Rubber as a Construction Material for Corrosion Protection: A Comprehensive Guide for Process Equipment Designers (Wiley-Scrivener)

Rubber as a Construction Material for Corrosion Protection: A Comprehensive Guide for Process Equipment Designers......Page 5
Contents......Page 9
Acknowledgements......Page 17
Preface......Page 19
1.1 Background......Page 23
1.4 Rubber......Page 25
1.7 Rubber Protects Corrosion Effects......Page 26
1.10 Rubber is Ablative......Page 27
References......Page 28
2.1 Background......Page 29
2.2 Compounding......Page 31
2.3 Scope of Compounding......Page 32
2.4 Basic Compounding Formulation......Page 33
2.6 Property Requirements of Vulcanized Rubber......Page 34
2.7 Basic Changes in Properties......Page 36
2.8 Compounding Ingredients......Page 37
Reference......Page 47
3.1 Liquid Ebonite......Page 49
3.2 Rubber-sulphur Reaction......Page 52
3.3 Retarding Accelerators......Page 53
3.4 Coefficient of Vulcanization......Page 54
3.5 Synthetic Rubbers Which Can Be Converted into Ebonite......Page 55
3.6 Technological Aspects of Ebonites......Page 56
3.7 Uses of Ebonites......Page 57
3.8 Main Properties Exhibited by Ebonites......Page 58
3.9 Processing of Ebonite......Page 62
3.11 Rubber-sulphur Ratio and Cure Time......Page 63
3.13 Method of Cure......Page 64
References......Page 65
4.1 What is Rubber Lining?......Page 67
4.2 Types of Corrosion......Page 68
4.3 Materials Selection......Page 70
4.4 Performance Tests......Page 71
4.7 Corrosive Chemicals......Page 72
4.8 Codes of Practice Relating to Corrosion......Page 75
4.9 Types of Rubber Lining......Page 78
4.10 Application Procedures for Rubber Lining......Page 85
4.11 Role of Impurities......Page 86
4.13 Lining Thickness......Page 87
4.15 Application of Calendered Sheet......Page 88
4.16 Inspection of Rubber Lining......Page 90
4.18 Sheet Laying and Rolling......Page 92
4.19 Lining Procedure for Pipes......Page 93
4.21 Design and Fabrication of Lining Supports for Handling Lined Equipment......Page 94
4.22 Surface Preparation for Rubber Lining......Page 96
4.23 Methods of Surface Preparation......Page 97
4.24 On Site Rubber Lining......Page 99
5.1 Historical Aspects......Page 101
5.3 Mullins Effect 82......Page 104
5.4 Payne Effect......Page 105
5.6 Resistance to Wear and Tear......Page 106
5.7 Chemical Compatibility......Page 107
5.8 Glass Transition Temperature......Page 108
5.10 Fluid Resistance......Page 110
5.12 Natural Rubber......Page 111
5.13 Synthetic Polyisoprene (IR)......Page 113
5.14 Styrene Butadiene Rubber (SBR)......Page 115
5.15 Butadiene Rubber......Page 117
5.17 Chlorobutyl (CIIR) and Bromobutyl (BIIR)......Page 119
5.18 Ethylene Propylene Rubbers (EPM and EPDM)......Page 120
5.19 Polychloroprene (CR)......Page 121
5.20 Nitrile Rubbers......Page 123
5.21 Chlorosulphonated Polyethylene (CSM)......Page 124
5.22 Silicone Rubber......Page 125
5.24 Polyurethane (AU or EU)......Page 126
References......Page 128
6. Design Considerations for Fabrication of Equipment Suitable for Rubber Lining......Page 131
6.1 Mild Steel Vessels......Page 133
6.2 Pipes and Fittings......Page 136
6.3 Metal Defects Detrimental to Rubber Lining......Page 138
7.1 The Chemical Process......Page 141
7.2 Flue Gas Desulphurization Systems (FGD)......Page 144
7.3 Water and Waste Water Treatment Equipment......Page 145
7.4 Nuclear Power Water Treatment Plant......Page 146
7.6 Phosphoric Acid Equipment......Page 147
7.7 Hydrochloric Acid Handling Equipment......Page 148
7.8 Sodium Hypochlorite and other Bleach Equipment......Page 149
7.9 Gold Ore Processing Equipment......Page 150
7.10 Equipment for Evaporation......Page 151
7.13 Cyclone Separators......Page 152
7.14 Thickeners......Page 153
7.15 Perforated Plates......Page 154
7.16 Industry Equipment and Components......Page 157
References......Page 158
8.1 Critical Properties of Rubber......Page 159
8.4 State of Cure......Page 160
8.8 Plasticity......Page 161
8.10 Plasticity and Viscosity Test Methods......Page 162
8.11 Residual Scorch......Page 164
8.12 Vulcanization Studies......Page 165
8.13 Vulcanization Test......Page 166
8.14 Density of Solids......Page 172
8.15 Hardness......Page 173
8.16 Spark Testing......Page 175
8.17 Immersion Test......Page 178
8.18 Specifications and Codes of Practice......Page 179
9.1 The Rubber Bonding Process......Page 183
9.2 The Bonding Layer......Page 185
9.5 The Bonding Process......Page 186
9.6 Application of Bonding Agents......Page 187
9.7 Adhesive Manufacture for Ebonite Bonding......Page 188
9.8 Moulding of Rubber-Metal Bonded Product......Page 189
9.9 Compounding of Rubber for Metal-Rubber Bonding......Page 190
References......Page 191
10.1 Principles of Vulcanization......Page 193
10.3 Peroxide Vulcanization......Page 197
10.4 Vulcanization Conditions......Page 198
10.5 Techniques of Vulcanization......Page 199
10.6 Control of Production Cures......Page 205
10.8 Common Defects in Vulcanizates......Page 206
References......Page 208
11.1 Seawater......Page 209
11.2 Design Considerations in Seawater Corrosion Protecting System......Page 211
11.4 Elastomeric Polyurethane Coating......Page 213
11.5 Surface Preparation Methods......Page 214
11.6 Specific Corrosion Protection Measures......Page 215
11.8 Trash Rack and Traveling Water Screens......Page 216
11.10 Condenser Tubes and Tube Sheets......Page 217
11.12 Field Observations......Page 218
11.13 Material of Construction for Seawater Based Systems in Nuclear Power Plants......Page 220
References......Page 221
12.1 Well Fluid......Page 223
12.3 Stimulation Fluid......Page 224
12.4 Explosive Decompression......Page 226
12.5 Effect of Increasing Molecular Weight......Page 229
References......Page 233
13.1 Calendering Machine......Page 235
13.2 Calender Design Features......Page 236
13.3 Fabric Coating-Topping......Page 238
13.5 Rubber Sheets......Page 240
13.6 The Art of Calendering......Page 242
14. Moulding Technology......Page 247
14.1 Factors in Moulding......Page 248
14.2 Types of Moulding Process......Page 249
14.3 Press Curing......Page 250
14.4 Moulding of Hollow Parts......Page 252
14.5 Moulding Shrinkage......Page 253
14.6 Mould Lubricants......Page 254
14.7 Moulding Defects......Page 255
15. Service Life of Rubber-lined Chemical Equipment......Page 257
15.1 Materials that Improve the Ageing of Vulcanizates......Page 259
15.3 Heat......Page 261
15.6 Light......Page 262
15.8 Metals......Page 263
15.9 Fluids......Page 264
15.10  lPredictin g Life of Lining......Page 265
15.11 Hydrochloric Acid Tank Lining Life......Page 266
15.12 Residual Life of Natural Rubber Lining in a Phosphoric Acid Storage Tank......Page 267
15.13 Immersion in Fluids......Page 268
References......Page 269
16. Case Studies......Page 271
16.1 Case Study: Space Shuttle Challenger Disaster......Page 272
16.2 Case Study: Hinkle Reservoir......Page 274
16.3 Case Study: Ammonium Nitrate Explosion......Page 275
16.4 Case Study: "O" Ring Failure......Page 276
16.5 Case Study: Pebble Mill......Page 277
16.6 Case Study: Rubber and Ceramic Liners......Page 278
16.7 Case Study: Flue Gas Desulphurizing......Page 279
16.8 Case Study: Wrong Selection of Curing Method......Page 280
References......Page 283
Glossary of Terms......Page 285
Appendix 1. ASTM Elastomer / Rubber Designations......Page 297
Appendix 2. Properties of Specialty Rubbers......Page 299
Appendix 3. Temperature-Pressure Equivalents of Saturated Steam......Page 301
Appendix 4. List of Suppliers Who Publish Technical Literature on Rubbers and Chemicals......Page 303
Bibiliography......Page 307
About the Author......Page 309
Index......Page 311