Litzenburger ppt

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Composite Construction -

Thermoplastic

Liners for

Dual Laminates

& Steel

Tank Lining

Achim K.E. Litzenburger, * 1960

obtained a degree as « Diplom-Ingeneiur (FH) » in 1986

served in business as technical service manager, sales manager, group leader

experience in thermoplastics & additives, brick linings, surface treatment, analytics

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Founding

1857 by Carl Simon Söhne as a leather factory

Global operations

HQ in Kirn; Production Sites in DE, CZ, US & CNBranches in FR, GB, CH, IT, ES, PL, HK; Partners worldwide

Employees

1,237, approx. 1,000 of whom in Germany (2008)

Group revenue

EUR 303.7 million (2008)Products

Sheets, pipes, fittings, finished parts, rods, welding rods, profiles made of PE, PP, PVC, PETG, PVDF, E-CTFE

Production

Well in excess of 100,000 t.p.a.Markets

Industrial tank & equipment construction, mechanical engineering, transport technology, exhibition stand design, structural engineering, piping systems, automotive, environmental technology, life sciences

QM and EM

ISO 9001: 2008, ISO 14001: 2005, ISO/TS 16949 : 2002

Achim K.E. Litzenburger: Composites Africa 2009, ZA-Johannesburg

3 Achim K.E. Litzenburger: Composites Africa 2009, ZA-Johannesburg

Composite Construction

Definition & Structure

Dual Laminates

Steel Tank (Adhesive) Lining

Welding

Liner Materials & Adhesion Promoters

Quality Control of Semi-Finished Goods

Performance Criteria

Acceptance Tests

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Composite Constructions

consist of at least 2 different kind of materials that adhere together

always contain a chemical barrier layer (Liner)

realised as

Dual Laminates with Fibre Reinforced Plastic (GRP)

Adhesive Linings on steel (and concrete)

different from

Fix Point Linings (anchoring in concrete & plastics)

Loose or Hose Linings (PTFE in steel pipes)

Composite Construction Definition & Structure


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Liner

Thermoplastic (except: resin rich duroplastic layer)

Chemical Resistance

Abrasion Resistance

Structure

Duroplastic GRP (UP, VE)

Steel, concrete or other substrate (EP)

long term strength & mechanical stability

(GRP: reinforcement type, glass content, fibre orientation)



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Liner as Chemical Barrier Layer (SIMONA® PE-HWU)

Structure (GRP, Steel, Concrete)Adhesion Promoter (-SK)



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Composite Construction Dual Laminates

Construction / Fabrication (DIN EN 13121 / ASME RTP-1)

Thermoplastic laid on mandrill or (rectangular) mould

Weld seams prepared for (hot gas) welding

Weld seams removed were appropriate

Adhesive (duroplastic) resin layer with carbon fabric stripes

(Duroplastic) resin & glass rovings, mats, or chopped strands laid wet

Mandrill or mould removed after curing

Add dished ends, manholes & stub ends

Tightness proof, e.g. Spark Testing


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Liner Pre-Set

Wooden mandrills

Supporting steel rings & bars


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Cylinder winding

horizontal or vertical

dished or segmented ends to be connected


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Dished End Fabrication

hand lay up with chopped strands


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Design / ProcessingThermoformed Stub End →(SIMONA® PVDF-CV)

Welded Stub End ↓(SIMONA® PP-C-PK / PP-C/-H pipe + Glass fabric)


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Construction / Fabrication

Preparation of substrate (Steel) by means of shot blasting

Prime substrate (if necessary / required)

Coat substrate and soak adhesion promoter of the liner

Adhere liner sheet one by one (by means of weights or vacuum)

Weld liner sheets

Tightness Proof, e.g. by Spark Testing

Composite Construction Steel Tank (Adhesive) Lining


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Vakuumtechnik

Foil

Card Board

Vacuum Hose

Fabric

Liner plus adhesive

Sealing

Shot blasted Steel plus adhesive


Adhesion by means of Vacuum


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Steel Tank Lining with SIMONA®

PVDF-SK


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FRP

Cap Strip / Carbon Fabric

Weld Seam

Composite Construction Welding

Liner

Hot Gas Welding often applying to Dual Laminates


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Weld Seam Preparation

(Loose) fabric fibres may (partially) penetrate the weld seam

Remove Fabric at least 2 mm aside the welding area

Decreases risk of discontinuities (holidays) and thus increases weld strength on long term


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Weld Seam

Steel

Adhesive


Hot Gas Welding often applying to Adhesive Linings

Liner


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Welding DVS 2207

Hot Gas Welding (for Dual Laminates & Lining)

Polyolefins, PVC’s, Fluoroplastics #3

E-CTFE under inert atmosphere? Cap Strips increase adhesion?

Heated Tool Butt Welding (for Dual Laminates)

PE #1 PP #11 PVC #12 PVDF #15

Flow Fusion Welding


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PE-HDPP-C / PP-HPVC-NI / -RI (-U)PVC-C

PVDF-H / PVDF-CE-CTFEE-TFE

FEPPFAMFAm-PTFE

and …

Composite Construction Liner Materials


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Composite Construction Liner Materials

Amorphous Plastics = GOOD Adhesion

PVC-NI (U) / -RI & PVC-C can be directly bonded to

UP/VE resins

EP resins

Contact Adhesives

Semi-crystalline Plastics = POOR Adhesion

PE-HD, PP-C, PP-H, PVDF-H, PVDF-C, E-CTFE, PFA, MFA, E-TFE, FEP, m-PTFE & Fluoroelastomers require an Adhesion Promoter to ensure long term adhesion performance to resins & adhesives

Embedding a fabric into the molten thermoplastic

Pre-treatment of liner (PVDF / E-CTFE)


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Thermoplastic Polyester-Fabric (SK)

3-dimensional stretchable Glass-Fabric (GK)

Thermoplastic PP-Fabric (PK) *

Polyacrylnitrile-Fabric

PTFE-Fabric*

Carbon-Fabric

Natural-fibre based Fabrics

* patented

Composite Construction Adhesion Promoters for Sheets

Thermoplast

FRP, Steel or Concrete

Fabric

Adhesive /

Reactive Resin


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Composite Construction Adhesion Promoters for Sheets

Favourable Combinations:

SIMONA® PP-C-PK

SIMONA® PVDF-SK

SIMONA® E-CTFE-GKPP Fabric (PK) molten into PP-C


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Sanding (SV)predominantly for PE-HD / Concrete Applications

Glass-Fabric (GK) pressed into the by means of gas jet (re-) molten (PP-) surface

Polyacrylnitrile-Fabric

Chemically treated (CV)

Composite Construction Adhesion Promoters for Pipes & Fittings


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Composite Construction Adhesion Promoters for Pipes & Fittings

Favourable Combinations:

PVDF(-EL)-CV surface treatment after solvent cleaning provides a ready-for-lamination material


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Frontal Traction Adhesion Strength (FAS) a.o. DIN 53766-1 Type B

Composite Construction Quality Control of Semi-Finished Goods

Simplified arrangement (Type A)

Fabric backed liner

Adhesive / Resin


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Indicative Adhesion Performance (FAS)

fabric rupture

fabric pull-off perfect

fair

Req. FAS [MPa]BAYER WN 1250-2

PE 3.5

PP 3.5

PVC 7

PVDF 5

E-CTFE 5


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Peel Strength (PS-CD)

a.o. ASTM 1781 „Climbing Drum“


LinerAdhesion PromoterSubstrate

Req. PS-CD ASME RTP-1

50 in.-lbs./in.


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Lap Shear Strength (LSS)

a.o. DIN EN 13121-3, ASTM D 3846


LinerAdhesion PromoterSubstrate


Req. LSS [MPa]

PP(-H) 3.5PVC-U 7PVDF 5

E-CTFE, FEP, PFA 5

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Ring- & Segment- Shear Strength of reinforced pipes (PSS)

a.o. DIN 53769-1

pipes Ø ≤

90 mm

pipes Ø > 90 mm


Req. PSS [MPa]DIN 16964

PE 2.5PP 3.5

PVC 7PVDF 5


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Composite Construction Performance Criteria

Process

Temperature

Chemical Resistance

Permeation

Adhesion

Thermal Expansion

Service Condition (Continuous, Batch, Cycles, Gradients)

Pressure

Abrasion Resistance

Other

Design

Desired Life Time

Material Costs

Fabrication Capabilities


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Composite Construction Performance - Temperature

-40

-20

0

20

40

60

80

100

120

140

PVC-CAW PVC-C PE-HWU-SK

PP-DWU-SK

PP-C-PK

PVDF-SK -CV

PVDF-GK

E-CTFE-GK

[°C]

peak

peak


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Composite Construction Performance - Chemical Resistance

R Mass

Δm [%]

E- Modulus

QEC

Tensile Strength

QσS

Elongation at Break

QεR

Remark

PE

PP

<-2 / <+10 >38 >80 <50 / <200 Colour

PVC-U

PVC-C

<-0,8 / <+3,6 >83 >80 <50 / <125 Stress Cracks

PVDF

E-CTFE

<-0,8 / <+3,6 >43 >80 <50 / <125


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Composite Construction Performance - Chemical Resistance

Adhesion Promoters immersed in HNO3

11% + HF 7% at 40°CMaterial Original After 28 d

Thermoplastic PolyesterSIMONA® PE-HWU-SK, 4 mm

Whitish Yellowish; Incidental fibrous

E-Glass SIMONA® E-CTFE-GK, 2,3 mm

Off-white Dissolved (1 d)

PolyacrylnitrileE-CTFE-GK (KF) 2,3 mm

Pale orange Incidental fibrous

PolypropyleneSIMONA® PP-C-PK, 6 mm

Off-white Unchanged


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Composite Construction Performance - Permeation

Physical Process: Absorption – Diffusion – Desorption

Gases permeate faster than Liquids (higher partial pressure)

“curve” varies for individual species

liner thickness decreases linear (H2O permeation through PVDF)

strongly (operational) temperature driven


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Performance - FAS Polyolefins & PVC‘s

[MPa]

[°C]

PP-C-PK

PP-DWU-SK

PVC-CAW

PE-HWU-SK

Resin:

Palatal A 410

PP-DWU-GK


0

2

4

6

8

10

12

14

-35 -10 0 23 50 80 110 140

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[MPa]

[°C]

PVDF-C-SK

PVDF-SK

E-CTFE-GK

PVDF-GK

Resin:

Palatal A 410

Composite Construction Performance – FAS Fluoroplastics


0

2

4

6

8

10

12

14

16

18

-35 -10 0 23 50 80 110 140

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Composite Construction Performance – Design, Permeation & Processing

Dual Laminate after frequent cycles at elevated (110°C) and cold (20°C) temperature cycles …

… pay attention to different thermal elongation of substrate and liner

… take care for void-free lamination


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Composite Construction Performance - Material Costs

Relative Price Index of assorted (Liner-) Plastics

1/kg


0

5

10

15

20

25

30

35

40

PE-HWU PP-C / PP-DWU

PVC-CAW

PVC-C PVDF E-CTFE PFA

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Composite Construction Acceptance Tests

Visual Defects

Colour Penetration Test

Water tightness test (with or without pressure)

High Voltage Spark Testing


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Composite Construction Acceptance Tests

High Voltage Spark Test (Holidays / Disontinuities)

Carbon Fabric mandatory for Dual Laminates

Spark Testing with 3 to 6 KV/mm

Travel of 20-40 cm/s on weld seam surface

Decrease voltage for repeated tests (by 10%)


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Achim K.E. Litzenburger

Technical Service & Marketing

Fluoroplastics & Liners

Teichweg 16

DE-55602 Kirn

Phone: +49-6752-14396

Fax: +49-6752-14302

Mail to: [email protected]

Visit: www.simona.de



mailto:[email protected]

http://www.simona.de/

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