chlorinated solvents
discoloration

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38
Q

is susceptible to stress-corrosion cracking in certain
environments.

A

Mild steel

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39
Q

T/F: The corrosion resistance of the low alloy steels (<5% of alloying
elements), where the alloying elements are added to improve the
mechanical strength and not for corrosion resistance, is not significantly
different from that of the plain carbon steels

A

T

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40
Q

have a high resistance to mineral
acids, except hydrofluoric acid.

A

High silicon irons

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41
Q

High silicon irons have how much silicon?

A

14-15%

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42
Q

are particularly suitable for use with sulphuric acid at all concentrations and
temperatures

A

High silicon irons

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43
Q

very brittle

A

High silicon irons

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44
Q

are the most frequently
used corrosion resistant materials in the
chemical industry

A

stainless steels

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45
Q
  • To impart corrosion resistance to stainless steel, the chromium
    content must be above ____,
A

12%

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46
Q

T/F:The higher the chromium content of stainless steel, the more resistant is the alloy to corrosion in oxidizing conditions

A

T

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47
Q

is added to improve the corrosion
resistance in non-oxidizing environments

A

Nickel

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48
Q

Types of Stainless Steels

A

Ferritic
Austenitic
Martensitic

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49
Q

Ferritic

A

13-20% Cr, <0.1% C, with no nickel

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50
Q

Austenitic

A

18-20% Cr, >7% Ni

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51
Q

Martensitic

A

12-14% Cr, 0.2 to 0.4% C, up to 2% Ni

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52
Q

is the structure desired for corrosion resistance, and it is
these grades that are widely used in the chemical industry.

A

uniform structure of Austenite (face-centered cubic, with the carbides
in solution)

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53
Q

Commonly used grades of Austenitic stainless steel

A

304
304L
321
347
316
316L
309
310

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54
Q

the so-called 18/8 stainless steels

A

304

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55
Q

the most generally used stainless steel.

A

304

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56
Q

AISI

A

AMERICAN IRON AND STEEL INSTITUTE

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57
Q

It contains
the minimum Cr and Ni that give a stable austenitic structure.

A

304

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58
Q

The carbon content is low enough
for heat treatment not to be normally needed with thin sections to prevent weld decay

A

304

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59
Q

low carbon version of type 304 (<0.03% C) used for thicker welded sections, where
carbide precipitation would occur with type 304.

A

304L

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60
Q

: a stabilized version of 304

A

321

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61
Q

What stabilizes type 321

A

titanium

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62
Q

It has a slightly higher strength than 304L, and is more suitable for hightemperature use

A

321

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63
Q

Stabilized with Niobium

A

347

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64
Q

What was added in 316 to improve corrosion resistancein reducing conditions

A

Molybdenum

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65
Q

examples of reducing conditions in which the addition of molybdenum in type gives corrosion resistance?

A

dilute sulphuric acid
solutions containing chlorides

66
Q

a low carbon version of type 316, which should be specified if welding or heat
treatment is liable to cause carbide precipitation in type 316

A

316L

67
Q

alloys with a high chromium content, to give greater resistance to oxidation at
high temperatures

A

309/310

68
Q

are susceptible to embrittlement due to sigma
phase formation at temperatures above 500°C.

A

alloys with greater than 25% Cr

69
Q

is an intermetallic compound, FeCr.

A

Sigma phase

70
Q

They have greater strength than the plain carbon steels particularly at elevated temperatures

A

Austenitic stainless steel

71
Q

They do not become brittle at low temperatures

A

Austenitic stainless steel

72
Q

Thermal conductivity of stainless steel is significantly ____ than that of mild steel

A

Lower

73
Q

Thermal conductivity of Stainless steel type 304 at 100°C

A

16 W/m°C

74
Q

Thermal conductivity of mild steel @100°C

A

60 W/m°C

75
Q

Are non-magnetic in the annealed condition

A

Austenitic stainless steel

76
Q

Increasing corrosion resistance order

A

304
304L
321
316
316L
310

77
Q

T/F: Higher the alloying content, the better the corrosion resistance over a wide range of conditions strongly oxidizing to reducing but higher cost

A

T

78
Q

Problems associated with using stainless steel

A

Intergranular corrosion (weld decay) and stress corrosion cracking

79
Q

Stress corrosion cracking in stainless steel is caused by a few ppm of?

A

Chloride ions

80
Q

Are used for corrosion resistance when oxidizing conditions exist

A

Stainless steel

81
Q

If reducing conditions are likely to occur what will be used?

A

High nickel alloys

82
Q

Contains between 29 to 30% nickel and 20% chromium

A

Super austenitic

83
Q

Have good resistance to acids and acid chlorides

A

Super austenitic

84
Q

They are more expensive than the lower content 300 series, austenitic stainless steels

A

Super austenitic

85
Q

Contain high percentages of chromium stainless steel

A

Duplex and Super duplex

86
Q

Because their structure is a mixture of the austenitic and ferritic phases

A

Duplex

87
Q

They have a better corrosion resistance than the austenitic stainless steels and are less susceptible to stress corrosion cracking

A

Duplex

88
Q

Chromium content of duplex stainless steel

A

20%

89
Q

Chromium content of super duplex grades

A

25%

90
Q

We’re developed for use in aggressive off-shore environments

A

Super-duplex

91
Q

Can be readily cast, wrought and machined

A

Duplex range

92
Q

The cost of ____ is comparable with 316 steels

A

Duplex

93
Q

Super-duplex costs _____ higher than the cost of duplex

A

50%

94
Q

Has good mechanical properties and easily worked

A

Nickel

95
Q

The pure metal of nickel is not generally used for chemical plant T/F:

A

T

96
Q

Main use of nickel

A

Equipment handling caustic alkalis at temperatures above that at which carbon steel could be used (above 700°C)

97
Q

Is not subject to corrosion cracking like stainless steel

A

Nickel

98
Q

Classic nickel-copper alloy with the metals ratio 2:1

A

Monel

99
Q

Most commonly used alloy for chemical plant after stainless steel

A

Monel

100
Q

More expensive than stainless steel but is not susceptible to stress-cracking corrosion in chloride solutions

A

Monel

101
Q

Can be used to equipment handling alkalis, organic acids and salts and seawater

A

Monel

102
Q

76% Ni, 7% Fe, 15% Cr

A

Inconel

103
Q

Used primarily for acid resistance at high temperatures

A

Inconel

104
Q

Resistant to furnace gases if sulphur free

A

Inconel

105
Q

Not suitable for use in sulphiding environments

A

Inconel

106
Q

Nickel alloy with higher chromium content (21%) and 25%have better oxidation resistance at higher temperatures

A

Incoloy
RA-33

107
Q

Covers a range of nickel, chromium, molybdenum, iron alloys

A

Hastelloys

108
Q

Developed for corrosion resistance to strong mineral acids like HCl

A

Hastelloys

109
Q

Hastelloys B

A

65 NI 28 Mo 6 Fe

110
Q

Hastelloy C

A

54 NI 17 Mo 15 Cr 5 Fe

111
Q

Where does copper is used in food industry

A

Brewing

112
Q

Relatively soft, very easily worked metal a d is used extensively for small bore pipe and tubes

A

Copper

113
Q

Relatively soft, very easily worked metal a d is used extensively for small bore pipe and tubes

A

Copper

114
Q

Copper alloyed with zinc

A

Brass

115
Q

Copper alloyed with tin

A

Bronze

116
Q

Other bronzes

A

Aluminum Bronze
Silicon Bronze

117
Q

Attacked by mineral acids except dilute, cold, underrated sulfuric acid

A

Copper

118
Q

Resistant to caustic alkalis except ammonia and to many organic acids and salts

A

Copper

119
Q

T/F: Brass and bronze have similar corrosion resistance to the pure metal

A

T

120
Q

Main use in the chemical industry is for valves, and other fittings, and for heat exchanger tubes and tube-sheet

A

Copper

121
Q

Cupro-nickel has how much Cu?

A

70%

122
Q

Good resistance to corrosion erosion a d are used for heat exchanger tubes particularly where seawater is the coolant

A

Cupro-nickel alloys

123
Q

Has higher resistance to corrosion but lacks mechanical strength than it’s alloys

A

Pure aluminium

124
Q

Main structural alloys used

A

Duralumin or Dural

125
Q

Dural is aluminium and _ Alloy

A

Copper

126
Q

Composition of Dural

A

4% Cu and 0.5% Mg

127
Q

Have tensile strength equivalent to mild steel

A

Dural

128
Q

T/F: Pure metal can be used as a cladding on during plates to combine corrosion resistance of pure metal and strength of Alloy

A

T

129
Q

Corrosion resistance of aluminium is due to the formation of?

A

Thin oxide film

130
Q

Suitable for use in strong oxidizing conditions

A

Aluminium

131
Q

Attacked by miineral acids and alkalis

A

Aluminium

132
Q

Aluminium is suitable for concentration of HNO3 greater than

A

80%

133
Q

Widely used in the textile and food industry

A

Aluminium

134
Q

Used for storage and distribution of demineralised water

A

Aluminium

135
Q

one of the traditional materials of
construction for chemical plant but has now,
due to its price, been largely replaced by
other materials, particularly plastics.

A

Lead

136
Q

It is a soft, ductile material, and is mainly
used in the form of sheets (as linings) or pipe

A

Lead

137
Q
  • It has a good resistance to acids, particularly
    sulphuric.
A

Lead

138
Q

now used quite widely in the chemical industry, mainly for its
resistance to chloride solutions, including sea water and wet chlorine.

A

Titanium

139
Q

rapidly attacked by dry chlorine, but the presence of as low a
concentration of moisture as 0.01% will prevent attack

A

Titanium

140
Q

depends for its resistance on the
formation of an oxide film

A

Titanium

141
Q

is also used in other halide services, ex. in
liquid phase oxidation processes, such as the
manufacture of terephthalic acid, that use bromide
as catalyst or promoter

A

Titanium

142
Q

Alloying titanium with_____significantly improves the corrosion
resistance, particularly to HCl.

A

palladium (0.15%)

143
Q

being increasingly used for heat exchangers, for both shell
and tube, and plate exchangers, replacing cupro-nickel for use with sea
water.

A

Titanium

144
Q

corrosion resistance of tantalum is similar to that of

A

glass

145
Q

Called metallic glass

A

Tantalum

146
Q
  • It is expensive, about five times the cost of
    stainless steel, and is used for special
    applications, where glass or a glass lining
    would not be suitable.
A

Tantalum

147
Q

are used to repair glasslined equipment

A

Tantalum plugs

148
Q

used in the nuclear industry, because
of their low neutron absorption cross-section and resistance to hot water
at high pressures.

A

Zirconium and Zirconium alloys

149
Q

finding use where resistance to hot
and boiling acids is required: nitric, sulphuric, and particularly
hydrochloric

A

Zirconium

150
Q

used for vessels and equipment handling hydrofluoric
acid

A

Silver linings

151
Q

for special applications in the food and pharmaceutical
industries where it is vital to avoid contamination of the product.

A

Silver

152
Q

rarely used as a material of construction because of its high cost.

A

Gold

153
Q

It is highly resistant to attack by dilute nitric acid and hot concentrated
sulphuric acid, but is dissolved by aqua regia (a mixture of concentrated
nitric and sulphuric acids).

A

Gold

154
Q

attacked by chlorine and bromine, and
forms an amalgam with mercury

A

Gold

155
Q
  • It has been used as thin plating on condenser
    tubes and other surfaces
A

Gold

156
Q
  • It has been used as thin plating on condenser
    tubes and other surfaces
A

Gold

157
Q

has a high resistance to oxidation at high temperature

A

Platinum

158
Q

One of its main uses has been in the form of an alloy with copper, in the
manufacture of the spinnerets used in synthetic textile spinning
processes.

A

Platinum

159
Q
A
160
Q
A

ChE Design (4 decks)

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