GB2536955A - Jacketed autoclave low surface energy coating - Google Patents

Jacketed autoclave low surface energy coating Download PDF

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Publication number
GB2536955A
GB2536955A GB1505727.6A GB201505727A GB2536955A GB 2536955 A GB2536955 A GB 2536955A GB 201505727 A GB201505727 A GB 201505727A GB 2536955 A GB2536955 A GB 2536955A
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United Kingdom
Prior art keywords
coating
surface energy
low surface
substrate
solvent
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GB1505727.6A
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GB201505727D0 (en
GB2536955B (en
Inventor
D'souza-Mathew Mark
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Lbbc Tech
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Lbbc Tech
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Priority to GB1505727.6A priority Critical patent/GB2536955B/en
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    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D163/00Coating compositions based on epoxy resins; Coating compositions based on derivatives of epoxy resins
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J3/00Processes of utilising sub-atmospheric or super-atmospheric pressure to effect chemical or physical change of matter; Apparatus therefor
    • B01J3/04Pressure vessels, e.g. autoclaves
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08GMACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G59/00Polycondensates containing more than one epoxy group per molecule; Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups
    • C08G59/18Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing
    • C08G59/40Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
    • C08G59/50Amines
    • C08G59/5006Amines aliphatic
    • C08G59/502Polyalkylene polyamines
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D5/00Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced; Filling pastes
    • C09D5/16Antifouling paints; Underwater paints
    • C09D5/1656Antifouling paints; Underwater paints characterised by the film-forming substance
    • C09D5/1662Synthetic film-forming substance

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Paints Or Removers (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

A low energy coating composition for use in jacketed autoclaves comprises fluoropolymer granules, a curing agent and a thermosetting liquid epoxy resin. The composition may be prepared by dispersing the fluoropolymer in a solvent, adding the curing agent and mixing, the solvent is removed by heating and the resulting fluoropolymer and curing agent are added to the liquid epoxy resin with stirring. The coating may be applied to the substrate surface of an autoclave and cured at 90°C for between 4 and 16 hours. The substrate may be preheated to the required temperature prior to the application of the coating. Preferred components are PTFE for the fluoropolymer (MW 30005/mol, mean diameter 4µm), IPA for the solvent, triethylene tetra amine (TETA) for the curing agent, and a liquid epoxy resin derived from unfilled bisphenol A and epichlorohydrin. Use of the coating substantially reduces the fouling of the interior walls through wax deposits.

Description

Jacketed Autoclave Low Surface Energy Coating
Background to the Invention
Typical steam injection autoclaves used for sterilization and various chemical or physical processes are designed in a modular fashion, where the steam generating boiler is located in a section separate from the main chamber. Automated jacketed autoclaves employ a design where the autoclave section is nestled within the steam generating boiler, and is connected to the same via a valve controlled short section of pipe.
The design of these autoclaves is employed in the dewaxing stage of wax-core inorganic-shell moulds used in the investment casting process. The design is such to ensure the fastest possible injection of steam at the right temperature, thereby facilitating rapid wax removal without initiating the undesirable wax expansion and steam condensation processes, which often cause cracking of the inorganic moulds.
During the de-waxing process these machines are exposed to a wide variety of organic fouling materials arising from the pattern and runner waxes contained in the cores of the investment moulds.
Due to the turbulent interaction between condensing steam and this eluted hydrocarbon mixture, fouling is generally observed on the vessel walls.
The fouling species have been found to be a mixture of organic and inorganic components, which build up over time and negatively affect the radiant heat transfer from the boiler to the autoclave section, further amplifying the problem.
In extreme cases this can lead to an effective reduction in the working area of the vessel, thus noticeably affecting the performance of the autoclave.
As a basic protection against corrosion of the vessel walls, the surfaces exposed to steam, and hence waxes are coated to safeguard against explosions, which might occur if the interfacial metal degrades.
Standard surface coatings used in these vessels are asphaltene based to withstand the high operating temperatures and pressures: typ. 210°C & 10 bar respectively. These coatings have been observed to encourage the wetting / spreading of the spattered hydrocarbons across the internal surface of the vessel, which ding to the internal surfaces, necessitating regular cleaning using abrasive methods. These abrasive methods risk damage to the interfacial metal or generate large amounts of debris which have an unwelcome impact on processes occurring in the vicinity of the factory floor.
An alternative corrosion resistant coating has thus been sought, which additionally has a broad spectrum low energy surface, intended to discourage the adsorption of the numerous and often varied components of investment casting waxes, and particulate matter from the inorganic moulds that surround them.
Through this investigation, a novel phenomenon has been discovered, which exploits the autoclave construction to facilitate substrate driven, controlled curing of a three part coating, leading to an improvement in the low surface energy characteristics at the interface.
Summary of the invention
The invention resides in the creation of a stable coating similar in principle to traditional 'non stick' coatings, which does not require frequent abrasive cleaning efforts, the method of preparation and application to a substrate, and finally a means of exploiting the nature of the coating in performing a non abrasive cleaning routine.
This inventive coating consists of three basic components which are mixed and cured under strictly controlled conditions.
The first component consists of unfilled PTFE granules which are dispersed in a solvent, such as Isopropyl Alcohol (IPA).
This is added to an aliphatic amine curing agent containing Triethylene Tetra Amine (TETA), and processed as described in the detailed description.
This combination is stirred into an unfilled Bisphenol A & Epochlorohydrin derived thermosetting liquid epoxy resin.
After degassing and a short incubation period, the resultant coating is ready for application.
Soon after application onto a freshly prepared surface, the boiler section of the jacketed autoclave is brought upto working pressure, radiating heat through the interfacial metal, facilitating a directionally driven cure of the coating.
Detailed description of the process
The following formulation describes the preparation of the coating.
PTFE granules dispersed in IPA are added to an aliphatic amine curing agent containing Triethylene Tetra Amine (TETA) with a H-equivalent content of approximately 25 g/eq. The percentage of PTFE granules used in this method are 25wt%, are unfilled, and have an average molecular weight of 3000g/mol, with a mean diameter of -4pm (Range 1-15).
The mixture is stirred and heated at 85°C to allow the solvent to evaporate, which is confirmed by weight loss measurements.
The entire volume of this mixture is then introduced to the stirred vortex of a container of unfilled Bisphenol A / Epochlorohydrin derived thermosetting liquid epoxy resin, which needs to have a viscosity ranging between 8 -14 Pa.s, a density of -1.16 g/ml at 25°C, and a weight per equivalent ranging between 179 -190 g.
The resultant mixture is then stirred for at least 10 minutes.
(If the ambient temperatures are low, making the viscosity of the resin high, rendering visible bubbles, it is recommended that the mixture is degassed in an ultrasonic bath to assist with their removal, or done so within a vacuum chamber).
Using a cup sprayer, the mixture is evenly sprayed onto a freshly degreased and shot blasted surface of the autoclave vessel. Alternatively, the mixture can be applied using a clean foam roller or epoxy compatible brush.
(It is possible to spray onto a lower temperature substrate, so long as this variable can be increased to 90°C rapidly after application.) A substrate driven temperature gradient is required, and this is made possible by specifying a heating setpoint in the program logic controller, and leaving the jacketed autoclave vessel door ajar during the curing stage.
After holding at this temperature for approximately 4 hours, the vessel can be assumed as ready for operation. After 16 hours at temperature, the assumption can be made that the coating is fully cured.
It is essential that at the end of the thermosetting reaction, their average interfacial contact angle at the interface is high enough to impress a fluropolymer like low energy surface, while being low enough to resist complete de-lamination from the epoxy matrix when exposed to shear forces within a pressurized environment.
Gentle heat applied to the substrate immediately after application accelerates the crosslinking reaction. A substrate driven cure is required to force the unfilled PTFE granules to migrate towards the air-epoxy interface, where they will reduce the surface energy of the coating.
The controlled curing of the coating through radiant heat from the boiler section of the autoclave ensures that the cross-linking of the epoxy is catalysed from the substrate outwards, while allowing the embedded PTFE granules to travel through the uncured matrix until they reach the interface.
In addition, because these granules do not participate in the reaction, and are thus regarded as immiscible, the effect will be that they organize in a close packed configuration, locked at the interface in a bid to minimize system free energy.
The quantities of the curing agent may need to be varied to ensure that sufficient precursors for the cross-linking reaction are available.
The unique geometry of the automated jacketed autoclave allows for a good degree control over the substrate temperature, and the cross-linking reaction of the PTFE filled epoxy coating can thus be catalysed from the substrate towards the surface of the coating.
The large size of these pressure vessels, the scarcity of size compatible ovens, the logistical complexities and repairability essentially excludes the use of traditional methods for implementing thermoplastic fluorinated coatings, and thus the fluropolymer additive approach is especially useful.
********.**************

Claims (10)

  1. Claims.1. A jacketed autoclave low surface energy coating comprising fluropolymer granules dispersed in a solvent mixed with a curing agent and stirred into a thermosetting liquid epoxy resin.2. A jacketed autoclave low surface energy coating according to claim 1, wherein said granules consist of unfilled Poly Tetra Ethylene (PTFE) with an average molecular weight of 3000g/mol with a mean diameter of -4pm (Range 1-15).
  2. 2. A jacketed autoclave low surface energy coating according to claim 1, wherein said solvent consists of Isopropyl Alcohol (IPA).
  3. 3. A jacketed autoclave low surface energy coating according to claim 1, wherein said curing agent is an aliphatic amine containing Triethylene Tetra Amine (TETA) with substantially 25% H-equivalent content.
  4. 4. A jacketed autoclave low surface energy coating according to claim 1, wherein said thermosetting liquid epoxy resin derived from unfilled Bisphenol A / Epochlorohydrin having a dynamic viscosity in the range of 8 to 14 Pa.s, a density of 1.16 g/ml at 25°C and a weight per equivalent between 179 -190 g.
  5. 5. A method of preparing of a jacketed autoclave low surface energy coating according to claim 1, wherein the mixture of said solvent, granules and curing agent is stirred at 85°C to allow the IPA to evaporate before adding to said thermosetting resin.
  6. 6. A method of preparing coating of a low surface energy coating according to claim 1, wherein said mixture of said solvent, granules and curing agent is introduced into the stirred vorted of said thermosetting epoxy resin, and left stirring for at least 10 minutes.
  7. 7. A method of curing tcuring the coating described in claims 1 to 5, wherein the substrate is heated to substantially 90°C before said coating is sprayed on, and holding said substrate at that temperature for between 4 to 16 hours until curing is complete.
  8. 8. A method of coating a substrate with the coating of claims 1 to 5, wherein said coating is applied by means of a foam roller or brush before heating the substrate to 90°C and holding it at that temperature for between 4 and 16 hours until curing is complete.
  9. 9.A method of coating a substrate with the coating of claims 6 or 7, wherein after application of said coating, the substrate is held at a temperature of 90°C for between 4 -16 hours.
  10. 10.MMMMMMMMMMMMMMMMMMMM * * ****** **** * ** *** *** ****** * ** * MMMMMMMMMMMMMMMMMMMMMMMMM ********************************************************** Amendments to the claims have been filed as follows Claims.1. Low surface energy coating for use in a jacketed autoclave comprising fluropolymer granules dispersed in a solvent mixed with a curing agent, wherein said solvent is allowed to evaporate before a thermosetting liquid epoxy resin is added to said mixture.2. Low surface energy coating for use in a jacketed autoclave according to claim 1, wherein said granules consist of unfilled Poly Tetra Fluoro-Ethylene (PTFE) with an average molecular weight of 3000g/mol with a mean diameter of -4pm (Range 1-15).3. Low surface energy coating for use in a jacketed autoclave according to claims 1 and 2, wherein said solvent consists of Isopropyl Alcohol (IPA).4. Low surface energy coating for use in a jacketed autoclave according to claim 1, wherein said curing agent is an aliphatic amine containing Triethylene Tetra Amine (TETA) with substantially 25% H-equivalent content.5. Low surface energy coating for use in a jacketed autoclave according to claim 1, wherein said thermosetting liquid epoxy resin derived from unfilled Bisphenol A / Epochlorohydrin having a dynamic viscosity in the range of 8 to 14 Pa.s, a density of 1.16 (r) g/ml at 25°C and a weight per equivalent between 179 -190 g.a) 6. A method of preparing of a low surface energy coating for a jacketed autoclave O according to claim 1, wherein the mixture of said solvent, granules and curing agent is stirred at 85°C to allow said solvent to evaporate before adding to said thermosetting resin.N7. A method of preparing coating of a low surface energy coating according to claim 1, wherein said mixture of said solvent, granules and curing agent is introduced into the stirred vortex of said thermosetting epoxy resin, and left stirring for at least 10 minutes.8. A method of curing the coating described in claims 1 to 5, wherein a substrate is heated to substantially 90°C before said coating is sprayed on, and holding said substrate at that temperature for between 4 to 16 hours until curing is complete.9. A method of coating a substrate with the coating of claims 1 to 5, wherein said coating is applied by means of a foam roller or brush before heating the substrate to 90°C and holding it at that temperature for between 4 and 16 hours until curing is complete.10. A method of coating a substrate with the coating of claims 1 to 5, wherein after application of said coating, the substrate is held at a temperature of 90°C for between 4 -16 hours.************************
GB1505727.6A 2015-04-02 2015-04-02 Low surface energy coating for jacketed autoclaves and method of preparing and applying such a coating Expired - Fee Related GB2536955B (en)

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GB2536955A true GB2536955A (en) 2016-10-05
GB2536955B GB2536955B (en) 2020-04-01

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111978769A (en) * 2020-09-11 2020-11-24 中国石油大学(华东) Coating, preparation method thereof and anti-wax deposition method for crude oil conveying pipeline

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0051267A1 (en) * 1980-10-29 1982-05-12 E.I. Du Pont De Nemours And Company Low curing epoxy N-resin coating composition and its use for coating a substrate
US4335030A (en) * 1981-06-30 1982-06-15 E. I. Du Pont De Nemours And Company Aqueous dispersion of fluoropolymers in combination with epoxy-type film formers
US5075378A (en) * 1985-12-23 1991-12-24 The Standard Oil Company Coating of an epoxy resin, fluorocarbon polymer fluorinated curing agent

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0051267A1 (en) * 1980-10-29 1982-05-12 E.I. Du Pont De Nemours And Company Low curing epoxy N-resin coating composition and its use for coating a substrate
US4335030A (en) * 1981-06-30 1982-06-15 E. I. Du Pont De Nemours And Company Aqueous dispersion of fluoropolymers in combination with epoxy-type film formers
US5075378A (en) * 1985-12-23 1991-12-24 The Standard Oil Company Coating of an epoxy resin, fluorocarbon polymer fluorinated curing agent

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111978769A (en) * 2020-09-11 2020-11-24 中国石油大学(华东) Coating, preparation method thereof and anti-wax deposition method for crude oil conveying pipeline
CN111978769B (en) * 2020-09-11 2021-10-19 中国石油大学(华东) Coating, preparation method thereof and anti-wax deposition method for crude oil conveying pipeline

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GB2536955B (en) 2020-04-01

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Effective date: 20230402