Abtrex rubber systems and suppliers

ABTREX INDUSTRIES INC.LININGS FOR ABRASION AND CORROSION

FABRICATORS • MANUFACTURERS • APPLICATORS

AND MORE……www.Abtrex.com Abtrex Inc. 800-959-0125

ABTREX HISTORY 1969 - Harold Byars starts Abtrex in metro-Detroit with partner, Jim

Graham Abtrex serves the electroplating industry providing vulcanized plating

equipment including cathodes and tanks

1980 – Abtrex purchases American Fiberglass Fabricators in Elkhart, Indiana

1985 –Abtrex opens Pittsburgh (Leetsdale, PA) facility Located on a rail spur, Abtrex enters into bulk material transport industry

1985 – Abtrex buys Blastco (abrasive blasting company) in South Bend, IN Entire Indiana operation is relocated from Elkhart to South Bend

2009 – Abtrex opens railcar lining operation in Cleveland, TX Located on UTLX property, Abtrex installs state-of-the-art robotic water

blaster to strip old linings from railcars

2011 – Abtrex acquires KSF Chemical Processes in Cambridge, ON

KSF owned intellectual property for Wean United Acid Recovery Systems

2014 – Abtrex Indiana breaks ground on new fabrication facility

ABTREX INDUSTRIES’ FACILITIES

South Bend, Indiana50,000ft², 30 employees

Metal & Plastic Fab, Linings & Coatingswww.Abtrex.com Abtrex Inc. 800-959-0125

OUR QUALITY

www.Abtrex.com Abtrex Inc. 800-959-0125

OUR SAFETY

ABTREX SAFETY• Experience Modification Rate (EMR):

0.81• No recordable incidents this year• No lost days for 3+ years


CAPABILITIES• Engineering Services• Corrosion and Abrasion Resistant Linings

• Tank and Vessel Fabrication• Metal• Plastic• Fiberglass

• Pipe Fabrication• Rubber-lined Steel Pipe and Fittings• Fiberglass Reinforced Plastic (FRP) Pipe and Fittings

• Field Installations, Maintenance & Repairs


DESIGN AND BUILD SERVICES

Engineering and Design Tools

Solidworks 3D CAD design SoftwareSIEMENS Unigraphics PLM SoftwareAutodesk AutoCAD Software

• 3-D Modeling Software:

• General FEA (Finite Element Analysis)www.Abtrex.com Abtrex Inc. 800-959-0125

DESIGN AND BUILD SERVICES

Electro-Galvanizing Rollwww.Abtrex.com Abtrex Inc. 800-959-0125

RUBBER COMPOUNDS & MANUFACTURERS

COMPOUNDS• Natural (NR)• Styrene Butadiene

(SBR)• Neoprene (CR)• Nitrile (NBR)• Butyl (IIR)• Bromobutyl (BIIR)• Chlorobutyl (CIIR)• FDA-Approved• Non Staining• Hundreds more

MANUFACTURERS


RUBBER MANUFACTURING• Natural Rubber is tapped from

trees much like maple syrup• Countries of origin:

• Malaysia• Liberia• Indonesia• India• Brazil

Synthetic Rubber was developed in 1942 due to shortage of material and costs related to WWIIwww.Abtrex.com Abtrex Inc. 800-959-0125

RUBBER MANUFACTURING• Raw materials are combined per

compound recipes• Ingredients are blended in Banbury

mixers• Some linings need extra mixes to

breakdown• Rubber is cross linked by sulfur

and carbon black

Rubber Mill

Banbury Mixer

Carbon Black and Sulfur

RUBBER MANUFACTURINGCalender Process

• Blended rubber material is processed through a series of hard pressure rollers to create a smooth sheet of rubber

• Heat is applied during calendering process to ensure maximum ply adhesion

• Extruder & Inverted Cracker help to breakdown rubber

• No heat memory generated• Helps maintain proper cure


PRE-CURED VS. UNCURED RUBBER

UncuredAdvantages:

• Most Suitable for Shop work• Superior Bond in an

Autoclave• Ease of Application

Disadvantages:• Special (Cold) storage

needed• Potentially higher cost to

cure in field

Pre-CuredAdvantages:

• Most Suited for field service• Can be used on large diameter

vessels when steam is not available• No special storage needed

Disadvantages:• Lower bond strength• Can be difficult to apply

ELASTOMER SELECTION


ELASTOMER SELECTION

Common Rubber Lining Materials(Higher durometer rubbers generally help reduce water permeation)

Lining Type Optimum Conditions Max Temp. Limitations

Natural Rubber 60 Duro. Sliding abrasion 160°F Heat, solvents, oil

Natural Rubber 40 Duro. Impingement abrasion 170°F Heat, solvents, oil

SBR Synthetic Rubber High abrasion 180°F Heat, Oil & Gasoline

Neoprene Oil & Heat resistant 220°F Solvents

Nitrile Hydrocarbon solvents. oil 220°F High abrasion

Chlorobutyl Chemical Resistant 230°F Oil & Gasoline

Bromobutyl Acid, caustic & Heat resistant 260°F Oil & Gasoline


ELASTOMER SELECTION

Recommended Lining Thickness


APPLYING RUBBER – ABRASIVE BLAST

Surfaces to be lined are blasted to an SSPC-SP5 / NACE 1 White Metal Blast Cleaning profile


SSPC-SP1 Solvent CleaningSSPC-SP2 Hand Tool CleaningSSPC-SP3 Power Tool CleaningSSPC-SP5 / NACE 1 White Metal Blast CleaningSSPC-SP6 / NACE 3 Commercial Blast CleaningSSPC-SP7 / NACE 4 Brush-Off Blast CleaningSSPC-SP10 / NACE 2 Near-White Blast CleaningSSPC-SP11 Power Tool Cleaning to Bare Metal




Blasted surfaces are verified per ASTM D4417

Digital Surface Profile Gauge

Replica Tape & Micrometer/Thickness Gauge


APPLYING RUBBER – ADHESIVE SYSTEM

Surfaces are prepped post-blast with adhesive system

Three-Part System1.Primer (Green) -

applied to substrate.

2.Covercoat (Red) – applied over primer.

3.Cement (Black) – applied to both substrate and sheet rubber.


APPLYING RUBBER – PATTERNS

Surfaces are measured and sheet rubber is cut into patterns to match the part’s geometry

APPLYING RUBBER – SKIVING

Rubber panels are skived with a 45° up skive on the bottom and the top has a 45° down

skive

Seam Styles: Skive Butt Joint and Overlap


APPLYING RUBBER – STITCHING

Every square inch of rubber is stitched, or pressed into the blasted and cemented profile


APPLYING RUBBER – LINING PIPE

• Sheet rubber is rolled into a tube and sealed at both ends.

• Rubber bladder is inflated to specified psi.• Air pressure is used instead of hand stitching to bond

rubber to substrate.


• Strings are run to allow air to escape between lining and substrate



• Collars are bolted to each end of pipe



• Ends are capped with blind flanges. • One end has an air fitting to inflate bladder.


APPLYING RUBBER – AUTOCLAVE CURE

• Vulcanization Process – pressurized steam cure• Rubber manufacturer provides specifications for cure temperature

and time (eg. 6 hours at 275°F)• Autoclave is pressurized to approx. 10 to 30 psi (varies with

temperature)• Data (temperature, time and pressure) for cure is captured on a

chart recorder• Linings for vacuum service will require longer cure times

TEMPERATURES FOR VARIOUS

PRESSURESPress. Temp.10psi 240°F (115°C)15psi 250°F (121°C)20psi 258°F (125°C)30psi 274°F (134°C)

APPLYING RUBBER – INTERNAL PRESSURE CURE

• Used for larger parts that cannot be placed in autoclave• Condensation needs to drain• Thick steel creates a greater heat sink and requires

longer heat-up times. www.Abtrex.com Abtrex Inc. 800-959-0125

APPLYING RUBBER – ATMOSPHERIC CURE

• Used for larger parts that cannot be placed in autoclave• Requires longer cure times than autoclave• Slightly lower durometer hardness than autoclave cured

liningswww.Abtrex.com Abtrex Inc. 800-959-0125

TESTING RUBBER LININGS:HOLIDAY/SPARK TESTING

• Per ASTM D5162-08 - Standard Practice for Discontinuity (Holiday) Testing of Nonconductive Protective Coating on Metallic Substrates

• Detects pinholes in linings before & after cure

• Methods:• Method A – Low Voltage Wet

Sponge• Method B – High Voltage

Spark• Can potentially damage

lining• Test voltages determined

by material thickness (see table)

High-Voltage Spark Tester Low-Voltage Sponge Tester

• Per ASTM D 429 - Standard Test Methods for Rubber Property—Adhesion to Rigid Substrates

• Measures static strength of rubber adhesion to metals or other rigid materials

• Eight different methods• Types of Failure measured:

• R – Failure in the rubber• RC – Failure in the rubber-cover cement• CP – Failure in the cover cement-prime cement• M or CM – Failure in the prime cement-metal interface

TESTING RUBBER LININGS:ADHESION TESTING

Method B

TESTING RUBBER LININGS:DUROMETER HARDNESS

• Per ASTM D2240 - Standard Test Method for Rubber Property — Durometer Hardness

• Determines indentation hardness of thermoplastic elastomers, vulcanized rubber, cellular and gel-like materials and some plastics

• 12 classifications of rubber hardness: A, B , C, D, E, M, O, OO, OOO, OOO-S and R

Digital Durometer

GaugeGauges are calibrated to hardness standards

Installed, cured lining being tested

RUBBER LINED SLURRY PIPELINES

• Mineral Concentrates:• Iron ore• Gold• Base Metals (Cu, Ni, Pb, Zn)

• Rare Earth minerals• Oil Sands• FGD (Gypsum)• Potash• Tailings


RUBBER-LINED STEEL PIPE

RUBBER-LINED STEEL ABSORBER RECYCLE PIPE COMPONENTS


I.D. of Absorber Recycle Pipe Header for Duke Energywww.Abtrex.com Abtrex Inc. 800-959-0125


48” RUBBER-LINED A/R PIPE WITH AWWA RING FLANGES AND VERTICAL SUPPORT

BRACKETS www.Abtrex.com Abtrex Inc. 800-959-0125

PIPELINE WEAR FACTORS

Material Being Handled Particle sizeParticle shapeParticle HardnessChemical composition

Lining materialAbrasion resistanceChemical ressistanceTemperature resistanceImpact resistanceThickness

DesignFlow velocityImpact velocityImpact angleBend radiusPiping Layout


PVC

Mild Steel

HDPE

Alumina

HCWCI

Rubber

PU

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

Wear Rate (mm³/hr.)

Figure 16 -- Olengorsky Iron Ore18

(25 NB Pipe, 18% vol. concentration, 3.7 m/s velocity)

Material

PIPELINE WEAR RATES

Ref. SME Paper Combating Pipeline Wear by N.R. Stewart


PIPE FLOW VELOCITY

Minimum velocity to avoid settling (Wilson)Example: 250mm pipe, 0.5mm, 3.8 sg gives 4.5 m/s.


GENERAL GUIDELINES FOR LINED PIPING SYSTEMS

Select optimum flow velocity Maximum 10 m/s for elastomer linings

Use 3D/5D Elbows – 3 to 5 times pipe diameter(as opposed to standard long radius elbows which are 1.5 times pipe diameter)

Avoid inclined pipe runs Vertical or Horizontal piping preferred

Avoid direct impingement on tank walls and bottom Direct impingement is preferred to angular impingement Use “rock box” tank design if possible

Launder bottom slope 10-15%


OUR CUSTOMERS


REFERENCES Corn Sweetener

Archer Daniels Midland Company (ADM) Contact: Darryl Munsinger400 West Erie Rd Phone: 507-537-2511Marshall, MN 56258-2744 Cargill Inc. Contact: Ms. Adebola Durosawo3201 Needmore Rd Phone: 937-237-2561Dayton, OH 46414

Field Erected Tanks M.L. Smith Jr., Inc. Contact: Moe Hansen2330 Farmerville Hwy Phone: 318-255-4474Ruston, LA 71213-1717

Kennedy Tank Contact: Paul Bolin833 East Sumner Avenue Phone: 317-780-3528Indianapolis, IN 46227


REFERENCESPlating/Galvanizing

Walbridge Coatings Contact: David Swemba30610 E Broadway Phone: 419-661-5952Walbridge, OH 43465

Lacks Enterprises Contact: Ben Wesley5460 Cascade Road SE Phone: 616-443-6087Grand Rapids, MI 49546

IN Tek/IN Kote (Areclor-Mittal) Contact: James McGranahan30755 Edison Road Phone: 574-654-1733New Carlisle, Indiana 46552

Steel ProcessingSteel Warehouse Contact: Jerry Czajkowski2722 West Tucker Dr. Phone: 574-236-5100South Bend, IN 46619 US Steel Contact: Samer Aweidah600 Grant Street Phone: 412-433-5833Pittsburgh, PA 15219 [email protected]

mailto:[email protected]

REFERENCESPower Plants

Duke Energy Contact: Russ Steinmetz6293 Beaver Rd Phone: 513-467-4839Rabbit Hash, KY 41091 [email protected] EON-US Contact: Charles Ransdell820 W. Broadway Phone: 502-627-3299Louisville, KY 40232 Hitachi America Limited Contact: William Knowles50 Prospect Phone: 914-524-6700Tarry Town, NY 10591

Big Rivers Electric (Coleman Station) Contact: Christa Lucas4982 River Rd Phone: 270-844-6983Hawesville, KY 42348

Duke Energy Progress Contact: Reggie Clay1700 Dunnaway Rd.Phone: 336-597-6116Semora, NC 27343 [email protected]



REFERENCESMining Equipment

FLSmidth Salt Lake City Contact: Mark Nielsen7158 South FLSmidth Drive Phone: 801-871-7936Midvale, Utah, USA 84047 [email protected] Weir Minerals Contact: Debra Switzer2701 S Stoughton Rd. Phone: 970-665-9149Madison, WI

[email protected]

Metso Minerals Industries, Inc. Contact: Betsy Day240 Arch St. Phone: 717-849-7201York, PA 17403

Eriez – Flotation Division Contact: Kris Barnes7168 Honeyman St. - Unit 1 Phone: 604-952-2300Delta, BC Canada V4G 1G1

URS Contact: Michelle Rodriguez8181 E. Tufts Avenue Phone: 303-796-4719Denver, CO 80237 [email protected]





THANK YOU!

Doug Hardy, Sales Engineer • 800.959.0125 • [email protected]

Chuck Groom, Project Manager • 800.959.0125 • [email protected]

Keith Byars, President • 800.959.0125 • [email protected]

Please contact us for more information or questions about today’s presentation.

www.Abtrex.com





Abtrex rubber systems and suppliers

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