KCH Surface Lining

su r fa c e P r o t e ct i onCorrosion Protection – Optimum Solutions for Every Project www.kch-group.com Intense research and development work combine with a high level of production know-how and longstanding installation experience to complete the picture. or from fiber-reinforced phenolic resin materials to ensure reliable and long-lasting resistance to chemicals. as well as the installation and repair of these high-tech items. KCH supplies optimum high-quality products to cater for virtually all corrosion protection applications. Besides offering a high level of materials and production expertise to its globally active customers. thermal and mechanical stresses. many of them employees with long service records. as well as the proper processing and installation of our materials and products. Not least of these is the high level of skill and professionalism among our workforce. on request. 2 . tanks and process equipment exposed to high chemical. Its operations span the globe. KCH Composites also provides comprehensive services such as individual advice and planning. A high level of development and production skills combines with many years‘ installation experience and close customer contact to make our range of products and services so unique. These items are manufactured either from fiber glass-reinforced plastics with or without an inner liner. our workforce is growing ever more skilled in solving technical problems Production and Sales Sales Office while upholding quality standards. With its long-standing experience and vast know-how to draw on. C OMPOSITES The product portfolio of KCH Surface Protection includes piping systems. brick linings and tiling systems for industrial surface protection and anti-corrosion systems. Needless to say. B USINESS A REAS S URFACE P ROTECTION The product portfolio of KCH Surface Protection includes rubber linings and coatings. KCH’s excellent international reputation is based on numerous factors. this range also includes advice in the planning and design of anti-corrosion and surface protection systems. Aided by regular training programs and direct contacts with our customers in an advisory role.KCH – Your Partner for Industrial Surface Protection Systems Worldwide The KCH Company Group has been specializing in industrial surface and corrosion protection systems for 140 years now. P OLYMER C OATINGS KCH’s polymer products are ideal materials for protecting structures and building components under high chemical and thermal stress. The hard or soft 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.Wide-Ranging Applications for Our Materials ABOVE: SULFURIC ACID PLANT AT CODELCO/ SALVADOR (LURGI). tanks. BELOW: SECONDARY CONTAINMENT COATING. process equipment and other plant components therefore need to be given reliable and long-lasting protection. B RICK L ININGS S YSTEMS AND T ILING R UBBER L ININGS Rubber linings are used for protecting highly stressed steel structures and concrete components exposed to corrosive stresses. in particular chemical. KCH supplies an extensive range of corrosion-resistant materials for the purpose. Various floor coatings. mortars and specialty materials have given excellent service in their respective applications. The main purpose of brick linings and tiling systems is to protect the underlying membrane against mechanical damage and to greatly enhance the chemical resistance of the entire corrosion protection system. To ensure proper performance over the long term. thermal and mechanical loads. We offer acid-proof bricks and tiles for almost any application. Components in chemical processing plants are exposed to a wide variety of stresses. tank coatings. 3 . in environmental protection and in other areas. This is because these materials offer particular advantages: • General corrosion resistance – the material is almost completely insensitive to variations in concentrations. The linings are manufactured in KCH’s own workshops and installed in a vulcanized or unvulcanized state. With all-metal constructions. rubber lining materials are highly beneficial.g. On-site rubber linings can be used for high-quality corrosion protection even on large. KCH rubber linings are also available with various official approvals (e. 4 . • For special applications. immobile steel or concrete structures. Rubber linings from KCH can be installed either in our workshops (shop lining) or directly on site (on-site lining). • High resistance to mechanical stress afforded by the steel base – pressure vessel designs in accordance with all recognized standards are possible. The use of all-plastic construction is restricted by the mechanical properties in the case of vessels above medium size.Our Rubber Material S PECIAL A DVANTAGES In industry. ABOVE RIGHT: DEMISTER IN A COATED SCRUBBER HEAD. O UR P RODUCT P ORTFOLIO GENAKOR VULCOFERRAN ® VULKODURIT ® KERABUTYL ® KERAPREN ® KERAPALON ® KERAFLON HAWOLINING PVDF (double-layer rubber/PVDF lining material) ® ® ABOVE: RUBBER-LINED STORAGE TANK. A crucial factor is the size of the item to be protected. WHG. KTW. FDA). these variations can lead to serious damage. H ARD AND S OFT R UBBER L ININGS The hard or soft rubber linings supplied are based on natural or synthetic rubbers. BELOW: RUBBER-LINED REACTOR. They thus provide the connection between the semifinished ceramic products and membrane.Our Polymer Products Polymer coating systems are manufactured by KCH in a large variety of products. as well as the application method. For special applications. vinyl ester.g. Schlüter-DILEX-HKW) Coating R 35 Polymer mortar Coating Concrete Concrete Separating sheet Soft rubber Coating Expansion joint coating in vehical traffic area PE O-ring seal Permanently elastic jointing mortar Acid-proof tiles laid in polymer mortar Concrete Concrete 115 (240) approx. epoxy novolac and hybrid novolac. O UR P RODUCT P ORTFOLIO : KERAFLAKE KERAPLAN ® KERANOL ® KORROPLAST ® KERACID ® KERAKRET ® KERAPOX ® ® Wall/pedestal coating with coved profile and connecting substrate Transition zone between wall and coating 20 Wall finish. novolak vinyl ester. KTW. a distinction can be made between the following tank. 125 (250) minimum 100 5 . and also between the individual ceramic tiles and bricks. Depending on the application method used. available on site Plaster Coating Coved profile Concrete (e. KCH employs various polymer and sodium silicate mortars.g. vessel and floor 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 benefits include: • High chemical resistance • High compressive strength • High thermal stability • Large color range • Short installation times • Electrical discharge capability The range of base resins includes epoxy resin. Chemical-resistant mortars produce the horizontal and cross joints in vessel linings composed of a membrane layer with a tile or brick covering. KCH coating systems are also available with various official approvals (e. filler and reinforcement. They differ in the type of base resin. polyester. FDA). WHG. These systems are ideal for steel and concrete tanks and equipment. Depending on the type of chemicals involved. 125 (250) 115 (240) approx. mortars and bricks are used in all manner of combinations. as they prevent direct contact between the aggressive media and the membrane. WELL-ESTABLISHED QUALITY KCH offers customized solutions with a long-standing record of excellent performance: • Chemical resistance. For good results. thermal and chemical stresses involved. e. either by its skilled workforce or by installation partners under KCH supervision.Rubber lining or polymer coating Jointing/ laying material Equipment Acid-Proof Bricks and Tiles Acid-proof brick The main purpose of brick linings is to protect the underlying membrane – a rubber lining or polymer coating – against thermal and mechanical stresses in chemically stressed vessels. depending on the mechanical. Brick linings also increase the chemical resistance and durability of the corrosion protection system. piping. alkalis. ducts and pits. LEFT: QUENCHER WITH MULTILAYER LINING. the materials used must be of optimum quality. ABOVE RIGHT: COATING OF A FLUE GAS DUCT IN A FLUE GAS DESULFURIZATION PLANT. The aim is to provide a durable and hence cost-effective solution. Whatever your requirements: By teaming up with KCH you’ll be working alongside experts right from the time you select suitable materials. MATCHING YOUR NEEDS Membrane layers. process equipment. solvents and oxidizing media • Mechanical load-bearing capacity • Thermal stability The high quality of KCH products is guaranteed by the company’s own materials development work on mortars. 6 . and also by controlled manufacture and careful processing. against acids. O UR P RODUCT 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 of rubber ABOVE: STRUCTURAL SKETCH OF A TANK BRICK LINING.g. Power Industry/Flue Gas Desulfurization Plants An acid gas typically produced in coal-fired power stations during combustion is sulfur dioxide. etc.000 m2 of on-site rubber linings. Most desulfurization processes used for this purpose employ limestone and lime milk or sea water. as well as the scrubbing tower with all internals. Clean gas Heat exchanger Clean gas fan Demister Bypass Slurry Absorber Limestone Limestone slurry production and gypsum processing Gypsum Boiler Raw gas 7 . hot Raw gas duct. Flake coatings have been in use since 1980. Depending on the coal’s sulfur content and the size of the power station. Statutory regulations have therefore been adopted in many countries of the world to stipulate the removal of sulfur dioxide from power station exhaust gases. cold Raw gas inlet Flue gas scrubber Raw gas duct. KCH has successfully used rubber linings in flue gas desulfurization (FGD) plants. Such components are the raw gas ducts with bypass. where it causes acid rain. upstream of scrubber Clean gas duct.000 tons of this gas is released into the atmosphere. gypsum and slurry tanks. the company has installed more than 1. an annual amount of up to 120. laminate systems) • Acid-proof ceramic brick linings P LANT S ECTION Raw gas duct. Over this period. which may react with water to form sulfuric acid. O UR P RODUCT P ORTFOLIO • Shop and on-site rubber linings • Polymer coatings (spray-/trowel-applied systems. the stack and heat exchanger.000. All power station components coming into contact with the sulfurous exhaust gases during these processes need to be reliably protected against corrosion. The corrosion-resistant materials specified are rubber linings with vulcanized or unvulcanized rubber sheeting for manual installation. downstream of scrubber Heat exchanger Stack Other tanks and equipment items (emergency storage tanks. and also brick linings and polymerbased coatings. the clean gas ducts.) Piping systems R UBBER L INING C OATING (X) X X B RICK L INING X (X) X (X) X X X X X (X) X X X EXPERIENCE WITH FGD PLANTS Stack For more than 30 years now. In addition. ABOVE RIGHT: AGITATOR IN A PAPER MILL. 8 . silicon oxide. a brick lining is installed on top. graphite. carbon. venturi scrubbers and acid storage tanks in steel are lined with a membrane layer in rubber sheeting or thermoplastic polymers. Their key advantage is that they do not require any supporting structure and therefore considerably reduce the manufacturing and assembly costs involved. often several layers thick. self-supporting domed grids have been specially developed in diameters of up to 10. insulating ceramics or foam glass. The bricks are made from ceramics. This means that adequately resistant materials need to be used in these plants. BELOW RIGHT: PICKLING TANK. To protect this layer from thermal or mechanical stresses and direct attack by acid. the specially shaped bricks with the cross-partition rings placed on top ensure free gas flow through the packed section. They are embedded in laying and jointing mortars based on sodium silicate and/or special polymers. at least 55 percent.000 millimeters. Drying and absorption towers. Prepared phosphate rock Digestion tanks 3) 5) H3PO4 process equipment 2) 3)4)5) H3PO4 storage tanks 3) 4)5) Transport 3) H2SO4 storage tanks 3) 4) Sulfuric acid plant 2) Sulfur burning1) Mineral pyrite O2 1) 2) 3) 4) 5) Refractory lining Acid-proof brick lining and tiling Rubber lining Coating and flooring Carbon brick lining Spray header Packing 2" Membrane layer Acid-proof bricks 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. i. This ensures that the packed scrubber has a high efficiency level.Sulfuric Acid Plants/Phosphoric Acid Plants High sulfuric acid concentrations and the production processes involved in such plants demand hardwearing protection against corrosion.e. For the packed towers in sulfuric acid production plants. The relevant process tanks are given corrosionresistant rubber and brick linings.Steel .Other Application Fields STEEL.Rubber lining . As a rule. nickel or other metals are obtained by mining. Ores containing copper. Process sections exposed to high temperatures are given a brick lining in addition. KCH offers a system consisting of a vinyl ester resin laminate combined with ceramic tiles embedded in polymer mortars. Protective granite ribs Roller slider in polyester concrete "A" Layer build-up: . To protect the components involved in the process. PULP AND PAPER INDUSTRY ORE PROCESSING/STEEL PRODUCTION The ground wood used as a basis for pulp and paper manufacture is treated with chemicals in digesters operated at elevated pressure and temperature. KCH supplies the required ceramic and carbon tiles for embedding in chemically resistant polymer mortar.Steel . chlorine dioxide. The rubber lining both acts as a membrane layer and affords hard-wearing protection in certain process sections. KCH offers welltried vinyl ester resin systems and ceramic brick linings with corrosionresistant polymer mortars to protect the scrubber from corrosion. The corrosive and toxic gas constituents produced in this process are removed in a scrubbing process. The acids used in the pickling processes gradually degrade and therefore need to be regenerated.1 layer of acid-proof tiles laid in polymer mortar Partition wall in acid-proof standard bricks laid in polymer mortar Detail "A" 9 .Rubber lining .2 layers of standard bricks laid in polymer mortar Stub end build-up: . and heat and pressure are applied in order to extract the metals from the slurry. Iron ore is melted in blast furnaces to produce crude steel. Regeneration takes place in a system located downstream of the pickling tank. Some process sections like the venturi scrubber and storage tank are given rubber and brick linings as well. This process employs various chemicals such as chlorine. Cellular pulp still contains substances that need to be treated by subsequent bleaching. The corrosion-resistant materials employed in these processes depend on the type of steel to be treated. gold. hypochloride. hydrogen and oxygen.AND METAL-WORKING INDUSTRY/PICKLING TANKS Steel sheets are treated by special pickling processes before being electroplated and supplied to the customer. synthetic rubber linings are used in combination with a hard-wearing ceramic or carbon brick lining embedded in polymer mortar. Acids are added to the rocks. hot Raw gas duct. cold Absorber. inlet Venturi. inlet Absorber Clean gas duct Stack Slurry tank Venturi. WITH S TATIONARY T ANKS Industries Chemical industry AND P ROCESS E QUIPMENT Typical corrosion protection materials KERABUTYL V 1) KERABUTYL BS 1) ® KERABUTYL BS 1) ® GENAKOR 022 1) ® KERABUTYL VC 1) ® KERACID ES 110 3) ® ® Application fields Reactor (phosphoric acid) H2SO4 storage tank H3PO4 storage tank Pigment reactor HCl storage tank Wastewater treatment basin Raw gas duct. spray jets Demister HCl pickling tank H2SO4 pickling tank Stainless steel pickling tank Agitator Thickener Reactor Bleaching tower Carbon bricks in ®KERANOL FU 320 4) Acid-proof bricks in ®KERANOL WG 311 Carbon bricks in ®KERANOL FU 320 4) 4) Acid-proof tiles in ®KERANOL FU 310 2) 4) Power industry KORROPLAST VE 310 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) ® ® Acid-proof bricks in ®KERANOL FU 310 4) Acid-proof bricks in ®KERANOL WG 3114) Acid-proof bricks in ®KERANOL FU 310 4) Acid-proof bricks in ®KERANOL FU 310 Acid-proof bricks in ®KERANOL FU 310 Carbon bricks in ®KERANOL UP 320 4) Acid-proof bricks in ®KERANOL FU 320 Acid-proof tiles in ®KERANOL FU 310 4) Acid-proof bricks in ®KERANOL FU 320 Acid-proof tiles in KERANOL VE 310 ® 4) 4) 4) Metal-working industry Metal ore processing Pulp and paper industry 1) Rubber lining KERABUTYL VC 1) KERABUTYL V 1) ® KERABUTYL WBC ® ® ® ® 1) KERABUTYL BB-S 1) KERABUTYL BS 1) ® VULCOFERRAN 2208 ® 4) 1) 2) 4) KORROPLAST VE 510 2) Tank coating 3) Floor coating 4) Mortar 10 .Typical Applications LEFT: PICKLING VAT. RIGHT: ABSORBER CERAMIC BRICK-LINED FLOOR. The certificate is valid for: Floorings. but also optimum processing and testing of our products. piping. manufacture. If our products are installed by your own personnel. G ENERAL C ONTRACTING For decades now.Our Complete Range of Products and Services ENGINEERING AND SUPERVISION Once our KCH experts have teamed up with you to determine the operating conditions – in particular the chemical. pipes and fittings with corrosion-resistant linings. processing and services & installation SCC** KTA 1401 Rule VGB Working Group of Nuclear Power Station Operators Proof of qualification for the system. rubber linings. maintenance and reconditioning of vessels and piping made of thermoplastics and thermosets WHG 11 . industrial corrosion protection and environmenal protection Certificate on the implementation of a Safety Management System in conformity with the guiding principles SCC**: 2002 (general certification). containments. You stand to benefit not only from KCH’s wide range of materials but also from the company’s development work in the field of products and processes. the best material is chosen for the job in hand. as well as the installation. This is because KCH supplies everything you need from a single source – from initial technical advice to quality assurance of the final product. KCH has been working to develop new and ever more cost-effective technical solutions. After the best material has been selected. sale and production of corrosion-resistant linings and coatings. sealing faces. installation and servicing of process equipment. process equipment and components for the chemical industry. our specialists can be made available on request to supervise proper on-site installation in good time. transportation. acidproof linings and/or tiling systems for nuclear plants 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 for vessels. Our aim has always been to offer you the optimum right across the board – not just optimum materials. mechanical and thermal stresses – and also the geometry of the components. KCH sets great value on quality and reliability. coatings. the product is manufactured as specified and then installed at the customer’s site on the date agreed.and product-related Quality Assurance for the planning. C OMPANY C ERTIFICATES DIN EN ISO 9001 Certificate meeting DIN EN ISO 9001:2000 Proof of implementation and maintenance of a Quality Management System for the development. as well as systems. In doing so. these data should be regarded merely as general information that gives no guarantee of any specific properties and/or suitability of those products for any particular application.com For further information on industrial corrosion protection. In view of the variety and large number of application possibilities. our technical service will supply a profile of characteristics for your specific application requirements without delay. SP 900-02/2008e Printed in Germany www. On request.com .kch-group. please contact us for specific information on the properties required for the application concerned. 2008 ® registered trademarks of KCH Group companies The data contained herein represent the current state of our product knowledge and are intended to provide general information on our products and their application spectra.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 surface-protection@kch-group. Siershahn. Consequently.com Contact: © KCH Group GmbH. when ordering a product. please contact: Composites KCH Composites GmbH Berggarten 1 56427 Siershahn / Germany Phone: +49 2623 600-600 Fax: +49 2623 600-660 composites@kch-group.