The food and beverage industry depends on processing materials that will not contaminate the supply. When De Marne's stainless steel mustard piping system became compromised, they turn to an alternative material that could withstand the acidic and high temperature conditions of its line. About De Marne Since its startup in 1895, De Marne has been a major producer and world exporter of mustard. Named the official mustard supplier to the Royal Family, it’s highly regarded by consumers across the globe. Their products are available in all Dutch supermarkets, and are exported to many parts of Europe, the United States, Canada, Africa, New Zealand and Australia. The De Marne product presence is also expanding in eastern countries, such as Hungary, Czech Republic, Slovakia, Bulgaria, Romania and Poland. When corrosion was plaguing a previous system of piping and tanks, De Marne found a material that has now delivered reliability for more than a decade.
The chemical processing industry (CPI) continues to be a tough environment for creating safe composite structures that mitigate corrosion degradation. Today, more design engineers and material specifiers are calling for fiber reinforced plastics (FRP) in both new and replacement equipment used in chemical processing operations. B&D Plastics is a fabricator of dual laminate structures. Their unique fabricating process allows for the handling of fluids at very high temperatures and is impervious to corrosives. To develop products capable of standing up to its customers’ demanding applications, B&D Plastics specifies Corzan® chlorinated polyvinyl chloride (CPVC) manufactured by IPEX USA.
When the Environmental Protection Agency (EPA) published the Cluster Rule in 1998, pulp and paper manufacturers industry-wide began to make operational adjustments to become compliant by April 2001. Aimed at reducing emissions, the Cluster Rule called for the introduction of uniform pollution prevention and control technologies. For Smurfit-Stone Container Corporation, that meant a major reconfiguration of its bleached market pulp operation in Panama City, Florida, including extensive changes to its bleach plant. The corporation relied on BE&K Engineering Co. to identify cost-effective construction materials that would provide reliable performance in the harsh environment.
Industrial applications create some of the harshest conditions to which a material can be subjected. Consequently, the materials intended for use in these environments must be especially resilient. For instance, extremely corrosive chemicals essential in applications, such as chemical processing and wastewater treatment, must be stored, processed and transported safely and effectively. This requires containment materials that possess very high corrosion-resistant properties. The vessels designed to contain these chemicals have been traditionally composed of steel, fiberglass or exotic alloys, but chemical tank manufacturers have learned that the lifespan of these materials is limited by their inherent chemical resistance qualities. As a result, fabricators have begun the practice of adding more robust chemical-resistance layers into dual-laminate tanks to create longer-lasting containers. This has directly helped to limit the amount of downtime manufacturers must endure related to repairs and tank replacement.
In 2006, Netherlands-based AkzoNobel Base Chemicals B.V. constructed its chlorine plant based on Asahi membrane electrolysis technology. Based on current experiences with chlorinated polyvinyl chloride (CPVC) in its Rotterdam-Botlek plant and recommendations from AkzoNobel Technology & Engineering in Arnhem, plant engineers chose Corzan® CPVC for its pipelines (total 1000 meters or 3280 feet). Specific applications included: Shower system using standalone CPVC Wet chlorine using FRP / CPVC Anolyte using FRP / CVPC A Corzan CPVC piping system offered a number of advantages over other piping options, as well as versatility across many distinct needs.
Past Performance of Corzan CPVC System Proves Claims of Durability and Cost-Effective Service Life In 2005, and again in 2006, a Colorado-based litho plant decided to modify its two aluminum substrate manufacturing lines to increase capacity. Because of its already well established reputation, there was only one piping material considered by the engineering design team – Corzan's chlorinated polyvinyl chloride (CPVC). This is because the high-performance material had already proven it provides an extended service life, improved process utilization and lower life-cycle costs. It had been doing so since 1992 when it was first used on a new fluid handling line at the manufacturing center for medical x-ray film, photographic papers and aluminum lithographic printing plates. Nearly 15 years later, that schedule 80, CPVC line was still fully operational, providing the necessary corrosion resistance and mechanical strength to effectively handle the harsh chemicals being pumped under pressures up to 80 psi at temperatures up to 180˚F without leaks.
When Goodrich’s Aerospace Landing Gear Division changed its chromium emission control system from a wet-pack scrubbing system to dry-mist eliminators, it wanted to be certain it satisfied Environmental Protection Agency (EPA) requirements. The system designer / supplier provided two separate systems for Goodrich, each serving half of the company’s chromium processing lines with the capability of changing from one to the other in the event of an emergency. The company designed a system well below the MACT standard of 0.015 mg/cu meter. The two systems were installed in December 1995 and January 1996. When independent test data was collected and tabulated in July 1996, both systems were at least 10 times better than the designer’s criteria and even lower than the 0.015 mg/cu meter required by the MACT standard.
Sulfuric acid is one of the most dangerous chemicals in the world. Because of its corrosiveness, high concentrations can cause expensive damage to industrial machinery, and even weak concentrations can cause eye, nose, throat and skin burns in people, along with chronic respiratory damage in case of long-term exposure. However, when processed and handled properly, sulfuric acid is one of the most useful industrial chemicals in the world—an important ingredient in fertilizer, batteries, detergents and other products that are used around the world every day. Sulfuric acid is a by-product of zinc. When zinc ore, which also contains sulfur, is heated to 1750°F (950°C), it releases sulfur dioxide gas, which is then collected, cleaned and processed into sulfuric acid.
At Delta Air Lines' Atlanta-based Technical Operations facility, the landing gear of its entire fleet is taken apart, cleaned, metal-plated, and put back together again. A polyvinyl chloride (PVC) system was servicing the ventilation needs in the facilities plating shop, operating under highly aggressive chemicals, very high temperatures, and corrosive conditions. When the system began to fail, Delta knew it had to be replaced by a stronger, more chemically resistant material that could withstand the facility’s corrosive environment. The engineers found the solution to their problem in Corzan chlorinated polyvinyl chloride (CPVC). The Landing Gear Facility At Delta’s plating facility, a combination of chromic acid, sulfuric acid, and hydrofluoric acid is used in the various plating solutions during the rework of the landing gear. Portions of parts that do not have to be plated are masked in a 200ºF wax for protection prior to working the part. During the plating operations, landing gear parts are stripped to their base metals and replated to prolong the life of the equipment. Engine parts are broken down into pieces ranging from 3.75 to 1.5 inches for metal plating. Numerous parts used on and in the airplanes are rebuilt, not replaced, until the end of their usable lives. Replacing PVC Previously, PVC components serviced Delta’s plating facility piping and ventilation needs. Approximately two-and-a-half years after its installation, the ventilation duct became brittle and started to crack under the facility’s extreme conditions. Condensate formed in the system’s duct work, causing it to leak at the joint welds. ALTERNATIVES TO PVC: Delta, knowing the system had to be replaced, reviewed a variety of potential materials. PVDF, pure fiberglass, stainless steel and overwrap were among the materials considered by the company. Generic CPVC was originally passed over because Delta closely associated it with the failing PVC system already in place. Why Delta Trusted Corzan CPVC The Corzan team, along with the consulting engineering firm of Rosser Internationals (Atlanta, GA), presented the case of why Corzan CPVC was different from generic CPVC, and why its material was most ideally suited for Delta’s landing gear metal plating shop. HIGH TEMPERATURE RESISTANCE: Fiberglass-reinforced Corzan duct efficiently handles high temperatures up to 148ºF, while Corzan piping services condensate return temperatures up to 180ºF. When steam finds its way past a trap, the material can operate at temperatures up to 220ºF for short durations. CORROSION RESISTANCE: In addition to handling these high temperatures, Corzan CPVC proved to be resistant to the aggressive and corrosive chromic acid, sulfuric acid, and hydrofluoric acid chemical combination used by Delta in its plating operations. FASTER INSTALLATION: Along with a reliability to stand up to heat, chemicals, and pressures, installation is faster with CPVC. It's a lot easier to handle. Two men can carry a pipe section, reducing the need for lifting equipment. You can't do that with eight-inch stainless steel pipes. Unlike steel, you don't have to thread Corzan pipe, and cementing sections together is a lot faster and more efficient than welding. Gary Hopkins, President/CEO at Plastek Werks, Inc. COST-EFFECTIVE LONG TERM: Delta was looking for a replacement material that would provide lower maintenance and better cost-effectiveness. Knowing that this was a $3.9 million retrofit, we needed a product that would give us a lifespan of at least 10 years. Other materials may have lasted that long, but we couldn't justify the high replacement cost. The performance benefits we're realizing with CPVC thus far looks to more than cover our return on investment. David Woods, manager of Technical Facilities for Delta Delta decided to integrate Corzan CPVC piping and ducts to handle condensate return and tank ventilation. Corzan CPVC Sheet Delta also opted to use Corzan CPVC sheet in the facility's 5,600 square foot chemical spill containment area, which is located below the plating bath tanks. Given the aggressiveness of the chemicals used in the plating baths, deterioration was a major concern. Concrete was considered, but couldn't stand up to the harsh environment. Delta needed a "solve-all" coating that could handle the chemicals' corrosive nature, and prevent releases to the environment. Corzan CPVC was used with an underlayment for cushioning to contain any spillage that can occur as the parts are moved from one metal plating bath to another. Also, it can handle the unlikely event of a tank failure or rupture. Under Budget and Ahead of Schedule With a retrofit project this size, getting the job done on budget and on time are primary goals. The project, scheduled to take up to 15 months to complete, took only eight. Achieving minimum downtime and increased operations can be challenging with systems such as ours, where corrosion can decrease equipment life, interrupt production, and create potential environmental issues. Since installing Corzan components, our parts are cleaned and refurbished as scheduled, not backing up on the plant floor because the plating system doesn’t work. David Woods, manager of Technical Facilities for Delta The Solution You Can Rely On Corzan CPVC is the reliable solution for both piping and fabrication, such as sheet and rod. To learn more, or if you are interested in a free consultation on chemical resistance, process suitability or any technical questions, contact us.
Insights from an industry leader By Bryan Hutton, Corzan® Industrial Piping Systems, part of The Lubrizol Corporation Chlor-alkali plants create some of the most corrosive environments imaginable. The transport of harsh chemicals at extreme temperatures in combination with the high voltage electrolysis process can quickly compromise the integrity of most piping systems. So when one of the largest producers of chlor-alkali products in the world needed a proven-effective solution for transporting and storing its hydrochloric acid, it turned to Thorpe Plant Services in Houston which turned to Corzan® Industrial Systems from The Lubrizol Corporation.