s u r fa fa c e P r o t e c t i o n
Corrosion Protection – Optimum Solutions for Every Project
KCH – Your Partner for Industrial Surface Protection Systems Worldwide
The KCH Company Group has been specializing in industrial surace and corrosion protection systems or 140 years now. Its operations span the globe. With its long-standing experience and vast know-how to draw on, KCH supplies optimum high-quality products to cater or virtually all corrosion protection applications. KCH’s excellent international reputation is based on numerous actors. Not least o these is the high level o skill and proessionalism among our workorce, many o them employees with long service records. Aided by regular training programs and direct contacts with our customers in an advisory role, our workorce is growing ever more skilled in solving technical problems
Production and Sales Sales Office
while upholding quality standards. Intense research and development work combine with a high level o
production know-how and longstanding installation experience to complete the picture.
SURFACE PROTECTION
COMPOSITES
The product portolio o KCH Surace Protection includes rubber linings and coatings, brick linings and tiling systems or industrial surace protection and anti-corrosion systems. A high level o development and production skills combines with many years‘ installation experience and close customer contact to make our range o products and services so unique. Needless to say, this range also includes advice in the planning and design o anti-corrosion and surace protection systems, as well as the proper processing and installation o our materials and products.
The product portolio o KCH Surace Protection includes piping systems, tanks and process equipment exposed to high chemical, thermal and mechanical stresses. These items are manuactured either rom fber glass-reinorced plastics with or without an inner liner, or rom fber-reinorced phenolic resin materials to ensure reliable and long-lasting resistance to chemicals. Besides oering a high level o materials and production expertise to its globally active customers, KCH Composites also provides comprehensive services such as individual advice and planning, as well as the installation and repair o these high-tech items, on request.
B USINESS AREAS
Wide-Ranging Applications for Our Materials
ABOVE: SULFURIC ACID PLANT AT CODELCO/ S ALVADOR (L URGI). BELOW: SECONDARY CONTAINMENT COATING .
Components in chemical processing plants are exposed to a wide variety o stresses, in particular chemical, thermal and mechanical loads. To ensure proper perormance over the long term, tanks, process equipment and other plant components thereore need to be given reliable and long-lasting protection. KCH supplies an extensive range o corrosion-resistant materials or the purpose.
R UBBER L ININGS Rubber linings are used or protecting highly stressed steel structures and concrete components exposed to corrosive stresses. The hard or sot rubber linings supplied are based on natural or synthetic rubbers and installed either in our workshop autoclave or as on-site lining at the customer’s premises.
POLYMER COATINGS KCH’s polymer products are ideal materials or protecting structures and building components under high chemical and thermal stress. Various fl oor coatings, tank coatings, mortars and specialty materials have given excellent service in their respective applications.
B RICK L ININGS AND T ILING S YSTEMS The main purpose o brick linings and tiling systems is to protect the underlying membrane against mechanical damage and to greatly enhance the chemical resistance o the entire corrosion protection system. We oer acid-proo bricks and tiles or almost any application.
Our Rubber Material
S PECIAL A DVANTAGES In industry, in environmental protection and in other areas, rubber lining materials are highly benef cial. This is because these materials oer particular advantages: • General corrosion resistance – the material is almost completely insensitive to variations in concentrations. With all-metal constructions, these variations can lead to serious damage. • High resistance to mechanical stress afforded by the steel base – pressure vessel designs in accordance with all recognized standards are possible. The use o all-plastic construction is restricted by the mechanical properties in the case o vessels above medium size. • For special applications, KCH rubber linings are also available with various ofcial approvals (e.g. WHG, KTW, FDA). Rubber linings rom KCH can be installed either in our workshops (shop lining) or directly on site (on-site lining). A crucial factor is the size o the item to be protected. On-site rubber linings can be used or high-quality corrosion protection even on large, immobile steel or concrete structures.
H ARD AND S OFT R UBBER L ININGS The hard or sot rubber linings supplied are based on natural or synthetic rubbers. The linings are manuactured in KCH’s own workshops and installed in a vulcanized or unvulcanized state.
OUR P RODUCT P ORTFOLIO GENAKOR VULCOFERRAN ® VULKODURIT ®KERABUTYL ® KERAPREN ® KERAPALON ® KERAFLON HAWOLINING PVDF (double-layer rubber/PVDF lining material) ® ®
ABOVE: RUBBER-LINED STORAGE T ANK. BELOW: RUBBER-LINED REACTOR. ABOVE RIGHT: DEMISTER IN A COATED SCRUBBER HEAD.
Our Polymer Products
Polymer coating systems are manuactured by KCH in a large variety o products. They dier in the type o base resin, f ller and reinorcement, as well as the application method. These systems are ideal or steel and concrete tanks and equipment. For special applications, KCH coating systems are also available with various of cial approvals (e.g. WHG, KTW, FDA). Depending on the application method used, a distinction can be made between the ollowing tank, vessel and fl oor coatings: • Spray-applied/brush-applied coatings • Trowel-applied coatings • Laminate coatings • Self-leveling coatings • Broadcast coatings • Screeds and leveling layers • Laying and jointing mortar Their benef ts include: • High chemical resistance • High compressive strength • High thermal stability • Large color range • Short installation times • Electrical discharge capability
The range o base resins includes epoxy resin, vinyl ester, novolak vinyl ester, polyester, epoxy novolac and hybrid novolac. Chemical-resistant mortars produce the horizontal and cross joints in vessel linings composed o a membrane layer with a tile or brick covering. They thus provide the connection between the semifnished ceramic products and membrane, and also between the individual ceramic tiles and bricks.
Depending on the type of chemicals involved, KCH employs various polymer and sodium silicate mortars.
Wall/pedestal coating with coved profile and connecting substrate
Transition zone between wall and coating
OUR PRODUCT P ORTFOLIO : KERAFLAKE KERAPLAN ®KERANOL ®KORROPLAST ® KERACID ® KERAKRET ® KERAPOX ® ®
20 Wall finish, available on site Plaster Coating Coved profile (e.g. Schlüter-DILEX-HKW) Coating
Concrete
Polymer mortar Coating 5 3 R
Concrete
0 0 1 m u m i n i m
Concrete
Expansion joint coating in vehical traffic area Separating sheet
PE O-ring seal
Soft rubber
Permanently elastic jointing mortar
Coating
Acid-proof tiles laid in polymer mortar
Concrete
Concrete
115 (240) approx. 125 (250)
115 (240) approx. 125 (250)
Rubber lining or polymer coating
Jointing/ laying material Equipment Acid-proof brick
Acid-Proof Bricks and Tiles
The main purpose o brick linings is to protect the underlying membrane – a rubber lining or polymer coating – against thermal and mechanical stresses in chemically stressed vessels, process equipment, piping, ducts and pits. Brick linings also increase the chemical resistance and durability o the corrosion protection system, as they prevent direct contact between the aggressive media and the membrane. For
good results, the materials used must be o optimum quality.
M ATCHING YOUR NEEDS Membrane layers, mortars and bricks are used in all manner o combinations, depending on the mechanical, thermal and chemical stresses involved. The aim is to provide a durable and hence cost-eective solution. Whatever your requirements: By teaming up
with KCH you’ll be working alongside experts right rom the time you select suitable materials.
WELL -E STABLISHED QUALITY KCH oers customized solutions with a long-standing record o excellent perormance: • Chemical resistance, e.g. against acids, alkalis, solvents and oxidizing media • Mechanical load-bearing capacity • Thermal stability The high quality o KCH products is guaranteed by the company’s own materials development work on mortars, and also by controlled manuacture and careul processing, either by its skilled workorce or by installation partners under KCH supervision.
OUR PRODUCT P ORTFOLIO • • • • •
Ceramic bricks Carbon bricks Graphite bricks Fused basalt and granite bricks Polymer-based laying and jointing mortars • Membrane layers based on polymers or made o rubber
ABOVE: STRUCTURAL SKETCH OF A T ANK BRICK LINING. LEFT: QUENCHER WITH MULTILAYER LINING. ABOVE RIGHT: COATING OF A FLUE G AS DUCT IN A FLUE G AS DESULFURIZATION PLANT.
Power Industry/Flue Gas Desulfurization Plants
An acid gas typically produced in coal-f red power stations during combustion is sulur dioxide, which may react with water to orm suluric acid. Depending on the coal’s sulfur content and the size o the power station, an annual amount o up to 120,000 tons o this gas is released into the atmosphere, where it causes acid rain. Statutory regulations have thereore been adopted in many
countries o the world to stipulate the removal o sulur dioxide rom power station exhaust gases. Most desulurization processes used or this purpose employ limestone and lime milk or sea water. All power station components coming into contact with the sulurous exhaust gases during these processes need to be reliably protected against corrosion. Such components are the
raw gas ducts with bypass, the clean gas ducts, the stack and heat exchanger, as well as the scrubbing tower with all internals. The corrosion-resistant materials specifed are rubber linings with vulcanized or unvulcanized rubber sheeting or manual installation, and also brick linings and polymerbased coatings.
OUR PRODUCT PORTFOLIO • Shop and on-site rubber linings • Polymer coatings (spray-/trowel-applied systems, laminate systems) • Acid-proof ceramic brick linings
P LANT SECTION
R UBBER LINING
C OATING
B RICK L INING
Raw gas duct, hot
(X)
Raw gas duct, cold
X
Raw gas inlet
X
X (X)
Flue gas scrubber
X
X
Raw gas duct, upstream of scrubber Clean gas duct, downstream o scrubber
(X)
X X
Heat exchanger
X
Stack
X
Other tanks and equipment items (emergency storage tanks, gypsum and slurry tanks, etc.) Piping systems
X X
E XPERIENCE WITH FGD PLANTS For more than 30 years now, KCH has successully used rubber linings in fl ue gas desulfurizatio n (FGD) plants. Over this period, the company has installed more than 1,000,000 m2 o on-site rubber linings. Flake coatings have been in use since 1980.
X
Clean gas Stack
(X)
Clean gas fan Heat exchanger Demister Slurry
Bypass Absorber
Boiler
Raw gas
Limestone Limestone slurry production and gypsum processing Gypsum
Sulfuric Acid Plants/Phosphoric Acid Plants
High suluric acid concentrations and the production processes involved in such plants demand hardwearing protection against corrosion. This means that adequately resistant materials need to be used in these plants. Drying and absorption towers, venturi scrubbers and acid storage tanks in steel are lined with a membrane layer in rubber sheeting or thermoplastic polymers. To protect this layer rom thermal or mechanical stresses and direct attack by acid, a brick lining is installed on top, oten several layers thick. The bricks are made rom ceramics, carbon, graphite, silicon oxide, insulating ceramics or oam glass. They are embedded in laying and jointing mortars based on sodium silicate and/or special polymers. For the packed towers in sulfuric acid production plants, sel-supporting domed grids have been specially developed in diameters o up to 10,000 millimeters. Their key advantage is that they do not require any supporting structure and thereore considerably reduce the manuacturing and assembly costs involved. In addition, the specially shaped bricks with the cross-partition rings placed on top ensure ree gas fl ow through the packed section, i.e. at least 55 percent. This ensures that the packed scrubber has a high efciency level.
Prepared phosphate rock Digestion tanks 3)5)
H3PO4 storage tanks 3)4)5)
Sulfuric acid plant 2)
H2SO4 storage tanks 3)4)
1) 2) 3) 4) 5)
H3PO4 process equipment 2)3)4)5)
Sulfur burning1)
Transport 3)
Mineral pyrite O2
Refractory lining Acid-proof brick lining and tiling Rubber lining Coating and flooring Carbon brick lining
Spray header
Membrane layer Acid-proof bricks
Packing 2"
Cross-partition rings Packing 3" Self-supporting domed grid SO2/SO3 gas (T=200°C)
A
H2SO4 94-98% T=60°C
Acid-proof brick lining Laying mortar: KERANOL WG311
LEFT : H2SO4 ABSORPTION TOWER. ABOVE R IGHT: AGITATOR IN A P APER MILL . BELOW RIGHT: PICKLING T ANK.
Other Application Fields STEEL- AND METAL-WORKING INDUSTRY/P ICKLING T ANKS Steel sheets are treated by special pickling processes beore being electroplated and supplied to the customer. The corrosion-resistant materials employed in these processes depend on the type o steel to be treated. As a rule, synthetic rubber linings are used in combination with a hard-wearing ceramic or carbon brick lining embedded in polymer mortar. The acids used in the pickling processes gradually degrade and thereore need to be regenerated. Regeneration takes place in a system located downstream o the pickling tank. Some process sections like the venturi scrubber and storage tank are given rubber and brick linings as well.
PULP AND P APER INDUSTRY
ORE PROCESSING/STEEL PRO -
The ground wood used as a basis or pulp and paper manuacture is treated with chemicals in digesters operated at elevated pressure and temperature. KCH supplies the required ceramic and carbon tiles or embedding in chemically resistant polymer mortar.
DUCTION
Cellular pulp still contains substances that need to be treated by subsequent bleaching. This process employs various chemicals such as chlorine, chlorine dioxide, hypochloride, hydrogen and oxygen. To protect the components involved in the process, KCH oers a system consisting o a vinyl ester resin laminate combined with ceramic tiles embedded in polymer mortars.
Protective granite ribs
Iron ore is melted in blast urnaces to produce crude steel. The corrosive and toxic gas constituents produced in this process are removed in a scrubbing process. KCH oers welltried vinyl ester resin systems and ceramic brick linings with corrosionresistant polymer mortars to protect the scrubber rom corrosion. Ores containing copper, gold, nickel or other metals are obtained by mining. Acids are added to the rocks, and heat and pressure are applied in order to extract the metals rom the slurry. The relevant process tanks are given corrosionresistant rubber and brick linings. The rubber lining both acts as a membrane layer and aords hard-wearing protection in certain process sections. Process sections exposed to high temperatures are given a brick lining in addition.
Roller slider in polyester concrete
"A" Layer build-up: - Steel - Rubber lining - 2 layers of standard bricks laid in polymer mortar
Detail "A"
Stub end build-up: - Steel - Rubber lining - 1 layer of acid-proof tiles laid in polymer mortar
Partition wall in acid-proof standard bricks laid in polymer mortar
Typical Applications
LEFT : PICKLING V AT. RIGHT: ABSORBER WITH CERAMIC BRICK-L INED FLOOR.
S TATIONARY T ANKS AND P ROCESS E QUIPMENT Industries
Application fields
Typical corrosion protection materials
Chemical industry
Reactor (phosphoric acid) H2SO4 storage tank H3PO4 storage tank Pigment reactor HCl storage tank Wastewater treatment basin Raw gas duct, hot Raw gas duct, cold Absorber, i nlet Absorber Clean gas duct Stack Slurry tank Venturi, inlet Venturi, spray jets Demister HCl pickling tank H2SO4 pickling tank Stainless steel pickling tank Agitator Thickener Reactor Bleaching tower
®
KERABUTYL V 1) KERABUTYL BS 1) ® KERABUTYL BS 1) ® GENAKOR 022 1) ® KERABUTYL VC 1) ® KERACID ES 110 3) ® KORROPLAST VE 310 2) ® KORROPLAST VE 310 2) ® KORROPLAST VE 310 2) ® VULCOFERRAN 2206 1) ® KERAFLAKE 6R 2) ® KORROPLAST VE 310 2) ® KERABUTYL BS 1) ® KORROPLAST VE 510 2) ® KERAFLAKE 6H 2) ® KORROPLAST VE 310 2) ® KERABUTYL VC 1) ® KERABUTYL V 1) ® KERABUTYL WBC 1) ® KERABUTYL BB-S 1) ® KERABUTYL BS 1) ® VULCOFERRAN 2208 1) ® KORROPLAST VE 510 2)
Carbon bricks in ®KERANOL FU 320 4) Acid-proo bricks in ®KERANOL WG 311 Carbon bricks in ®KERANOL FU 320 4)
2) Tank coating
3) Floor coating
4) Mortar
Power industry
Metal-working industry Metal ore processing Pulp and paper industry 1) Rubber lining
®
Acid-proo tiles in ®KERANOL FU 310
4)
4)
Acid-proo bricks in ®KERANOL FU 310
4)
Acid-proo bricks in ®KERANOL WG 3114) Acid-proo bricks in ®KERANOL FU 310 4) Acid-proo bricks in ®KERANOL FU 310 4) Acid-proo bricks in ®KERANOL FU 310 4) Carbon bricks in ®KERANOL UP 320 4) Acid-proo bricks in ®KERANOL FU 320 4) Acid-proo tiles in ®KERANOL FU 310 4) Acid-proo bricks in ®KERANOL FU 320 4) Acid-proo tiles in ®KERANOL VE 310 4)
Our Complete Range of Products and Ser vices
ENGINEERING AND SUPERVISION Once our KCH experts have teamed up with you to determine the operating conditions – in particular the chemical, mechanical and thermal stresses – and also the geometry of the components, the best material is chosen for the job in hand. You stand to beneft not only rom KCH’s wide range o materials but also rom the company’s development work in the feld o products and processes.
Ater the best material has been selected, the product is manuactured as specif ed and then installed at the customer’s site on the date agreed. In doing so, KCH sets great value on quality and reliability. I our products are installed by your own personnel, our specialists can be made available on request to supervise proper on-site installation in good time.
GENERAL CONTRACTING For decades now, KCH has been working to develop new and ever more cost-eective technical solutions. Our aim has always been to oer you the optimum right across the board – not just optimum materials, but also optimum processing and testing o our products. This is because KCH supplies everything you need from a single source – rom initial technical advice to quality assurance o the fnal product.
C OMPANY CERTIFICATES
VGB Working Group of Nuclear Power Station Operators
DIN EN ISO 9001
Certificate meeting DIN EN ISO 9001:2000 Proo o implementation and maintenance o a Quality Management System or the development, sale and production o corrosion-resistant linings and coatings, as well as systems, process equipment and components or the chemical industry, industrial corrosion protection and environmenal protection
SCC**
Certifcate on the implementation o a Saety Management System in conormity with the guiding principles SCC**: 2002 (general certification). The certificate is valid for: Floorings, transportation, processing and services & installation
KTA 1401 Rule
Proo o qualifcation or the system- and product-related Quali ty Assurance or the planning, manuacture, installation and servicing o process equipment, pipes and fttings with corrosion-resistant linings, coatings, rubber linings, acidproo linings and/or tiling systems or nuclear plants
WHG
Certificate meeting German Water Resources Act (WHG) § 19 I Proof of acceptance as specialists according to § 19 I WHG for the following activities: Coatings and rubber linings or vessels, piping, containments, sealing aces, as well as the installation, maintenance and reconditioning o vessels and piping made o thermoplastics and thermosets
Locations of KCH Company Group
Surface Protection KCH Industrial Surface Protection GmbH Berggarten 1 56427 Siershahn / Germany Phone: +49 2623 600-900 Fax: +49 2623 600-960
[email protected]
Composites KCH Composites GmbH Berggarten 1 56427 Siershahn / Germany Phone: +49 2623 600-600 Fax: +49 2623 600-660
[email protected]
For further information on industrial corrosion protection, please contact:
Contact:
© KCH Group GmbH, Siershahn, 2008 ® registered trademarks o KCH Group companies The data contained herein represent the current state o our product knowledge and are intended to provide general inormation on our products and their application spectra. In view o the variety and large number o application possibilities, these data should be regarded merely as general inormation that gives no guarantee o any specifc properties and/or suitability o those products or any particular application. Consequently, when ordering a product, please contact us or specifc inormation on the properties required or the application concerned. On request, our technical service will supply a profle o characteristics or your specifc application requirements without delay.
SP 900-02/2008e Printed in Germany
