FRP Vessels and Piping in

Chemical Processes

Michael P. Yeemike@rtconsults.com

NACE Coating Inspector Level 3 #50795

Richard Taraborelli P.E.Rich@rtconsults.com

RT Consultants NACE Conference: March 18, 2015

• Comparison of FRP to alternatives in the chlorine and sulfur rich chemical environments.

• Case Studies with FRP lined steel and dual laminate construction.

• Improvements in technology and cost economics.

• The value of knowing what you are receiving.

Table of Contents

“You can expect what you inspect- nothing more.”

- John H. Mallinson

• You must know what you require and know how to identify it. Quality Inspections are needed.

Let the Results Speak for Themselves

• FRP has a distinct advantage handling these two elements and compounds.

• Awareness of the importance of material selection for application.

Two Scenarios: Chlorine and Sulfur

• Taking Brine and separating NaCl to make caustic and chlorine.

• Considered the harshest environment for corrosion and chemical attack.

• Have greatest needs for protection from harsh chemicals.

Background of Chloro-Alkali Plants

Electrolysis of NaCl or KCl:

2 NaCl + 2 H2O → 2 NaOH + H2 + Cl2

Chlorine reaction with water

Cl2 + H2O → HCl + HOCl (*NaOCl)

Trace of chlorate is formed:

2 HOCl + ClO-→ ClO3- + 2 Cl- + 2 H+

Some plants may produce HCl:

H2 + Cl2 → 2 HCl

Chloro-Alkali Processes

• Planning/Design/Development

• Purchase/Installation

• Maintenance/Repair

• Inspections

• Downtime/Lost Business Cost

Comparing Alternate Solutions

Chemical Environment Vulnerabilities

Chlorine/Halogens Sulfur/Sulfur Compounds

• Permeation and diffusion.

• Aggressive ion exchange (valence number).

• Lots of vulnerable compounds.

• Used to make many composites/elastomers

• Hardening and brittle effect on steel/rubber (N/L steel, cross-linkage).

• Permeation and diffusion.

• Localized chemical attack.

•

The Typical Composite

Filament Winding or Laminate (Ex. Pipe, Tank, Ducting, etc.)

Interior

Corrosion FRP Barrier

Veil andMat layer

Exterior

Structural FRP (Provides the Strength)

Different ratios of resin/glass depending on design

• Most substitution of materials is between the two choices.

• Each material has its own area of superior performance.

• Mainly compared from a lining standpoint.

Apples to Apples: FRP to Rubber

Stainless Steel 316L in Chlorine Service after 2 years

*Severe Pitting and Cracking

Materials Sulphuric Acid Hydrochloric

Acid Acid Chloride

Salts

FRP (epoxy vinyl ester resin)

100ºC to 30% 80ºC to 15% 100ºC all

concentrations

ChlorobutylRubber lining 80°C to 20% 79°C to 15%

52°C for sea water

Stainless Steel 316L 30 ºC to 5% Will Rust outWill Rust out above 60°C

Chemical Resistance

Halogens/Sulfur

Rubber TechnologyHandbook Reference

Rubber not recommended for chlorine.

Comparison between Rubber and FRP lined equipment

FRP Lining

Good with Silica Carbide

Rubber Lining

Excellent Wear Resistance

(dependent on hardness

and size of particles)

Chemical Resistance

Permeation resistance

Installed Cost

Life cycle maintenance and

cost

Excellent

Excellent

$100,000

+15 years**

Good

Fair/Poor

$80,000

3-6 Years* (NaClO)

*Data from White’s Handbook of Chlorination

Properties

** FRP life expectancy dependent on curing formulation

Repairing Rubber to FRP

Rubber Linings

• Labor intensive

• Repair is deficient to original

• Bonding Issues

• Longevity Issues

Fiber Reinforced Polymers

• Easy to repair with qualified workers

• Repair is close to original (depends on location)

• Can be reused and relined

Dual Laminate FRP Tanks w/ CPVC Liner

Steel Tanks Internally Lined w/ FRP

Resin: Epoxy Novolac Resin for Tanks &

EN Formulated Steel Lining Systems

Case Study: Spent Sulfuric Acid Tanks

@ Max Temp = 140F

Lining Life = 10 - 15 yrs.

Recommend 5-yr. inspect intervals

Environment:

Up to 80% Sulfuric Acid w/ Dissolved Cl2

Design Expectorations:

Case Study: Spent Sulfuric Acid Service

•

•11.

Storage Tank in 36% phosphoric acid

Temp= Ambient

Age = 35+ years

Pulp/Paper Manufacturing

Design Expectorations:

Case Study: Phosphoric Acid Used in Water Treatment

Still in Service

FRP Distinct Environment Advantages

Scrubber Vessels

Piping for

chlorine/acids/caustic

Stack Liners

Brine piping and tanks

Chemical titration and mixing

Hydrocarbon and sulfur/halogen

compound storage

Rubber Distinct Environment

Advantages

Transporting Containers

Railcar linings

Abrasive slurries

Steel pickling

Vacuum service

Dual Laminate FRP

Stand alone Construction

Take steel or concrete

out of the equation.

Longer service life in

corrosive environment

and service.

Dual Laminates Considerations

Selection Parameters

Compatibility

Alkalinity

Permeation

Design Temperature

Complexity/Geometry

Fabricator Expertise

Service Life Expectations

Availability

Lining Materials Used

PVDF Homopolymer

PVDF Copolymers

ECTFE Homopolymer

ECTFE Copolymer

ETFE

MFA

FEP

PFA

PTFE not common...

Modularization of Large

Construction of FRP

Scrubber assembly for desulfurization

Inlet for Seawater

Case History: Flue Gas Towers

Location: Power Plant in Bełchatów

Service ConditionsChemicals: SO2,SO3, NOx, H2S

Dimensions: 34 meters long x 7.6 meters wide(One Section)

Exceptional Performance in sulfur rich conditions.

Oblation Technology

• Developed in streamlining FRP construction of larger objects.

• Can be engineered to withstand elements and comply with ASME Section X.

• Very Fast fabrication time= Labor Savings.

Tank Bottom Installation

Modularization for FRP= Oblation System

50 ft diameter, 40 ft high tank. Assembled in less than two months.

36% Concentration HCl Tanks

Large Stacks and Tanks

Sulfur Rich Exhaust

What Price Offers

Service Life

10 years Life

15 years Life

30 years+

Service Rating

Oilfield Service

ChemicalService/Treatment

ASME RTP-1 Tanks

Cost to Steel Ratio

1.2 Ratio 1.5 Ratio 2.0 Ratio

What Inspections Find

• Mechanical Abuse.

• Excessive Temperature.

• Chemical Attack

• Diffusion and Permeation

• Material Specifications

Elastomers Common Failures

Poor curing (initial)

Diffusion

Applied stress

Embrittlement

Micro-cracking

Swelling

Impact

Environmental cycling

Aging (Time)

Issues Affecting Laminate Performance

In the realistic world:

Lack of Fusion and Poor Fit

Nozzle Misalignment

Air Voids Defects

More Issues

Blisters Delamination from Substrate

Laminate CrackingStress FailureMatrix shrinkageDry Spots and bad cure

And More…

Compliance

• Drawings

• Design Specifications

• Materials (lot numbers)

• Ambient Conditions

• Standards (ASME RTP-1)

• Verify Quality Control

• Pass/Fail Criteria

Quality Assurance Through Inspections

FINAL INSPECTION

Documents Review

Non Conformance

Reports

Cutouts

Resin Cure

Peel Adhesion Test (picture)

Dimensions and thickness

Physical properties

Quality is What Will Last

It took a hammer with a crowbar to rip it off

• Proper Material Selection for Service

• Comprehensive and descriptive specifications

• Qualify experienced GRP manufacturer

• Quality assurance throughout the process

• Inspect, Inspect, Inspect…

Lessons Learned

Keys to a Successful Project

“You can expect what you inspect- nothing more.”

- John H. Mallinson

“I prefer a composite bike to a steel one. “

- Michael Yee