Composite Pipe and Valves for Sulphuric Acid Handling

Composite Pipe and Valves for Sulphuric Acid Handling

• Global manufacturer of FRP pipe & fittings. Part of NOV. • 14 manufacturing plants. • Produce products for a wide sector of industry. • Manufacture “engineered commodities” to ASTM, ASME, API, FM, CSA, ISO, and other international standards. • Heritage plants/brands of Star, (A. O) Smith, Fibercast, Centron, Ameron (Bondstrand) all under one manufacturing umbrella now.

n n n Canadian market distributor for NOV Fiber Glass Systems (CI, MOS, OG) Process Review / Material Selection Design and Specification Assistance Logistics and Customer Service Installation Training and Certification (ASME B 31. 3) and Quality Assurance

AGENDA n n n Introduction Product Descriptions Applications & Competitive Materials Case Histories & Specifications Special Considerations Question Period (Open Forum)

Z-CORE™ Pipe n n n 1” through 8” diameters 0%-100% Sulphuric Acid Pressure Rating: 150 psig Temperature Rating: -75° F to +275° F Construction Methods Materials of Construction

Nil-Cor® Composite Valves n n n 1” through 8” diameters Pressure Rating: 250 psig Temperature Rating: -75° F to +275° F Construction Methods Materials of Construction Flanged Ball Valves, Ball/Swing Check, Threaded End, Butterfly

Pipe Production n n Centrifugal Casting Construction Materials n n n Proprietary resin system 100 -mil Liner UV Protection

Valve Production n Compression Molding

Features n n n & Thick wall. 100 mil pure resin liner Controlled OD Resin Rich OD Light Weight (Pipe 1/6 th the weight of steel. Valves 1/3 rd) Small Diameters Readily Available (not always so with Lined Steel) Benefits Durability & Span Corrosion Resistance Ease of Installation UV barrier/15 year Installation & Load

Application n n Chemical Feed Chemical Waste Chemical Vent Process Lines

Application n Plain old carbon steel can be used to handle strong sulphuric acid (93 98%), but fails quickly if any moisture or condensation is added. This is why many of the Z-Core applications are at the loading facilities, as the lines are only used sometimes and sit empty with a bit of acid residue left.

Chemical Feed n sulfuric acid H 2 SO 4 competition: carbon steel, 316 stainless steel; pvdf lined-steel; teflon lined-steel; Hastalloy B; alloy 20 (aka Carpenter 20) n hydrochloric acid HCl competition: teflon lined-steel; alloy 20; Hastalloy B; Hastalloy C; Zirconium

The Competition… n n n 4” 4” Z-CORE pipe PTFE lined pipe Alloy 20 sch. 40 pipe Hastelloy C 276 sch. 40 pipe 4” Nickel 600 sch. 40 pipe 4” Titanium sch. 40 pipe $ 29. 00 foot $ 73. 00 foot $144. 00 foot $500. 00 foot $325. 00 foot $353. 00 foot Pricing on Alloys usually valid for one week. We can keep pricing up to a year.

Chemical Feed Case History n n Tetra Micronutrients Fairbury, NE 1000’ of 2” Z-CORE in 93% replaced schedule 160 carbon steel in 1997

Competition Cont’d n Competition: Various materials but primarily Duriron n n Problem 1: Many waste lines are buried which eliminates the use of lined-steel Problem 2: Many waste lines contain acids, solvents & base’s – not necessarily at the same time! ~ this limits the material selection.

Duriron n ® Weight: 114 lbs/ft 4” Cost: $87. 14/ft Pipe Lengths ≈ 7 ft.

Chemical Waste Case History n Mallinckrodt Pharmaceutical Saint Louis, Missouri Circa 1998 Mallinckrodt tested Z-CORE coupons in 20 different sumps for 12 months – In 1999 they wrote a specification & have purchased roughly $150, 000 – It has been double contained with Green Thread™ products

Chemical Vent Case History v Abbott Laboratories v v Chicago, IL Puerto Rico v Competition: PTFE-Lined v Chemical Vent MACT project $ 750, 000 of Z-CORE® products

Chemical Vent Case History n PPG Houston, Texas 10, 000’ feet of Z-CORE ≈ $1 million @ list price Service: Waste Vapor Temperature: varies up to 200°F maximum Concentrations vary Service Details: Vapors acetone acetic acid dichlorethane dimethylformamide ethyl acetate hexane hydrochloric acid methanol methylene chloride xylene sodium hydroxide styrene toluene phosgene !

Process Piping n n n 1. CHEMICAL FEED 2. CHEMICAL WASTE 3. CHEMICAL VENT 4. PROCESS PIPING Industry specific Since the pipe may be in direct contact with an end product the pipes impact on process purity is a consideration. The cleaning of pipe can also be a consideration in certain industries

Case History n Cargill n n n Blair, NE Eddyville, IA Memphis, TN Selected over teflon lined-steel for sulfuric acid. Also for hydrochloric acid – a large portion of which was process service $3 Million of Z-CORE® products

Case Histories n n n Black & Veatch Dupont Dominion Colour Sask. Power Resolute Forest Various Projects Various Locations Toronto, ON Boundary Dam Thorold, ON

Special Considerations Ø Ø Ø Double Containment Heat Tracing Steam Cleaning Conductivity Flanges & Gaskets Strength of Adhesive

Gaskets n n n Use Full-Face Teflon gasketing will be required in 99% of the services where Z-CORE products are utilized Garlock – Stress Saver Gore-Tex May need Back-Up Ring for torque

Socket Joining System • No Tooling Required • Easy for Close Tolerance • Pre-Spooling Available • ASME B 31. 3 Training and Certification • Site Quality Assurance

Z-Core™ and Nil-Cor® Product Data and Specifications n n ASTM D 2997, ASTMD 5685, Standard Test Methods Printed physical properties and ratings, as well as sample specification guides available. Additional stress inputs and engineering support available.