Rubber Lining - Teknikum · 2017-11-24 · structure with rubber lining is most competitive in the...

Rubber Lining

Your guide to productiverubber lining solutions

Rubber liningTeknikum

Rubber lining is at its best in places where there is both mechanical and chemical strain.

Our solutionsOur skilled staff and dialogue with the clients make us stand out from the other operators in the field. With solid knowledge of several fields, our professional staff will help you to find the best possible solution to your problem.

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Energy production Nuclear power Coal power

Water treatment plants Ship building Offshore industry

Chemical industry Metal industry Mining industry

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Basic elastomers can be categorized into natural rubber and synthetic rubbers. Natural rubber is coagulated from the milky sap or latex produced by rubber trees. This is how we get natural rubber. There are tens of different kinds of natural rubber depending on the variety of the rubber tree, preservation, drying method and purity. The methods of handling crude rubber have an effect on the qualities of the final product. Synthetic rubber is manufactured from crude oil by processing. Various basic elastomers with new and different qualities can be manufactured by cutting and joining together different kinds of hydrocarbon fibres. Rubber mixtures that contain a basic elastomer, alloy, additives and auxiliary substances are used to manufacture rubber products. The qualities of the rubber such as hardness, firmness, and chemical sturdiness can be altered by changing the mixture. The lining materials used by Teknikum have either been produced by our own mixing factory or by our international partners. Rubber receives its final qualities in a chemical reaction called vulcanization. During this reaction, vulcanization substance within the

rubber mixture forms double bonds between elastomer chains, bonding them together permanently. Before vulcanization, the rubber mixture is plastic mass that adapts to the shapes of even the most difficult shaped structures. Vulcanization is usually done in an autoclave. The autoclave is a pressure container, in which rubber material receives its desired qualities and a bonding between the lining material and the basic material is formed under the conditions of approximately 5 bar pressure and temperature of 140 degrees Celsius. There are also rubber mixtures that can be vulcanized in lower heat with the help of, for example, hot water or process temperature. It is also possible to use pre-vulcanized linings with which the attachment happens with a separate attaching membrane. Pre-vulcanized rubber varieties are especially popular in large scale wear protection targets.

Rubber is a process and construction material with a growing popularity. Rubber is elastic polymer material, so called elastomer, the qualities of which can be regulated according to the requirements of the product that will be manufactured from it.

General information about rubber

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Rubber lining can be used as a layer preventing corrosion in targets for which maintenance free, long-term protection for either strong acids or alkalis is wanted. Especially corrosion caused by the chlorides

in sea water can be effectively prevented by rubber lining. Rubber lining has been successfully used in as wear protection coating, especially in mining industry. The elastic qualities of rubber effectively prevent the

wearing effect of different burdens towards it. The kinds of processes, where there is both chemical corrosion and mechanical wear simultaneously, can be protected by rubber lining.

There are special rubber mixtures available for these targets.

Using structures with rubber lining in different fields of industry

Industrial processes utilize the chemical and mechanical qualities of rubber.

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Hannu Huovila/TVO


Nuclear powerThe cooling system of a nuclear power plant requires a lot of water. This is why they are built close to water, normally by the sea. The chlorides in sea water cause corrosion problems also in welded structures made of alloy steel. We have seen in practice that structures made of normal structural steel and enforced with rubber lining suitable for the prevailing conditions can function without repair for tens of years. We in Finland have over 30 years of experience on structures with vulcanite lining. Structures with rubber lining are used in both the water cooling system in the reactor and the condensers and their pipes in the turbine plant.

Materials: Vulcanites made of natural rubber or styrene butadiene rubber

Energy production

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Ion exchangers for water treatment plantsThere are high quality standards for the water to be used when making superheated steam. The desired qualities for the water can be achieved in a separate water treatment plant. The ion exchangers, in which the ion exchanging mass is stimulated in a pressure container according to a specific program with either acid or alkali, have at their best a structure lined with rubber. When using vulcanization as protective coating, a maintenance free working time of over 30 years can be achieved, according to experience from the field.

Coal power plantWhen burning coal, there is sulfur dioxide in flue gases. According to the environmental legislation, only certain concentrations of sulfur dioxide can be let to the atmosphere. Because of this, depending on the output of the plant, its flue gases must be cleaned effectively enough. Here in Finland this is usually done by sulfur removal plants functioning with wet method. In sulfur removal plants, a mixture of sea water and limestone is sprayed against the flue gases, and the sulfur dioxide in the flue gases forms gypsum together with the limestone. The process is conveyed in an absorption tower, in which the action occurs in a closed cycle. Because of this, both the chlorides in the sea water and the sulfur created in the process cause a strong corrosion effect. In addition, there is strong wear effect because of the finely grated limestone, both in the recycling tubes and in the absorption tower itself. Both corrosion and wear protection can be achieved efficiently with rubber lining.

Materials: Butyl rubber (BIIR) halogenated with bromine

Materials: Vulcanites made of natural rubber or styrene butadiene rubber

Concerning structures lined with rubber, electrical energy production can be divided into two different plant types: coal burning condensate power plants and nuclear power plants.

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Ship buildingIn ship building, both the sea water pipes and their filters are subject to both mechanical wear and corrosion. Rubber varieties which are soft and mostly based on natural rubber have proven to be functional solutions. There are legislative restrictions also against emissions of the ships. When it comes to flue gases, the concentration of sulfur dioxide is lowered with flue gas washers, in which

structures with rubber lining protect the system from corrosion. In these targets, the experiences that have been gained from coal power plants are utilized.

Marine technology

Materials: NR, BIIR, chloroprene

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Offshore industryIn addition to corrosion and wear, also the mechanical strain against the structures can be suppressed by using rubber materials as flexible elements. In oil production rafts that float in the sea, the strain caused by the waves to the pipes rising from the sea floor is suppressed onto the surface of the pipes with flexible vulcanized layers. In these cases, particularly strict technical requirements are applied to the rubber varieties in use.

An apparatus functioning in a marine environment utilizes the qualities of rubbereither as material preventing corrosion or as technical construction material.

Materials: Chloroprene, CSM

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Chemical industry

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High temperatures and negative pressure as well as chemistry set forth challenges to the methods with which the effects destroying structural materials can be eliminated. When it comes to rubber lining methods, a wide base of elastomers and a reliable fixing method make it possible to solve the problems with coating.

Under techno-economic scrutiny, a steel structure with rubber lining is most competitive in the kinds of targets where the proportions of the structures are considerable, such as large containers and tanks. Rubber lining can also be used to protect concrete structures.

The usage of rubber lining has originally sprung from the needs of chemical industry. Strong acids and alkalis and their concentrates present a real problem to the processing machinery. .

Materials: Several different possibilities depending on the process.

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Metal industry

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Tanks and storage containers containing the liquid circulating in them are typically equipped with a rubber lining suitable for the process.

The structures used in industry can be protected against corrosion and wear with rubber or other elastomers. Rubber lining is an economical way to create products that must function under difficult conditions virtually maintenance free as well as long-lived.

There are phases in manufacturing various metals in which for example the surface of steel is chemically treated.

Materials: Vulcanite, BIIR, CR, CSM

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Talvivaara


Coatings attached by vulcanization are being used in mining industry mostly in the ore beneficiation phase. In flotation, flotation elements and mixing bodies in these elements are typical structures where rubber lining is used. Tailings that are created as a side product are typically transported to a landfill with steel pipes lined with rubber. The chemical beneficiation process in which the wanted metals are dissolved from the ore is an extremely difficult challenge to the process equipment in the sense of a corrosion problem. Rubber lining is used to prevent mechanical wear of the structures that occurs simultaneously. Chemicals, high temperature and mechanical wear and tear strongly direct the choice of the rubber type. Also the methods of attachment must be chosen according to the environment.

Mining industry

Materials: BIIR and its various versions, CSM.

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24h care: Teknikum provides service and checks for the rubber parts subject to wear, thus ensuring the continuity of the process at the Yara Siilinjärvi factory.

Rubber as a coating for steel structures protects them either against mechanical wear or corrosion.

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Normative chemical durability

Rubber lining qualities

Nobonit Novenit Nokim Cr CSM/PVC BIIR

Acids

Acetic acid Hydrofluoric acid

Phosphoric acid Chromic acid 50 %

Formic acid Sulphurous acid

Sulphuric acid 30 % Sulphuric acid 50 % Sulphuric acid 80 % Sulphuric acid 90 %

Hydrochloric acid Nitric acid 5 % Nitric acid 20 % Nitric acid 40 %

Hydrogen peroxide 30 %

Alkalis and solutions of salts

Ammonium hydroxide Bisulfites

Phosphates Hypochlorites

Potassium hydroxide Carbonates

Chlorides Brine

Sodium hydroxide Soap solution 1 %

Sulfates

Nobonit Novenit Nokim Cr CSM/PVC BIIR

Gases

Chlorine Chlorine water

Chlorine dioxide Sulfur dioxide

Organic compounds

Alcohols Acetone

Petrol (gasoline) Benzene

Ethyl acetate Phenol

Chlorinated hydrocarbons Methyl ethyl ketone

Mineral oils Turpentine

Resistant in normal use, minor effect at most Fairly resistant, minor effect possible Resistant in appropriate conditions, otherwise considerable effect Not recommended

The relative effect on various rubber qualities at room temperature are shown in the table. When the temperature increases, the effect of the chemicals increases, and the increase is dependent on both the polymer and the chemical.

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Anticorrosion coatings

Typical physical attributes

Anti-wear coatings

PolymerSpecific gravity Hardness

Tensile strength

Elongation at break

Adhesion to steel

Control voltage

Operating temperature

Nobonit NR 1,06 70±5 ShD > 40 MPa > 5 % > 6 MPa 5 kV/mm < 100°C

Novenit NR 1,26 70±5 ShD > 40 MPa > 2 % > 6 MPa 5 kV/mm < 85°C

Nokim NR 0,96 40±5 ShA > 10 MPa > 700 % > 6 N/mm 5 kV/mm < 70°C

BIIR BIIR 1,27 50±5 ShA > 5 MPa > 370 % > 4 N/mm 4 kV/mm < 100°C

CR CR 1,44 55±5 ShA > 10 MPa > 360 % > 4 N/mm 2,5 kV/mm < 85°C

CSM/PVC CSM/PVC 1,44 70±5 ShA > 8 MPa > 300 % > 4 N/mm 5 kV/mm < 80°C

PolymerSpecific gravity Hardness

Tensile strength

Elongation at break

Tear strength

Control voltage

Operating temperature

S 166000 NR/BR 1,10 60 ShA > 20 MPa > 500 % > 50 N/mm < 90 mm3 / 10 N < 70°C

S 143 000 NR/BR 1,03 40 ShA > 8 MPa > 400 % > 25 N/mm < 60 mm3 / 5 N < 70°C

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Rubber lining, and the working methods associated with it, place particular demands on the structure of the object to be lined. Steel, cast iron and acid-proof steel can be lined with rubber. In some cases concrete surfaces can be lined, too. The object must be structured so that access to every surface to be lined is easy by and by hand tools. An appropriate structure will facilitate lining and ensure a good result. To secure a good rubber lining, the following factors should be taken into account concerning the structure of the object:

• The surface to be lined should be smooth and impermeable, without pores from casting or welding.

• The structure must be welded from the side that will be lined. The welding seams have to be solid, tight and polished.

• Riveted structures and spot welding must be avoided.

• The structure to be lined must have walls so thick, or so reinforced with struts, that it does not deform during lining, transportation or utilization.

• No air pockets must be left inside the metal structures. If air pockets cannot be avoided, exit apertures must be drilled for the air on the opposite side of the lining.

• Sharp corners and edges must be avoided, and corners are to be rounded to radius of 4 mm.

• Badly corroded metal parts cannot be lined.

• The thickness of rubber on the metal should be taken into account when the pipes and pumps are being designed.

• Piping of diameter 20-200 mm should be made of seamless pipe. Larger sizes may be welded. Long or bended pipes should be divided into sections to facilitate lining.

Structures that can be lined with rubber

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Complicated pipe constructions must be divided by collar attachments into standard parts to facilitate rubber lining. In cases that are unclear, please send the drawings to us, so we can give more detailed instructions.

Measurements of straight pipes, bends and T-pieces to be lined.

Nominal size mm

Straight pipes A max mm

90º curves B max mm

T-pieces C max mm

T-pieces F max mm

T-pieces E max mm

50 4000 150 4000 300 150

65 4000 150 4000 300 150

80 5000 200 5000 400 150

100 6000 200 6000 450 250

125 6000 200 6000 500 400

150 6000 200 6000 500 400

200 6000 300 6000 500 400

250 6000 300 6000 500 400

300 6000 400 6000 1000 500

350 6000 400 6000 1000 500

400 6000 400 6000 1000 500

500 12000 400 6000 1000 500

Measurements of pipes to be lined with rubberStructures that can be lined with rubber

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Teknikum Oy • P.O. Box 13 • FI-38211 Sastamala, FINLAND • Tel. +358 3 519 11 • www.teknikum.com

Kiikka plant

Vammala plant

Teknikum Group is one of the most significant European experts in polymer technologyThe history of Teknikum goes back to year 1896 when

Teknikum was part of Gummifabrik rubber factory and later

merged with Nokia Group. Teknikum has operated with

its present name since 1989 when major part of rubber

business line of Nokia Group was transferred to Teknikum

Group.

Teknikum Group includes the Finnish units of Teknikum Oy

Vammala, Teknikum Oy Kiikka and Teknikum Sekoitukset Oy

in Kerava. Teknikum also has sales companies in Germany

and Russia, a production company in China and a Joint

Venture company called T-Plasztik in Hungary.

Teknikum provides product and service solutions related to

protection from wear and corrosion, industrial hoses and

hose assemblies designed for transfer of liquids and other

materials, and polymer products that are designed and

customer-specifically manufactured. Teknikum’s success is

rooted in excellent products, efficient production, and high-

quality customer service.

With each customer project, our objective is to find a cost-

efficient, sustainable, and well-designed solution, whether

it is a tailored or standard product.

We reach our goals through motivated and competent

employees, innovative material solutions, and dealing with

challenges that different industry segments have.

Teknikum’s business culture is not merely result-oriented:

responsibility in our operations is very important to us. We

have defined principles of good corporate governance,

a purchasing and safety policy, and an updated, uniform

equality plan for the entire Group. We have strict principles

for occupational safety and job satisfaction, environmental

issues, and financial responsibility. These principles

guarantee that the employees are satisfied and the

company is successful.

JiPS

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