Chinese Southeast Asia Hydrometallurgical Chemical Project
Project Overview
A hydrometallurgical chemical processing project in Southeast Asia required specialized corrosion-resistant materials for a new production line handling chloride-containing acidic slurry.
The processing environment presented significant corrosion challenges for chemical equipment, particularly in reaction tanks, exhaust gas scrubbers, precision heat exchangers, and slurry transportation pipelines.
To address these requirements, the project specified a combination of 2205 duplex stainless steel, 904L super austenitic stainless steel, and Hastelloy C276 nickel-based alloy for different processing equipment.
The material supply also included 2205 seamless stainless steel pipes and Monel 400 round bars for slurry pipelines and agitator shaft components.
All supplied alloy materials were required to undergo solution treatment, pickling, and pitting corrosion verification to support local chemical safety inspection and equipment acceptance.
Project Requirements
The hydrometallurgical production process involved acidic slurry containing chloride ions, creating demanding operating conditions for metallic materials.
The project required a reliable alloy material supply solution that addressed several key engineering challenges:
- Corrosion Resistance: Materials suitable for chloride-containing acidic slurry and chemically aggressive operating environments.
- Material Selection: Different stainless steel and nickel alloy grades for reaction tanks, gas scrubbers, heat exchangers, and mechanical components.
- Quality Verification: Solution treatment, pickling, and pitting corrosion testing according to project requirements.
- Welding Performance: Materials with suitable welding characteristics for chemical equipment fabrication.
- Corrosion Allowance: Material performance meeting the design corrosion allowance under specified operating conditions.
- Project Acceptance: Material quality supporting local chemical safety inspection requirements.
These requirements called for an integrated supply of duplex stainless steel, super austenitic stainless steel, and nickel-based corrosion-resistant alloys.
Steel & Alloy Material Supply Details
The project involved five categories of corrosion-resistant metal products supplied for chemical processing equipment and associated piping systems.
| Material | Specification | Grade / Standard | Quantity |
|---|---|---|---|
| Duplex Stainless Steel Plate | 14 × 1800 × 8000 mm | S32205 (2205) / ASTM A240 | 64 Tons |
| Super Austenitic Stainless Steel Plate | 10 × 1500 × 6000 mm | 904L / ASTM A240 | 31 Tons |
| Nickel Alloy Plate | 6 × 1250 × 6000 mm | Hastelloy C276 / ASTM B575 | 7.2 Tons |
| Duplex Stainless Steel Seamless Pipe | Φ88.9 × 4.0 mm, 6 m fixed length | 2205 / ASTM A789 | 13 Tons |
| Nickel-Copper Alloy Round Bar | Φ40 mm | Monel 400 / ASTM B164 | 4.5 Tons |
Project Material Solutions
1. 2205 Duplex Stainless Steel for Reaction Tanks and Slurry Pipelines
The project used S32205 (2205) duplex stainless steel plates for reaction tanks operating in chloride-containing chemical processing environments.
With its combination of austenitic and ferritic microstructures, 2205 duplex stainless steel offers high mechanical strength and resistance to localized corrosion in appropriately selected service environments.
The material package included:
- 64 tons of 2205 duplex stainless steel plates
- 13 tons of 2205 duplex seamless stainless steel pipes
The seamless pipes, manufactured according to ASTM A789, were supplied in fixed 6-meter lengths for slurry transportation lines.
The combination of duplex stainless steel plates and seamless pipes supported both equipment manufacturing and associated process piping requirements.
2. 904L Super Austenitic Stainless Steel for Exhaust Gas Scrubbers
The exhaust gas scrubbing system required materials capable of handling corrosive chemical process conditions.
For this application, 904L super austenitic stainless steel plates were selected.
904L stainless steel is a high-alloy austenitic grade containing nickel, chromium, molybdenum, and copper, offering corrosion resistance in a range of acidic environments.
A total of 31 tons of 904L stainless steel plates were supplied in 10 × 1500 × 6000 mm specifications according to ASTM A240.
The material supported fabrication of exhaust gas scrubbing equipment requiring corrosion-resistant construction.
3. Hastelloy C276 for Precision Heat Exchangers
Precision heat exchangers operating in aggressive chemical environments require careful material selection to address corrosion risks.
The project specified Hastelloy C276, a nickel-molybdenum-chromium alloy recognized for its resistance to various corrosive chemical environments.
A total of 7.2 tons of C276 alloy plates were supplied in 6 × 1250 × 6000 mm specifications according to ASTM B575.
The use of C276 supported the project’s requirements for corrosion-resistant heat exchanger components exposed to demanding process media.
4. Monel 400 Round Bars for Agitator Shaft Components
In addition to stainless steel plates, pipes, and nickel alloy plates, the project required material for agitator shaft manufacturing.
A total of 4.5 tons of Monel 400 nickel-copper alloy round bars were supplied in Φ40 mm specifications according to ASTM B164.
These round bars were intended for further machining into agitator shaft components used in the chemical processing system.
Quality Control and Material Verification
Material quality was a critical consideration for this hydrometallurgical project because of the corrosive operating environment.
The project required the alloy materials to meet specified processing and corrosion verification requirements.
Solution Treatment and Pickling
The alloy materials underwent the specified solution treatment and pickling processes to support the required material condition and surface quality.
Pitting Corrosion Verification
Pitting corrosion testing was required to verify material suitability against the project’s acceptance criteria.
This was particularly important for the chloride-containing processing environment, where localized corrosion represented a major operational risk.
Welding Performance
The supplied alloy materials demonstrated stable welding performance during equipment fabrication, supporting manufacturing of the reaction tanks, scrubbers, heat exchanger components, and associated process systems.
The completed material inspection and processing requirements helped support local chemical safety acceptance.
Project Results
The material supply package successfully supported the construction and commissioning of the hydrometallurgical chemical production line.
The project achieved the following results:
- Qualified Material Processing: Alloy materials met the specified solution treatment and pickling requirements.
- Corrosion Verification: Pitting corrosion performance satisfied the project’s testing criteria.
- Stable Welding Performance: The supplied materials supported equipment fabrication and welding operations.
- Design Compliance: The alloy materials satisfied the specified design corrosion allowance for the chloride-containing acidic slurry conditions.
- Successful Commissioning: The hydrometallurgical production facility was successfully commissioned and entered stable operation.
By integrating multiple corrosion-resistant steel and nickel alloy grades into one material supply package, the project met the requirements of several chemical equipment applications.
Project Value Delivered
This Southeast Asian hydrometallurgical project demonstrates the importance of selecting appropriate alloy materials for aggressive chemical processing environments.
Through coordinated material supply and quality verification, the project benefited from:
- Integrated procurement of 2205, 904L, C276, and Monel 400 materials.
- Different alloy grades matched to specific equipment applications.
- Material processing and corrosion testing aligned with project requirements.
- Reliable fabrication support for reaction tanks, gas scrubbers, heat exchangers, and slurry pipelines.
- Successful equipment commissioning under challenging chemical processing conditions.
Corrosion-Resistant Alloy Solutions for Chemical Processing Projects
We supply stainless steel and specialty alloy materials for chemical processing, hydrometallurgy, and industrial equipment manufacturing projects.
Our product range for related applications includes duplex stainless steel plates and pipes, super austenitic stainless steel, nickel-based alloy plates, and nickel-copper alloy round bars.
Whether the project involves corrosive slurry transportation, chemical reaction equipment, exhaust gas treatment, or specialized heat exchanger systems, we support project-based material sourcing based on the required grades, dimensions, standards, and quantities.
Looking for corrosion-resistant materials for your next chemical processing project?
Contact us with your material specifications, operating requirements, and procurement list to discuss suitable stainless steel and specialty alloy supply options.
