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Composites in Mining and Minerals Processing

Lucy CranitchLucy Cranitch

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Lucy Cranitch

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Outline1 A li ti d 3 Working With Composites1. Application and

Opportunities for Composites in Mining• Vessels

3. Working With Composites• Design• Manufacture• Transport

• Pipelines• Infrastructure

• Transport• Installation• Use• Inspection & Testing2. Materials

• What Are Composites• Properties• Cost Comparison

• Inspection & Testing

Questions• Cost Comparison• Failure Modes

Questions

Lucy Cranitch

Questions

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Composites

• Fibreglass• FRP = Fibre Reinforced Plasticb e e o ced as c• GRP = Glass Reinforced Plastic• GRE = Glass Reinforced Epoxy• CFRP = Carbon Fibre Reinforced Plastic• CFRP = Carbon Fibre Reinforced Plastic

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PATHPATH Application and Opportunities for Composites in Mining

Minerals Processing Vesselsfor Composites in Mining

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PATHPATHMineral Processing Vessels Gas Cooling

Tower 10% S l h i id/MZinifex. Sulphuric Acid Plant.

StackTank Launders Sulphuric acid/ zinc sulphate

Mercury Removal Tower

Zinifex. Sulphuric Acid Plant.

Clarifier Cover WaterReactor Tanks Gas Flue valvesElectrolytic Cells

Clarifier Cover. Water Vapour + acid 70oC

Reactor Tanks Copper Sulphate

Gas Flue valves To 180oC

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Pipelines

• Western Corridor Recycled Water Pipeline

• Underground pipeline to take g p ptreated water industry.

• Output: up to 282 ML/day.• Pipe: Flowtite• Pipe: Flowtite• Length: 80 km• Diameter: 1000 and 1200 mm• Pressure: 1.6 and 2.5 MPa• Standard: AS 3571• Other composite parts: Bends

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Other composite parts: Bends and Tee Pieces

PATHPATHPipelinesin Iron Ore

• Transport iron ore as a slurry from mine to coast

• Return water to mine• Length: 290 km • Diameter: 600 mmDiameter: 600 mm• Pressure: up to 5 MPa• Standard: ISO14692 and AS

28852885• Drivers: salt & oxygen in water,

GRP cheaper than steel

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• Challenge: Abrasive solids

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Pipelines in Bore-fields

• Bore-fields between iron ore mine and coast• Top up pipeline with water

W t b d d b t i d t• Water may be ponded between mine and coast• Diameter: 450 mm• Pressure: up to 5 MPap• Drivers: salty water, composite can be cheaper than

HDPE

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Mining Infrastructure

Mine Vent Ducting

Rock Bolts

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Mining Infrastructure

Truck bodies & panels

Ladders, handrails, steps, platforms

St t i t f l

Wash plant pipes

Drill Rods

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Storage containers – water, fuel

PATHPATHMining InfrastructureGrating RebarHandrails

StairsCable Supports Roof and Wall Sheeting

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PATHPATH Courtesy of GCDA

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Outline1 A li ti d 3 Working With Composites1. Application and

Opportunities for Composites in Mining• Vessels

3. Working With Composites• Design• Manufacture• Transport

• Pipelines• Infrastructure

• Transport• Installation• Use• Inspection & Testing2. Materials

• What Are Composites• Properties• Cost Comparison

• Inspection & Testing

Questions• Cost Comparison• Failure Modes

Questions

Lucy Cranitch

Questions

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MaterialsReinforcement Carbon Highest specific stiffness PriceReinforcement1. support load

Carbon Highest specific stiffness Price

Kevlar Highest specific strength. Impact resistancepact es sta ce

Glass High strength, low price

Resin Epoxy Adhesion, mechanical Price

1. bond fibrestogether

2 distribute forces

properties

Vinyl Ester Chemical resistance, toughness2. distribute forces

3. barrier to water, chemicals, UV, abrasion

Polyester Inexpensive

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Materials – Reinforcement FormsType Form FunctionType Form FunctionE Glass Continuous Fibres

Unidirectional FabricStrength in 1 direction

Fabrics e.g. woven roving, cloth, stitched fabric

Strength in 1,2 or 3 directions

FibresChopped Strand Mat

Strength in all directionsInter-laminar adhesion

C glass, synthetic or carbon

Tissue/Veil Supports resin rich layer – provides moisture & chemical barrier

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barrier

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2

3

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M t l ResinsMaterialsMetals

• Carbon Steel

Resins• Epoxy - mechanical • Vinyl Esters – chemical properties

• Stainless Steel• 304• 316

Vinyl Esters chemical properties• Bisphenol Vinyl Ester – standard• Novolac Vinyl Ester – high performance

• Polyesters -316• 317

• TitaniumAl i i

Polyesters • Orthophthalic – low cost• Isophthalic - water• Terephthalic - fuel• Aluminium Terephthalic fuel• Chlorendic - chemical• Bisphenol A Fumarate - chemical

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Manufacture

Hand Lay Up Filament Winding Pultrusion

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Outline1 A li ti d 3 Working With Composites1. Application and

Opportunities for Composites in Mining• Vessels

3. Working With Composites• Design• Manufacture• Transport

• Pipelines• Infrastructure

• Transport• Installation• Use• Inspection & Testing2. Materials

• What Are Composites• Properties• Cost Comparison

• Inspection & Testing

Questions• Cost Comparison• Failure Modes

Questions

Lucy Cranitch

Questions

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Mining Industry DriversCOSTCOST• Extend life of assets – leads to less capital cost• Reduce maintenance - can be as high as 50% of operating costs• Increased cost of steel and fuel• Increased cost of steel and fuel

SAFETY - Fire, Corrosion, Lift loads, Electrocution• Less hazardous materials and designs

TIME• Quicker installation & start up

L d li ti f th t i l hil t d t i• Long delivery times for other materials whilst need to increase production now.

• Increase plant running time• Reduced failure & thus downtime

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• Reduced failure & thus downtime

PATHPATHWhy Change Materials?

• Don’t change unless impetus.Don t change unless impetus.• Mining Industry is conservative as failure is extremely expensive –

shutdowns cost at least $1 million per day.• Cost of equipment is balanced against benefitsq p g• Need solutions to existing problems

Mining Industry DriversReduce Costs

Increase Safety

Composite StrengthsCorrosion Resistance

Non Conductive or Conductivey

Increase Uptime

Non Conductive or Conductive

Light Weight

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Materials – Chemical Properties

Properties of Composites

Polyester Resin

Vinyl Ester Resin

Materials Chemical Properties

Resin ResinAcids (weak)

Acids (strong) x

Bases x

Solvents

S lt S l ti Salt Solutions

pH 0-14Can also be used for potable water if resin is certified for AS4020

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Can also be used for potable water if resin is certified for AS4020

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T k & P V l

Materials – Chemical Properties

Mining Industry DriversCost Reduction

• Tanks & Process Vessels• Pipelines• Grating & Handrails

C * Extend life of assets* Reduce maintenance – no paintingSafety

• Conveyors• Trucks & Mobile Equipment

y* No corroded gratings or handrailsIncrease Plant Running Time* Reduced failure & thus downtime Reduced failure & thus downtime

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PATHPATHCorrosion Resistance can Increase Safety

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Incitec Pivot Mt Isa

Materials – Chemical PropertiesIncitec Pivot - Mt Isa

Sulfuric Acid Plant continuously operating since 1999

• Sulfur dioxide and sulfur trioxide gas

Ducts

Sulfur dioxide and sulfur trioxide gas

• Sulfuric acid.

• 68oC DuctsSettlers Piping Radial Flow

ScrubberGas Cooling Tower

Inlet Manifold

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Jamison Cells

Materials – Chemical PropertiesBHP Billiton – Olympic Dam

Properties

Mixer Settlers & Internals

• Uranium solvent extraction plant• Precipitation and calcination plant• Copper solvent extraction plant

InternalsChemicals• ammonium sulphate• sulfuric acid

Tank• sulfuric acid• sodium carbonate• hydrogen peroxide

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Materials - Mechanical PropertiesMaterial Glass

CompositeMild Steel

Aluminium

Materials Mechanical Properties

SteeDensity (g/cm3)

1.5-2.5 7.8 2.7

T il St th 50 700 410 480 80 480Tensile Strength (MPa )

50-700 410-480 80-480

Tensile Modulus 10-60 190-210 70(GPa )Tensile Elongation (%)

1.6-2.1 22-37 2.5-23

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Elongation (%)

PATHPATHMaterials - Light Weight

Composites weigh 6 x less than steel for the same strength

Mining Industry Drivers

• Electrical guarding (lift loads)• Hatches (lift loads)

Mining Industry DriversCost Reduction* Reduced installation costs* Reduced fuel cost

• Tanks & process vessels (at Installation)

• Conveyors (fuel saving) T k & M bil E i t * Reduced fuel cost

Safety - Lift loads* Less hazardous materials & designs

• Trucks & Mobile Equipment (fuel saving)

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Increase Plant Running Time* Quicker installation & start up

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Materials - Light Weight

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Materials - Abrasion Properties

Can be improved by:• 3-5% hard fillers such as silicon carbide helps. Either in a

coating or part of the corrosion barrier• Flooring or trowel on pastes can have up to 40% silicon

carbide or other abrasion resistant fillers. • Use of a veil, particularly a carbon veil increases abrasion

resistance.

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Materials – Thermal Properties• Max temp of composites is determined by HDT of resin. • AS2634 - HDT of the resin shall be not less than 20°C above the

design temperature. • Some composites can be used up to 250°C

Isophthalic Polyester Standard Vinyl High Performance p yResin(ESTAREZ® 3-491P)

yEster Resin(HETRON® 922)

gVinyl Ester Resin(HETRON® 970/35)

HDT at 1.82 MPa (°C) 85 100 149Elongation to Break (%) 2.5 6.5 3.5

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Materials – Thermal Properties

Temp (C) Tensile Strength of Resin (MPa)

-43 11725 10925 10965 14795 147120 121150 74

Mild Steel CompositeCoeff-thermal expansion deg C x 10-6 12 5-35

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Materials – Thermal Properties

• Electrolytic Tanks and 60 El t l ti C ll

Delta Electrolytic Manganese Dioxide plant

Electrolytic Cells • 4% sulphuric acid at 97-100°C• Some tanks cycle between 97°C

and ambient every 6 hours• Larger tanks are typically between

60°C and 70°C• HETRON® 980 Resin• After 10 years of continuous y

operation, the resin was still performing well, although some mechanical issues had to be addressed

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PATHPATHMaterials – Non Conductive

Composites are natural insulators

Rio Tinto , Aluminium Smelter • Claustra Walls in Pot Room• Telescopic tools

Composites are natural insulators

• Telescopic tools.• Electrowinning

Materials RequirementsMaterials Requirements• electrically insulating.• fire retardant.• corrosion resistant• corrosion resistant.• lightweight.• pigmented.

high physical strength

Mining Industry Drivers* Safety – no electrical sparking,

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• high physical strength. Safety no electrical sparking, no electrocution

PATHPATHMaterials – Conductive

Composites can be made conductive

• Static charge can build-up in stacks, tanks, piping and ducts, , p p g

• EMP’s and solvent extraction require conductive laminates

• Grounding composite

Mining Industry Drivers

Cost Reductionequipment is critical. * Reduced failure = reduced rebuild cost

Safety * Reduced incidence of fire

Lucy CranitchIncrease Plant Running Time* Reduced failure & thus downtime

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Materials – Conductive

• Construction• Carbon Surfacing Veil saturated with resin containing 5 -15 % w/w

carbon/graphite filler.• Ensure continuity across joints where applicable• Grounding must be provided through to the outside of the g p g

equipment. Titanium or stainless steel bolts and a putty made from the carbon/graphite filler

• Test – Megger BM80 or BM 2580gg

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Materials – Fire Properties• Composites will burn but fire retardant composites available• Composites will burn but fire retardant composites available

including Hetron FR992, Hetron 197 or Derakane 510A and 510C• Ducts for flammable gases may require fire retardant resin for

internal layer. y• Tanks may require fire retardant resin for external layer.• Tested to AS1530 pt3, cone calorimeter or ASTM E-84 flame

spread of ≤25 (Class 1)

Resin Tendency Heat Flame Smoke

• Fire retardants can reduce chemical resistance

yto Ignite Developed Spread

HETRON ® 197 12 0 1 7

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Materials – UV Properties• UV can chalk outside layer of composites or degrade composites over

time• A pigmented layer will protect composites• Since pigmented layer limits inspection, it should be applied after all

QA complete• Alternatively UV inhibitors can be used in the resin

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Material Properties - Drivers for Composite Use

Corrosion resistance Long life with low maintenance reduce costSafety Safety

Non Conductive or C d ti i d

SafetyConductive as required

High strength and light Installation – quicker – save time, weight less hazardous, reduce cost

Safety Large unsupported covers possible

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Cost ComparisonA li C• Australian Company

• Tank: 3 m diameter, 5 m high• 70% Sulphuric Acid• Wall thickness 6 mm in steel and 15 mm in composites• Specific Gravity of steel 7.8 cf 1.6 for composites – tank half the

weight in compositeg p

Tank Material Tank Fabrication Cost Cost RatioSAF 2205 Stainless Steel $130,467 1.3316 Stainless Steel $110,897 1.1Mild Steel $58,710 0.6Composite $99,720 1.0

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Cost Comparison

• Pipe• Diameter 150 mm

P 700 kP• Pressure 700 kPa• 12 m length, 1 flange, 1 elbow 90 degrees, 2 joints/welds, 2 mild

steel supports

Pipe Material Fabrication Installation Supply & Installation

SAF 2205 Stainless Steel 6.3 1.1 3.6316 Stainless Steel 1.6 1.1 1.4Composite 1.0 1.0 1.0

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QUESTIONS?

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Outline1 A li ti d 3 Working With Composites1. Application and

Opportunities for Composites in Mining• Vessels

3. Working With Composites• Design• Manufacture• Transport

• Pipelines• Infrastructure

• Transport• Installation• Use• Inspection & Testing2. Materials

• What Are Composites• Properties• Cost Comparison

• Inspection & Testing

Questions• Cost Comparison• Failure Modes

Questions

Lucy Cranitch

Questions

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Failure Modes

• Poor QA during production• Chemical degradation

E i i i• Erosion in pipes• Cracking and Delamination• Impact

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Failure Modes - QAPoor QA During Production• Balance between Quality and Price• Resins which are not as corrosion resistantResins which are not as corrosion resistant• Fibre layout not consistent• Laminate too thin (hydro testing fail)

Not cured properly ( /i ffi i t t l t i iti t t d/• Not cured properly (wrong/insufficient catalyst, initiator, promoter and/or temperature. Postcure)

• Insufficient overlaps in laminate and at joints• Insufficient inspection and testing• Insufficient inspection and testing

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Failure Modes – Blisters & Softening• Fluids entering the laminate creates pressure.• Pressure causes the laminate to detach & blister.

Laminate FluidCorrect resin and tissues help minimise this. “The resin rich layer shall be of a minimum thickness of 0.25 mm and shall contain ‘C’ Glass surfacing tissue or synthetic fibres such as polyester or acrylic fibres of minimum dry thickness 0 25 mm Minimum resin

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such as polyester or acrylic fibres of minimum dry thickness 0.25 mm. Minimum resin content by weight shall be nominally 90%.” [AS2634]

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Failure Modes - Chemical Degradation

• Splash of 95% sulphuric Acidsulphuric Acid

• Wrong material in this environment

OrOr• Process conditions

outside of specificationspecification

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Failure Modes – Erosion of PipesCan be improved by:

• 3-5% hard fillers such as silicon carbide helps. Either in a coating or part of the corrosion barrier

• Use of a veil, particularly a carbon veil increases abrasion resistance.

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Failure Modes – Delamination & Cracks

• At flange faces• At corners• At secondary joins

• Procedure for flangeProcedure for flange tightening

• Avoid sharp corners• Don’t over pressurise• Don t over pressurise

pipes

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Failure Modes - Impact• Effects structural integrity but can also crack the internal resin• During transport

t t dl ddi d tiff i d i• use correct supports, cradles, padding and stiffening devices• During installation

• use lifting lugs, webbing or soft slings• avoid shock loads and sliding • ensure supports are correct

• During useDuring use• avoid hydroblasting• take care with forklifts etc.

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Outline1 A li ti d 3 Working With Composites1. Application and

Opportunities for Composites in Mining• Vessels

3. Working With Composites• Design• Manufacture• Transport

• Pipelines• Infrastructure

• Transport• Installation• Use• Inspection & Testing2. Materials

• What Are Composites• Properties• Cost Comparison

• Inspection & Testing

Questions• Cost Comparison• Failure Modes

Questions

Lucy Cranitch

Questions

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Design Life• It depends on the conditions of use• Design life of a minimum 20 years continuous operation is typical in the

mining industryg y• Design life up to 100 years now specified for water and waste industry

Examples:p• Bleach washer hoods were used for 17 years in a Canadian pulp and

paper mill. • High performance polyester have operated in chemical service for 25

years and still been in sound conditionyears and still been in sound condition.• Underground fuel storage tanks. Isophthalic resin. Exhumed after 25

years service and shown little or no physical or chemical degradation.

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Design Life Example

i

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Uptime

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Design – Resin SelectionResin Selection Guides

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Pi d D t

Design - StandardsPipes and Ducts• AS 2634. Australian Standard for “Chemical

Plant Equipment made from Glass-Fibre Reinforced Plastics (GRP) based onReinforced Plastics (GRP) based on Thermosetting Resins”

• AS 2566 Buried Flexible Pipelines• BS 7159 Code of Practice for Design andBS 7159 Code of Practice for Design and

Construction of Glass Reinforced Plastics (GRP) piping systems for individual plant sites.

• BS 6464 Reinforced Plastic Pipes, Fittings and Joints for Process Plants

• ISO 14692 Petroleum and natural gas industries — Glass-reinforced plastics (GRP) piping. [Use for high pressure or SX pipes]

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high pressure or SX pipes]

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Design DetailPressurePressure• API 15 HR Specification for High Pressure

Fiberglass Line Pipe – 2001 cover pipes rated for 3 45 MPa to 34 5 MPa

Supports

rated for 3.45 MPa to 34.5 MPa.• 18 MPa pipe typically available for oil and

gas.Supports• For pipes and ducts, BS 6464 contains information on installation

including supports, guides and anchors.• Pipe support spacing is important to limit deflection, for example using p pp p g p , p g

a maximum deflection to span ratio of 1:300. • A minimum contact arc of 120° under the pipe is typical. • Rubber packers can help

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Design - StandardsT k d P V lTanks and Process Vessels • AS2634. Chemical Plant Equipment Made From Glass-Fibre

Reinforced Plastics (GRP) Based on Thermosetting Resins.• BS4994. Design and Construction of Vessels and Tanks in Reinforced

Plastics• BS EN 13121 GRP Tanks and Vessels For Use Above Ground• BS EN 13923 Filament Wound FRP Pressure Vessels – Materials,

design, manufacturing and testing

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Design Detail - Tanks and Process Vessels

SupportSupport• Concrete slab or alternative

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Design - JointsButt and strap• Strength must be at least equivalent to

parent material• Laminate internal surface where

accessible• Widths are given in standardsg• Hand lay-up design thickness• Resin seal all cut ends

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Design - JointsB h j iBranch joints• Similar

Requirements to b tt d tbutt and strap joints

• Need additional i f t treinforcement to

replace strength of cut out.

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Design - JointsFlanges• Composite flanges• Compatible with steel• Compatible with steel• ANSI Dimensions • Full flat faced suggested. Flatness

importantimportant• Steel backing rings can be used • Washes under nuts• Care with bolt torque• Care with nozzle projections (not

too far)

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Tank Lining• Line concrete or steel tank with composites

Dual Laminate Systems – Line Fibre Composite tank with plasticy p p• Polypropylene• PVC & CPVC• Fluorinated – PVDF, ECTFE, FEPFluorinated PVDF, ECTFE, FEP• Test for suitability (corrosion & erosion) – in exact solution, under load• When acting as corrosion barrier - minimum bond strength of 7 MPa in

direct shear & 5 N/mm width in peel.p• Materials usually come glass backed for laminate adhesion

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PATHPATH Concrete Floor and Bund ProtectionBund Protection

Concrete

Primer - Resin + 10% Styrene Monomer.

Three layers of 450

Sand non

1 mmg/m2 powder bound chopped strand mat

One resin rich layer of Sand non slip surface 3 mm

1 mm

y20 g/m² surface tissue

0.5 mm

Top coat - Resin + 0.5% Wax in

Styrene

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Concrete Floor and Bund Protection

Concrete

Primer Resin + 10% Bund ProtectionPrimer - Resin + 10% Styrene Monomer.

Base coat - Resin +

Sand non slip surface

1 mm

5 15 mm

graded silica sand aggregate.

p5 - 15 mm

0 5 mm

Top coat - Resin + 0.5% Wax in Styrene

0.5 mm

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Concrete Floor and Bund Protection

Chemical Environments1 S l h i id H 0 8

Olympic Dam - 12,000 m2 of concrete protection across siteParticularly in solvent extraction area

1. Sulphuric acid, pH 0.82. Ammonia and ammonium

sulphate3. Ethanol3. Ethanol4. Kerosene5. Caustic soda & sodium

carbonate, pH 12-136 Chlorides6. Chlorides 7. Fluorides 8. Sodium chlorate

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Working With Composites

• Design• Manufacture

T t• Transport • Installation• Use• Inspection and Testing

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Manufacture - Post-cure

• Must post-cure using heat, when used in aggressive corrosiveapplicationsP t i l t (f th li ki ) Thi• Post-cure gives a more complete cure (further crosslinking). Thisgives higher mechanical properties, heat distortion temperature(HDT) & chemical resistance.

• Barcol hardness of at least 90% of datasheet value.

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TransportDuring transport use correct support cradles padding and stiffeningDuring transport use correct support, cradles, padding and stiffening devices

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Installation should use correct supports lifting lugs webbing or softInstallation

Installation should use correct supports, lifting lugs, webbing or soft slings, avoid shock loads, avoid sliding

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Use• Avoid hydroblasting or use lower pressure• Avoid impact from equipment and machinery• Ensure process control• Ensure process control

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Inspection and Testing

Non-Destructive Methods• Visual Inspection• Barcol Hardness Testing

C T ti ith A t• Cure Testing with Acetone• Tap Testing• Ultrasonic Testing• Acoustic EmissionAcoustic Emission

Destructive Methods• AS 3572 Plastics – Glass filament reinforced plastics (GRP) – Methods

of testof test. • Mechanical tests – tension, compression, shear, fatigue, creep, impact,

modulus, stress & strain to break• Microscopy– Optical, Scanning Electron Microscopy

A l t d i i h i l f ti t h t UV

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• Accelerated ageing – in chemicals, fatigue, stress, heat, UV

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Outline1 A li ti d 3 Working With Composites1. Application and

Opportunities for Composites in Mining• Vessels

3. Working With Composites• Design• Manufacture• Transport

• Pipelines• Infrastructure

• Transport• Installation• Use• Inspection & Testing2. Materials

• What Are Composites• Properties• Cost Comparison

• Inspection & Testing

Questions• Cost Comparison• Failure Modes

Questions

Lucy Cranitch

Questions

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Summary

Composites tend to replace more traditional materials including steel and concrete:• In corrosive environments • Where electrical insulation is required• Where light weight is required• Where low life cycle cost is desired• Where low life cycle cost is desired

With correct resin selection, materials design and manufacture, composite assets can give lifetimes of 20 to over 100 years depending on the application.

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Questions?

Dr Lucy CranitchMaterials Scientist

PATHPractical And Timely HelpPractical And Timely Help

Consulting in composites,plastics, rubber & coatings

M: 0420 664 631 E: lucy.cranitch@path2u.com.au

Lucy Cranitch