Fluoropolymers applications in chemical processing industries : the definitive users guide and databook

Title:

Personal Author:

Ebnesajjad, Sina

Series:

PDL handbook series

Publication Information:

Norwich, NY : William Andrew Pub., 2005

ISBN:

9780815515029

Subject Term:

Fluoropolymers -- Industrial applications

Added Author:

Khaladkar, Pradip R.

Available:*

Library	Item Barcode	Call Number	Material Type	Item Category 1	Status
Searching... PSZ JB	30000010106675	TP1180.F6 E36 2005	Open Access Book	Book	Searching... Unknown

This is a self-contained collection of data and information on applications of fluoropolymers components for corrosion control in chemical processing industries. Due to their superior properties, fluoropolymers have been rapidly replacing metal alloys for preserving the purity of processing streams in the chemical processing, plastics, food, pharmaceutical, semiconductor, and pulp and paper industries.

Author Notes

Sina Ebnesajjad is a Senior Technical Consultant in the Fluoropolymers Division of DuPont Fluoroproducts in Wilmington, Delaware, where he has been involved in a variety of technical assignments since 1982. He earned his MS and Ph.D. degrees in chemical engineering from the University of Michigan, Ann Arbor, and BS in chemical engineering from the Univisity of Tehran, Iran
Pradip R. Khaladkar is a Senior Consultant in DuPont Engineering Technology in Wilmington, Delaware, where he has been involved in a variety of materials engineering assignments since 1978. He earned his MS degree in chemical engineering from West Virginia University, Morgantown, and BS in chemical engineering from the Indian Institute of Technology, Bombay

J. S. Bergstrom and S. Brown

1 Introduction to Fluoropolymers	p. 1
1.1 Introduction	p. 1
1.2 What are Fluoropolymers?	p. 1
1.3 Fundamental Properties of Fluoropolymers	p. 2
1.4 Developmental History of Fluoropolymers	p. 3
1.5 Examples of Uses of Fluoropolymers	p. 5
References	p. 6
2 Materials of Construction	p. 7
2.1 Introduction	p. 7
2.2 Historical Background	p. 7
2.3 Definition of Polymer-based Materials	p. 8
2.4 Comparison Between Polymer-based Materials and Metals	p. 8
2.4.1 Position of Fluoropolymers in the Materials Spectrum	p. 10
2.5 Applications of Polymer-based Materials for Corrosion Control	p. 10
2.5.1 Applications of Fluoropolymers for Corrosion Control	p. 10
References	p. 14
3 Properties of Neat (Unfilled) and Filled Fluoropolymers	p. 15
3.1 Introduction	p. 15
3.2 Influence of Processing on Fluoroplastics	p. 15
3.3 Chemical Compatibility of Fluoropolymers	p. 15
3.3.1 Chemical Compatibility of Perfluoropolymers	p. 15
3.3.1.1 Effect of Ozone on Fluoropolymers	p. 16
3.3.1.2 Oxygen Compatibility of PTFE	p. 17
3.3.2 Chemical Compatibility of Partially Fluorinated Fluoropolymers	p. 17
3.3.3 Chemical Compatibility of Polychlorotrifluoroethylene	p. 18
3.4 Permeation Fundamentals	p. 18
3.4.1 Permeation Measurement and Data	p. 20
3.5 Environmental Stress Cracking	p. 21
3.6 Properties and Characteristics of PTFE	p. 23
3.6.1 Introduction to Filled PTFE Compounds	p. 23
3.6.1.1 Granular-based Compounds	p. 23
3.6.1.2 Fine Powder-based Compounds	p. 25
3.6.1.3 Compounding with Engineering Polymers	p. 25
3.6.1.4 Reinforced Gasketing Material	p. 26
3.6.1.5 Co-Coagulated Compounds	p. 26
3.6.1.6 Fabrication of Parts from Compounds	p. 26
3.6.1.7 Typical Properties of Filled Fluoropolymers	p. 27
3.6.2 Mechanical Properties of PTFE	p. 28
3.6.2.1 Deformation Under Load (Creep) and Cold Flow	p. 35
3.6.2.2 Fatigue Properties	p. 36
3.6.2.3 Impact Strength	p. 36
3.6.2.4 Hardness	p. 36
3.6.2.5 Friction	p. 36
3.6.2.6 PV Limit	p. 47
3.6.2.7 Abrasion and Wear	p. 47
3.6.3 Electrical Properties of PTFE	p. 47
3.6.4 Thermal Behavior of PTFE	p. 47
3.6.4.1 Thermal Stability	p. 47
3.6.4.2 Thermal Expansion	p. 51
3.6.4.3 Thermal Conductivity and Heat Capacity	p. 51
3.6.4.4 Heat Deflection Temperature	p. 51
3.6.5 Irradiation Resistance of PTFE	p. 51
3.6.6 Standard Measurement Methods for PTFE	p. 52
3.7 Properties and Characteristics of Melt-processible Fluoroplastics	p. 55
3.7.1 Mechanical and Dynamic Properties	p. 55
3.7.1.1 Tensile Properties	p. 55
3.7.1.2 Moduli	p. 55
3.7.1.3 Deformation Under Load (Creep)	p. 69
3.7.1.4 Poisson's Ratio	p. 69
3.7.1.5 Flex Fatigue Properties	p. 69
3.7.1.6 Impact Strength	p. 70
3.7.1.7 Hardness	p. 82
3.7.1.8 Friction, Wear, and Abrasion	p. 82
3.7.2 Thermal Properties of Melt-processible Fluoropolymers	p. 86
3.7.2.1 Thermal Stability	p. 86
3.7.2.2 Temperature-related Properties	p. 89
3.7.2.3 Thermal Aging	p. 89
3.7.3 Weatherability of Melt-processible Fluoroplastics	p. 94
3.7.4 Electrical Properties of Melt-processible Fluoroplastics	p. 96
3.7.4.1 Perfluoroalkoxy Polymers	p. 96
3.7.4.2 FEP	p. 98
3.7.4.3 PVDF	p. 98
3.7.4.4 ETFE	p. 100
3.7.4.5 ECTFE	p. 100
3.7.5 Optical and Spectral Properties of Melt-processible Fluoroplastics	p. 100
3.7.6 Radiation Effect on Melt-processible Fluoroplastics	p. 100
3.7.7 Flammability of Melt-processible Fluoroplastics	p. 110
3.7.8 Biofilm Formation of Melt-processible Fluorplastics	p. 110
References	p. 112
4 Selecting Fluoropolymers for Corrosion Control	p. 117
4.1 Introduction	p. 117
4.1.1 Corrosion of Metals	p. 117
4.1.2 Corrosion of Polymer Materials	p. 117
4.1.3 Approaches to Selection	p. 117
4.2 Economics of Selecting Fluoropolymers	p. 118
4.3 Preparing to Determine Compatibility	p. 118
4.4 Current Technology for Determining Compatibility	p. 118
4.4.1 Experience	p. 118
4.4.2 Manufacturers' Literature	p. 119
4.4.3 Testing	p. 149
4.4.3.1 Coupon Testing	p. 149
4.4.3.2 Simulated Testing	p. 150
4.4.3.3 Special Testing	p. 154
4.4.4 Fabrication Considerations in Materials Selection	p. 154
4.4.5 Inspection and Maintenance Aspects of Materials Selection	p. 157
References	p. 157
5 Manufacturing of Parts from Polytetrafluoroethylene Polymers	p. 161
5.1 Granular Resin Processing	p. 161
5.1.1 Resin Selection	p. 161
5.1.2 Compression Molding	p. 162
5.1.2.1 Equipment	p. 162
5.1.2.2 Densification and Sintering Mechanism	p. 163
5.1.2.3 Billet Molding	p. 164
5.1.3 Automatic Molding	p. 167
5.1.4 Isostatic Molding	p. 168
5.1.4.1 Introduction to Isostatic Molding	p. 168
5.1.4.2 Comparison of Isostatic with Other Fabrication Techniques	p. 169
5.1.4.3 Wet- and Dry-Bag Isostatic Molding	p. 170
5.1.5 Ram Extrusion	p. 170
5.1.5.1 Introduction to Ram Extrusion	p. 170
5.1.5.2 Ram Extrusion: Basic Technology	p. 170
5.2 Fine Powder Resin Processing	p. 174
5.2.1 Resin Handling and Storage	p. 174
5.2.2 Paste Extrusion Fundamentals	p. 175
5.2.3 Extrusion Aid or Lubricant	p. 176
5.2.4 Wire Coating	p. 176
5.2.4.1 Blending the Resin with Lubricant	p. 176
5.2.4.2 Preforming	p. 176
5.2.4.3 Extrusion Equipment and Process	p. 177
5.2.5 Extrusion of Tubing	p. 178
5.2.5.1 Spaghetti Tubing	p. 178
5.2.6 Pressure Hoses	p. 178
5.2.6.1 Blending Lubricant and Pigment and Preforming	p. 183
5.2.6.2 Extrusion Process for Pressure Hoses	p. 183
5.2.6.3 Quality Control of Pressure Hoses	p. 183
5.2.7 Unsintered Tape	p. 185
5.3 Fluoropolymer Dispersion Processing	p. 185
5.3.1 Dispersion Applications	p. 186
5.3.2 Storage and Handling of Dispersions	p. 186
5.3.3 Dispersion Formulation and Characteristics	p. 187
5.3.3.1 Formulation	p. 188
5.3.4 Glass Cloth Coating by Dispersion	p. 188
5.3.4.1 Equipment	p. 189
5.3.4.2 Processing	p. 189
5.3.5 Dispersion Impregnation of Flax and Polyaramide	p. 191
5.3.5.1 Processing	p. 191
5.3.6 Coating Metal and Hard Surfaces with Dispersion	p. 191
References	p. 192
6 Manufacturing Parts from Melt-processible Fluoropolymers	p. 193
6.1 Introduction	p. 193
6.2 Materials of Construction	p. 193
6.3 Rheology of Fluoropolymer Melts	p. 193
6.3.1 Characterization of Rheology of Fluoropolymers	p. 194
6.4 Thermal Stability of Fluoropolymers	p. 198
6.5 Melt Extrusion	p. 199
6.5.1 The Extruder	p. 199
6.5.2 Film Extrusion	p. 202
6.5.3 Sheet Extrusion	p. 202
6.5.3.1 Production	p. 202
6.5.4 Pipe and Tube Extrusion	p. 202
6.5.4.1 Production	p. 203
6.5.5 Coextrusion	p. 203
6.5.6 Drawdown Ratio (DDR)	p. 205
6.6 Fluoropolymer Tube Extrusion	p. 206
6.6.1 Sizing of Tubes	p. 206
6.6.1.1 Small Diameter Tubes	p. 207
6.6.1.2 Medium Diameter Tubes	p. 207
6.6.1.3 Large Diameter Tubes	p. 208
6.6.2 Heat Shrink Tubes	p. 208
6.7 Fluoropolymer Film Extrusion	p. 209
6.7.1 PVDF Films	p. 210
6.7.2 ETFE and ECTFE Films	p. 214
6.7.3 Perfluoropolymer Films	p. 217
6.8 Injection Molding	p. 219
6.8.1 Injection Molding of Fluoropolymers	p. 219
6.8.1.1 Injection Molding Equipment	p. 219
6.8.1.2 Process Conditions and Operations	p. 222
6.8.1.3 Dimensional Stability of Parts	p. 225
6.9 Rotational Molding	p. 226
6.9.1 Basic Process Technology	p. 229
6.9.2 Rotomolding and Rotolining Processing Conditions	p. 229
6.9.2.1 ECTFE	p. 231
6.9.2.2 ETFE	p. 232
6.9.2.3 PFA	p. 232
6.9.3 Conclusion	p. 233
6.10 Other Part Manufacturing Techniques	p. 235
6.10.1 Compression Molding of Fluoropolymers	p. 235
6.10.2 Transfer Molding of Fluoropolymers	p. 237
6.10.2.1 Mold Design	p. 237
6.10.2.2 Operation of the Mold	p. 239
6.10.2.3 Transfer Molding Process Variables	p. 239
6.10.3 Examples of Transfer Molded Parts	p. 241
6.10.4 Blow Molding Fluoropolymers	p. 244
6.11 Vacuum Bagging	p. 248
References	p. 250
7 Fabrication Techniques for Fluoropolymers	p. 253
7.1 Introduction	p. 253
7.2 Machining	p. 253
7.2.1 Sawing and Shearing	p. 254
7.2.2 Drilling (Tapping and Threading)	p. 254
7.2.3 Skiving	p. 254
7.3 Adhesive Bonding Methods	p. 255
7.3.1 Contact Adhesives	p. 255
7.3.2 Bonding Adhesives	p. 255
7.3.3 Sodium Etching	p. 256
7.3.4 Plasma Treatment	p. 258
7.3.5 Flame Treatment	p. 261
7.3.6 Corona Discharge (Hybrid Plasma) Treatment	p. 262
7.4 Welding and Joining	p. 265
7.4.1 Welding Techniques	p. 266
7.4.2 Welding PTFE	p. 267
7.4.3 Welding FEP	p. 269
7.4.4 Welding PFA	p. 269
7.4.5 Welding PVDF	p. 271
7.4.6 Welding ETFE	p. 273
7.5 Heat Bonding	p. 273
7.5.1 Sheet Liners	p. 274
7.6 Thermoforming	p. 274
7.7 Other Processes	p. 274
References	p. 276
8 Design and Construction of Linings and Vessels	p. 279
8.1 Introduction	p. 279
8.2 Lining of Vessels	p. 279
8.2.1 Adhesively Bonded Linings for Vessels	p. 280
8.2.2 Rotolining	p. 281
8.2.3 Spray and Baked Coatings	p. 286
8.2.3.1 Powder Coating Processes	p. 287
8.2.3.2 Liquid Dispersion Coatings	p. 295
8.2.4 Loose Lining	p. 295
8.2.5 Dual Laminate	p. 296
8.3 Lining of Pipes and Fittings	p. 299
8.4 Lined Valves	p. 299
8.4.1 Plug Valves	p. 301
8.4.2 Ball Valves	p. 301
8.4.3 Butterfly Valves	p. 301
8.4.4 Diaphragm Valves	p. 301
8.4.5 Clamp Valves	p. 301
8.5 Lined Hoses	p. 301
8.6 Lined Expansion Joints	p. 304
8.7 Lining or Coating of Internals	p. 304
8.8 Design and Fabrication of Vessels for Lining	p. 304
8.9 Shop Versus Field Fabrication	p. 304
References	p. 309
9 Operations and Maintenance	p. 311
9.1 Operations	p. 311
9.2 Maintenance	p. 311
9.2.1 Visual Examination	p. 311
9.2.1.1 Visual Inspections of Vessels	p. 311
9.2.1.2 Visual Inspection of Piping and Fittings	p. 312
9.2.1.3 Visual Inspection of Valves	p. 312
9.2.1.4 Visual Inspection of Hoses	p. 312
9.2.1.5 Visual Inspection of Expansion Joints	p. 312
9.2.2 Nondestructive and Destructive Examination	p. 312
9.2.3 Non-Intrusive Examination	p. 313
9.2.4 Risk-based Inspection Strategy (RBI)	p. 313
9.3 Repairs	p. 314
10 Failure Analysis	p. 315
10.1 Introduction	p. 315
10.2 Part Failure	p. 315
10.3 Defect Analysis	p. 316
10.4 Application of Failure Analysis Methodology	p. 322
10.4.1 Infrared Spectroscopy	p. 324
10.4.2 Electron Microscopy Techniques	p. 328
10.4.2.1 Scanning Electron Microscopy (SEM)	p. 328
10.4.2.2 Transmission Electron Microscopy (TEM)	p. 328
10.4.2.3 Energy Dispersive X-Ray (EDX) Spectroscopy	p. 328
10.4.3 Mass Spectroscopy (MS)	p. 328
10.4.4 Gas Chromatography (GC)	p. 331
10.4.5 Nuclear Magnetic Resonance (NMR)	p. 331
10.4.6 Differential Scanning Calorimetry (DSC)	p. 331
10.4.7 Differential Thermal Analysis (DTA)	p. 332
10.4.8 Dynamic Mechanical Analysis (DMA)	p. 339
10.4.9 Thermogravimetric Analysis (TGA)	p. 342
10.5 Surface Analysis	p. 342
10.5.1 Electron Spectroscopy for Chemical Analysis (ESCA)	p. 342
10.5.2 Secondary Ion Mass Spectroscopy (SIMS)	p. 345
10.6 Examples of Failure Analysis	p. 345
10.6.1 Case 1: Failed Lined Pipe	p. 345
10.6.2 Case 2: Failed Check Valves	p. 345
10.6.3 Case 3: Black Spots on FEP Coating	p. 348
10.6.4 Case 4: Braided Hose Failure	p. 348
10.7 Physical Defects Due to Part Fabrication	p. 350
10.7.1 Polytetrafluoroethylene (PTFE)	p. 350
10.7.2 Melt-processible Fluoropolymers	p. 352
10.7.2.1 Injection Molding	p. 352
10.7.2.2 Rotational and Transfer Molding	p. 352
10.7.3 Measurement of Flaws	p. 352
References	p. 356
11 Modeling and Mechanical Analysis of Fluoropolymer Components	p. 359
11.1 Introduction	p. 359
11.2 Review of Modeling Techniques	p. 359
11.3 Currently Available Material Models	p. 360
11.3.1 Linear Elasticity	p. 362
11.3.2 Hyperelasticity	p. 362
11.3.3 Linear Viscoelasticity	p. 363
11.3.4 Dual Network Fluoropolymer (DNF) Model	p. 364
11.4 Failure and Deformation Predictions	p. 368
11.4.1 Failure under Monotonic Loading	p. 369
11.4.2 Failure under Cyclic Loading	p. 370
11.5 Examples	p. 371
11.5.1 Corrugated PTFE Hose	p. 371
11.5.2 Threaded Connection Gasket	p. 372
11.6 Summary	p. 378
References	p. 380
12 Cost Analysis	p. 381
12.1 Introduction	p. 381
12.2 Cost Analysis	p. 381
References	p. 384
13 Safety, Disposal, and Recycling of Fluoropolymers	p. 385
13.1 Introduction	p. 385
13.2 Toxicology of Fluoropolymers	p. 385
13.3 Thermal Properties of Fluoropolymers	p. 385
13.4 Emission During Processing	p. 386
13.5 Safety Measures	p. 386
13.5.1 Ventilation	p. 386
13.5.2 Processing and Fabrication	p. 389
13.5.2.1 Sintering	p. 389
13.5.2.2 Paste Extrusion	p. 389
13.5.2.3 Dispersion Coating	p. 389
13.5.2.4 Melt Processing	p. 389
13.5.2.5 Machining	p. 390
13.5.2.6 Soldering and Melt Stripping	p. 390
13.5.2.7 Welding Fluoropolymer	p. 390
13.5.2.8 Welding and Flame-Cutting Fluoropolymer-Lined Metals	p. 390
13.5.3 Spillage Cleanup	p. 390
13.5.4 Equipment Cleaning and Maintenance	p. 390
13.5.5 Protective Clothing	p. 390
13.5.6 Personal Hygiene	p. 390
13.5.7 Fire Hazard	p. 390
13.5.8 Material Incompatibility	p. 391
13.6 Food Contact and Medical Applications	p. 391
13.7 Fluoropolymer Scrap and Recycling	p. 391
13.8 Environmental Protection and Disposal Methods	p. 391
References	p. 392
14 Future Trends	p. 393
14.1 Introduction	p. 393
14.2 Fluoropolymer Applications	p. 393
14.3 Fluoropolymer Resin Manufacturing	p. 393
14.4 Growth of Fluoropolymer Industries	p. 393
14.5 Technological Needs of Chemical Processing Industry	p. 394
14.5.1 Non-destructive and Non-intrusive Condition Assessment	p. 394
14.5.2 Accelerated Testing for Compatibility	p. 394
References	p. 394
Appendix I Permeation Properties of Perfluoroplastics	p. 395
I.1 Perfluoroalkoxy Resin	p. 395
I.1.1 Permeability to Gases	p. 395
References	p. 400
Appendix II Permeation Properties of Partially Fluorinated Fluoroplastics	p. 401
II.1 Polyvinylidene Fluoride	p. 401
II.1.1 Permeability	p. 401
II.1.2 Permeability To Gases	p. 401
II.1.3 Permeability To Liquids	p. 401
II.2 Ethylene Tetrafluoroethylene Copolymer	p. 410
II.3 Ethylene Chlorotrifluoroethylene Copolymer	p. 412
II.3.1 Permeability to Gases and Water Vapor	p. 412
II.4 Polyvinyl Fluoride	p. 417
II.5 Fluorinated Polyethylene	p. 417
II.5.1 Permeability to Oxygen	p. 417
References	p. 420
Appendix III Permeation of Automotive Fuels Through Fluoroplastics	p. 421
III.1 Test Method	p. 421
III.1.1 Fuel Types	p. 421
References	p. 422
Appendix IV Permeation of Organic and Inorganic Chemicals Through Fluoroplastic Films	p. 423
References	p. 426
Appendix V Chemical Resistance of Thermoplastics	p. 427
V.1 Chemical Resistance of Fluoropolymers	p. 427
V.2 PDL Resistance Rating	p. 427
Glossary	p. 521
Trademarks	p. 549
Index	p. 551

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