INDUSTRIAL & FERTILIZER MATERIALS INDUSTRIAL & FERTILIZER MATERIALS MATERIALS

1. A REFRESHER ON
INDUSTRIAL & FERTILIZER MATERIALS
By Waqas CH

2. YOUR ASSESSMENT
1 – Iron with temporary magnetic field
2 – Stainless Steel Urea Grade or 25-22-02
5 -
a - Austenitic b - Martensitic
c - Ferritic d - Duplex
4 - Material which contains by mass more iron than any other material
6 - No
7 – Low Carbon Steel
8 - Copper
9 - Killed Carbon Steel
3 - Yes

3. MATERIAL CLASSIFICATION
METALS
NON - METALS
NON - FERROUS
FERROUSFERROUS
MATERIALS

4. FERROUS METALS
ORIGINAL DEFINITION
- IRON CONTENTS GREATER THAN 50%.
REVISED DEFINITION (1993)
- MATERIAL WHICH CONTAINS BY MASS MORE IRON THAN ANY
OTHER SINGLE ELEMENT.
Cr : 26 max.
Ni : 22 max.
Mn : 02 max.
Si : 1.5 max.
Total : 51.5 max.
SS 310

5. CLASSIFICATION FERROUS METALS
FERROUS METALS
CARBON STEEL
CAST IRON
ALLOY STEEL
WROUGHT IRON
BASED ON “C” ADDITION

6. IRON ORE
COKE
LIME STONE
BLAST FURNACE
IRON MAKING STEEL MAKING CONTINUOUS CASTING PRODUCTS
BASIC OXYGEN FURNACE
ELECTRIC ARC FURNACE BILLETS
CASTING
REHEATING FURNACE
PLATES
RODS
PIPE
PIG IRON
WROUGHT IRON

7. CLASSIFICATION FERROUS METALS
FERROUS METALS
CARBON STEEL
CAST IRON
ALLOY STEEL
WROUGHT IRON
BASED ON “C” ADDITION

8. PROPERTIES OF MATERIALS
ELASTICITY
-The property of a material due to which it comes to its original shape
after the removal of load is called elasticity.
- There is a certain limit of every material upto which it can regain its
original shape. This limit is called Elastic Limit.
PLASTICITY
-The property of a material due to which it is permanently deformed
(re-shaped) on the application of load, without any rupture is called
plasticity.

9. PROPERTIES OF MATERIALS
HARDNESS
- It is the property of a material due to which it resists wear, abrasion
and indentation.
- Also hardness is the property which enables to cut the other material.
TOUGHNESS
-Ability of material to resist fracture due to sudden shocks
(impact loads) or bending/twisting is called toughness.

10. PROPERTIES OF MATERIALS
STIFFNESS
- Ability of a material to resist deformation due to the external forces
is called stiffness.
BRITTLENESS
- The property of a material to easily break up into pieces
without deformation is called brittleness.
DUCTILITY
- Ability of a material to be drawn into wires or undergo elongation
without fracture is called ductility.

11. PROPERTIES OF MATERIALS
STRENGTH
- It is the ability of a material to withstand the external forces of different
types before undergoing the permanent deformation or fracture
- Tensile strength ….. Maximum tension beared per unit area
- Compressive strength ….. Maximum compression beared per unit area
- Shear strength ….. Maximum shearing force beared per unit area

12. PROPERTIES OF MATERIALS
MALLEABILITY
- If a material can be rolled or hammered to thin sheet, it's
property is called malleability
CONDUCTIVITY
- Ability of a material to allow the passage of heat or electricity
through it, is called its conductivity
WELDABILITY
- Ability of a material to join by welding

13. EFFECT OF CARBON ON STEEL
Hardness Strength Ductility Weldability
Carbon

14. WROUGHT IRON
COMPOSITION
MECHANICAL PROPERTIES
- CONTAINS SMALL AMOUNT OF SLAG (SiO2)
- CARBON CONTENTS LESS THAN 0.08 % CARBON
USES
- EASILY WELDABLE
- LOW STRENGTH , MALLEABLE AND DUCTILE
- CURRENTLY WROUGHT IRON IS NOT PRODUCED DUE TO HIGH
MANUFACTURING COST
- MODERN WROUGHT IRON PRODUCTS ARE ACTUALLY MADE
FROM LOW CARBON STEEL

15. CARBON STEEL
CARBON STEEL IS CLASSIFIED ACCORDING TO:
ITS TREATMENT FOR DEOXIDIZATION
ITS CARBON CONTENTS
TYPE OF STEEL FOR WHICH:
- CARBON CONTENTS ARE < 2%
- NO ALLOYING ELEMENT IS ADDED EXCEPT CARBON

16. CARBON STEEL CLASSIFICATION
ACCORDING TO CARBON CONTENTS
CARBON STEEL
LOW CARBON STEEL
MEDIUM CARBON STEEL
HIGH CARBON STEEL
CARBON CONTENTS < 0.3 %
CARBON CONTENTS BETWEEN 0.3 % AND 0.6%
CARBON CONTENTS BETWEEN 0.6 % AND 2.0%

17. EFFECT OF CARBON ON MICROSTRUCTURE
Low Carbon Steel Medium Carbon Steel
High Carbon Steel Cast Iron

18. LOW CARBON STEEL
COMPOSITION
MECHANICAL PROPERTIES
- LESS THAN 0.3 % CARBON
GENERAL USES
- GRADES HAVING CARBON B/W 0.1 % TO 0.3 % ARE HEAT TREATABLE
- EXCELLENT FORMABILITY AND WELDABILITY
- SHEETS MANUFACTURING, PIPING AND PRESSURE VESSEL
COMPONENTS

19. LOW CARBON STEEL
USED AT FERTILIZER PLANT
- LOW, MEDIUM AND HIGH PRESSURE STEAM/CONDENSATE
- PIPING, VALVES AND VESSELS FOR
- COOLING WATER, INSTRUMENT AIR, FUEL GAS, NATURAL GAS
- LIQUID AMMONIA (HIGH TEMPERATURE)
- LOAD BEARING STRUCTURES AND SHEETS
LOW CARBON STEEL GRADES
 API 5L GRADE B
 ASTM A - 105
 ASTM A - 234

20. MEDIUM CARBON STEEL
COMPOSITION
MECHANICAL PROPERTIES
- CARBON CONTENTS BETWEEN 0.3% TO 0.6%
GENERAL USES
- HEAT TREATABLE
- GOOD BALANCE BETWEEN STRENGTH AND DUCTILITY
- MANUFACTURING OF GEARS, CRANKSHAFT ETC.

21. HIGH CARBON STEEL
COMPOSITION
MECHANICAL PROPERTIES
- CARBON CONTENTS BETWEEN 0.6% TO 2.0%
GENERAL USES
- LOW DUCTILITY
- HIGH STRENGTH
- HIGH STRENGTH WIRES AND SPRINGS
- POOR WELDABILITY AND FORMABILITY

22. CARBON STEEL CLASSIFICATION
ACCORDING TO DEOXIDIZATION TREATMENT
CARBON STEEL
CAPPED STEEL
SEMI KILLED STEEL
KILLED STEEL
NO DEOXIDIZER IS ADDED
DEOXIDIZERS ARE ADDED IN SMALL QUANTITY
DEOXIDIZERS ARE ADDED IN SUFFICIENT
QUANTITY
RIMMED STEEL
MOLTEN STEEL IS CAPPED TO STOP RIMMING ACTION

23. KILLED CARBON STEEL
COMPOSITION
MECHANICAL PROPERTIES
- CARBON STEEL WITH INCLUSION OF SILICON OR ALUMINUM
GENERAL USES
- INCREASED STRENGTH DUE TO HOMOGENOUS MICRO STRUCTURE
- PRESSURE VESSEL, PIPING ETC.
USES AT FERTILIZER PLANT
- PIPING, VALVES AND VESSELS FOR LOW TEMPERATURE LIQUID
AMMONIA
- DIFFICULT WELDING AS HEAT TREATMENT IS INVOLVED

24. CAST IRON
COMPOSITION
MECHANICAL PROPERTIES
- CARBON CONTENTS BETWEEN 2% AND 5%
GENERAL USES
- MELTING TEMPERATURE BELOW CARBON STEEL
- POOR WELDABILITY AND DUCTILITY
- EXCELLENT FLUIDITY (REQUIRED FOR CASTING PURPOSE)
- SILICON INCLUSION BETWEEN 1% AND 3%
- MANUFACTURING OF PUMPS, TURBINES, COMPRESSORS AND GEAR BOX
CASINGS

25. CLASSIFICATION FERROUS METALS
FERROUS METALS
CARBON STEEL
CAST IRON
ALLOY STEEL
WROUGHT IRON
BASED ON “C” ADDITION

26. ALLOY STEELS
ALLOY STEEL
LOW ALLOY STEEL
HIGH ALLOY STEEL
ALLOYING ELEMENT UP TO 8.0%
ALLOYING ELEMENT GREATER THAN 8.0%
CORROSION RESISTANT
HEAT RESISTANT
WEAR RESISTANT
Cr-Mo Alloy

27. Cr – Mo STEELS
GENERAL USES
- PRESSURE VESSEL, PIPING AT HIGH TEMPERATURE
COMPOSITION
- Cr UPTO 2.25% AND Mo UP TO 1.25%
MECHANICAL PROPERTIES
- HIGH STRENGTH AT TEMPERATURES UP TO 650 0
C
- DIFFICULT WELDING AS HEAT TREATMENT IS INVOLVED
ALLOYING EFFECT
- Cr INCREASES CORROSION RESISTANCE
- Mo ADDS ELEVATED TEMPERATURE STRENGTH

28. Cr - Mo STEEL GRADES
 A-335 GRADE P11 (PLANT-I KS)
Cr – Mo STEELS
 A-335 GRADE P22 (PLANT-I KS)
USES AT FERTILIZER PLANT
- PIPING, VALVES AND VESSELS FOR VER HIGH PRESSURE STEAM (KS)

29. STAINLESS STEEL
WHEN Cr CONTENTS ARE GREATER THAN 11.5 %, Cr REACTS WITH ATMOSPHERIC
O2 AND FORM THIN PASSIVE Cr-O2 LAYER ON STEEL SURFACE PREVENTING
OXIDATION OF Fe CONTENTS
Cr–O2 LAYER
STEEL

30. EFFECT OF CHROMIUM

31. STAINLESS STEEL
FERRITIC
MARTENSITIC
DUPLEX
AUSTENITIC
STAINLESS STEEL

32. SCHAFFLER DIAGRAM

33. COMPOSITION
MECHANICAL PROPERTIES
GENERAL USES
- GOOD WELDABILITY
- EXCELLENT CORROSION RESISTANT
- FOOD PROCESSING, CORROSIVE SERVICES e.g. UREA, ACID etc.
- CAN BE USED AT LOW AND HIGH TEMPERATURE (UP TO 900 0
C)
Ni UP TO 30%
Cr UP TO 30%
C 0.3%
AUSTENITIC STAINLESS STEEL
- CANNOT BE HARDENED BY HEAT TREATMENT

34. USED AT FERTILIZER PLANT
- ALL PRESSURE UREA SERVICE AND UREA FLUSHING CIRCUIT
- PIPING, VALVES AND VESSELS FOR
- MDEA, PROCESS GAS, DEMIN WATER
AUSTENITIC STAINLESS STEEL
AUSTENITIC GRADES
 SS- 304
 SS- 316
 SS- 316L Modified
 25 Cr – 22Ni – 02 Mo
 SS- 321

35. CONCEPT OF SENSITIZATION IN STAINLESS STEEL
CHROMIUMCARBIDE
(Cr23 C6)
GRAIN BOUNDARIES
CHROMIUM
AT HIGH TEMPERATURE (> 750 0
C) Cr REACTS WITH C AND FORMS CrC
TO PREVENT SENSITIZATION Ti OR Nb IS ADDED TO FORM TiC OR NbC

36. COMPOSITION
MECHANICAL PROPERTIES
GENERAL USES
- POOR WELDABILITY
- MODERATE CORROSION RESISTANT
- SHAFTS, SURGICAL INSTRUMENTS, FASTENERS
- CAN BE HARDENED BY HEAT TREATMENT
MARTENSITIC STAINLESS STEEL
C 1.2%
Cr UP TO 17%
Ni 0%

37. USED AT FERTILIZER PLANT
- PUMP SHAFTS, IMPELLERS FOR CORROSIVE SERVICE
MARTENSITIC GRADES
 SS- 416
 SS- 420
MARTENSITIC STAINLESS STEEL
 SS- 440
 SS- 410

38. COMPOSITION
MECHANICAL PROPERTIES
GENERAL USES
- POOR WELDABILITY
- MODERATE TO GOOD CORROSION RESISTANT
- DOMESTIC EQUIPMENTS
FERRITIC STAINLESS STEEL
- CANNOT BE HARDENED BY HEAT TREATMENT
C .3%
Cr UP TO 30%
Ni 0%

39. COMPOSITION
MECHANICAL PROPERTIES
GENERAL USES
- GOOD STRENGTH : GREATER THAN AUSTENITIC AND OTHER GRADES
- GOOD CORROSION RESISTANCE
- OFF-SHORE APPLICATIONS, HIGH PRESSURE UREA
DUPLEX STAINLESS STEEL
- GOOD WELDABILITY
C .3%
Cr UP TO 30%
Ni UP TO 8%

40. USED AT FERTILIZER PLANT
- UREA REACTOR (STAMI CARBON PLANTS)
DUPLEX STAINLESS STEEL
- STEMS FOR HIGH PRESSURE UREA VALVES
DUPLEX GRADES
 HVD-1
 FERRALIUM ALLOY

41. SS – 304
18 Cr – 8 Ni
SS - 316
SS - 317
ADD Mo (2%)
FOR PITTING RESISTANCE
ADD MORE Mo (4%)
FOR PITTING RESISTANCE
ADD Nb + Ta
TO REDUCE SENSITIZATION
SS - 347
ADD Ti
TO REDUCE SENSITIZATION
SS - 321
LOWER C
SS - 317L
SS - 316L
SS - 304L
ADD Cr & Ni
STRENGTH & CORROSION RESIST.
SS – 310
SS - 309
REDUCE Ni
TO REDUCE AUSTENITIC STRUCTURE
DUPLEX
STEEL
NO Ni
FERRITIC
STEEL
INCREASE C
LOWER Cr
MARTENSITIC
STEEL

42. MATERIAL DESIGNATION SYSTEM
- American Society for Testing MaterialsASTM
- American Iron and Steel InstituteAISI
- Society of Automotive EngineersSAE
- Unified Numbering SystemUNS
- German StandardsDIN
- British StandardsBS
- Japanese StandardsJS

43. AISI/SAE DESIGNATION SYSTEM
CLASSIFY MATERIAL ON THE BASIS OF COMPOSITION
CARBON AND ALLOY STEEL (EXCEPT STAINLESS STEEL)
13 Y 12X
CARBON %AGE
MATERIAL TYPE
PREFIX M OR E
Z
ADDITION OF ELEMENTS
SUFFIX H
- Carbon Steel10
- 1% Cr & 0.3% Mo Steel41
- Merchant Quality SteelM
- Electric Furnace SteelE
- BoronB
- LeadL
- HardenabilityH

44. AISI/SAE DESIGNATION SYSTEM
STAINLESS STEEL
3 16
No Specific Interpretation
MATERIAL TYPE
Z
Element addition
- Austenitic Stainless Steel2
- Austenitic Stainless Steel3
- Low Carbon (<0.03%)L
- High Carbon ContentsH
- Added NitrogenN
- Added CopperCu
- Martensitic & Ferritic4

45. ASTM STANDARDS
Ferrous Metals
DESIGNATION SYSTEM
ASTM A 182 / 182 M - 93b F 304LASTM A 182 / 182 M - 93b F 304L
Arbitrary Number
Metric System
Year of Revision
AISI NO
CLASSIFY PRODUCTS ON THE BASIS OF MANUFACTURING METHOD
MOST WIDELY USED SYSTEM – COVERS ALL DETAILS REQUIRED FOR MATERIAL
PROCUREMENT
Grade

46. ASTM STANDARDS
DESIGNATION SYSTEM
- Corrosion ResistantC
- Heat ResistantH
- Addition of MolybdenumM
- Carbon PercentageDigital No.
- PipeP
- TubeT
- Tube and PipeTP
- ForgingF
EXAMPLES
A 403/A 403M -93 WP304L
A 351 Grade HK40
A 336/A 336M-89 Class F22
A 351 Grade CF8M
- WroughtW

47. UNIFIED NUMBERING SYSTEM (UNS)
JOINT VENTURE AS ASTM AND SAE TO GENERATE UNIFIED COMPUTER FRIENDLY
SYSTEM
1040 1X
ELEMENT ADDITION
TYPE OF STEEL
AISI/SAE NUMBER
- Carbon and Alloy steelsG
- Cast IronsF
- Heat and Corrosion
Resistant Steels
H
- Boron1
- Lead4
- Electric Furnace Steel6

48. MATERIAL COMPOSITION
WHERE TO FIND
BLACK BOOK BY CASTII PUBLISHING (PDF FORMAT)
KEY TO STEEL (SOFTWARE)
ASTM STANDARDS

49. THE END

50. Cr – Mo STEELS

51. C .3%
Cr UP TO 30%
Ni UP TO 8%
C 0.3%
Cr UP TO 30%
Ni 0%
Ni UP TO 30%
Cr UP TO 30%
C 0.3%
C 1.2%
Cr UP TO 17%
Ni 0%

52. STAINLESS STEEL
CONCEPT OF SENSITIZATION
CHROMIUM CARBIDE (Cr23 C6)
CHROMIUM DEPLETED LAYER

53. MATERIAL CLASSIFICATION
FERROUS METALS
CAST IRON
LOW ALLOY STEEL
HIGH ALLOY STEEL
CARBON STEEL
LOW CARBON
HIGH CARBON
MEDIUM CARBON

54. STAINLESS STEEL
Ni UP TO 30%
Cr
UP TO 30%
C .3%
AUSTENITIC
STAINLESS STEEL
C 1.2%
MARTENSITIC
STAINLESS STEEL
Cr UP TO 17%
Ni 0%
C .3%
DUPLEX
STAINLESS STEEL
Cr UP TO 30%
Ni UP TO 8%
C .3%
FERRITIC
STAINLESS STEEL
Cr UP TO 30%
Ni 0%

55. AUSTENITIC STAINLESS STEEL
UN-STABILIZED GRADE
- SS 304
- SS 316
- 25 Cr – 22 Ni – 2 Mo
- 316L + G510
STABILIZED GRADE
- SS 321
- SS 347
Cannot Be Used for High
Temperature
Can Be Used for High
Temperature

56. SS – 304
18 Cr – 8 Ni
SS - 316
SS - 317
ADD Mo (2%)
FOR PITTING RESISTANCE
ADD MORE Mo (4%)
FOR PITTING RESISTANCE
ADD Nb
TO REDUCE SENSITIZATION
SS - 347
ADD Ti
TO REDUCE SENSITIZATION
SS - 321
LOWER C
SS - 317L
SS - 316L
SS - 304L
ADD Cr & Ni
STRENGTH & CORROSION RESIST.
SS – 310
SS - 309
AUSTENITIC STAINLESS STEEL

57. CARBON STEEL
CARBON STEEL
MEDIUM CARBON STEEL
HIGH CARBON STEEL
LOW CARBON STEEL CARBON CONTENTS < 0.3 %
CARBON CONTENTS BETWEEN 0.3 % AND 0.6%
CARBON CONTENTS BETWEEN 0.6 % AND 2.0%

58. OBJECTIVE

59. CARBON STEEL CLASSIFICATION
ACCORDING TO CARBON CONTENTS

60. SHAEFFLER DIAGRAM