AP955A - A process for manufacturing a tank or container by using a polymer concrete mixture. - Google Patents

A process for manufacturing a tank or container by using a polymer concrete mixture. Download PDF

Info

Publication number
AP955A
AP955A APAP/P/1998/001411A AP9801411A AP955A AP 955 A AP955 A AP 955A AP 9801411 A AP9801411 A AP 9801411A AP 955 A AP955 A AP 955A
Authority
AP
ARIPO
Prior art keywords
process according
corrosion resistant
resin binder
mixture
fibre material
Prior art date
Application number
APAP/P/1998/001411A
Other versions
AP9801411A0 (en
Inventor
David Alfred Lawrence
Original Assignee
Polymer Concrete Industries Pty Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Polymer Concrete Industries Pty Limited filed Critical Polymer Concrete Industries Pty Limited
Publication of AP9801411A0 publication Critical patent/AP9801411A0/en
Application granted granted Critical
Publication of AP955A publication Critical patent/AP955A/en

Links

Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02Macromolecular compounds
    • C04B26/04Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L33/00Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
    • C08L33/04Homopolymers or copolymers of esters
    • C08L33/06Homopolymers or copolymers of esters of esters containing only carbon, hydrogen and oxygen, which oxygen atoms are present only as part of the carboxyl radical
    • C08L33/08Homopolymers or copolymers of acrylic acid esters
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00853Uses not provided for elsewhere in C04B2111/00 in electrochemical cells or batteries, e.g. fuel cells
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00948Uses not provided for elsewhere in C04B2111/00 for the fabrication of containers
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20Resistance against chemical, physical or biological attack
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00Polymer mixtures characterised by other features
    • C08L2205/14Polymer mixtures characterised by other features containing polymeric additives characterised by shape
    • C08L2205/16Fibres; Fibrils
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08LCOMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L23/00Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
    • C08L23/02Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
    • C08L23/10Homopolymers or copolymers of propene

Landscapes

  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

A process for manufacturing a corrosion resistant tank or container comprises the steps of mixing a filler material consisting of a corrosion resistant aggregate with a corrosion resistant resin binder and a polypropylene based fibre material to form a polymer concrete mixture and, introducing this mixture into a mould and allowing it to cure, the mould being optionally vibrated to produce a homogenous casting. The corrosion resistant tank or container is preferably a corrosion resistant electrolytic cell used in the electrolylic treatment of metals and salts.

Description

BACKGROUND OF THE INVENTION
THIS invention relates to the manufacture of tanks or containers, and in particular to the manufacture of corrosion resistant tanks or containers.
Corrosion resistant containers in the form of acid resistant electrolytic cells are used for the electrolytic treatment of metals and salts. The basic method employed for the recovery of metals is to dissolve the metal in an acid solution. This solution is passed through a series of electrolytic cells (tanks). The cells are fitted with negatively and positively charged anodes and cathodes. Through a process of electrolysis the metal in the acid solution is deposited on the cathode leaving behind all other metals as a sludge. The pure metal adhering to the cathodes is stripped from the cathodes at regular intervals.
The acid solution employed in metal recovery is highly corrosive. In order to protect the cell or tank structure from corrosive damage, the interior walls and base are covered with a corrosion resistant material such as lead sheets, plastics or rubber liners or other protective systems, for example.
A disadvantage of coating the surfaces which are exposed to the corrosive medium is that they can be damaged by mechanical action. This damage usually occurs when the metal laden cathodes are removed for stripping. The cathodes often dislodge from the lifting mechanism, fall into the cell or tank and puncture or severely damage the protective lining or coating.
AP/P/ 98 / 0 14 11
AP 00955
-2The repairs to this damage can only be undertaken periodically and thus the cell structure is subject to corrosive action by the leaking cell contents. This action weakens the cell and creates a potentially dangerous situation after a period of time.
In order to avoid the inherent danger described above and also to create an efficient electrolytic process the structure of electrolytic cells and tanks have undergone changes.
The basis of the changes have been to select corrosion resistant aggregates, which are carefully graded and batched into suitable mixtures of matched granule distribution. This mixed aggregate is then mixed with a highly corrosion resistant vinyl ester or similar resin to form a polymeric concrete. When catalysed and introduced into prepared moulds this mixture, when cured, provides an extremely robust and corrosion resistant structure.
There are a number of methods of cell manufacture. One such method is to prepare a polymeric concrete mixture and introduce this mixture into a prepared mould in a minimum period of time. This mould is vibrated during filling in order to improve the integrity of the casting by consolidating the wet mixture and also to remove air bubbles from the mixture. This method of producing a cell or tank results in an integrally cast unit with no jointing required at a later stage.
A major problem which is encountered when using this system of casting cells or tanks is cracking of the casting as a result of the thermal forces generated during catalysation of the resin binder.
AP/P/ 9 8/0 1411
AP 00955
-3 SUMMARY OF THE INVENTION
According to the invention there is provided a process for manufacturing a corrosion resistant tank or container comprising the steps of:
(a) .mixing a filler material consisting of a corrosion resistant aggregate with a corrosion resistant resin binder and a polypropylene based fibre material to form a polymer concrete mixture; and (b) introducing the mixture of step (a) into a mould and allowing it to cure, the mould being optionally vibrated to produce a homogenous casting.
The corrosion resistant tank or container is preferably a corrosion resistant electrolytic cell used in the electrolytic treatment of metals and salts.
In step (a), the fibre material can be added to a pre-mixture of filler material and resin binder.
AP/P/ 9 8/01411
Alternatively, the fibre material and filler material can be pre-mixed, prior to being mixed with the resin binder.
The fibre material preferably comprises halogenated polypropylene fibres, in particular fluorinated polypropylene fibres.
The fibres are preferably about 20 to about 30mm in length, typically chopped or cut from strands of the fibre material.
The fibre material is preferably added to the polymer concrete mixture in an
AP 00955
-4amount of about 1,35 to about 2,3 kilograms of fibre material per cubic metre of casting volume.
The resin binder is preferably catalysed to assist the curing stage.
The polymer concrete mixture in step (a) preferably comprises about 9% to 15% by mass catalysed resin binder and about 85% to 91% by mass of filler material, based on the combined mass of resin binder and filler material.
Conventional additives can be added to the polymer concrete to assist the curing process, including promoting agents, accelerators, and wetting and dispersing agents. In particular, it has been found to be particularly advantageous to add a wetting agent to the resin, based on the mass of fines in the aggregate batch material. The wetting agent is preferably added in an amount of 0,75 % to 2 % by mass of the fines present in the mixture.
The corrosion resistant aggregate material is preferably a silica quartz material.
AP/P/ 9 8/01411
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
The present invention involves the addition of a polypropylene based fibre material and suitable wetting agent to a polymer concrete mix to be used in the manufacture of corrosion resistant tanks or containers, particularly electrolytic cells used in the electrolytic treatment of metals and salts.
The polymer concrete material is produced by mixing a corrosion resistant aggregate filler material with a suitable resin binder. The aggregate material is preferably a top grade silica quartz material. Available materials permitting, the
AP 00955
-5silica aggregate is batched as follows in order to provide a homogenous casting:
Silica flour 150 Mesh 10%
0,075 to 0,3mm diameter sand 10%
0,3 to 0,8mm diameter sand . 10%
-0,8 to 2,4mm diameter sand 30%
2,4 to 5,0mm diameter sand 40%
The chosen resin binder is a vinyl ester type resin with the following properties:
a) Viscosity 300 to 450 cst (3 x 104 to 4,5 x 104 m2/s)
b) Styrene Content 25 to 35%
c) Tensile elongation 5 to 7%
d) Flexural Modulus 3 to 3,5 Gpa
As the curing process is a catalysed process, a suitable catalyst is added to the binder resin. Although any suitable catalyst system can be used, a preferred system is a methyl ethyl ketone peroxide type LA3 catalyst. The catalyst is added to the resin in an amount of about 1,25 to about 1,75% of catalyst per
mass of resin.
AP/P/ 9 8/01411
The resin binder should be promoted and accelerated according to the resin manufacturer's specifications. Standard cobalt octoate and dimethylaniline (DMA) are used for acceleration and promotion purposes.
In addition, a wetting and disbursing agent such as BYK.-W966, produced by Byk Chemie of Germany, for example, is added to the resin, depending on the mass of fines in the aggregate batch material. The wetting agent is added in an
AP 00955
-6amount of 0,75% to 2% by mass of fines present in the mixture. By “fines” is meant that portion of the silica aggregate consisting essentially of silica flour 150 mesh and 0,075 to 0,3mm diameter sand.
The batch mixing of the polymer concrete can be carried out in a custom built or conventional mechanical mixer. The polymer concrete is mixed in the following proportions;
Catalysed resin content by mass 9% to 15%
Filler content by mass 8 5% to 91 %.
The fibre material, in the form of flourinated polypropylene fibres, can either be added to the pre-mixed polymer concrete mixture or, if desired, it can be added to the silica aggregate prior to mixing with the resin binder.
Although flourinated polypropylene fibres are preferred, any other suitable polypropylene fibre material, particularly halogenated polypropylene fibres, can be used. The fibres are cut or chopped from strands of the fibre material into lengths of about 20 mm to about 30 mm.
The mixture of resin binder, silica aggregate and fibre material is mixed thoroughly prior to being introduced into the casting mould. The mould can be vibrated to ensure a homogeneous casting. Once the mould is filled to the desired level, a final vibrating cycle is maintained until visible quantities of resin rise to the upper surface of the casting. The vibration is then stopped and the concrete is allowed to gel and set.
When the exposed surface of the casting has set and is hard to the touch, the mould is manipulated in such a manner as to enable partial removal of the inner core. Timely removal of the inner core allows shrinkage of the casting to take
AP/P/9 8 / 0 1 4 11
AP 00955
-7place without any detrimental effect to the actual casting. The complete mould can be dismantled after approximately 6 hours. The casting is removed from the mould and the mould can then be prepared for a new casting.
If desirable, mild steel, stainless steel or non-metallic reinforcing bars can be incorporated into the casting to add additional strength and rigidity.
It is believed that the major advantage of the present invention over conventional processes for producing corrosion resistant tanks or containers is that the addition of the fluorinated polypropylene fibres assists in the combating of cracking caused by the thermal forces generated during catalysation of the resin binder. In addition, the addition of the fluorinated polypropylene fibres limits crack propagation in the polymer concrete walls of the container or tank once cast. The addition of a suitable wetting agent is believed to enhance these advantages.

Claims (14)

1. A process for manufacturing a corrosion resistant tank or container comprising the steps of:
(a) mixing a filler material consisting of a corrosion resistant aggregate with a corrosion resistant resin binder and a polypropylene based fibre material to form a polymer concrete mixture; and (b) introducing the mixture of step (a) into a mould and allowing it to cure, the mould being optionally vibrated to produce a homogenous casting.
2. A process according to claim 1, wherein the corrosion resistant tank or container is a corrosion resistant electrolytic cell used in the electrolytic treatment of metals and salts.
3. A process according to claim 1 or claim 2, wherein in step (a), the fibre material is added to a pre-mixture of filler material and resin binder.
4. A process according to claim 1 or claim 2, wherein the fibre material and filler material are pre-mixed, prior to being mixed with the resin binder.
5. A process according to any preceding claim, wherein the fibre material comprises halogenated polypropylene fibres.
6. A process according to claim 5, wherein the halogenated polypropylene
AP/P/ 9 8/01411
AP 00955
-9fibres are fluorinated polypropylene fibres.
7. A process according to any preceding claim, wherein the fibres are about 20 to about 30mm in length.
8. A process according to claim 7, wherein the fibres are chopped or cut from strands of the fibre material.
9. A process according to any one of the preceding claims, wherein the fibre material is added to the polymer concrete mixture in an amount of about 1,35 to about 2,3 kilograms of fibre material per cubic metre of casting volume.
10. A process according to any one of the preceding claims, wherein the resin binder is catalysed to assist the curing stage.
11. A process according to any one of the preceding claims, wherein the polymer concrete mixture in step (a) comprises about 9% to 15% by mass catalysed resin binder and about 85% to 91% by mass of filler material, based on the combined mass of resin binder and filler material.
12. A process according to any one of the preceding claims, wherein a wetting agent is added to the resin, based on the mass of fines in the aggregate batch material.
13. A process according to claim 12, wherein the wetting agent is added in an amount of 0,75% to 2% by mass of the fines present in the mixture.
14. A process according to any one of the preceding claims, wherein the corrosion resistant aggregate material is a silica quartz material.
APAP/P/1998/001411A 1997-11-12 1998-11-09 A process for manufacturing a tank or container by using a polymer concrete mixture. AP955A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
ZA9710188 1997-11-12

Publications (2)

Publication Number Publication Date
AP9801411A0 AP9801411A0 (en) 1998-12-31
AP955A true AP955A (en) 2001-04-06

Family

ID=25586712

Family Applications (1)

Application Number Title Priority Date Filing Date
APAP/P/1998/001411A AP955A (en) 1997-11-12 1998-11-09 A process for manufacturing a tank or container by using a polymer concrete mixture.

Country Status (1)

Country Link
AP (1) AP955A (en)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0648303A1 (en) * 1992-06-17 1995-04-19 Bäckman, Sture Wall panel and method and device for manufacturing this panel
EP0699716A2 (en) * 1994-09-01 1996-03-06 General Electric Company Compositions of poly(phenylene ether) and polyester resins
WO1997019135A1 (en) * 1995-11-24 1997-05-29 Chisso Corporation Propylene composition, process for preparing the same, polypropylene composition, and molded articles

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0648303A1 (en) * 1992-06-17 1995-04-19 Bäckman, Sture Wall panel and method and device for manufacturing this panel
EP0699716A2 (en) * 1994-09-01 1996-03-06 General Electric Company Compositions of poly(phenylene ether) and polyester resins
WO1997019135A1 (en) * 1995-11-24 1997-05-29 Chisso Corporation Propylene composition, process for preparing the same, polypropylene composition, and molded articles

Also Published As

Publication number Publication date
AP9801411A0 (en) 1998-12-31

Similar Documents

Publication Publication Date Title
DE69700948T2 (en) PROCESS AND APPARATUS FOR THE PRODUCTION OF POLYMER COMPOSITE MATERIALS
JP2008088633A (en) Burying type form made of polymer cement mortar
US12037500B2 (en) Composition and production method for 3D printing construction material
US20230331890A1 (en) Composition and production method for 3d printing construction material
US4621010A (en) Corrosion resistant structures and elements and method of making same
Yıldız et al. Utilization of glass fiber reinforced polymer wastes
JP2023538641A (en) Composition
AP955A (en) A process for manufacturing a tank or container by using a polymer concrete mixture.
JP2018052748A (en) Fiber-reinforced cement molded body and manufacturing method thereof
CN110590259A (en) Manufacturing method of recycled concrete pipe by taking construction waste as raw material
JPH06321650A (en) Lightweight concrete material, lightweight concrete using the same, and method for manufacturing lightweight concrete using the same
CN120463435A (en) A low-cement-dosage basalt fiber high-performance cement concrete and its preparation method and application
Mohammed et al. Study and evaluation of rock wool board by using PVA/PU as a polymer blend binder
JP6593358B2 (en) Hydrated cured body and method for producing the same
CN115477808A (en) Preparation method of carbon fiber reinforced high-precision template
EP0224370A2 (en) Process for the preparation of polymer concrete having low shrinkage
JPH1053473A (en) Permeable concrete
CN105254312A (en) Formula and making method of tundish current regulator
CN119339854B (en) Modification of FRP aggregates recycled from retired wind turbine blades and its concrete material and structure design method
CN117164307B (en) Hybrid fiber high ductility cement-based composite material prepared using regenerated sand and preparation method thereof
RU2857332C1 (en) Method of manufacturing electrolytic polymer concrete bath
JP2004182782A (en) Method for producing resin for recycled board and method for producing recycled board
CN117799184A (en) Preparation method of machine tool base
GB2162787A (en) Producing corrosion resistant structures
JP3609352B2 (en) Composite material