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Plastics for Process Plants and
Equipment
Symposium on Mineral Processing,
Plant Design, Control and Practice
October 2002
Prolite Plastics
Guyle McCuaig
Design Issues Associated with
Plastics in Hydrometallurgy
Existing applicable international standards
Industries served and suggested materials
Suggested high temperature service ranges
New hydrometallurgy technologies
History of plastics in the mining industry
Chemical corrosion advantages of Dualaminates
Comparison to metallic equipment
Restrained pipe structures vs. HDPE pipe in field
Thermoplastic concrete lining methods
Low temperature study of plastics in hydrometallurgy
Existing Applicable International
Standards
1 DIN 16965 Part 2: Type B pipes dimensions
2 DIN 16964: General quality requirements and testing
3 DIN 53769 Part 1: Determination of the adhesive shear strength of Type B pipeline components
4 DIN 16966 Part 2, DIN 16966 Part 4, DIM 16966 Part 5
5 DIN 16966 Part 8: Laminated joints dimensions for Type B piping
6 BS 6464: 1984 – British Standard specification for reinforced plastics pipes, fittings and joints for process
plants
7 PRN 88: Swedish pressure piping code plastics
8 DIN 16962 Part 4-12: Polypropylene pipe and fittings, dimensions, fusion and general quality requirements
9 DIN 16963 Part 4-10: Polyethylene pipe and fittings, dimensions, fusion and general quality requirements
10 DVS 2207 Part 15: Heating element butt welding of PVDF and ECTFE pipe and fittings
11 CGSB 41-GP-22: Cdn. Std. for: Process equipment; Reinforced polyester; Chemical resistant, custom contact
moulded pipe and fittings (NBS PS-15-69 American equivalent)
12 ASME B31.3-1996: Process piping, ASME code for pressure piping B31.3
13 ASTM C1147-95: Standard practice for determining the short term tensile weld strength of chemical resistant
thermoplastics
14 ANSI/AWS G1.10:2000 – Guide for the evaluation of hot gas and heated tool thermoplastics welds
15 CEN (Europe): IN process standard for approval testing of plastics welding personnel in Europe
Industries Served and Suggested
Materials
Zinc Sulphide/Oxide Launders @ 90° C Sulphuric Acid PP-H/FRP
Copper Electrowinning @ 70° C Sulphuric Acid PVC/FRP
Magnesium Electrolysis @ 100° C HCl PVDF/FRP
Silver Electrolysis @ 80° C Nitric Acid PVDF/FRP
Indium, Germanium Electrolysis @ 80° C HCl
FRP
PVC/FRP
PVDF/FRP
Columbium & Zirconium for Organic Raffinate HCl, BenzeneFuran
ECTFE/FRP
Off-Gas Scrubbing of SO2 (Gold) H2SO4
PP/FRP
PVC/FRP
Zinc Electrolysis Cell Feed H2SO4 PP/FRP
Selenium Reduction from Silver Refining SO2 ECTFE/FRP
Phosphoric Acid in Fertilizer Manufacturing H3PO4
FRP
PP/FRP
Low Concentration Leaching of Copper Ores H2SO4 HDPE Pipe
Perchloric Acid Laboratory Fumehoods Perchloric Acid PVC/FRP
Hydrometallurgical and
Electrochemical Processes:
Typical Materials
TABLE 3
Mineral Process Industries Served and Suggested Materials
Suggested Thermoplastic & Dual
Laminate Pipe Temperature &
Service Ranges
LINERMAX. TEMP
PLASTIC ONLY
MIN.
TEMP.MATERIAL SPEC.
MAX. TEMP
SERVICE
DUAL LAM.
MIN. TEMP.
SERVICE
DUAL LAM.
DIN 16964 BOND
STRENGTH N/MM2
PVC 60ºC -15ºC ASTM 1784 80ºC -15ºC 7
CPVC 90ºC -15ºC ASTM 1784 100ºC -15ºC 7
PP-H 90ºC -15ºC ASTM D4101 100ºC -30ºC 3.5
PVDF 140ºC -40ºC ASTM D3222 121ºC -40ºC 5
ECTFE 180ºC -76ºC ASTM D3275 121ºC -50ºC 5
MFA 260ºC -190ºC ASTM D6314 121ºC -50ºC 5
HDPE 80ºC -50ºC D1248 85ºC -50ºC 3.5
PFA 260ºC -190ºC D3307 121ºC -50ºC 5
Zinc Sulphide/Oxide PP/FRP
Launders
• Zinc sulphide slurry
• 80ºC service
• Clarifier bypass line
15% sulphuric acid
complete with high
percentage solids
• Extreme outdoor
temperature
Copper Electrowinning
PVC/FRP Header
• Copper ore in
concentrated sulphuric
acid solution at 70ºC
• Large 24” diameter
PVC/FRP piping
carrying heavy liquid
• Low level organic
precipitate carrier
• High altitude plant
Copper Electrowinning PVC and FRP
Fences Used in Solvent Separation
• Copper sulphate
solution separating
organic precipitate
• PVC fences complete
with FRP beams and
thermoplastic fasteners
• Inserted into HDPE
lined concrete cells
Magnesium Extraction from
Asbestos PVDF/FRP Ducting
• High temperature
ducting in PVDF/FRP
for collection of off gas
containing product
magnesium (100ºC) in
HCl carrier
• Fire retardant resin
(brominated vinylester)
• 50 psi rating-outdoors
Silver Electrolysis in Nitric Acid
PVDF/FRP
• PVDF/FRP piping for
nitric acid transfer used
in gold parting
• PVDF liner with epoxy
novolac resin exterior
• Hi-purity PVDF for
gold/silver collection
and electrolysis
Indium and Germanium
Electrolysis
• PVDF/FRP baskets for
Germanium collection
in Indium process
• Membrane liner
inserted to collect
heavy precipitate
• High concentration
HCl service at 80 ºC
Columbium and Zirconium
Raffinate in Furan Tanks
• Furan resin tanks for
ambient temperature
extraction of Zirconium
and Columbium raffinates
• Organic solvents and
concentrated HCl
• Abrasion and fire
retardancy issues
Gold Roaster Off-Gas Scrubbing
PP/FRP Tower
• European designed
sulphuric acid gas
collection tower from
gold roasting process
• High temperature 90ºC
service with sulphuric
liquid and gas phase
• Packed bed and Venturi
scrubbing system
Zinc Electrolysis PP/FRP Cell
Feed Tank
• Main zinc electrolyte
European designed
rectangular cell house
feed tank
• Heavy continuous
liquid loading and
thermal cycling
• Electrochemical
currents and 80ºC
Selenium Reduction in Silver
Refining in ECTFE/FRP
• Selenium reduction
vessel using
concentrated HCl and
some SO2 gas
• Permeation problem
with SO2 gas solved
with ECTFE liner
• Agitation and abrasion
severe within vessel
Phosphoric Acid Produced in
Fertilizer Plant
• Phosphoric acid
corrosion problems
solved with vinyl ester
resins with straight FRP
liners
• Vacuum service solved
with laminate theory
• Replaced SS 316 and
other metals
Low Concentration Sulphuric
Acid Leaching of Ores
• HDPE pipe is slotted
and laid out over a
vast controlled area to
distribute sulphuric
acid on ore bed
• Leachate is collected
in a flexible PVC liner
and distributed by pipe
to refining process
Large Diameter HDPE Pipe
Installation for Mining Tailings
• HDPE pipe is the most
versatile and forgiving
thermoplastic used in
mineral processing
• Lightweight - up to 63”
• Abrasion resistant
• Inexpensive and easily
welded by butt fusion or
gasket joined
UHMW Lined Steel Hopper For
Abrasion Resistance
• UHMW lined steel
slurry hopper for
severe abrasion
• Ambient temperature
• Can be relined by
mechanical fastening
technique
• Is not considered
liquid tight or welded
Perchloric Acid Laboratory
Fumehoods in PVC/FRP
• Perchloric acid and
aqua regia venthoods
in laboratories
• Can be washed down
with water to avoid
explosive mixture
• PVC/FRP construction
for long term
corrosion and safety
HDPE Concrete Liner for Dome
of 130 ft dia. Sludge Digestor
• 130 ft. dia. domes for
sludge digestor tanks
• HDPE concrete liner
welded and fastened to
internal forms
• Concrete roof to be
poured on top surface
• All internally welded
Conclusion and Future of Dualaminates in the
Mineral Process Industry and Hydrometallurgy
Thermoplastics, thermosets and dualaminate equipment and piping has been growing in the
world-wide mineral processing industry for everything from liquid slurry lines, to gas transfer lines to
high pressure piping and vessels.
Plastic materials have non-metallic/non-electromagnetic properties which is important for
electrochemical corrosion, grounding, and safety, as well as for eliminating the need for costly
instrumentation.
In leaching processes, plastics have lightweight properties where piping can be easily moved,
in outdoor operations can resist temperatures as low as -50°C and will withstand corrosion and U.V.
attack for long periods of time. In remote mountain operations the plastic piping is moved much more
easily than metal or concrete.
In gas cleaning operations, high temperature fluoropolymers have and will replace existing lead
lined, acid brick lined or alloy materials in the following years.
The critical decision in choosing a thermoplastic, a thermoset or a dualaminate material for your
processing application is now made easier with a wider range of material options.