How Improper Material Selection Impacts the Chemical Industry

In a conversation with Industry Outlook magazine, Rohit Ojha shared his insights on consequences impacting operational efficiency, strategies to minimize disruptions and associated expenses, implementation measures to prioritize safety in material selection, how proactive material choices align with sustainability goals and more.

What are the potential long-term consequences that the chemical industry may face due to improper material selection, and how do these consequences impact operational efficiency, safety, and overall sustainability?

In the chemical industry, choosing the wrong materials can have consequences on operational efficiency, safety, and overall sustainability. These include premature equipment failures, or wear and tear leading to unplanned downtime, disrupted production schedules, and increased maintenance costs. 

Moreover, using incompatible materials for storage, tubes, or piping can trigger leaks, fires etc. It can also cause environmental pollution by releasing hazardous chemicals or generating waste that is difficult or expensive to treat. Furthermore, it can hinder sustainability efforts due to the potential increase in energy consumption, waste generation, and the utilization of non-renewable resources.

That is why it is important to choose the right material for your chemical operations. Take ourSanicro® 35, for instance. The grade combines the best features of a super austenitic stainless steel and a nickel alloy. It has excellent corrosion resistance, for service in highly corrosive environments, contributing to an extended lifecycle of the material used.

How can chemical industry professionals enhance risk assessment and mitigation strategies during the material selection process to prevent incidents related to corrosion, chemical reactions, or material degradation over time?

This would involve thoroughly evaluating material properties, including corrosion resistance, chemical compatibility, and long-term performance under expected operating conditions. Potential failure modes should also be identified and evaluated by considering stress, temperature, and chemical exposure. Optimal product selection is ensured by choosing a reliable and experienced partner who is committed to research and development for superior materials.

Additionally, inspection and maintenance programs should be established to monitor material integrity and address any signs of degradation or wear.

What are the environmental and regulatory implications associated with improper material selection in the chemical industry, and how can proactive material choices align with sustainability goals and compliance with industry regulations?

The improper selection of materials can result in environmental consequences caused by the release of hazardous chemicals, air and water pollution, soil contamination, and harm to delicate ecosystems. Failure to adhere to environmental regulations can result in hefty fines, penalties, and legal action. These can also tarnish a company's reputation, leading to loss of business and distrust by customers, investors and industry.

To mitigate these risks, companies should choose materials that help minimize resource consumption, energy requirements, and waste generation. Whenever possible, renewable, or recycled materials should be employed to reduce their environmental footprint. When we use materials with a long product lifecycle, fewer resources are needed to produce replacements, reducing the demand for raw materials. They are also less likely to end up in landfills, reducing the amount of waste generated.

The end-of-life of materials should be carefully considered in the early stages by selecting those that can be easily disassembled, recycled, or reused. Life Cycle Assessment (LCA) is a valuable tool to systematically evaluate and enhance these choices, ensuring environmental responsibility and compliance.

To what extent can improper material selection contribute to increased operational downtime and maintenance costs within chemical facilities, and what strategies can be employed to minimize disruptions and associated expenses?

Corrosion and material degradation can trigger premature equipment failures, resulting in production disruptions and costly repairs. Additionally, poorly selected materials necessitate frequent unplanned maintenance, further disrupting operations and increasing labor costs. They can also lead to increased inventory costs when obsolete or incompatible materials need to be replaced prematurely.

Adopting predictive maintenance techniques can anticipate equipment failures and enable proactive maintenance scheduling, reducing unplanned downtime. Conducting a thorough root cause analysis of material failures is also crucial to identify underlying causes and prevent recurrence. Optimizing inventory management practices can ensure the availability of critical spare parts and minimize supply chain disruptions. Lastly, businesses can also foster a culture of continuous improvement so that lessons learned from material failures are incorporated into future material selection decisions.

How does improper material selection pose safety risks for both on-site personnel and the surrounding communities, and what measures should be implemented to prioritize safety in material selection, storage, and handling?

The selection of the right materials is a crucial aspect of ensuring the safety and efficacy of any application. Choosing materials incompatible with each other or with the intended use can lead to hazardous consequences, including fires, explosions, and the release of toxic fumes. 

Furthermore, some materials are inherently toxic and pose health risks to workers and the environment if improperly handled. Hence, comprehensive Safety Information Sheets (SIS) with detailed information on handling and storage, as well as composition and ingredientsfor all chosen materials should be readily available to users. 

During the materials assessment stage, a thorough hazard assessment should be conducted, evaluating the material's properties, intended use, and potential exposure routes for workers and the environment. Then, a formal material selection process should be implemented to guarantee that only materials meeting the safety and performance requirements of the application are chosen. This process should involve input from engineers, safety professionals, and other relevant stakeholders.

Workers should also receive proper training on the hazards associated with the materials they handle and their safe handling and storage procedures. They should also have access to a comprehensive and updated inventory of all on-site materials to track their location and usage, ensuring that they are properly stored and handled.

How can investments in material testing and ongoing research contribute to informed material selection decisions in the chemical industry, and what role does collaboration with research institutions and industry partners play in this process?

Ongoing testing of materials is crucial for assessing whether theycan withstand the stresses and strains of their intended use, in environments that are not only challenging but also ever-changing. The materials must be durable enough to resist heat, moisture, and chemical degradation. Moreover, they should not react with each other or with other chemicals in the process environment in a way that could create safety and environmental hazards to workers or the community around the area.

Ongoing research into new materials and technologies can also help identify safer and more sustainable alternatives to traditional materials. Collaboration with research institutions and industry partners is essential for advancing material science and developing safer and more sustainable materials. Research institutions can provide expertise in material characterization, synthesis, and testing, while industry partners can provide real-world insights into the challenges and opportunities of using new materials in chemical processes.

Alleima, for instance, boasts expertise in metallurgy, housing a portfolio of 1,500 alloy recipes, over 900 of which are actively processed for diverse niche applications. Our dedication extends to the constant development of new, patent-protected alloy concepts. Through active and close relationships with educational and research institutes, we accelerate the development of innovative materials that improve safety and sustainability in the chemical industry.

By working together, we can accelerate the development of new and improved materials that will ensuresafety, efficiency and sustainability in the chemical industry.