Material of Plant Construction

1. MATERIALS OF PLANT
CONSTRUCTION
Prepared By: Dipal R Prajapati
Assistant Professor
Pioneer Pharmacy Degree College
Vadodara

2. FACTORS AFFECTING SELECTION OF
MATERIAL FOR PLANT CONSTRUCTION.
Three type of factors.
1. Chemical factors
2. Physical factors
3. Economical factors

3. CHEMICAL FACTORS
• 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.
• 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.

4. 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

5. 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.

6. 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.
Thermal
conductivity
• The materials used for evaporators, dryers and heat exchanger
should have a good thermal conductivity.
• Resistant film retard the rate of heat transfer.
Thermal
expansion
• If the material has high coefficient of expansion , the temp changes
cause increase in stress and risk of fracture.
• The material should be able to maintain size and shape of equipment
at working temperature.

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

8. Ease of
fabrication
• During fabrication, the materials under go various processes such
as casting, welding, forging etc.
• Glass and plastic can be easily molded into containers of diff. size
and shape.
Cleansing
• Smooth and polished surfaces allow the process of cleansing easy.
• Stainless steel and glass are easy for cleansing.
Sterilization
• In the production of parenterals, ophthalmic products, antibiotics and
biologicals, sterilization is an essential step which is obtained by
autoclaving .
• The material should be able to withstand the steam pressure.

9. ECONOMICAL 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.

10. Material of plant construction
Ferrous
Non-Metals
Cast
Iron
Steel
Carbon
Stainless
Steel
Inorganic
Glass
Organic
Non-Ferrous
Metals
Aluminum Lead
Rubber Plastic

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

12. 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.

13. • Cheap
• Resistant to conc.. H2SO4. HNO3, and dilute alkalis.
• It has low thermal conductivity so used for construction of outer
jackets of steam pans.
Advantages
• 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.
Disadvantages
• Supports for plant.
• Jackets of steam pans.
• Lining with enamel, plastic or suitable protective materials
Uses

14. Modifications
1. Gray Cast iron
3. High
Silicon cast
Iron
4. Nickel resistant
cast iron
2. Malleable
Iron

15. GRAY CAST IRON
• Carbon
• Silicon
Composition
• Low cost
• Easy to cast into intricate shades and linings,
Properties
• Brittle
• Poor resistant to impact and shock.
Disadvantages

16. MALLEABLE IRON
• White cast iron
• Carbon 2-5 %
Composition
• Corrosion resistant
• Type 1 easy to machine.
Properties
• Type 2 less easy to machine.
Disadvantages

17. HIGH SILICON CAST IRON
• Cast iron
• Silicon 13- 16 %
Composition
• Resistant to corrosion, oxidizing and reducing
environment.
• Used in H2SO4 services.
Properties
• Not easily machined and welded.
Disadvantages

18. NICKEL RESISTANT CAST IRON
• Superior toughness
• Impact resistant.
• Easy to weld and machine.
• Corrosion resistant and heat resistant.
Properties
• Oxidizing agents are highly detrimental.
• There is a Little attack from neutral or
alkaline solution.
Disadvantages

19. • Cheapest
• Easily weld able and used in fabrication
Advantages
• 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
• Used in construction of bars, pipes and plates.
• Used to fabricate large storage tanks for water and
organic solvents.
• Also used for supporting structures.
Uses
CARBON STEEL OR MILD STEEL
CARBON STEEL IS AN IRON ALLOY, WHICH CONTAINS
ONLY A SMALL PERCENTAGE OF CARBON.

20. Modifications
Alloying it
with other
metals alter
the properties
1. Nickel improves
toughness, corrosion
resistant
3. Molybdenum
provides
strength at
elevated temp.
4. Silicon increases hardness,
abrasive and corrosion
resistant
2. Chromium
increases
hardness, abrasive
and corrosion
resistant

21. Different Types & Alloys of Carbon Steel
1.Low Allow Steel
2.Alloying with Nickel
3.Allowing with Silicon
Chromium.
Low conc. of Iron, carbon,
manganese, Nickel,
Chromium & molybdenum.
Nickel.
Nickel, Chromium.
High mechanical strength.
Corrosive resistant to
environment.
Increase hardness.
High corrosion resistant.
Abrasion resistant.
Corrosion resistant.
Resistant to oxidation.
Variety of Carbon Composition Advantages
Allow

22. STAINLESS STEEL
• 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 amount of other elements such as copper, molybdenum, & selenium are added.
• S.S has the advantages of ease of fabrication.
• Properties of S.S.
1. Heat resistant
2. Corrosion Resistant
3. Ease of fabrication.
4.Tensile strength
5. Cleaning and Sterilization.

24. MARTENSITIC
• Chromium : 12- 20 %
• Carbon : 0.2-.4 %
• Nickel up to : 2.0 %
Composition
• Mildly corrosion resistant atm % organic exposure.
Advantages
• Ductility is poor.
Disadvantages
• Sinks, bench tops, storage tanks, buckets etc.
Uses

25. AUSTENITIC
• Chromium : 13-20 %
• Carbon : 0.1 % < 0.25 %
• Nickel up to : 6-22 %
Composition
• Highly corrosion resistant.
• Readily cleaned, sterilizable.
• Easy to weld.
Advantages
• Not easy to machine.
Disadvantages
• Fermentors, storage vessels, evaporators, extraction vessels, buckets,
funnels..
Uses

26. FERRITIC
• Chromium : 15-30 %
• Carbon : 0.1 %
• Nickel up to : nil
Composition
• Better corrosion resistant.
• Easy to machine.
• Resistant to temp and temp.
Advantages
• Not good against reducing agents, HCl..
Disadvantages
• Tower linings, Baffles, Separator, tower, heat exchanger,
tubings, condensers, furnace parts, pumps shafts, valve
parts..
Uses

27. Non-ferrous metals
1.Aluminium
2.Lead

28. 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.

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

30. 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.

31. • It has the lowest cost.
Advantages
• 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
• 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.
Uses

32. LEAD ALLOY 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.

33. NON-METAL INORGANIC
1.GLASS
2.GLASSED STEEL

34. 1.GLASS
• Sand : Silica pure (SiO2) : Base material
• Soda Ash : Na2CO3 : Improves the properties.
• Lime stone : CaCO3 : Improves the properties.
• Cullet : Broken glass : Fusion agent
Composition
• 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.
Advantages
• 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.
Disadvantages
• Mostly used in pharmaceutical industries as a containers.
Uses

35. 1. GLASS
• The glass that is prepared by silicon dioxide alone is the most resistant, but relatively
brittle.
• It can be melted and molded 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.

36. 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.

37. DifferentTypes of Glass
I
II
III
IV
Highly resistant borosilicate.
( Alkali & earth cations are
replaced by boron)
Treated soda-lime glass
Soda-lime glass
General purpose soda-lime
glass.
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
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.
Types
General
Description Properties Uses

38. 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
• Used for handling of strong acids, alkalis and saline solutions.
• For small scale manufacture and pilot plant work glassed steel vessels are used.
Uses

39. NON-METAL ORGANIC
1. RUBBER
2. PLASTIC

40. 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.

41. 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.
Soft Rubber
• 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.

42. 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.

43. SOME VARIETIES OF SYNTHETIC RUBBER.
• Five type of Synthetic Rubber
1. Neoprene
2. Nitrile Rubber
3. Butyl Rubber
4. Silicon Rubber
5. Polyisoprene

44. 1. NEOPRENE (POLYCHLOROPRENE)
Properties
• Does not burn readily like natural rubber.
• 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.

45. 2. BUTYL RUBBER.
Properties
• Resistant to mineral acids and alkalis, concentrated acids
(except nitric acid and sulphuric acid).
Uses
• Used for closure of freeze dried pdt containers bcz of its
low water vapor permeability.

46. • Resistant to oil and solvents.
3.Nitrile Rubber
• Resistant to high and low temp.
• Resistant to attack to aliphatic solvents,
oils and greases.
4.Silicone Rubber
• Stable at high temp. translucent, flexible.
5.Polyisoprene

47. 2. PLASTICS
• Light in weight 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.

48. Advantages
• Low thermal and electrical resistance.
• Excellent resistance to weak mineral acids.
• Unaffected by inorganic salts.
• Resistant to small changes to pH.
Dis-
advantages
• Low mechanical strength.
• High expansion rates.

49. TYPE OF 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.
Thermosetting
plastics
• 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

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

51. 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
plasticizer added.
• They are used in fabrication of tanks, pipes, funnel, buckets.

52. Metallic
surfaces
• Plastics of polyethylene 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.

53. Thank You