FRP for HCL Applications

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frp for hclThere are many applications for hydrochloric acid (HCL).  From the manufacturing of high fructose corn syrup, dyes, phenols, and plastics to chemical intermediates such as ferric chloride which is used as a flocculant in sewage treatment and drinking water production. 

From picking, metal cleaning, to the ore reduction of metals (i.e. vanadium, tantalum, tungsten and tin) —hydrochloric acid has proven its usefulness throughout many industries.

Regardless of your industry if you use HCL you need a safe and economical way to handle this corrosive material.  FRP is an ideal solution for handling corrosive materials offering a myriad of benefits that will save money over the long-term.  The inherent corrosion resistant characteristic of our FRP makes it a cost-effective, strong, light-weight solution for corrosion resistant equipment applications in the chemical process industries and in water and waste water treatment areas.  Similarly, the design flexibility of FRP allows it to be adapted very easily to fill niche roles in many other industries, for example, food and beverage, pharmaceutical, and HVAC.

FRP Has Long Service Life in Corrosive Environments

In a filament wound composite pipe, the cost of adding a corrosion barrier/liner is not all that great in comparison to the true cost of the pipe. The selection of the proper type and thickness of the corrosion barrier/liner can more than double the service life of the pipe.

FRP has a distinct advantage over metal alloys, such as titanium, and rubber-lined steel with lower installation costs, reduced maintenance, and long service life proven with over 20 years of successful operating experience at many plants and facilities around the world. More importantly, FRP is recognized as having superior corrosion resistance and abrasion resistance when compared to specialty alloy metals, in stringent chemical processing and in aggressive hydrometallurgical environments.

HCL Applications

  • Manufacture of Dyes, Phenols and Plastics.
  • Ore reduction (manganese, radium, vanadium, tantalum, tin and tungsten)
  • Food processing (corn, syrup, sodium glutamate)
  • Pickling and metal cleaning
  • Water treatment – Resin regeneration and demineralizers
  • Manufacture of chemical intermediates, such as FeCl3, ZnCL2, AlCl3, etc.
  • General Cleaning in households and in commercial, industrial and institutional establishments.

FRP Chemical Processing Applications

In the chemical processing industry FRP are typically used for pipes, ductwork, storage tanks and basins, absorption towers, drying towers, solvent extraction vessels, gas scrubbers, packed reaction columns, pressure vessels, process reaction vessels, stacks, process containment equipment, packing support systems, packed bed distributors, bed limiters, and distributor feed headers—to list some examples.  We offer FRP solutions; new design or an incremental improvement that will interface into an existing design—we have the capacity and capabilities to enhance your project.

FRP for Structural Repairs – The Advantages of Structural FRP

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frp repairRecently featured by Energy-Tech Magazine, “ASME: Repair of pressure boundary and structural components with composites,” by John Charest is a great overview of the advantages of FRP when used for structural repairs.

“Deterioration of components and structures at power generating facilities has caused unscheduled plant outages, personnel safety concerns and significant impact on operating budgets. However, a new technology is available that can increase the usable life of components and structures, while significantly reducing the economic burden normally associated with repair or replacement options.” The new technology? Fiberglass reinforced polymers (FRP) of course.

FRP repairs offer a number of advantages over other material choices. FRPs tend to be light weight but strong and, “are comprised of high strength fibers in an epoxy matrix… These long fibers tend to have fewer defects, which leads to stiffer, stronger properties.” While strength is undoubtedly a huge advantage, one of the biggest advantages is the ease with which FRP repairs can be performed. “The work is performed quickly and can often be completed during regularly scheduled shutdown times.” The ability to perform repairs without plant downtime is a huge boon. The exact repair procedure is determined by the type of repair needed and the surface material the FRP will be applied over.

According to Charest, “Many of the FRP installations currently in-service at power generation facilities have been utilized to repair piping. Primarily, these installations have been made by applying the FRP on the inside of the piping. These applications have successfully provided pressure boundary and structural integrity.” FRP can also be used as, “a structurally acceptable method to rehabilitate aging plant equipment, piping and structures,” says Charest.

High strength-to-weight ratio, dimensional stability, long service life, and reduced maintenance cost combined with ease of installation make FRP an ideal repair material.

To read the full article, click here.

Corrosion Resistance: FRP for Copper Recovery Systems

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corrosion resistance and copper recovery systemsThere are many advantages to using Fiber Reinforced Polymers (FRP); high strength-to-weight ratio, dimensional stability, long service life, and reduced maintenance cost—to name a few.  FRP can also be formulated with enhanced properties such as corrosion and abrasion resistance and smoke and flame retardance.  In many stringent industrial applications, including copper recovery, where other materials fall short FRP has the ability to endure, thrive, and perform. 

FRP is commonly used as a cost-effective material solution because it can be formulated to withstand strong acids, bases, and organic compounds.   Moreover, FRP is recognized as having superior corrosion resistance, when compared to specialty alloy metals, in aggressive hydrometallurgical and chemical process environments.

Copper Recovery

The copper recovery process is dynamic and has been simplified over time with the development of chemical processes and other technological advances.  In copper recovery systems many of the chemicals/compounds that are used are hazardous and highly corrosive.  For this reason, careful planning and thought must go into what building materials are selected for facilities.  FRP has evolved in concert with the ever-changing metal and extraction industry and is now poised to fill many material niches.

In the copper recovery industry FRP is currently filling a niche as a cost-effective, corrosion resistant material, which can be utilized for many processes and applications including:

  • Leaching
  • Stripping
  • Solvent extraction
  • Sulfuric acid
  • Copper sulfate electrolytes 

In the copper recovery process copper is leached from ore with sulphuric acid and is easily recovered in a pure metallic form by the well known process of solvent extraction. At the center of the process is the copper recovery reagent that is used to selectively extract copper from the aqueous leach solution.  In general terms, the copper recovery process can be broken down into three basic steps: leaching (sulfuric acid), solvent extraction, and stripping (high acidity coppers sulfate electrolytes).  Beyond these three steps, the process of copper recovery has many areas where FRP products can be used; for example, transportation, storage, and general infrastructure needs. 

FRP 

FRP offers design flexibility; in metal extraction and refining industries it can be used for pipes, ductwork, tanks, solvent extraction vessels absorption towers, basins, floor coverings, grating, and electrowinning tankhouses— just to name a few.   Case in point, FRP grating has been successfully used as a walkway/platform material in copper recovery systems around vats in the electrowinning process.

Whether you’re handling corrosive compounds such as sulfuric acid or high acidity extractants and stripping agents, FRP will withstand the harshest environments and is a corrosion resistant, cost-effective choice.  In the metal and extractions industry FRP has a distinct advantage over metal alloys, including titanium, and rubber-lined steel with lower installation costs, reduced maintenance, and long service life proven with over 20 yrs of successful operating experience at many plants/facilities around the world.

FRP Sustainability, Green Construction and LEED

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frp sustainabilitySustainability is big word these days.  It can mean a lot of different things, depending on the context—it can also be overused or misunderstood.  In recent years the demand for more green construction or sustainable construction has been driven largely by consumers in the construction sector.

In this context, sustainable construction aims at reducing the environmental impact of a building of its entire lifetime, while optimizing its economic viability.  The benefits of green construction are many; lower operating costs, increased asset value, reduced waste sent to landfills, conservation of energy and water, and reduced greenhouse gas emissions, for example. 

That’s all fine and well—but have you ever stopped to think how Fiber Reinforced Polymers fit into this equation?   Currently, Fiber Reinforced Polymer (FRP) products are a cost-effective material choice in many green construction circumstances. Furthermore, as their international recognition and reputation as an ecologically sustainable product continues to grow, so do the uses and applications.  For FRP manufactures this is good news.

The LEED Program (Leadership in Energy and Environmental Design) was developed by the U.S. Green Building Council to provide a framework for implementing practical and measurable green building solutions. The LEED green building rating system is the internationally accepted benchmark for the design, construction and operation of green buildings. Voluntary participation in the program by builders demonstrates initiative to develop high performance sustainable buildings with energy savings, lower carbon footprints, and environmental responsibility. 

FRP products are gaining more attention as a LEED recognized, or certifiable environmentally sustainable building material. For example FRP products can now qualify for many credits under the LEED building rating system such as Energy Performance, Regional Materials, and Heat Island Effect—to name a few.

When composites are compared to other traditional materials such as concrete, wood or terra cotta, the total life-cycle assessment of fiberglass contributes to its viability as a green building product. When consideration is taken for the energy consumed in production, installation and environmental sustainability, fiberglass products generate a much smaller impact than other traditional materials and can be used in ways that are less energy or carbon intensive.

Energy Performance

One of the key attributes of composites, which makes it a LEED recognized green material, is its thermal integrity—minimizes heat loss during winter and heat gain during summer. 

Key Green Building Considerations

  • Light Weight- reduces transportation costs, less need for heavy lifting on-site
  • Less Dead Weight-less structural material is required, reduces resource consumption
  • Long Lifespan-durability, resists environmental degradation
  • Resistance- corrosion, rot, mildew, mold, insects; reduces replacement costs and the use of toxic chemicals used in maintenance
  • Maximizes Energy Performance
  • Environmentally Responsible Material Choice- LEED recognized

FRP architectural components are highly desirable for their design flexibility, high strength-to weight ratio, cost-effectiveness, flame retardance, and overall durability.  Added to the list now is the potential for internationally recognized LEED credits.  For example, as a builder you can achieve credits (on path to certification) for using locally or regionally sourced materials, innovative design, and moisture management components (e.g. our fiberglass products are impervious to water, and will not rot or swell) —among much else. 

There are many categories, classifications, credentials, prerequisites, and credits to understand for the voluntary LEED Certification and the onus is always on the builder.  With single-source design-build capabilities we can help you.  We offer a wide variety of custom composite products/components for a wide range of architectural applications and green construction projects.  Contact us.

LEED: http://new.usgbc.org/leed


Is FRP Combustible?

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is frp combustibleFiber Reinforced Polymers (FRP) and Combustion

Combustion/fire is a serious concern regardless of the industry.  Fire resistant composites are essential for numerous applications including construction materials, structural heat resistant barriers, fire proofing, and generally speaking, improved thermal stability.

Heat Resistant Phenol Resins

One remarkable advantage of using custom Fiberglass Reinforced Polymers (FRP) is that they can be designed, formulated and manufactured per your requirements.  When discussing combustion, heat, or fire resistance, in terms of FRP, it is important to consider composition of laminates, resins, and enhancements such as fillers, additives, and modifiers.

Enhancement of Phenol Resin Matrices

In some cases, resins matrices may be enhanced with the addition of fillers, additives and modifiers to demonstrate improved heat resistance. There are specially filled resins which exhibit fire retardance features to insulate and protect structures from jet fires or extreme temperatures from nitro combustion (burning of film materials).

The advantages of FRP laminates in case of combustion or heat:

  • No auto-propagation of flame
  • Very low smoke development
  • Very low toxic fume emission
  • Low heat release
  • No release of flammable vapors
  • Very low loss of strength at high operating temperatures up to 200 ºC
  • Low thermal conductivity

Fillers, Additives, and Modifiers

Many of the enhanced qualities, such as heat resistance, are the result unique material formulations, for example, using fillers, additives and modifiers in the manufacturing process.  Similarly, it has been demonstrated that stabilizers can help to mitigate the effects of prolonged exposure to heat, and are an essential ingredient when creating durable heat resistant FRP.

Hydration Fillers

Included in this category are materials containing ATH (alumina trihydrate), bromine, chlorine, borate, and phosphorus.  The filler alumina tri-hydrate is frequently used in this application because it gives off water when exposed to high temperatures thereby reducing flame spread and development of smoke.  Another common hydration filler used for fire resistance throughout the fiberglass industry is calcium sulfate.

Stabilizers

Simply put, heat stabilizers are additives that protect or reduce the effects of heat or radiation on plastics or polymers.  In some cases, heat stabilizers are used in thermoplastic systems to inhibit polymer degradation that results from exposure to heat.  The effectiveness of the stabilizers against weathering (heat degradation, UV radiation etc.) depends on solubility, ability to stabilize in different polymer matrices, the distribution in matrices, and evaporation loss during processing and use.

Heat stabilizers are mainly used for construction products made of polyvinyl chloride, for instance window profiles, pipes and cable ducts.  However, it is also important in the manufacturing of FRP and the uses/applications are potentially limitless.

Composite Expertise

With our composite expertise and precision manufacturing capabilities, we are prepared to help you with your high-temperature composite needs. 

Corrosion Resistance Makes FRP Ideal for Handling Sodium Hypochlorite

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handling sodium hypochlorite

There are many compounds used in industrial processes that require special considerations and materials when handling them.  Sodium Hypochlorite (NaClO) is not an exception.  NaClO is an unstable compound that is used in water purification, typically on a large-scale for surface purification, bleaching, odor removal, and water disinfection. Sodium hypochlorite is poisonous for water organisms- hence its use in water purification and water treatment.

Developed in France, in the late 1700’s, it has been used both domestically and industrially (originally to whiten cotton), for its stain removal and bleaching/whitening abilities. Sodium hypochlorite is a clear, slightly yellowish solution with a characteristic odor.  As a bleaching agent for home use it usually contains 5% sodium hypochlorite with a pH of around 11.

In an industrial application, it most likely contains concentrations of approximately10-15% sodium hypochlorite (with a pH of around 13, it burns and is corrosive). Because this compound is unstable and corrosive special regulations and specifications must be met when processing or handling it. Fiberglass Reinforced Polymers (FRP), provide a perfect answer to handling this and other chemical compounds.

FRP custom products are unique in many ways, but one attribute has gotten a lot of attention recently- corrosion resistance.  FRP products can be formulated with special resins and advanced laminate scheduling techniques to provide a corrosive or abrasive barrier. This is particularly useful in FRP products such as pipe, ductwork, tanks, basins, and vessels. 

How does Sodium Hypochlorite React with Water?

Understanding the connection or chemical reaction that takes place between water and sodium hypochlorite can help to illustrate the inherent attributes that make FRP so valuable.  The reaction that takes place my interest you.

Some basic information; when sodium hypochlorite is dissolved into water two things transpire.  First, the pH of the water is increased. Secondly, two things form as a result of the chemical reaction: hypochlorous acid and the more inert hypochlorite ion. 

How are Sodium Hypochlorite and Hydrochloric Acid Connected?

In some circumstances when sodium hypochlorite or any compound is used in a process, another reagent must be used to counteract it effects.  In this case, the chemical reagents typically used to lower the pH of the water (during treatment) after it has increased, are hydrochloric acid (HCl), sulfuric acid (H2SO4), or acetic acid (CH3CO2H).  FRP is an excellent material choice for handling corrosive, unstable, and acidic compounds.

FRP Has a Key Role in This Process

Because FRP products are so versatile and have many desirable attributes (i.e. corrosion resistance) they are the ideal choice for storage, processing, and hauling of chemicals.  Another often overlooked benefit of FRP is that it is a non-reactive surface, which is critical when dealing with many chemical compounds such as sodium hypochlorite, hydrochloric acid, and sulfuric acid. FRP products can also be customized to meet industry regulations, specifications, and codes.