CH3031 Material Selection Syllabus:
CH3031 Material Selection Syllabus – Anna University Regulation 2021
COURSE OBJECTIVES:
To understand various degradation mechanism that engineers’ face in chemical plants
To mitigate with right choice metallurgy or chemical solution or operational changes
UNIT I CORROSION
Different Degradation Mechanism as seen in various Chemical process industries, Corrosion (wet H2S, Naphthenic acid bearing Crude Processing, CO2 stress corrosion cracking, polythionic acid formation potential, amine stress corrosion cracking, microbiologically induced corrosion, corrosion under insulation, galvanic corrosion, caustic embrittlement, introduction & diffusion of hydrogen, Chloride stress corrosion cracking, etc.) ;Monitoring and prevention, NACE (National Association of Corrosion Engineers) guidelines, Life Cycle Cost Optimization and right MOC (Material of construction), Trade-off between MOC Vs Chemical inhibitors / Additives Solutions ;‘NO HARM’ requirements in chemical solutions, Operation within ‘best operating zone’, Corrosion coupons and test methods in lab, Need & challenges in asset Integrity management, Coatings, Leak Detection & Repair. Case Studies – From Industries on operational excellence viz. Trouble shooting, Efficacy of chemicals, Processing different feedstocks with confidence, Design tips, Safety & Environmental Incidents, etc.
UNIT II ASSETS RELIABILITY ENHANCEMENT & INCIDENT ELIMINATION
Risk envelope, Inputs on FERT (Fire, Explosivity, Reactivity and Toxicity), Quantification of unplanned interruption viz. impact on Safety, Environment and Loss of properties / business erosion, Early Event Detection using AI / ML, Surface Chemistry, Advanced Lab Techniques (SEM – Scanning Electron Microscopy, Corrosion probes, Field Signature Method, Non-intrusive techniques, Ultimate Analysis, Atomic ratios on debris, Tell-Tale Indications, etc.), Case Studies – From Industries on process / equipment reliability viz. Asset integrity, Asset sweating within safe operating window, Design errors, Safety & Environmental Incidents, Human factors, etc.
UNIT III FLOW AND ACOUSTIC INDUCED VIBRATION IN PIPES
Flow Induced Vibration in pipes: Flow regimes – Slug flow, plug flow, annular, dispersed, etc. Flows in Vertical and Horizontal pipes, Design criticalities in two phase (gas & liquid) and slurry flow (solid and liquid), Handling of steam condensate& prevention of water hammering, Piping Configurations for symmetrical flow distribution, Use CFD (Computational Fluid Dynamics) to assess – selective erosion in some section of pipes, cycling pattern of vibration, heat flux or fluid film temperature variation in heater tubes, etc., Suitability of Material of Constructions for different operating severity and feed stocks including changes in process conditions during start up, shut down, catalyst pre-sulphating, etc. Acoustic induced vibrations in pipes due to high velocity gas streams in pipes (Near sonic velocity conditions). Case Studies – From Industries on operations & maintenance aspects viz. Trouble shooting and controlling flow regimes to avoid vibration, Design tips, Safety & Environmental Incidents, etc.
UNIT IV FOULING AND COKING
Asphaltenes precipitation, Wax deposits, Gum formation, Ageing of hydrocarbon on prolonged storage and filter plugging ;Dewatering and prevention of ingress of corrosion products leading to fouling, dead zone (stagnant) prevention, Inserting storage tanks to avoid oxidation induced feed / product degradation, Incompatibility of mixing, Shear stress assessment, Assessment of Coke precursors and elimination / removal during processing ;Chemical (anti-foulant) additives to mitigate fouling / coking, process variables impacting fouling specially in exchangers, heater pipes and column internals, Methods of decoking – steam-air decoking, mechanical, pigging and spalling ;Use of quench oil in gas / naphtha cracker heaters to keep asphaltenes in suspension, polymerisation prevention, hypothesis on coking viz. pyrolytic coke, filamentous coke, amorphous coke formation, etc. Case Studies – From Industries on operational excellence viz. Trouble shooting, Efficacy of chemicals, Processing different feedstocks with confidence, Design tips, Safety & Environmental Incidents, etc.
UNIT V ADVANCEMENT IN MATERIAL SCIENCE
Academy to list the course content including use of graphene, metal organic framework, super conductors, replacement of Lithium for battery making, etc. In addition, Nano materials, there are lot more efforts needed to minimize dependence on import for some of the metals used in catalyst, defence needs, etc. which can only be substituted with effective end application needs and metallurgy and or alloy use. Case Studies – From market and strategic needs.
TOTAL: 45 PERIODS
OUTCOMES:
On completion of the course, the students will be able to
CO1 – understand the basic concept on corrosion and their types in chemical industry
CO2 – know the degradation mechanism that engineers’ face in chemical plants
CO3 –recognize the different flows in pipes and their acoustic induced vibrations
CO4 – gain knowledge in the concept of fouling in pipes and different methods of decoking
CO5 – gather some knowledge on advancement in material science usage.
TEXTBOOKS
1. Corrosion Mechanisms (Chemical Industries) – Florian Mansfeld
2. Organic Chemicals in the Environment Mechanisms of Degradation and Transformation – Alasdair H. Neilson, Ann-Sofie Allard
REFERENCE BOOKS
1. NACE documents – American Petroleum Institute (API) 571 standards