MATERIAL SCIENCE (ECH 3101)

SEMESTER 1 2019/2020
REPORT TITLE:
MATERIAL FOR CONSTRUCTION OF CRUDE
ACETIC ACID TANK
Lecturers : Dr Mohd Yusof bin Harun
Group’s Name : Unity Sdn Bhd

Group Members Matric No.

Tan Shu Jia 200518
Sneeha Shanmugam 200967
Nur Adleena Ezzaty Binti Md Noor 200368
Table of Content

No. Content Pages

1. Material Suitability 2

2. Cost 3

3. External Factors 4

4. Concern and Limitations of Type 304L stainless steel 5

5. Alternative Material & Comparison with Selected Material 6

6. References 7&8

7. Appendix
Appendix A: Chemical Composition of Selected Material 9
Appendix B: Properties of Selected Material 10

1
1.0 Material Suitability

The process unit selected is crude acetic acid tank, which serve the function as
a temporary storage tank before the crude acetic acid is directed to the next section
of the process line, which is the distillation column.

The material that is suitable for the construction of the crude acetic acid tank is
Type 304L stainless steel. [1] SS304L is an extra-low carbon variation of SS304 with
a maximum of 0.03% carbon content in the alloy. The chemical composition of the
alloy and comparison with SS304 is shown in Table A.1 and Table A.2 in Appendix A.
SS304L is chosen because the low carbon content of this alloy effectively prevents
the carbide precipitation due to welding, which may eventually lead to intergranular
corrosion at grain boundaries that weakens the alloy. Thus, SS304L can be used in
“as welded” condition in severe corrosive conditions. [2] It also has high corrosion
resistance towards most of the organic and inorganic acids, thus suitable be used in
constructing crude acetic acid tank.

In addition, this alloy does not need annealing since the pressure applied in the
crude acetic acid tank is 1 bar. Annealing is only necessary in high stress application.
Besides that, SS304L is very ductile and can be readily formed and drawn cold working.
Therefore, it can be formed into complex shapes by common forming fabrication
method, such as rolling.

As noted in AK Steel data sheet, SS304L has great oxidation resistance up to

1690 ̊F (899 ̊C) in continuous exposure, while in periodic service, is about 1500 F
̊
(816 ̊F). SS304L also performs excellent low-temperature properties. For example, the
tensile strength is higher in lower temperature (510 MPa at 100 C
̊ ) compared to at
higher temperature (20MPa at 1100 ̊C). In the crude acetic acid tank, the continuous
temperature exposure is maintained at 20 ̊C, which totally suits the properties of
SS304L.

According to North American Stainless Steel Grade Sheet, SS304L can also
be stress-relieved at 850 ̊F to 1100 ̊F for 1 hour with little danger of sensitization, which
avoid the carbide precipitation at grain boundaries that may cause the alloy be
susceptible to intergranular corrosion.

2
2.0 Cost

According to Alibaba.com [3], Shanghai Jeepan Industrial Co., Ltd. sells SS304L strips
at price range from $1800 (RM 7454.16) to $2500 (RM 10353.00) per ton with custom
width, length and thickness according to customer’s requirements. The average price
is $2150 (RM 8905.30) per ton. An assumption of the capacity of crude acetic acid
tank based on industrial scale can be made to estimate the cost of constructing the
particular process unit.

Assume the crude acetic acid tank is in cube-shaped, with a volume of capacity
1000m3 :

Total Surface Area of Cube = 6 x 10m x 10m

= 600m2

Assume the thickness of a standard crude

10m acetic acid tank is 3mm.

10m Volume of SS304L strips needed

= 600m2 x 0.003m
10m
= 1.80m3

Mass = Density x Volume

= 8.0 g 1.80 m3 1 kg 0.001 ton 10^6 cm3
cm3 1000 g 1 kg 1 m3
= 14.4 ton

Cost = Price per ton x Mass

= $ 2150 per ton x 14.4 ton
= $ 30960

Therefore, the estimated cost for a 1000m3 SS304L crude acetic acid tank is $30960,
which is approximately RM 128236.32. It shows that the cost of constructing an
industrial crude acetic acid tank using SS304L is quite expensive.
3.0 External Factors

Although SS304L is versatile and performs a wide range of excellent properties, there
are some external factors such as temperature, relative humidity and air pollution that
can affect the performance of this alloy.

(A) Temperature

The mechanical properties, such as ultimate tensile strength (UTS) and ductility
(showed by % elongation), of SS304L decreases significantly with increase in
temperature. As noted in North American Stainless Steel Grade Sheet, the strength
value of SS304L falls rapidly at temperature above 425 ̊C.

(B) Relative Humidity

Corrosion is the deterioration of a metal as a result of chemical reactions between it

and the surrounding environment, especially with oxygen. When iron reacts with water
in the air, iron oxides or rust will form which eventually destroys the metal. [4] Although
SS304L is highly resistant to corrosion, it will experience atmospheric pit corrosion
(small areas of localized corrosion) under continuously exposure to a 33% relative
humidity with MgCl2 droplets, a common constituent in marine aerosol. This concern
must be take into account if the factory is built near coastline. [5] At Seri Kembangan,
Selangor, the mean monthly relative humidity is around 80%. This does not affect the
performance of SS304L because it is very corrosion resistance in non-marine
atmosphere.

(C) Air Pollution

Heavy air pollution in some of the industrial locations may have significant impact on
the SS304L. [6] The presence of sulphur oxides (SOx), nitrogen oxides (NOx),
hydrogen sulphide, ammonia, carbonyl sulphide (COS) and other pollutants in the
atmosphere lead to the occurrence of acid rains. As a result, it will cause the deposition
of those pollutants on the alloy surface (or in other words in electrolyte), therefore
cause the atmospheric corrosion of the alloy. [7] According to the data adapted from
Air Pollutant Index of Malaysia, the API of Putrajaya, the nearest district to Serdang,
is around 50, which is at good level. Therefore, SS304L is suitable to use to construct
the crude acetic acid tank if the factory is located at this area since the concentration
of air pollutants is low and would not cause atmospheric corrosion of the alloy.

4
4.0 Concern and Limitations of Type 304L Stainless Steel

SS304L has a short life usage compared to the other types of stainless steel.
[8] The maximum usage years of SS304L is 10 years. This means that after 10 years,
we will have to replace the current storage tank to a new one. This can be a hassle
because replacing a storage tank is not an easy job as it involves a high cost and man
work.

Besides that, SS304L can be easily cracked due to the internal stress. Internal
stress is normally applied to the SS304L when there are works that require heat
treatment. The internal stress can be caused by bending and welding. Stainless steel
is more likely to crack, due to this internal stress.

Next, SS304L can turn into golden brown colour after exposed to heat. This
factor depends on the location the storage tank is placed in a chemical plant. If the
storage tank is placed under sunlight (a form of continuous supply of heat), the storage
tank can turn into golden brown. As a result, we will have to replace the current storage
tank to a new one. If the storage tank is placed in an interior chemical plant-based
location, the storage tank has to fit well inside the confined space to not create any
hassle to the chemical plant owners.

On the other hand, [9] SS304L does not have the chloride resistance as other
stainless steels because it does not contain molybdenum. This factor is quite a
disadvantage because the presence of chloride as impurities in the working
environment can corrode the SS304L. Solutions with minimum concentration of 25
ppm of sodium chloride can begin to corrode the alloy. As a result, the end product will
contain impurities too. In order to avoid this problem, it has to be ensured that there is
no form of chlorides present in the compound that enters the SS304L storage tank.

Furthermore, [10] SS304L that is required to build storage tanks can have a
higher shipping cost compared to any other products. This is due to the heavier weight
of the stainless steel than any other products. Tax charges on stainless steel could
also vary compared to other products due to its heavier weight.

5
5.0 Alternative Material & Comparison with Selected Material

The alternative material that is suitable for the construction of crude acetic acid tank
is High-Density Polyethylene (HDPE), one type of polymer. [11] HDPE is preferable to
construct the crude acetic acid tank because it has good chemical resistance and do
not reactive with the acetic acid so it will not cause any production of other products.
[12], [13] Table below shows the comparison of some properties between HDPE and
SS304L.

Component HDPE SS304L

HDPE tend to absorb
chemicals such as oil,
grease, and even some
solvents. This will discolor
Absorption Factor the plastic and can be a
problem for sanitary
applications. For example,
if enough residue is
accumulated, it could be
transferred to parts during a
wash process.
The melting point of HDPE
is around 260 ̊F, which
means that it will lose a
Melting Point
significant portion of its
(̊F) tensile strength well before
hitting that temperature.
Density Lower density
3 3
(g/cm ) (1-1.3 g/cm )
Ultimate Tensile Strength Low tensile strength
(MPa) (24-80)
Specific heat capacity Higher specific heat
(J/kg-K) capacity (1330 to 2400)
Elongation at break (%) Bigger range (2.5-100)
Mechanical Temperature Low (90)
( ͦC)
Stainless steel is much less
absorbent than polymer,
which makes it easier to
sanitize for applications that
require clean conditions. In
addition, steel can be heat-
sanitized without causing
damage to it.
Stainless steel, which can be
used in temperatures of up to
1600 ̊F without losing tensile
strength.
Higher density
3
(8.0 g/cm )
Higher tensile strength
(580-1180)
Low specific heat capacity
(480)
Smaller range (8-43)
Higher (710)

6
References

[1] Bell, T. (2019, January 25). Learn About the Difference Between Types 304 and
304L Stainless Steel. Retrieved from https://www.thebalance.com/type-304-
and-304l-stainless-steel-2340261.

[2] Advantages and Disadvantages on 304 Stainless Steel - Industry News - News
Center - 304 stainless steel sheets. (n.d.). Retrieved from
http://www.shscov.com/index.php?c=msg&id=303&.

[3] 304 304l Stainless Steel Strips Price Per Kg - Buy 304l Stainless Steel
Strips,Stainless Steel Strips 0.7mm,Stainless Steel Strips Price Per Kg
Product on Alibaba.com. (n.d.). Retrieved from
https://www.alibaba.com/product-detail/304-304L-Stainless-Steel-Strips-
Price_60800582852.html?spm=a2700.7724838.2017115.144.450d439aLaiM
oW.

[4] Guo, L., Street, S. R., Mohammed-Ali, H. B., Ghahari, M., Mi, N., Glanvill, S., …
Davenport, A. J. (2019). The effect of relative humidity change on
atmospheric pitting corrosion of stainless steel 304L. Corrosion Science, 150,
110–120. doi: 10.1016/j.corsci.2019.01.033

[5] Average monthly humidity in Seri Kembangan (Selangor), Malaysia. (n.d.).

Retrieved from https://weather-and-climate.com/average-monthly-Humidity-
perc,seri-kembangan-selangor-my,Malaysia.

[6] Penflex. (2019, July 25). Environmental Corrosion of Stainless Steel. Retrieved
from https://www.penflex.com/environmental-corrosion-of-stainless-steel/.

[7] Regional Haze Situation. (2019, December 16). Retrieved from

http://apims.doe.gov.my/public_v2/home.html.

[8] Pump, P. (2018). What is the difference between 304 & 316L Stainless Steel?
(pp. 3–5). pp. 3–5.

[9] Reliance Foundry. (2017). 304 vs 316 Stainless Steel | Metal Casting Blog.
Retrieved from http://www.reliance-foundry.com/blog/304-vs-316-stainless-
steel#gref

[10] Stainless Steel Vs Plastic Storage Tanks - HPI Process, Inc. (n.d.). Retrieved
from http://www.hpipro.com/blog/things-know-stainless-steel-vs-plastic-
storage-tanks/

7
[11] HDPE (High Density Polyethylene). (n.d.). Retrieved from
https://www.upcinc.com/resources/materials/HDPE.html.

[12] Steel, M. (n.d.). Comparing HDPE to Stainless Steel for Parts Washing Baskets.
Retrieved from https://www.marlinwire.com/blog/hdpe-vs-stainless-steel

[13] Iron Alloy. (n.d.). AISI 304 Stainless Steel vs. HDPE. Retrieved from
https://www.makeitfrom.com/compare/AISI-304-S30400-Stainless-Steel/High-
Density-Polyethylene-HDPE.

8
APPENDIX A: Chemical Composition of Selected Material

Table A.1: Standard Chemical Composition of SS304L

% Present
Element
Min Max
Carbon (C) 0.030
Manganese (Mn) 2.000
Phosphorus (P) 0.045
Sulphur (S) 0.030
Silicon (Si) 1.000
Chromium (Cr) 18.00 20.00
Nickel (Ni) 8.00 12.00
Source: “Long Products Stainless Steel Grade Sheet” by North American Stainless.
Retrieved from https://www.northamericanstainless.com/wp-
content/uploads/2010/10/Grade-304-304L.pdf

Table A.2: Comparison of Chemical Composition between SS304 and

SS304L

Composition SS304 (wt%) SS304L (wt%)

Carbon (C) 0.08 max 0.03 max
Manganese (Mn) 2.00 max 2.00 max
Phosphorus (P) 0.045 max 0.045 max
Sulphur (S) 0.030 max 0.030 max
Silicon (Si) 0.75 max 0.75 max
Chromium (Cr) 18.00 – 20.00 18.00 – 20.00
Nickel (Ni) 8.00 – 12.00 8.00 – 12.00
Nitrogen (N) 0.10 max 0.10 max
Iron (Fe) Balance Balance
Source: “304/304L Stainless Steel” by AK Steel. Retrieved from
https://www.aksteel.com/sites/default/files/2018-01/304304L201706_1.pdf

9
APPENDIX B: Properties of Selected Material

Table B.1: Properties of SS304L

Properties Value
Density 8.0 g/cm3
Tensile Strength, Ultimate 564 MPa
Tensile Strength, Yield 210 MPa
Elongation at Break (in 50mm) 58%
Modulus of Elasticity 193 GPa- 200 GPa
Hardness, Knoop 158
Magnetic Permeability 1.008
Specific Heat Capacity 0.5 J/g C
̊
Melting Point 1400 ̊C – 1450 C
̊
Source: ASM Aerospace Specification Metals Inc. Data Sheet. Retrieved from
http://asm.matweb.com/search/SpecificMaterial.asp?bassnum=MQ304L.

Table B.2: Mechanical Properties of Annealed SS304 at Elevated

Temperature
Temperature ( ̊C)
Property 100 300 500 600 700 800 900 1000 1100
Tensile 510 435 410 360 245 135 75 40 20
strength
(MPa)
0.2% Proof 220 145 125 110 95 70
Stress (MPa)
Elongation 52 40 36 35 35 37 42 73 96
(% in 50mm)
Source: “Long Products Stainless Steel Grade Sheet” by North American Stainless.
Retrieved from https://www.northamericanstainless.com/wp-
content/uploads/2010/10/Grade-304-304L.pdf

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