Composites USAA Critical Process Systems Group Company

CorrstopTM

CSDual Laminate Equipment

Dual LaminateEquipment & Structures

A two constituent composite in which thermosetting Fiber Reinforced Plastic (FRP/GRP) represents the basic structural element while any of a wide range of available thermoplastics represent the mating service face. While maintaining separate identities, upon either soluble or mechanical joining, the integrated materials in effect form a single construction. Essentially, FRP/GRP is employed for its durability and Thermoplastics for their extraordinary impermeability.

HomogeneousService Face Material InvariabilityService Face SmoothnessLow Coefficients of Thermal Expansion & FrictionDesign Freedom in both Round and Flat GeometriesCorrosion Resistance Throughout

Introduction

Service Face Materials

Dual Laminate construction cost effectively extends the practical performance range of FRP/GRP while outperforming numerous metal alloys. Enhanced physical properties including chemical, thermal and abrasion resistance continue to drive the use of Dual Laminate as the material of choice for demanding and critical service environments, most notably, corrosion mitigation. Dual Laminate is proven unequalled in high-purity liquid and gas processes.

Application

Attributes

PVC Polyvinyl Chloride

CPVC Post Chlorinated PVC

PP-H Polypropylene Homopolymer

PP-R Polypropylene Random Copolymer

PVDF Polyvinylidene Fluoride (Kynar)

Ethylene Chlorotrifluoroethylene (Halar)

ETFE Ethylene Tetrafluoroethylene (Tefzel)

MFA (Hyflon)

FEP Fluorinated Ethylene Propylene (Teflon)

PFA Perfluoroalkoxy Copolymer (Teflon)

User Benefits

Compared to alternative materials of construction including hybrids, the benefits of dual laminate construction include:

Initial CostStrengthWeightVersatilityLife ExtensionMaintenance CostSuperior Corrosion Resistance

Valuable Experience, Contemporary Processes

As an internationally acclaimed authority drawing upon experience extending to a fourth decade, Composites USA is uniquely qualified in the design, manufacture and construction of Dual Laminate process equipment and structures. Utilizing applied pressure, thermo and vacuum forming processes, Thermoplastic materials are infinitely shaped to accommodate the most complex design configurations. FRP/GRP laminates are produced under hand lay-up, filament winding and numerous vacuum forming processes.

When it must be optimally corrosion resistant, intrinsically pure, lightweight, strong and everlasting, it must be Dual Laminate superbly crafted by Composites USA.

Table 1. Service Face Materials Physical Properties

Specific GravityElongation at Break

Tensile Strength psi 20,0003,8403,4006,2506,4004,90071115,000MPa 453250

Tensile Modulus psi 1,550,00039,80060,500156,500MPa 109002804251100

Flex Modulus psi 1,150,00098,90098,900184,900241,800241,800320,000200,000MPa 8090660660130017002250

Flex Strength psi 25,0002,5602,5605,5006,2586,38110,5256,685MPa 17618183944447447

Shore D 60566775777773-6 10 in/in °F 157050754070

Maximum Service Temperature °F 300500400300300250300200°C 149260204149149121149

Heat Distortion Temperature °F 200-280118118270170150235107°C 93-13848481326611342

Heat Melting Point °F N/A590525515465315342330°C 310274268241157172166

Fire Class V-0V-0V-0V-0V-0V-0HB/V-2

141272544

The information in this table has been provided by thermoplastic manufacturers for unfilled materials. Tests were run at ambient temperatures. FRP values are for a typical glass/vinyl ester Type II laminate.

HardnessThermal Expansion Coefficient

241,8001700

250,0001750

341,4002400

170,7001200

1.612.152.151.71.691.781.760.91% 3-62001520-80200-300 300299200

8,000

415,000

15,100104

80

190

18082

230110

V-0

360,0002500

1.5520-30

6,300

415,000

15,100104

80

140

13557

220104

V-0

360,0002500

1.3220-30

D638

D790

D790

D2240D696

D648 @264 psi

UL-94

D638

D792

335545

1700140628602860

77

938860

80853535

PVC PFACPVC ETFE FEPPVDF ECTFEPPProperties PVDF AS FRPASTM Unit

Once design and subsequent submittals approvals are met, projects are then assigned to the production facility best equipped for the unique manufacturing requirements of each. Specialized forming and tooling capabilities, material application systems and logistics each share vital roles in such assignment. Well tenured, highly qualified craftspeople consistently supported by the industry’s most technically advanced auto and manual thermosetting and thermoplastic forming and welding equipment then bring to bear their considerable expertise in rendering a product which can best be described as a critically rendered art form.

The Process

Since 1982, Composites USA continues to execute on the requests of many of the world’s most discerning and demanding users. From intricate and complex parts to multi-million dollar design, fabrication, and construction schemes, we invoke hundreds of years of combined experience and technological superiority in each and every initiative undertaken.

With industry recognized Approvals and Listings from Factory Mutual, Underwriters Laboratories, and the U.S. Government, Composites USA is well positioned to be your sole source provider for reinforced plastic needs.

Why Composites USA?

Composites USA’s highly respected position in both the global marketplace and industry is dependent upon our perpetual commitment and devotion to consistent delivery of products, systems and construction which define excellence. Persistent improvement, and investment in technology, human, material and quality assurance resources coupled with a self-challenging, never satisfied business culture guarantee unmatched quality without exception.

Independent QA/QC, conformance with industry’s most stringent standards, on-premises R&D / testing laboratories and a dedicated Management Team and Workforce all serve to ensure a realized Best Quality Attainable product.

Composites USA always invites external Systems, Facilities and Safety compliance audits.

Product Integrity

PVC PFACPVC ETFE FEPPVDF ECTFEPP

HCI, <36% 300300300300285140180104

149140608240

HCI, 36% 3003003003002856373NR

1402023

Sulfuric Acid, 100% 30030012073NR

1491495023

Sulfuric Acid, 98% 300300300250150NR73NR

1491491491206523

Sulfuric Acid, >50% 300300300250250140180104

149149149120120608240

Nitric Acid, 70% 30030075121121NR73NR

14914925505023

Nitric Acid, 35% 3003001502121216373NR

14914965100502023

Sodium Hydroxide, 50% 300300230250NR212180140

1491491101201008260

Sodium Hydroxide, 10% 300300230300120212180140

149149110149501008260

Sodium Hypochlorite, 12.5% 30030030025020063180104

14914914912095208240

Hydrofluoric Acid, 70% 300300250212200NRNRNR

14914912010095

Hydrofluoric Acid, 40% 300300275250250140160104

149149130120120607040

149149149

149149149149

NR NR NR

NR = Not Recommended The information in this table has been provided by thermoplastic manufacturers.

Table 2: Corrosion Resistance of Typical Thermoplastic Liner Materials

Halar lined forty eight inch diameter reactor head.

°F

°C

°F

°C

°F

°C

°F

°C

°F

°C

°F

°C

°F

°C

°F

°C

°F

°C

°F

°C

°F

°C

°F

°C

Table 3. Cost Comparisons of Typical Vessel Configurations

Hastalloy C-276

FEP / FRP

ECTFE / FRP

PVDF / FRP

CPVC / FRP

PP / FRP

PVC / FRP

316 Stainless Steel

Vinyl Ester FRP

100% 200% 300% 400% 500% 600% 700%

100% 200% 300% 400% 500% 600% 700%

Relative Costs Compared to Vinyl Ester FRP

720%

711%

465%

409%

232%

214%

190%

157%

100%

606%

545%

331%

328%

201%

175%

173%

168%

100%100%

325%

302%

210%

194%

144%

139%

133%

104%

Vessel Materialof Construction

Process Tanks

Scrubbers

Storage Tanks

PVDF lined nine foot diameter tanks.

Other Composites USA products:

Consulting DesignManufacturingConstructionInspection/Testing

Services

FM Approved / UL Listed FRP Duct - Dual GuardSpecialized Composite Plastic Equipment - Flame GuardFluoropolymer Coated Stainless Steel Duct - Pure GuardFiberglass Scrubbers & Skid SystemsFiberglass Tanks & VesselsFiberglass Stacks

Technical information contained in this document is subject to change without notice.

COPYRIGHT 2015 COMPOSITES USA

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