Abtrex rubber systems and suppliers
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Transcript of Abtrex rubber systems and suppliers
ABTREX INDUSTRIES INC.LININGS FOR ABRASION AND CORROSION
FABRICATORS • MANUFACTURERS • APPLICATORS
AND MORE……www.Abtrex.com Abtrex Inc. 800-959-0125
ABTREX HISTORY 1969 - Harold Byars starts Abtrex in metro-Detroit with partner, Jim
Graham Abtrex serves the electroplating industry providing vulcanized plating
equipment including cathodes and tanks
1980 – Abtrex purchases American Fiberglass Fabricators in Elkhart, Indiana
1985 –Abtrex opens Pittsburgh (Leetsdale, PA) facility Located on a rail spur, Abtrex enters into bulk material transport industry
1985 – Abtrex buys Blastco (abrasive blasting company) in South Bend, IN Entire Indiana operation is relocated from Elkhart to South Bend
2009 – Abtrex opens railcar lining operation in Cleveland, TX Located on UTLX property, Abtrex installs state-of-the-art robotic water
blaster to strip old linings from railcars
2011 – Abtrex acquires KSF Chemical Processes in Cambridge, ON
KSF owned intellectual property for Wean United Acid Recovery Systems
2014 – Abtrex Indiana breaks ground on new fabrication facility
ABTREX INDUSTRIES’ FACILITIES
South Bend, Indiana50,000ft², 30 employees
Metal & Plastic Fab, Linings & Coatingswww.Abtrex.com Abtrex Inc. 800-959-0125
OUR QUALITY
www.Abtrex.com Abtrex Inc. 800-959-0125
OUR SAFETY
ABTREX SAFETY• Experience Modification Rate (EMR):
0.81• No recordable incidents this year• No lost days for 3+ years
www.Abtrex.com Abtrex Inc. 800-959-0125
CAPABILITIES• Engineering Services• Corrosion and Abrasion Resistant Linings
• Tank and Vessel Fabrication• Metal• Plastic• Fiberglass
• Pipe Fabrication• Rubber-lined Steel Pipe and Fittings• Fiberglass Reinforced Plastic (FRP) Pipe and Fittings
• Field Installations, Maintenance & Repairs
www.Abtrex.com Abtrex Inc. 800-959-0125
DESIGN AND BUILD SERVICES
Engineering and Design Tools
Solidworks 3D CAD design SoftwareSIEMENS Unigraphics PLM SoftwareAutodesk AutoCAD Software
• 3-D Modeling Software:
• General FEA (Finite Element Analysis)www.Abtrex.com Abtrex Inc. 800-959-0125
DESIGN AND BUILD SERVICES
Electro-Galvanizing Rollwww.Abtrex.com Abtrex Inc. 800-959-0125
RUBBER COMPOUNDS & MANUFACTURERS
COMPOUNDS• Natural (NR)• Styrene Butadiene
(SBR)• Neoprene (CR)• Nitrile (NBR)• Butyl (IIR)• Bromobutyl (BIIR)• Chlorobutyl (CIIR)• FDA-Approved• Non Staining• Hundreds more
MANUFACTURERS
www.Abtrex.com Abtrex Inc. 800-959-0125
RUBBER MANUFACTURING• Natural Rubber is tapped from
trees much like maple syrup• Countries of origin:
• Malaysia• Liberia• Indonesia• India• Brazil
Synthetic Rubber was developed in 1942 due to shortage of material and costs related to WWIIwww.Abtrex.com Abtrex Inc. 800-959-0125
RUBBER MANUFACTURING• Raw materials are combined per
compound recipes• Ingredients are blended in Banbury
mixers• Some linings need extra mixes to
breakdown• Rubber is cross linked by sulfur
and carbon black
Rubber Mill
Banbury Mixer
Carbon Black and Sulfur
RUBBER MANUFACTURINGCalender Process
• Blended rubber material is processed through a series of hard pressure rollers to create a smooth sheet of rubber
• Heat is applied during calendering process to ensure maximum ply adhesion
• Extruder & Inverted Cracker help to breakdown rubber
• No heat memory generated• Helps maintain proper cure
www.Abtrex.com Abtrex Inc. 800-959-0125
PRE-CURED VS. UNCURED RUBBER
UncuredAdvantages:
• Most Suitable for Shop work• Superior Bond in an
Autoclave• Ease of Application
Disadvantages:• Special (Cold) storage
needed• Potentially higher cost to
cure in field
Pre-CuredAdvantages:
• Most Suited for field service• Can be used on large diameter
vessels when steam is not available• No special storage needed
Disadvantages:• Lower bond strength• Can be difficult to apply
ELASTOMER SELECTION
www.Abtrex.com Abtrex Inc. 800-959-0125
ELASTOMER SELECTION
Common Rubber Lining Materials(Higher durometer rubbers generally help reduce water permeation)
Lining Type Optimum Conditions Max Temp. Limitations
Natural Rubber 60 Duro. Sliding abrasion 160°F Heat, solvents, oil
Natural Rubber 40 Duro. Impingement abrasion 170°F Heat, solvents, oil
SBR Synthetic Rubber High abrasion 180°F Heat, Oil & Gasoline
Neoprene Oil & Heat resistant 220°F Solvents
Nitrile Hydrocarbon solvents. oil 220°F High abrasion
Chlorobutyl Chemical Resistant 230°F Oil & Gasoline
Bromobutyl Acid, caustic & Heat resistant 260°F Oil & Gasoline
www.Abtrex.com Abtrex Inc. 800-959-0125
www.Abtrex.com Abtrex Inc. 800-959-0125
ELASTOMER SELECTION
Recommended Lining Thickness
www.Abtrex.com Abtrex Inc. 800-959-0125
APPLYING RUBBER – ABRASIVE BLAST
Surfaces to be lined are blasted to an SSPC-SP5 / NACE 1 White Metal Blast Cleaning profile
www.Abtrex.com Abtrex Inc. 800-959-0125
SSPC-SP1 Solvent CleaningSSPC-SP2 Hand Tool CleaningSSPC-SP3 Power Tool CleaningSSPC-SP5 / NACE 1 White Metal Blast CleaningSSPC-SP6 / NACE 3 Commercial Blast CleaningSSPC-SP7 / NACE 4 Brush-Off Blast CleaningSSPC-SP10 / NACE 2 Near-White Blast CleaningSSPC-SP11 Power Tool Cleaning to Bare Metal
APPLYING RUBBER – ABRASIVE BLAST
www.Abtrex.com Abtrex Inc. 800-959-0125
APPLYING RUBBER – ABRASIVE BLAST
Blasted surfaces are verified per ASTM D4417
Digital Surface Profile Gauge
Replica Tape & Micrometer/Thickness Gauge
www.Abtrex.com Abtrex Inc. 800-959-0125
APPLYING RUBBER – ADHESIVE SYSTEM
Surfaces are prepped post-blast with adhesive system
Three-Part System1.Primer (Green) -
applied to substrate.
2.Covercoat (Red) – applied over primer.
3.Cement (Black) – applied to both substrate and sheet rubber.
www.Abtrex.com Abtrex Inc. 800-959-0125
APPLYING RUBBER – PATTERNS
Surfaces are measured and sheet rubber is cut into patterns to match the part’s geometry
APPLYING RUBBER – SKIVING
Rubber panels are skived with a 45° up skive on the bottom and the top has a 45° down
skive
Seam Styles: Skive Butt Joint and Overlap
www.Abtrex.com Abtrex Inc. 800-959-0125
APPLYING RUBBER – STITCHING
Every square inch of rubber is stitched, or pressed into the blasted and cemented profile
www.Abtrex.com Abtrex Inc. 800-959-0125
APPLYING RUBBER – LINING PIPE
• Sheet rubber is rolled into a tube and sealed at both ends.
• Rubber bladder is inflated to specified psi.• Air pressure is used instead of hand stitching to bond
rubber to substrate.
APPLYING RUBBER – LINING PIPE
• Strings are run to allow air to escape between lining and substrate
www.Abtrex.com Abtrex Inc. 800-959-0125
APPLYING RUBBER – LINING PIPE
• Collars are bolted to each end of pipe
www.Abtrex.com Abtrex Inc. 800-959-0125
APPLYING RUBBER – LINING PIPE
• Ends are capped with blind flanges. • One end has an air fitting to inflate bladder.
www.Abtrex.com Abtrex Inc. 800-959-0125
APPLYING RUBBER – AUTOCLAVE CURE
• Vulcanization Process – pressurized steam cure• Rubber manufacturer provides specifications for cure temperature
and time (eg. 6 hours at 275°F)• Autoclave is pressurized to approx. 10 to 30 psi (varies with
temperature)• Data (temperature, time and pressure) for cure is captured on a
chart recorder• Linings for vacuum service will require longer cure times
TEMPERATURES FOR VARIOUS
PRESSURESPress. Temp.10psi 240°F (115°C)15psi 250°F (121°C)20psi 258°F (125°C)30psi 274°F (134°C)
APPLYING RUBBER – INTERNAL PRESSURE CURE
• Used for larger parts that cannot be placed in autoclave• Condensation needs to drain• Thick steel creates a greater heat sink and requires
longer heat-up times. www.Abtrex.com Abtrex Inc. 800-959-0125
APPLYING RUBBER – ATMOSPHERIC CURE
• Used for larger parts that cannot be placed in autoclave• Requires longer cure times than autoclave• Slightly lower durometer hardness than autoclave cured
liningswww.Abtrex.com Abtrex Inc. 800-959-0125
TESTING RUBBER LININGS:HOLIDAY/SPARK TESTING
• Per ASTM D5162-08 - Standard Practice for Discontinuity (Holiday) Testing of Nonconductive Protective Coating on Metallic Substrates
• Detects pinholes in linings before & after cure
• Methods:• Method A – Low Voltage Wet
Sponge• Method B – High Voltage
Spark• Can potentially damage
lining• Test voltages determined
by material thickness (see table)
High-Voltage Spark Tester Low-Voltage Sponge Tester
• Per ASTM D 429 - Standard Test Methods for Rubber Property—Adhesion to Rigid Substrates
• Measures static strength of rubber adhesion to metals or other rigid materials
• Eight different methods• Types of Failure measured:
• R – Failure in the rubber• RC – Failure in the rubber-cover cement• CP – Failure in the cover cement-prime cement• M or CM – Failure in the prime cement-metal interface
TESTING RUBBER LININGS:ADHESION TESTING
Method B
TESTING RUBBER LININGS:DUROMETER HARDNESS
• Per ASTM D2240 - Standard Test Method for Rubber Property — Durometer Hardness
• Determines indentation hardness of thermoplastic elastomers, vulcanized rubber, cellular and gel-like materials and some plastics
• 12 classifications of rubber hardness: A, B , C, D, E, M, O, OO, OOO, OOO-S and R
Digital Durometer
GaugeGauges are calibrated to hardness standards
Installed, cured lining being tested
RUBBER LINED SLURRY PIPELINES
• Mineral Concentrates:• Iron ore• Gold• Base Metals (Cu, Ni, Pb, Zn)
• Rare Earth minerals• Oil Sands• FGD (Gypsum)• Potash• Tailings
www.Abtrex.com Abtrex Inc. 800-959-0125
RUBBER-LINED STEEL PIPE
RUBBER-LINED STEEL ABSORBER RECYCLE PIPE COMPONENTS
RUBBER-LINED STEEL PIPE
I.D. of Absorber Recycle Pipe Header for Duke Energywww.Abtrex.com Abtrex Inc. 800-959-0125
RUBBER-LINED STEEL PIPE
48” RUBBER-LINED A/R PIPE WITH AWWA RING FLANGES AND VERTICAL SUPPORT
BRACKETS www.Abtrex.com Abtrex Inc. 800-959-0125
PIPELINE WEAR FACTORS
Material Being Handled Particle sizeParticle shapeParticle HardnessChemical composition
Lining materialAbrasion resistanceChemical ressistanceTemperature resistanceImpact resistanceThickness
DesignFlow velocityImpact velocityImpact angleBend radiusPiping Layout
www.Abtrex.com Abtrex Inc. 800-959-0125
PVC
Mild Steel
HDPE
Alumina
HCWCI
Rubber
PU
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
Wear Rate (mm³/hr.)
Figure 16 -- Olengorsky Iron Ore18
(25 NB Pipe, 18% vol. concentration, 3.7 m/s velocity)
Material
PIPELINE WEAR RATES
Ref. SME Paper Combating Pipeline Wear by N.R. Stewart
www.Abtrex.com Abtrex Inc. 800-959-0125
PIPE FLOW VELOCITY
Minimum velocity to avoid settling (Wilson)Example: 250mm pipe, 0.5mm, 3.8 sg gives 4.5 m/s.
www.Abtrex.com Abtrex Inc. 800-959-0125
GENERAL GUIDELINES FOR LINED PIPING SYSTEMS
Select optimum flow velocity Maximum 10 m/s for elastomer linings
Use 3D/5D Elbows – 3 to 5 times pipe diameter(as opposed to standard long radius elbows which are 1.5 times pipe diameter)
Avoid inclined pipe runs Vertical or Horizontal piping preferred
Avoid direct impingement on tank walls and bottom Direct impingement is preferred to angular impingement Use “rock box” tank design if possible
Launder bottom slope 10-15%
www.Abtrex.com Abtrex Inc. 800-959-0125
OUR CUSTOMERS
www.Abtrex.com Abtrex Inc. 800-959-0125
REFERENCES Corn Sweetener
Archer Daniels Midland Company (ADM) Contact: Darryl Munsinger400 West Erie Rd Phone: 507-537-2511Marshall, MN 56258-2744 Cargill Inc. Contact: Ms. Adebola Durosawo3201 Needmore Rd Phone: 937-237-2561Dayton, OH 46414
Field Erected Tanks M.L. Smith Jr., Inc. Contact: Moe Hansen2330 Farmerville Hwy Phone: 318-255-4474Ruston, LA 71213-1717
Kennedy Tank Contact: Paul Bolin833 East Sumner Avenue Phone: 317-780-3528Indianapolis, IN 46227
www.Abtrex.com Abtrex Inc. 800-959-0125
REFERENCESPlating/Galvanizing
Walbridge Coatings Contact: David Swemba30610 E Broadway Phone: 419-661-5952Walbridge, OH 43465
Lacks Enterprises Contact: Ben Wesley5460 Cascade Road SE Phone: 616-443-6087Grand Rapids, MI 49546
IN Tek/IN Kote (Areclor-Mittal) Contact: James McGranahan30755 Edison Road Phone: 574-654-1733New Carlisle, Indiana 46552
Steel ProcessingSteel Warehouse Contact: Jerry Czajkowski2722 West Tucker Dr. Phone: 574-236-5100South Bend, IN 46619 US Steel Contact: Samer Aweidah600 Grant Street Phone: 412-433-5833Pittsburgh, PA 15219 [email protected]
REFERENCESPower Plants
Duke Energy Contact: Russ Steinmetz6293 Beaver Rd Phone: 513-467-4839Rabbit Hash, KY 41091 [email protected] EON-US Contact: Charles Ransdell820 W. Broadway Phone: 502-627-3299Louisville, KY 40232 Hitachi America Limited Contact: William Knowles50 Prospect Phone: 914-524-6700Tarry Town, NY 10591
Big Rivers Electric (Coleman Station) Contact: Christa Lucas4982 River Rd Phone: 270-844-6983Hawesville, KY 42348
Duke Energy Progress Contact: Reggie Clay1700 Dunnaway Rd.Phone: 336-597-6116Semora, NC 27343 [email protected]
REFERENCESMining Equipment
FLSmidth Salt Lake City Contact: Mark Nielsen7158 South FLSmidth Drive Phone: 801-871-7936Midvale, Utah, USA 84047 [email protected] Weir Minerals Contact: Debra Switzer2701 S Stoughton Rd. Phone: 970-665-9149Madison, WI
Metso Minerals Industries, Inc. Contact: Betsy Day240 Arch St. Phone: 717-849-7201York, PA 17403
Eriez – Flotation Division Contact: Kris Barnes7168 Honeyman St. - Unit 1 Phone: 604-952-2300Delta, BC Canada V4G 1G1
URS Contact: Michelle Rodriguez8181 E. Tufts Avenue Phone: 303-796-4719Denver, CO 80237 [email protected]
www.Abtrex.com Abtrex Inc. 800-959-0125
THANK YOU!
Doug Hardy, Sales Engineer • 800.959.0125 • [email protected]
Chuck Groom, Project Manager • 800.959.0125 • [email protected]
Keith Byars, President • 800.959.0125 • [email protected]
Please contact us for more information or questions about today’s presentation.
www.Abtrex.com
www.Abtrex.com Abtrex Inc. 800-959-0125