Derakane TM Specialty Resin Systems for

Corrosion Resistance FRP

Our commitment to Corrosion Resistance
March 19
- Markets
- What is FRP
- Corrosion Resistance
- CR Structure
- Lining Vs FRP
• - Derakane TM
Introduction
• Corrosion Resistance
• Testing, Database, and Literature
• Linings, Dual Laminate vs. full FRP
• Derakane™ Product Overview
• Case History

August 2019
 Corrosion Market Applications
Chemical Processing & Mining (Copper, Nickel, Air Pollution Control
Pulp & Paper
Waste Water Lithium, Rare Earth) (FGD)

A global, project driven (EPC) business, for applications with corrosive chemical environments

Projects can vary from small maintenance work to large “Mega Projects”

Key markets are chemical processing, mining & phosphate extraction, pulp & paper & air pollution control

Markets are driven by different macroeconomic trends

Competition is generic and non generic (metals)

Vast number of years of experience and data plays a key role in defining the reliability of the resins systems.

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− DERAKANE ™ Epoxy Vinyl Ester Resins have over 54
years of field experience in corrosion resistance
applications with case studies around the world in
different industries.
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Ashland Corrosion Science Centers, Dublin & Kehl

Complimentary
Service

Handling more than 4000 enquiries a year.

− Ashland supports the industry by providing CR recommendations to the
asset owners, engineering firms and consultants around the world.
− Central hub for tracking information & projects.
− Mining our corrosion database for project intel and market trends
− Organizing and running Seminars with End Users and Engineering Companies
− Kehl (EMEA, India, APAC), Dublin (NA & SA)
− Combined Technical Expertise of >200 years
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 Derakane Technical Services

− Analytical Services / Testing

Capability
− Extensive corrosion testing ASTM C-
581
− Corrosion Resistance Guide
− Global Technical Service Expertise
− Proven performance through
hundreds of case studies
− Ashland Corrosion Science Centers

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What is FRP?

Mould
Fibre + Matrix Composite
Temperature

- Fibre – Provides strength and stiffness.

- Fibreglass, Carbon Fibre

- Matrix – Protects and transfers load between the fibres.

- Polyester, Epoxy, Vinyl ester, Polyurethane

- Process
- Hand layup, Filament Winding, RTM, Pultrusion, RIM.

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 Failures by chemical degradation

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chemical or corrosion resistant recommendation

chemical attack could happen by:

- disintegration or degradation (e.g. HF, Abrasion, Erosion)

- oxidation (e.g. concentrated oxidative acid)
- hydrolysis (e.g. hot water)
- diffusion (e.g. HCl)
- thermal degradation
- combinations of these mechanisms, and possibly others.

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 Corrosion Resistance barrier and structural layer

Ashland provides recommendation for the corrosion- resistance structurs

a laminate is typically made with a:

-corrosion or chemical resistant barrier (or barrier layer CBL): in total 2.5 to 6.3 mm
thick, in contact with the chemical environment. can be “corroded”, protects the
structural layer.

- structural laminate: brings strength and stiffness to the composite structure.

should not be “corroded”.

Inside, in contact
Outside
with chemicals

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CBL Structural layer
 what do we need for a chemical or corrosion
recommendation?
1) Application type (Tank, Pipe; lining or Full FRP)
2) History of the equipment if available
3) Detail Chemical composition in contact with resin
- chemicals: name or cas number
- chemicals mixed together or present one of the other
4) operating and design conditions:
- concentration, ph
- temperature
- min, max, cyclic temperature changes
- remarks: abrasion risk

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 recommendations are based on a variety of sources:
- including evaluations of actual field service performance
- laboratory (ASTM C581), 50 years of tests!
- field tests of FRP laminate construction
- and the combined knowledge of the Technical Services Team

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how do we do our corrosion resistance tests? ASTM
C-581
− post cured laminates immersed in an given
environment at a defined temperature.

− properties of the laminate (e.g. visual appearance,

hardness, mechanical strength, etc.) checked after
1, 2, 3, 6 and 12 months

− concentration and temperature limits are derived

from the results.

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 chemical resistance guide

Over 1000 Chemicals across the entire DERAKANE™ resin family

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 Corrosion Resistance Structure
− The inner surface of all laminates shall consist of a protective layer:
− Single Protective Layer (SPL= Veil or Resin)
− Chemical Resistance Layer (CRL) or ThermoPlastic Liner (TPL)

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Lining versus Full FRP

Building of a corrosion resistance barrier, painting the resin is not

sufficient

Types of FRP linings

• Flake glass lining

– Glass flakes mixed into resin

• Chopped glass lining

– Chopped glass applied with a chopper gun

• Prefabricated sheets
– Sheets fabricated in factory and shipped to site

• Glass mat lining

– Chopped strand glass mat and veil
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 Lining versus Full FRP

• do not have their own structural integrity, quality substrate important

• should be limited to max 60-70°C (and without thermal shocks)
=>higher risk of delamination in high service temperature
• in case of permeation, diffusion(e.g. water vapor), substrate may not be resistant!
• only skilled applicator: surface well prepared, no dust, dry substrate…
• DERAKANE 8084 is suggested as a primer
=> good adhesion properties
• good ventilation required to avoid styrene rich atmosphere
• Wax or Low styrene Emission systems in the last layer to get a good cure of the
resin.

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 dual laminate vs. Full FRP

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 dual laminate vs. Full FRP
• offer to go beyond the limits of non-lined FRP: strong acids and caustics, organic
solvent
• backing textile important on the thermoplastic
 brings surface roughness for a mechanical adhesion for the FRP lamination
 glass or synthetic or other, depends on the chemicals
• a corrosion resistant barrier in FRP after the TP could be required
• only experienced persons with good welding skills!

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 DERAKANE Resins are based on epoxies:

O O

O O

Bis-A Epoxy Resin

O O O

O O O

Novolac Epoxy Resin

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 Bisphenol-A Epoxy Resin Methacrylic Acid
OH
O O
O O O O
+ HO

O
n=0-2

Bisphenol-A Epoxy Vinyl Ester Resin

O
CH
OH 3
OH
O
O
O O O O
HO
CH O Ester Groups
3
n

Epoxy Backbone Toughness

Hydroxyl Groups Adhesion and Glass Wetting

Methyl group Shielding Corrosion Resistance

Terminal Unsaturation Reactive Sites for Crosslink Polymerization

• Resin is thinned in Styrene for processing requirements

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• Styrene acts as the crosslinking agent upon polymerization
 Unsaturated Polyester Resins

Isophthalic Polyester Backbone

R2 C O

C C U C C O C O C O O C R2

C O C C O C C C C O C C U C C

Multiple Ester Groups and Internal Double Bonds

Good reactivity, but decreasing mechanical properties (brittle)

and reduced chemical resistance (acid & brine)

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 DERAKANE ™ Product Families

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 DERAKANE ™ versus
DERAKANE MOMENTUM ™ Resins
General Benefits of MOMENTUM™ resins
• - Longer Commercial warranty
• - Higher Reactivity
• - Quicker Gel-to-Cure
• - Improved Exotherm Management
• - Low Color
• - Easier Workability
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Just like DERAKANE™ Resins,
only better.
• Same strong chemical backbone
• Same exceptional corrosion resistance
• Over 50 years of proven track record
• Decades of case histories of success in
hundreds of applications and chemical
environments
 They look different. They act different.

Fewer lay-up sessions per

part.

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 You can see the difference.

− faster roll-out with DERAKANE MOMENTUM Resins

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 DERAKANE™ 411-45 Resin. FeCl3-Tank, dismantled 1998
due to a Plant shut down (in perfect condition)

Troublefree service for 31 years

1967 1998

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hydrochloric acid tank, 27 years

15-30 % HCl at 40°C

Volume: 44 m3
DERAKANE™ 470 Resin
1971-1998
No need for repair during
entire service period.

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scrubbing system for wet phosphate fertilizer
processes
FRP advantage:
-can be used up to elevated
temperature,
- can handle fumes and
liquids
- can handle also ammonia
gas.

DERAKANE 470, in service since 1999:

flue gases treated: P2O5, HF, phosphate dust,
water vapor up to 110°C (230 ºF).

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 Our commitment to Corrosion Resistance
March 19 Thank you

• Introduction
• Corrosion Resistance
• Testing, Database, and Literature
• Linings, Dual Laminate vs. full FRP
• Derakane™ Product Overview
• Case History