New Developments in

Stainless SteelFor Sugar & Distillery Industry

Rajeev GuptaGM- Marketing

Jindal Stainless

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24-3-2018

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Agenda _________________________________________________________________

1. Stainless Steel- Industry Initiatives

2. Stainless Steel- Grades & Characteristics

3. Applications of Stainless Steel in Sugar Industry Equipments

4. Stainless Steel Usage - Best Practices

5. Q & A

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Stainless Steel Industry- Initiatives _________________________________________________________________

1. SS – Demo & Training Van

2. Portal for Stainless Steel Fabricators

3. New Applications

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1. Training & Demo Van _______________________________________________

Features-

1. All Interiors in Stainless Steel- PVD Walls & Roof, Chequered Floor, Cabinets, Internal Lighting

2. Welding & Finishing Equipments3. External Power Source/ Generator 4. Display Items – Miniatures, Furniture, Household Items5. Jindal Stainless Branding

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1. Training & Demo Van _______________________________________________

Objectives-

1. Supporting Customers Training- Fabricators, (Industrial, Household)2. Support Fabricators - Development of New Items3. Support - Concerns resolution4. Support for Road Shows

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2. Portal-Search Your Fabricators _______________________________________________

Features-1. Fabricators being added segment wise, product wise. – All Details2. Consumers can search fabricators product wise/ application wise; visualize products 3. Dealers/ Distributors can search fabricators for supply of material. 4. Fabricators can register themselves online. 5. Capture consumer contact details, interest in various products; connect them with

fabricators and also rate their services and leave comments

Stainless Steel Role of Alloying Elements

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What is Stainless Steel?Cross-and-Balls

Stainless steel is an alloy of iron (Fe) and chromium (Cr).

Iron Chromium

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What is Stainless Steel?Stainless Steel belongs to a family

of steels containing a minimum of

10.5% chromium.

A higher chromium content makes

stainless steel material more

resistant to corrosion.Chromium

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Effect of Chromium Content on Atmospheric Corrosion Resistance (uniform corrosion)

0 2 4 6 8 10 12 14 16% Chromium

0.025

0.050

0.075

0.100

0.125

0.150

0.175

0.200mmpyCorrosion Rate

Stainless Steels> 10.5 Cr %

Plain Carbon Steel

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Why Stainless Steel Does not Rust ?

Stainless Steel Surface Damage Self Repairing

SELF REPAIRING SURFACE

PASSIVE FILM on STAINLESS STEEL:Oxy-hydroxides of Fe and Cr

2-3 nm thick (0,002-0,003 µm)

TransparentAdherentSelf repairing

Oxygen

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Alloying Elements

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• Principal Elements– Ferritic/ Martenistic- Carbon + Chromium– Austentic/ Duplex …………………. + Nickel

• Other Elements-– Manganese/ Silicon– Molybdenum/ Niobium/ Titanium/ Tungsten/ Nitrogen

Nitrogen (N)• Enhances strength

and pitting and crevice corrosion

Molybdenum• Increases pitting and

crevice corrosion resistance caused by salt & pollution

Nickel (Ni)• Accentuate ductility,

toughness, and weldability

Chromium (Cr)• Improves Corrosion

Resistance

Iron (Fe)

Stainless Steel

Passive Film

< 10.5% Cr

>= 10.5% Cr

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The Solution

The estimated savings in annual replacement material costs due to upgrading with appropriate stainless steel grade can

go up to even 50%

Right Grade Of Stainless Steel

300 SeriesClassification Grade Major Applications

Austenitic Type

301L, 301 Railway rolling stock. Steel belt, metal gasket, springs

304, 304L Sundries, kitchen utensils, LNG tanks, others, Oil refinery and papermaking equipment

316/ 316L Chemical and paper industry equipment and VTR guide rollers

317/ 317L Chemical, paper, Dye and fertilizerIndustry equipment

321 Chemical, paper, Dye and fertilizerIndustry equipment

347 Chemical, paper, Dye and fertilizer Industry equipment

309, 309S, 310, 310S Furnace Parts, Burning Chambers, Concentrated Acid Tanks

Stainless Steel Grades

200 SeriesClassification Grade Major Applications

Austenitic Type

J4 Decorative trims, Pipes, Tubes for general non-corrosive usage, White goods, Polishing application, ABC Sector

JSL AUS General usage such as Kitchen, Furniture, Utensils, White Goods, suitable for Deep Drawing

204Cu 16% Cr grade, suitable for Utensils, White Goods, Polishing application, ABC Sector

201LN Cryogenic Vessels

201, 202 Recommended as replacement for 304 in low corrosive environments.

JSL TUBE Recommended for pipes & tubes, Flatware, Non-corrosive general application

Stainless Steel Grades

400 Series

Classification Grade Major Applications

Ferritic Type

409/ 409L Automotive parts and exhaust purifiers

409M Automotive exhaust pipes

430 Kitchen utensils, sundries, stove reflectors

410S Automotive exhaust gas purifiers and exhaust pipes

439 Bicycle rims & automotive parts such as wheel cover

436LM Automotive trim, muffler

441 Suitable for replacing 304 in most of the application

Stainless Steel Grades

400 SeriesClassification Grade Major Applications

Martensitic Type

410 Turbine blades, spoons, forks, Sundries and distillation columns trays

420 Machine parts, table knives

415 Hydro turbine components

JBS Razor Blades

Stainless Steel Grades

SUGGESTED GRADES OF SS DEPENDING ON APPLICATION

Ferritic/Ferritic-Martensitic

409M, 410, 439, 441

Mainly suitable for applications which require 1. Excellent oxidation and atmospheric corrosion resistance2. Very high abrasion resistance3. Very high wet sliding abrasion resistance 4. Higher thermal conductivity and excellent weldability5. Low maintenance and stable price and where corrosion allowance on thickness is not required.

Austenitic

304/L, 316L, J4, JSLAUS, 204Cu

Mainly suitable for applications involving 1. Higher corrosion due to the low pH of raw mixed juice 2. Presence of SO2 and other chemicals during processing.

Price Comparison

Considering the nature of service conditions, following table recommends suitable cost effective stainlesssteel grades. The following prices have been considered for the materials

MaterialMaterial Price Rs/Kg

Carbon Steel0.5X

409M Ferritic Stainless Steel0.7 X

J4 Austenitic Stainless Steel0.85 X

204Cu Austenitic Stainless Steel1 X

316L Austenitic Stainless Steel1.4 X

304 Stainless Steel1.2X

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3. New Applications _________________________________________________________________

1. Stainless Steel – Floors

2. Stainless Steel Cladding

3. Stainless Steel Conveyors

4. Stainless Steel Tanks

5. Stainless Steel Piping

Distillery Industry- SS Washbacks/ Distillery Tanks

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• Fermenting Vessels• Receiving Tanks• Cooling Vehicles• Pipes and Tubes• Storage• Floors

Sugar Industry- Life Cycle Cost

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• Surface Condition• Material Thickness• Presence of Deposits and

Corrosion– General– Pitting– Crevice – Galvanic

Sugar Industry- Sweet Success

• Two Main Raw Materials– Sugar Cane (2/3rd)– Sugar Beet (1/3rd)

• Harsh Conditions– Corrosion– Rapid Wear– Environment – Heat, Acidity etc.

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Conveyor _________________________________________________________________

LIFE CYCLE COST ANALYSIS

MOC Length Width ThicknessWeight (Kgs) Rate

Cost of Material Life Maint Cost

Material Loss/yr. Salvaging Cost

Life Cycle/year

MS 40000 2000 8 4992 40 199680 5 19968 2 19968 39936SS-J4 40000 2000 6 3744 115 430560 10 0 0.25 107640 32292

SAVINGS OVER EXISTING MATERIAL 19*all dimensions are approximate and converted to rectangular dimensions for ease of calculations.

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Mill House – Plates _________________________________________________________________

LIFE CYCLE COST ANALYSIS

MOC Length Width Thickness Weight (Kgs) RateCost of Material Life Maint Cost

Material Loss/yr.

Salvaging Cost Life Cycle/year

MS+SS 5000 3000 9 1053 70 73710 10 14742 2 7371 8108SS-J4 5000 3000 6 702 115 80730 10 0 0.25 20183 6055

SAVINGS OVER EXISTING MATERIAL 25*all dimensions are approximate and converted to rectangular dimensions for ease of calculations.

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Raw Juice Buffer Tank / Receiving Tanks/ Sulphiter Juice Tanks _________________________________________________________________

LIFE CYCLE COST ANALYSIS

MOC Length Width Thickness Weight (Kgs) RateCost of Material Life Maint Cost

Material Loss/yr.

Salvaging Cost Life Cycle/year

MS 6000 3000 10 1404 40 56160 8 8986 2 5616 7441SS-J4 6000 3000 6 842 115 96876 14 0 0.25 24219 5190

SAVINGS OVER EXISTING MATERIAL 30*all dimensions are approximate and converted to rectangular dimensions for ease of calculations.

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Piping _________________________________________________________________

LIFE CYCLE COST ANALYSIS

MOC Length WidthThickne

ssWeight (Kgs) Rate

Cost of Material Life

Maint Cost

Material Loss/yr.

Salvaging Cost

Life Cycle/y

earMS 100000 500 6 2340 40 93600 2 3744 2 9360 43992

SS-J4 100000 500 6 2340 115 269100 6 0 0.25 67275 33638SAVINGS OVER EXISTING MATERIAL 24

*all dimensions are approximate and converted to rectangular dimensions for ease of calculations.

Ideal Material Characteristics

Corrosion and erosion resistance

Abrasion resistance -Particularly resistant to wet abrasion

High strength and light weight

Good fabricability• Welding• Bending• Cutting & Shearing• Forming

Good white colouration

Availability at affordable cost

What is Stainless Steel?

• Corrosion resistant,

• Exceptional hygienic properties,

• Amongst the easiest materials to fabricate products with,

• Excellent cryogenic properties,

• Stronger than carbon steels,

• Lifespan of many times that of carbon steel products, low maintenance,

• 100 % Recyclable,

• Non-toxic.

Why use Stainless Steel?

Solution Stainless Steel -Ferritic Grades

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Sugar Industry- Ni/ Cr

• Nickel– Corrosion Resistant Ingradient– Austenitic- 300 Series– Expensive

• Chromium– Ferritic- 400 Series– Upstream Processes

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Sugar Industry- 410 Grade

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• Utility Grade- 410– May develop rust coloured

patina– Doesn’t affect structural

integrity– Is not a problem where

aesthetic beauty is not a concern

• For more corrosive applications– Higher Alloyed Ferritics– Contains Ti, Nb, Mo

Ferritic Grades- Cane Sugar processing

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Ferritic Grades- Beet Sugar Processing

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Case Studies

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Sugar Industry- Ferritic Grades

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Properties Requirement for Sugar Industry EquipmentProcess Properties Requirement

Raw Cane handling Corrosion abrasion resistanceExcellent Slideability, improved flowMaintenance FreeLong Service lifeGood forming and Fabrication characteristics

Pressure Feed Mill and Diffusers Abrasion protectionMechanical strengthScaling and oxidation resistance

Bagasse handling Corrosion abrasion resistanceExcellent Slideability, improved flowMaintenance FreeLong Service lifeGood forming and Fabrication characteristics

Juice Production and Handling Resistance to acidic conditionsCorrosion resistance

Downstream operations Resistance to aggressive corrosive conditionsExcellent performance under heated conditionsWide range of material forms to suit designrequirementsMaintenance free

Recommended stainless steel grades for different equipment in sugar industryItem Factors Recommended 200/300

Series Grades Recommended Ferritic Grades

Cane Carrier and cane table Wear due to abrasion, andcorrosion J4 409M, 410

Fibrizer Hood Wear due to abrasionJ4 409M, 410

Rake type inter carrier,wear pads of trough andrakes

WearJ4 410, 409M

Mill imbibition piping Corrosion204Cu 439

Donnely chutes CorrosionJ4 410

Juice pump body impellers Corrosion, abrasion204Cu 439

Mill juice gutters Corrosion204Cu 439

Whirler Tanks, screenedjuice and unscreened juice

Corrosion, sugar qualityJ4-16 Cr, 204Cu 439, 441

Bagasse carrier trough CorrosionJ4 410, 409M

Sugar cane juice ductsCorrosion

204Cu 439, 444

Clarifier mud scrapers Abrasion, corrosionJ4 410, 409M

Juice sulphiter Corrosion316 L 444

Recommended stainless steel grades for different equipment in sugar industryItem Factors Recommneded 200/300

Series Grades Recommended Ferritic Grades

SO2 gas pipeline Corrosion 316 L 444Sulphited juice line Corrosion 204Cu 439Gas cooler Corrosion and Erosion 316L 444Pre-evaporator tubes( 1st and2nd process)

Corrosion204Cu 439

Pre-evaporator tubes( 3rd and5th process)

Corrosion316L 444

Evaporator pipes to condenser Corrosion 316L 444Condensers Corrosion 316L 444Centrifugal Machine casing Corrosion/ erosion J4 409M, 410Sugar Bins Corrosion, Erosion J4 409Sugar Hoppers Erosion, corrosion J4 409MMolasses Gutters Erosion, Corrosion J4 409M

Horiziontal and VerticalCrystallization Unit

Erosion, corrosion204Cu 439

DryersCorrosion 204Cu 439

Syrup tankCorrosion 204Cu 439

Performance of various grades

Benefits

Substantial improvementin the Life

of equipment

Reduction in

discolorationof Sugar

Savings in Repair and Repainting

costs

Weight reduction

of equipment

Reduction in

Breakdown

Stainless Steel Usages-Best Practices

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SS Finish

A Pattern Created on Stainless Steel for Aesthetic cum Functional reasons is known as Finish. It is either;

1. Transferred2. Mechanical3. Blasted

Bad Polishing

Good Polishing

Environment

Deicing Salt exposure

Local Weather Pattern

Design Considerations

Maintenance Schedule

Embossed patterns 9

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Coloured finishes4, 5,7

This is only a selection of the colour effects that can be produced by electrolytically colouring stainless steel

Basics of Grinding

• Start with Coarse Grit – 40• Do not jump Grits – like 40 – 120, use intermediate

Grits to cover coarse grinding marks – like 40, 80, 120

• Decide your shape and choose the correct Tool• Do Not use ONE Tool for all shapes

Picklingwith mixed nitric – hydrofluoric acids

Before After

It is advisable not to locate stainless steel elements in such locations.

If you must use stainless steel, make sure a regular cleaning regimen is mandated.

Avoiding Iron contamination is the Biggest Difference

If you choose the right grade and fabricate it properly, you can do more with stainless steel

than you can with carbon steel

Grinding wheels should be dedicated for use only on stainless steel; Do not ever use them on carbon steel.

Use only stainless steel brushes

Original Appearance

Carbon Steel being cut nearby

Sparks of carbon steel rain on stainless steel product

End Result

Use wood or plastic separators on shelves. Mild steel shelves should not be in direct contact with stainless steel

Do not mark with crayon on bare sheets. Mark on Polythene

protective sheets

NiDI

NiDI

NiDI

Bad Fit-up

Three commonmistakes.

NiDI

Good Fit-up

NiDI

Avoid Distortion

First welds

NiDI

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Thank You