Chemical processing facilities rely on their equipment to operate smoothly in harsh conditions that can fail prematurely if the wrong alloys are used, or components produced with sub-standard quality. The effects of exposure to corrosive chemicals, high-pressure systems, and extreme temperature fluctuations places additional stress on parts and materials, so expertise in manufacturing is critical to both productivity and safety.

At Ferralloy, we specialize in supplying alloy castings, forgings, and fabrications of custom manufactured products for chemical processing applications, such as flanges, fittings, pipe & tube, valve bodies, manifolds, heat exchanger components, pressure vessel parts, and more.

Learn more about our manufacturing capabilities, material options for chemical processing applications, and Ferralloy’s commitment to efficient, responsive service.

Custom Forged, Cast, and Fabricated Components for the Chemical Industry

Parts and components used in chemical and petrochemical plants need to be physically tough to withstand harsh operating conditions. They must also meet tight requirements for dimensional accuracy and tolerances, with minimal variation between each piece, ensuring quick replacement and field installation – with minimum downtime.

Ferralloy’s capabilities meet these needs with precision manufacturing processes:

  • Forging. Our closed-die and rolled ring forgings achieve superior grain structure and mechanical properties. Forging eliminates the risk of internal voids and improves directional strength for high-pressure valve bodies and piping flanges.
  • Casting. Investment and sand casting are well-suited to produce parts with complex geometries, eliminating the need for extensive machining, fitting and welding.
  • Fabricating. Our fabrication services include plasma and laser cutting, metal rolling and bending, TIG/MIG & Robotic welding, and assembly. We offer NDT services including Dye-Penetrant inspection, Hydrostatic, UT, MT and X-ray weld inspection services.

Best Materials for Corrosive, High-Pressure, and Extreme Temperature Environments

Chemical processing equipment is exposed to conditions that rapidly degrade conventional metals. We work with materials that better resist corrosion, high pressures, and adverse temperatures.

  • Corrosion resistance. Acids, caustics, and sulfur compounds attack metal surfaces continuously. Metals that resist chemical attack well include:
  • High-pressure and temperature resistance. Chemical processing operations must handle a high range of pressures and temperatures in order to initiate and control chemical reactions, and to facilitate blending, separation and extraction, filtration, and other processes used to create chemical and physical changes in material compounds such as liquids, solids, and gases. There are many alloys and superalloys available to maintain structural and dimensional integrity of equipment used for these applications, such as:
    • 300 Series Stainless Steel 316L, 17-4PH, 321 and others.
    • Nickel-based alloys Hastelloy, Monel, Inconel, and Haynes.
    • Duplex stainless steels such as 2205 and 2207

Material Expertise and Reliable Quality in Petrochemical Manufacturing

Material type, composition, and quality have a major impact on the useful life of parts and, by extension, equipment. We are committed to supplying high quality materials and manufacturing capabilities that are compatible with the extreme conditions found in chemical and petrochemical processing. This includes:

  • Alloy expertise. We offer a comprehensive selection of alloys and superalloys, including hard-to-find and specialty metals that resist high-temperature scaling, sulfidation, carburization, hydrogen embrittlement, and other hazards.
  • Certified quality assurance. We are compliant with manufacturing standards including API, AMS, ASME, ISO 9001 and AWS. Products are delivered with material certifications (MTR’s) with chemical composition and analysis, mechanical properties, welding certifications, NDT results and heat treating charts.
  • Global reach. Our Ohio warehouse location is certified with U.S. Customs as a Foreign Trade Zone (FTZ) facility, which allows us to efficiently source materials worldwide, in some cases duty and tariff free for items that are designated for export shipment.

Global Supply Capabilities for Reliable Performance

Supply chain reliability is as critical as part performance. At Ferralloy, we understand that production delays have a downstream effect that impacts both products and profits.

Our global network provides:

  • Lead time predictability. We offer scheduling options for standard and expedited lead time, to align with your maintenance windows or project timelines.
  • Technical engineering support. Our team can provide design and engineering services including 3D solid modeling, FEA testing, and third party material failure analysis. We will help select the correct alloy and materials that best suited for your project, and designed to achieve maximum life expectancy and performance of your equipment in service.
  • Inventory Programs. As a money saving option, we offer an inventory stocking program and partial shipments for frequently used items so that you don’t have to carry excess inventory at your facility.

Quality Parts and Manufacturing for the Chemical Industry with Ferralloy

Whether you need replacement components for an existing facility, or custom manufactured castings and forgings for a new installation, we provide the manufacturing capabilities, engineering knowledge, experience in the industry, and global resources needed for everyone in the chemical and petrochemical industries.

Request a quote or contact our technical team today to discuss your project and for pricing details.