Specialty Resin Systems for Corrosion
Resistance FRP
Our commitment to Corrosion
Resistance
- Markets March 19
- What is FRP
- Corrosion Resistance
- CR Structure
- Lining Vs FRP
• - Derakane TM
Introduction
• Corrosion Resistance
• Testing, Database, and Literature
• Linings, Dual Laminate vs. full FRP
• Derakane™ Product Overview
• Case History
August 2019
Corrosion Market Applications
Chemical Processing & Mining (Copper, Nickel, Pulp & Paper Air Pollution Control
Waste Water Lithium, Rare Earth) (FGD)
A global, project driven (EPC) business, for applications with corrosive chemical environments
Projects can vary from small maintenance work to large “Mega Projects”
Key markets are chemical processing, mining & phosphate extraction, pulp & paper & air pollution control
Markets are driven by different macroeconomic
trends Competition is generic and non generic
(metals)
Vast number of years of experience and data plays a key role in defining the reliability of the resins systems.
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− DERAKANE ™ Epoxy Vinyl Ester Resins have over
54 years of field experience in corrosion
resistance applications with case studies
around the world in different industries.
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Handling
more than 4000 enquiries a year.
− Ashland supports the industry by providing CR recommendations to
the asset owners, engineering firms and consultants around the
world.
− Central hub for tracking information & projects.
− Mining our corrosion database for project intel and market trends
− Organizing and running Seminars with End Users and Engineering Companies
− Kehl (EMEA, India, APAC), Dublin (NA & SA)
− Combined Technical Expertise of >200 years
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Derakane Technical Services
− Analytical Services / Testing
Capability
− Extensive corrosion testing ASTM C-
581
− Corrosion Resistance Guide
− Global Technical Service Expertise
− Proven performance through
hundreds of case studies
− Ashland Corrosion Science Centers
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What is FRP?
Mould
Fibre + Matrix Composite
Temperature
- Fibre – Provides strength and stiffness.
- Fibreglass, Carbon Fibre
- Matrix – Protects and transfers load between the fibres.
- Polyester, Epoxy, Vinyl ester, Polyurethane
- Process
- Hand layup, Filament Winding, RTM, Pultrusion, RIM.
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Failures by chemical degradation
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chemical or corrosion resistant recommendation
chemical attack could happen by:
- disintegration or degradation (e.g. HF, Abrasion, Erosion)
- oxidation (e.g. concentrated oxidative acid)
- hydrolysis (e.g. hot water)
- diffusion (e.g. HCl)
- thermal degradation
- combinations of these mechanisms, and possibly others.
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Corrosion Resistance barrier and structural layer
Ashland provides recommendation for the corrosion- resistance
structurs a laminate is typically made with a:
-corrosion or chemical resistant barrier (or barrier layer CBL): in total 2.5 to 6.3
mm thick, in contact with the chemical environment. can be “corroded”, protects
the structural layer.
- structural laminate: brings strength and stiffness to the composite structure.
should not be “corroded”.
Inside, in
contact with Outside
chemicals
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CBL Structural layer
what do we need for a chemical or
corrosion recommendation?
1) Application type (Tank, Pipe; lining or Full FRP)
2) History of the equipment if available
3) Detail Chemical composition in contact with resin
- chemicals: name or cas number
- chemicals mixed together or present one of the other
4) operating and design conditions:
- concentration, ph
- temperature
- min, max, cyclic temperature changes
- remarks: abrasion risk
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recommendations are based on a variety of sources:
- including evaluations of actual field service performance
- laboratory (ASTM C581), 50 years of tests!
- field tests of FRP laminate construction
- and the combined knowledge of the Technical Services Team
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how do we do our corrosion resistance tests?
ASTM C-581
− post cured laminates immersed in an
given environment at a defined
temperature.
− properties of the laminate (e.g. visual
appearance, hardness, mechanical strength,
etc.) checked after 1, 2, 3, 6 and 12 months
− concentration and temperature limits are
derived from the results.
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chemical resistance guide
Over 1000 Chemicals across the entire DERAKANE™ resin family
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Corrosion Resistance Structure
− The inner surface of all laminates shall consist of a protective layer:
− Single Protective Layer (SPL= Veil or Resin)
− Chemical Resistance Layer (CRL) or ThermoPlastic Liner (TPL)
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Lining versus Full FRP
Building of a corrosion resistance barrier, painting the resin is
not sufficient
Types of FRP linings
• Flake glass lining
– Glass flakes mixed into resin
• Chopped glass lining
– Chopped glass applied with a chopper gun
• Prefabricated sheets
– Sheets fabricated in factory and shipped to site
• Glass mat lining
– Chopped strand glass mat and veil
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Lining versus Full FRP
• do not have their own structural integrity, quality substrate important
• should be limited to max 60-70°C (and without thermal shocks)
=>higher risk of delamination in high service temperature
• in case of permeation, diffusion(e.g. water vapor), substrate may not be resistant!
• only skilled applicator: surface well prepared, no dust, dry substrate…
• DERAKANE 8084 is suggested as a primer
=> good adhesion properties
• good ventilation required to avoid styrene rich atmosphere
• Wax or Low styrene Emission systems in the last layer to get a good
cure of the resin.
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dual laminate vs. Full FRP
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dual laminate vs. Full FRP
• offer to go beyond the limits of non-lined FRP: strong acids and caustics, organic
solvent
• backing textile important on the thermoplastic
brings surface roughness for a mechanical adhesion for the FRP lamination
glass or synthetic or other, depends on the chemicals
• a corrosion resistant barrier in FRP after the TP could be required
• only experienced persons with good welding skills!
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DERAKANE Resins are based on epoxies:
O O
O O
Bis-A Epoxy Resin
O O O
O O O
Novolac Epoxy Resin
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Bisphenol-A Epoxy Resin Methacrylic Acid
OH O
O O
O O O
+ HO
O
n=0-2
Bisphenol-A Epoxy Vinyl Ester Resin
CH3
OH OH
O O O O
O Ester Groups
CH3
n
Epoxy Backbone Toughness
Hydroxyl Groups Adhesion and Glass Wetting
Methyl group Shielding Corrosion Resistance
Terminal Unsaturation Reactive Sites for Crosslink Polymerization
Resin is thinned in Styrene for processing requirements
Styrene
20 acts as the crosslinking agent upon polymerization
Unsaturated Polyester Resins
Isophthalic Polyester Backbone
R2 C O
CU C
C C OC OCOOCR2
COCCOCCCCOCCUCC
Multiple Ester Groups and Internal Double Bonds
Good reactivity, but decreasing mechanical properties (brittle) and reduced chemical resistance (acid & brine)
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DERAKANE ™ Product Families
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DERAKANE ™ versus
DERAKANE MOMENTUM ™ Resins
Just like DERAKANE™ Resins,
only better.
General Benefits of MOMENTUM™ resins
• - Longer Commercial warranty
• Same strong chemical backbone
• - Higher Reactivity
• Same exceptional corrosion resistance
• - Quicker Gel-to-Cure
• Over 50 years of proven track record
• - Improved Exotherm
• Decades of case histories of success
Management
• - Low Color in hundreds of applications and
• - Easier Workability chemical environments
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They look different. They act different.
Fewer lay-up sessions per
part.
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You can see the difference.
− faster roll-out with DERAKANE MOMENTUM Resins
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DERAKANE™ 411-45 Resin. FeCl3-Tank, dismantled 1998
due to a Plant shut down (in perfect condition)
Troublefree service for 31
years 1967 1998
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hydrochloric acid tank, 27 years
15-30 % HCl at 40°C
Volume: 44 m3
DERAKANE™ 470 Resin
1971-1998
No need for repair
during entire service
period.
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scrubbing system for wet phosphate fertilizer
processes
FRP advantage:
-can be used up to
elevated
temperature,
- can handle fumes
and liquids
- can handle also ammonia
gas.
DERAKANE 470, in service since 1999:
flue gases treated: P2O5, HF, phosphate dust,
water vapor up to 110°C (230 ºF).
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Our commitment to Corrosion
Resistance March 19
Thank you
• Introduction
• Corrosion Resistance
• Testing, Database, and Literature
• Linings, Dual Laminate vs. full FRP
• Derakane™ Product Overview
• Case History
