WO2021124124A1

WO2021124124A1 - Injectable resin composition and system for carrying out a chemical process

Info

Publication number: WO2021124124A1
Application number: PCT/IB2020/061995
Authority: WO
Inventors: Matthias WALSCHBURGER; Karl-Heinz Schofalvi
Original assignee: Koch Knight, Llc
Priority date: 2019-12-16
Filing date: 2020-12-16
Publication date: 2021-06-24

Abstract

The disclosure relates to resin based compositions and their use in the repair of vessels configured to carry out a corrosive chemical process. The disclosure also relates to systems and methods for the injection of a resin based composition into a vessel configured to carry out a corrosive chemical process.

Description

Injectable Resin Composition and System for Carrying out a Chemical Process

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application benefits from and claims priority to U.S. Provisional Patent Application Serial No. 62/948,551 , filed December 16, 2019, the entire disclosure of which is incorporated by reference herein in its entirety as if fully set forth.

BACKGROUND

The cleaning of gases generated during the smelting process of metals, or in burning of sulfur, is performed within a system of absorption and drying towers or columns. The towers are usually made of carbon steel and are internally lined with an anti-acid membrane, and one or several layers of anti-acid bricks laid into silicate mortar, as shown in FIG. 1 (12: carbon steel; 14: membrane; 16: mortar; 18: bricks; 20: acid exposed face).

[In these towers, S0₂ and S0₃ gas flows in countercurrent to the acid irrigated by a distributor on top of the mass transfer media and is transformed into sulfuric acid. Both the brick and the mortar of the anti-acid lining are porous, permitting a migration of acid therethrough towards the anti-acid membrane and the steel. As there is normally a space between the brick and the membrane, over time the membrane gets degraded and acid starts attacking the steel shell. The steel shell becomes thinner and eventually acid leaks through holes on the surface.

When the acid contacts the membrane, the reaction produces a protective layer of carbon on the surface. The carbon, despite being stable under acid attack, ends up being washed off by the continuous flow of acid along the wall. The membrane is reduced in thickness as the carbon washes away, removing the last barrier for the acid to reach the steel shell. Carbon attacked by acid generates iron sulphate, which is also acid resistant; but the iron sulphate too is washed away by the flow of acid. If the washing process is constant, the thickness of the steel shell layer is reduced by corrosion, until it finally perforates, as shown in FIG. 2.

Such acid-leaks cannot be repaired by welding, because the welding process would destroy the existing membrane behind the steel plate, causing bigger or adjacent problems if the membrane is not restored.

BRIEF SUMMARY OF THE DISCLOSURE

It is impossible to detect all voids or cracks that may have appeared inside the tower brick lining and that have been infiltrated by the acid, but one can detect the existing cavities between the steel shell and the ceramic lining. It is nearly impossible to use any type of acid-resistant material to fill those cavities. Thus, a resin composition disclosed herein is used and has special characteristics to fulfill the following purposes, among others: (1) a low viscosity of the injection resin, allowing an even distribution inside the void, (2) no solvents are used in the material, (3) easy to handle, to maintain, and to store.

The present disclosure provides a system for carrying out a chemical process, including an acid tower and a resin based composition, said tower having a wall with an outer metal layer, a middle membrane layer and an inner layer, said resin based composition being dispersed in interstices between said metal layer and said inner layer. In certain embodiments, the inner layer includes a brick layer, and said membrane layer is positioned between said metal layer and said brick layer. In certain embodiments, the resin-based composition includes at least one resin component; at least one rheology modifier; optionally at least one anti-foaming component; optionally at least one curing agent; and optionally at least one additive. In some embodiments, the system further includes a device for injecting a resin-based composition into a wall of a vessel.

BRIEF DESCRIPTION OF THE FIGURES

The accompanying drawings illustrate one or more embodiments and/or aspects of the disclosure and, together with the written description, serve to explain the principles of the disclosure. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like elements of an embodiment, and wherein:

FIG. 1 is a depiction of the wall of an acid tower for cleaning gases generated during the smelting process of metals or the burning of sulfur.

FIG. 2 is a depiction of the wall of an acid tower after corrosion of the membrane and perforation of the steel shell with acid.

FIG. 3 is a depiction of the wall of an acid tower following the injection of a resin-based composition.

FIG. 4 is a depiction of a device suitable for injecting a resin-based composition into an acid tower.

FIG. 5 is a depiction of the injection of a resin-based composition into a breach in an acid tower.

FIG. 6 is a depiction of a device suitable for injecting a resin-based composition into an acid tower.

FIG. 7 is a depiction of an NPT push connector used for injecting high viscosity material.

FIG. 8 is a depiction of a static mixer.

FIG. 9 is a depiction of a method for repairing an acid tank. DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG. 3 illustrates the wall 32 of an acid tower once the resin-based composition 34 is injected, repairing the breach 36 in the wall 32. FIG. 4 shows one device 400 suitable for injecting the resin-based composition into the breach 36 of the acid tower. FIG. 5 shows injecting the resin-based composition 34 into the breach 36 of the acid tower by drilling a hole into the steel shell 52, putting a thread 54 into this hole and screw in a zerk 56. FIG. 6 shows one device suitable for injecting the resin-based composition into the breach of the acid tower, wherein the device includes two resin component reservoirs 62 and 64, a pressurized air source 66, and a mixer 68. FIG. 7 shows a NPT push connector used for injecting high viscosity material. FIG. 8 shows a static mixer.

The present disclosure also provides an injectable resin composition including at least one resin component; at least one rheology modifier; optionally at least one anti-foaming component; optionally at least one curing agent; and optionally at least one additive.

In certain embodiments, the resin component is selected from the group consisting of a vinyl ester resin, an epoxy resin, a urethane resin, and combinations thereof. In some embodiments, the resin component is a vinyl ester resin, said vinyl ester resin being Derakane 470-300. In some embodiments, the resin is an epoxy resin. In some embodiments, the resin is an epoxy novolac resin or a bisphenol F epoxy. In some embodiments, the resin component is an epoxy resin, the epoxy resin being selected from the group consisting of Araldite GY 6010, Araldite PY 289, Araldite PY 313, EpiRez WD-510, Epokukdo YH-300, Docure KH-819, Epokukdo YD-114F, Epokukdo YDPN-638, and Epokukdo YDF-170/175. In some embodiments, the resin is Epokukdo YDPN-638. In some embodiments, the resin is Epokukdo YD-170. In some embodiments, the resin component is a urethane resin.

In some embodiments, the rheology modifier is a diluent. In some embodiments, the rheology modifier is sorbitol polyglycidyl ether. In some embodiments the rheology modifier is neopentyl glycol diglycidyl ether. In some embodiments, the rheology modifier is EP-PE510. In some embodiments, the rheology modifier is EP-DE203.

In an embodiment, the rheology modifier is fumed silica. The concentration of fumed silica is for example from about 1 % by weight to about 10% by weight of the composition, or more particularly, about 1.6% or about 9% by weight of the composition.

In certain embodiments, the anti-foaming component is BYK-310, BYK-330, BYK-A-530, BYK-S 732 or BYK 066N depending on requirements. In some embodiments, the anti-foaming component is foam sub.

In some embodiments, the curing agent is a cycloaliphatic amine modified curing agent. In some embodiments, the curing agent is selected from the group consisting of Aradur 2975, Aradur 265, Aradur 77, Aradur450, Docure KH-819 and Epikure 3072. In some embodiments, the curing agent is Docure KH-819.

In an embodiment, the additive is selected from the group consisting of Schwego fluor 6536, Dow additive 163, Wedron 730/480, Wedron 430, Best 1220, Glass Flakes and silica sands.

In an embodiment, the composition does not comprise a catalyst or an initiator. In some embodiments, none of the components in the composition are cross-linked to one another.

In particular embodiments, the composition comprises one or more epoxy resins, one or more diluents, an antifoaming component, and a curing agent. In some embodiments, the composition comprises an epoxy novalac resin, a bisphenol F epoxy, sorbitol polyglycidyl ether, neopentyl glycol diglycidyl ether, foam sub, and a cycloaliphatic amine modified curing agent.

In some embodiments, the composition comprises about 29.4 wt% to about 49.4 wt% epoxy novolac resin. In some embodiments, the composition comprises about 34.4 wt% to about

44.4 wt% epoxy novolac resin. In some embodiments, the composition comprises about 39.4 wt% epoxy novolac resin. In some embodiments, the composition comprises 39.4 wt% epoxy novolac resin. In some embodiments, the epoxy novolac resin is Epokukdo YDPN-638.

In some embodiments, the composition comprises about 4.5 wt% to about 24.5 wt% bisphenol F epoxy. In some embodiments, the composition comprises about 9.5 wt% to about

19.5 wt% bisphenol F epoxy. In some embodiments, the composition comprises about 14.5 wt% bisphenol F epoxy. In some embodiments, the composition comprises 14.5 wt% bisphenol F epoxy. In some embodiments, the bisphenol F epoxy is Epokukdo YD-170.

In some embodiments, the composition comprises about 1 .0 wt% 11 .0 wt% sorbitol polyglycidyl ether. In some embodiments, the composition comprises about 3.0 wt% 9.0 wt% sorbitol polyglycidyl ether. In some embodiments, the composition comprises about 6.0 wt% sorbitol polyglycidyl ether. In some embodiments, the composition comprises 6.0 wt% sorbitol polyglycidyl ether. In some embodiments, the sorbitol polyglycidyl ether is is EP-PE510.

In some embodiments, the composition comprises about 1 .0 wt% 11 .0 wt% neopentyl glycol diglycidyl ether. In some embodiments, the composition comprises about 3.0 wt% 9.0 wt% neopentyl glycol diglycidyl ether. In some embodiments, the composition comprises about 6.0 wt% neopentyl glycol diglycidyl ether. In some embodiments, the composition comprises 6.0 wt% neopentyl glycol diglycidyl ether. In some embodiments, the neopentyl glycol diglycidyl ether is EP-DE203.

In some embodiments, the composition comprises about 0.1 wt% to about 1 .7 wt% foam sub. In some embodiments, the composition comprises about 0.4 wt% to about 1 .2 wt% foam sub. In some embodiments, the composition comprises about 0.8 wt% foam sub. In some embodiments, the composition comprises 0.8 wt% foam sub.

In some embodiments, the composition comprises about 23.3 wt% to about 43.3 wt% cycloaliphatic amine modified curing agent. In some embodiments, the composition comprises about 28.3 wt% to about 38.3 wt% cycloaliphatic amine modified curing agent. In some embodiments, the composition comprises about 33.3 wt% cycloaliphatic amine modified curing agent. In some embodiments, the composition comprises 33.3 wt% cycloaliphatic amine modified curing agent. In some embodiments, the cycloaliphatic amine modified curing agent is Docure KH-819.

In some embodiments, the composition comprises about 541 .02 pounds/100 gal. to about 600.02 pounds/100 gal. epoxy novolac resin. In some embodiments, the composition comprises about 556.02 pounds/100 gal. to about 586.02 pounds/100 gal. epoxy novolac resin. In some embodiments, the composition comprises about 571.02 pounds/100 gal. epoxy novolac resin. In some embodiments, the composition comprises 571.02 pounds/100 gal. epoxy novolac resin. In some embodiments, the epoxy novolac resin is Epokukdo YDPN-638.

In some embodiments, the composition comprises about 190.38 pounds/100 gal. to about 230.38 pounds/100 gal. bisphenol F epoxy. In some embodiments, the composition comprises about 200.38 pounds/100 gal. to about 220.38 pounds/100 gal. bisphenol F epoxy. In some embodiments, the composition comprises about 210.38 pounds/100 gal. bisphenol F epoxy. In some embodiments, the composition comprises 210.38 pounds/100 gal. bisphenol F epoxy. In some embodiments, the bisphenol F epoxy is Epokukdo YD-170.

In some embodiments, the composition comprises about 76.405 pounds/100 gal. 96.405 pounds/100 gal. sorbitol polyglycidyl ether. In some embodiments, the composition comprises about 81.405 pounds/100 gal. 91.405 pounds/100 gal. sorbitol polyglycidyl ether. In some embodiments, the composition comprises about 86.405 pounds/100 gal. sorbitol polyglycidyl ether. In some embodiments, the composition comprises 86.405 pounds/100 gal. sorbitol polyglycidyl ether. In some embodiments, the sorbitol polyglycidyl ether is is EP-PE510.

In some embodiments, the composition comprises about 74.405 pounds/100 gal. 94.405 pounds/100 gal. neopentyl glycol diglycidyl ether. In some embodiments, the composition comprises about 79.405 pounds/100 gal. 89.405 pounds/100 gal. neopentyl glycol diglycidyl ether. In some embodiments, the composition comprises about 84.405 pounds/100 gal. neopentyl glycol diglycidyl ether. In some embodiments, the composition comprises 84.405 pounds/100 gal. neopentyl glycol diglycidyl ether. In some embodiments, the neopentyl glycol diglycidyl ether is EP-DE203.

In some embodiments, the composition comprises about 6.27 pounds/100 gal. to about 16.27 pounds/100 gal. foam sub. In some embodiments, the composition comprises about 8.27 pounds/100 gal. to about 14.27 pounds/100 gal. foam sub. In some embodiments, the composition comprises about 11 .27 pounds/100 gal. foam sub. In some embodiments, the composition comprises 11.27 pounds/100 gal. foam sub.

In some embodiments, the composition comprises about 451.5 pounds/100 gal. to about 521.5 pounds/100 gal. cycloaliphatic amine modified curing agent. In some embodiments, the composition comprises about 466.5 pounds/100 gal. to about 496.5 pounds/100 gal. cycloaliphatic amine modified curing agent. In some embodiments, the composition comprises about 481.5 pounds/100 gal. cycloaliphatic amine modified curing agent. In some embodiments, the composition comprises 481 .5 pounds/100 gal. cycloaliphatic amine modified curing agent. In some embodiments, the cycloaliphatic amine modified curing agent is Docure KH-819.

In one aspect, the present disclosure provides a method of repairing a vessel used for carrying out a corrosive chemical process. The method includes injecting a suitable amount of a resin composition into damaged areas of the vessel. The composition includes at least one resin component, at least one rheology modifier (or hardener), optionally at least one anti foaming component, optionally at least one curing agent, and optionally at least one additive.

In some embodiments, the injecting is performed under a pressure lower than 3,000 psi, or more particularly, under a pressure between 100 and 300 psi.

In one aspect, the present disclosure provides a device for injecting an injectable resin- based composition into a wall of a vessel used for carrying out a corrosive chemical process, the device including an injection nozzle, a mixer 68, a pressurized air source 66, and at least two reservoir tanks (62, 64), wherein the injection nozzle regulates injection pressure to a pressure lower than 30 psi (FIG. 6).

In one aspect, the present disclosure provides an acid tower including a wall 32 with an outer metal layer 38, a middle membrane layer 40 and an inner layer 42, a resin based composition being dispersed in interstices between said metal layer and said inner layer. In an embodiment, the acid tower further includes a mortar layer 44 located between the middle membrane layer 40 and the inner layer 42 (FIG. 3). The resin-based composition includes at least one resin component, at least one rheology modifier, optionally at least one anti-foaming component, optionally at least one curing agent, and optionally at least one additive.

The present disclosure provides products used in injection applications - EPOXIGARD HC, VINGARD HC. These are being used in the targeted applications of injection tower repair and coating of surfaces in the same application field of use. These two products are representatives of the two major chemical platforms: EPOXY NOVOLAC (severe acidity applications) and VINYL ESTER COMPOUNDS (moderate acidity applications).

The resin disclosed herein may be selected from the group consisting of EPOXIGARD P moisture tolerant epoxy primer, EPOXIGARD SL high performance epoxy Self-levelling coating/membrane, EPOXIGARD FSL high performance flexible self-levelling epoxy coating, EPOXIGARD HSL high performance self-levelling epoxy Novolac coating, EPOXIGARD HC high performance epoxy Novolac injection resin, EPOXIGARD H high build Novolac epoxy lining, EPOXIGARD V high performance epoxy lining for vertical surfaces, EPOXIGARD HSP sprayable epoxy Novolac coating, EPOXIGARD HVG high grade glass flake filled epoxy Novolac membrane, EPOXIGARD HVG trowelable glass flake epoxy Novolac membrane, EPOXIGARD SC scratch coat, EPOXIGARD FJ flexible epoxy joint, EPOXIGARD HFG high flow epoxy Novolac grout, EPOXIGARD HPC epoxy Novolac polymer concrete, EPOXIGARD HG epoxy Novolac grout, EPOXIGARD P high moisture tolerant epoxy resin primer, EPOXIGARD LA Novolac epoxy lining system reinforced with woven or non-woven glass fiber mats, EPOXIGARD TA trowelable highly filled epoxy Novolac membrane, EPOXIGARD CSC carbon filled conductive scratch coat, PUREGARD SL self-levelling filled membrane, PUREGARD VG trowelable urethane membrane, PUREGARD TA UV stable aliphatic urethane Membrane, VINGARD P vinyl ester primer, VINGARD SL high performance vinyl ester coating, VINGARD HC Flake filled vinyl ester lining, VINGARD HVG flake filled vinyl ester lining, VINGARD CSC graphite filled vinyl ester coating, VINGARD AR abrasion resistant reinforced vinyl ester lining, VINGARD HLA vinyl ester lining system reinforced with woven or non-woven glass fiber mats, VINGARD HC injection resin, VINGARD PC carbon filled vinyl ester polymer concrete, KNIGHT-GARD FVT tile, KNIGHT-GARD FVT hex tile, KNIGHT-GARD ceramic tile, KNIGHT-GARD scrim, and EPOXINITE CSC, EPOXINITE H mortar systems and various KNIGHT-GARD abrasion improving fillers based on different ingredients.

In some embodiments, the resin composition disclosed herein may be used in Epoxy Novolac Systems, including but not limited to, acid towers, process vessels, a system of absorption and drying towers or columns wherein the cleaning of gases generated during the smelting process of metals, or in burning of sulfur, is performed, and coatings application in similar environments.

In some embodiments, the resin composition disclosed herein may be used in Vinyl Ester Systems, including but not limited to, for injection/pumping applications in Pulp &

Paper and Phosphoric Acid environments, and coating applications in same.

In some embodiments, the resin composition disclosed herein may be used in corrosion resistant tank coatings, including but not limited to, sulfuric acid, phosphoric acid, bleach towers, and chemical and oil storage.

In some embodiments, the resin composition disclosed herein may be used in Pulp and Paper applications. In some embodiments, the resin composition disclosed herein may be used in Plating Lines. In some embodiments, the resin composition disclosed herein may be used in Wastewater Treatment. In some embodiments, the resin composition disclosed herein may be used in Refinery Processes.

The present disclosure provides EPOXIGARD HC composition having the following characteristics: with low viscosity; with a low pressure injection machine voids can be fully filled; the resin reacts with the acid, coloring it, but that does not affect neither the quality of the acid nor the resin injected; penetrates small cracks and voids; as it is a 100% solids material (no VOC) it hardens and cures to form an acid resistant membrane without enabling new paths; can be re-injected at new ports any time to catch places which were not treated before. In some embodiment, FIG. 3 shows a leak repaired by the resin composition disclosed herein.

In some embodiments, the coating formed by the resin composition disclosed herein may last more than four or five years without failures. In some embodiments, the resin composition and the apparatus disclosed herein allow injection around the gas and acid nozzles, and on the perimeter of the tower from top to bottom. In some embodiments, the resin composition and the apparatus disclosed herein provide an inexpensive solution to a new tower capital investment. In some embodiments, the resin composition and the apparatus disclosed herein provide quick turnaround scheduling.

The present disclosure provides a method to repair a hollow spot behind an inner layer, such as a brick layer. The method comprises preliminary inspection and location of hollow spots behind the inner layer, preparation of the area, positioning of scaffolding and protection against the weather if necessary (excessive exposure to sunlight accelerates the reaction of the resin), location of injection ports of the material or resin composition disclosed herein, empty the tower to avoid pockets of trapped acid under high pressure behind the brick lining, injection process starting from the lower tower areas and advancing progressively towards the top of the structure, and sealing of the injection points. Depending on the area to be injected, in some embodiments, the repair can be carried out with a crew of 6 to 8 workers. In some embodiments, the duration of the work depends on the extent of the damage, the time available, the crew employed and whether or not rotating turns are used.

In some embodiments, the present disclosure provides an injectable resin composition, wherein the composition is acid resistant. In an embodiment, the injectable resin composition includes at least one resin component and at least one rheology modifier. Various resins and rheology modifiers may be used to create an injectable resin composition effective in injection applications. In some embodiments, the present disclosure provides an injectable resin composition including the VINGARD HC compound and a rheology modifier.

In some embodiments, the injectable resin composition disclosed herein has a slight pinkish hue in the cured system. In some embodiments, the injectable resin composition disclosed herein is optically clear in the cured system.

The present disclosure provides a delivery system for the injectable resin composition disclosed herein, including but not limited to, EPOXIGARD HC and VINGARD HC. In some embodiments, the present disclosure provides the delivery system as shown in FIG. 4. The present disclosure provides an injection device that the mixing relation of the two components of the resin, mainly resin and hardener (rheology modifier), can be varied from a relation of 1 :1 up to 4:1. This capability provides the flexibility to use this device with different resins needed to inject towers. The different resins may be chosen in accordance to the chemical resistance of the resin injected and the chemicals they will be exposed to inside the tower.

On the front panel of the device (FIG. 6) there are two reservoir tanks (62, 64). The pump delivers each resin component out of these tanks at a predetermined pressure. To these two reservoir tanks (62, 64), the static mixer 68 is connected. The static mixer 68 mixes the two resin parts from two reservoir tanks (62, 64) together and from there on the chemical reaction of the resin starts. This is an added advantage of a two-component injection device, machine, or pump. There is no mixing inside the device which can compromise the moving parts. The static mixer 68 has in his inside two spirals that mix the components together and these spirals can be exchanged if the resin hardens.

The added advantage of being able to control the injection pressure from a very low pressure up to 3000 psi enables one to do an injection into the void between the brick and the steel in brick lined towers at low pressure. A high pressure in this interstice between brick and steel inside the tower can dislocate the brick lining bringing the whole lining to a collapse.

In some embodiments, the present disclosure provides two different injection nozzle assemblies to deliver the resin from the machine to the interstice between the mantle and the brick. To attach them to the steel mantle of the tower, one may drill a hole into the steel shell 52, put a thread 54 into this hole and screw in a zerk 56 (FIG. 5) or a NPT push connector 72 (FIG. 7), or other check valve types. Depending on the ambient temperature, the resin has a different viscosity. At low temperatures, the viscosity is higher, and a bigger delivery diameter of the injection nozzle helps to push the resin into the tower, which is achieved with the injection nozzle in FIG. 7. At higher temperatures, the viscosity of the resin mix is lower, and the zerk delivery nozzle can be used which has a relatively small diameter. The zerk used is also special as it cannot have a high-pressure spring in the inside which would require a high pressure of the pump to activate, thus generating a harmful high pressure in the interstice between the brick and steel.

The following examples are provided to further elucidate the advantages and features of the present application but are not intended to limit the scope of the application. The examples are for the illustrative purposes only.

Example 1 : Formulation of a Resin-Based Composition

A resin-based composition was prepared as described below. The following products were used in the amounts specified:

(a) 571.02 pounds/100 gal YDPN-638 (epoxy novolac resin);

(b) 86.405 pounds/100 gal EP-PE510 (sorbitol polyglycidyl ether, an epoxy diluent);

(c) 84.405 pounds/100 gal EP-DE203 (neopentyl glycol diglycidyl ether, an epoxy diluent);

(d) 210.38 pounds/100 gal YD-170 (bisphenol F epoxy);

(e) 11 .27 pounds/100 gal foam sub (air release agent/defoamer); and

(f) 481.5 pounds/100 gal KH819 (cycloaliphatic amine modified curing agent).

Preparation of Part A: The YDPN-638 was stored in a hotbox overnight prior to preparation of the composition. To a stainless-steel tank, the entire quantities of the following four components were added in order: (1) YDPN-638, (2) EP-PE510, (3) EP-DE203, and (4) YD- 170. The contents of the tank were mixed for ten minutes. Then, foam sub was added to the tank, and the contents were mixed for an additional 10 minutes. The composition was analyzed for quality and filled into containers.

Preparation of Part B: Separately, the entire contents of KH819 were filled into separate containers.

To form the resin-based composition, two equivalents of Part A and one equivalent of Part B, by volume, are combined.

Example 2: Acid Resistance of a Resin-Based Composition

Three batches of the resin-based composition of Example 1 were prepared by combining two equivalents of Part A and one equivalent of Part B, by volume. The composition was cut into square pucks and transferred to a teflon jar containing sulfuric acid. The puck was allowed to soak in the acid for seven days either at room temperature or in a 60 °C oven. Afterward, the puck was double rinsed in distilled water and allowed to dry for 12 hours at 90 °C before measuring any degradative weight loss. The results of the study are depicted in Table 1 and indicate that the resin-based composition is resistant to highly concentrated acids at room temperature and at elevated temperatures.

Table 1

Starting Final Weight

Batch No. Conditions Weight (g) Weight (g) Change (%)

1 98% H2SO4; room temp 10.475 10.482 + 0.073%

2 98% H2SO4; room temp 15.210 15.223 + 0.087%

3 98% H2SO4; room temp 15.399 15.411 + 0.074%

1 50% H2SO4; 60 °C 12.118 12.174 + 0.461%

2 50% H2SO4; 60 °C 15.540 15.617 + 0.492%

3 50% H2SO4; 60 °C 14.657 14.525 - 0.901%

Example 3: Injection of a Resin-Based Composition into an Acid Tower Part A and Part B of the resin-based composition of Example 1 were poured into the two separate reservoir tanks of a Pneumatic Two Component grout pump (e.g., device 400 in Fig. 4 or device 600 in Fig. 6). The separate components in the reservoir tanks (e.g., tanks in Fig. 4, or tanks 62 and 64 in Fig. 6) were maintained at a temperature between 20 °C and 25 °C throughout the injection process. Hoses were connected from the reservoirs to a static mixer. During injection, two equivalents of Part A, by volume, were pumped into the static mixer for every one equivalent of Part B, by volume. The inlet pressure was not allowed to exceed 120 psi; the air volume (of dry air) was maintained at or greater than 6.5 cft./min; and the output regulator of the pump was set at a value no greater than 30 psi. The pump was engaged, and a small volume of epoxy was pumped into a plastic cup as a test batch for gelling and setting before proceeding.

A plurality of injection ports (e.g., similar to thread 54 of Fig. 5) were added (or already present) in the acid tower. The pump arrangement was attached to a check valve (e.g., zerk 56 or push connector 72) at the lowest central injection port of the acid tower. Injection of the resin- based composition proceeded side-to-side and then upward until the highest port was injected. The pumping was performed in increments (e.g., intervals of pumping and then not pumping) to allow the material to flow and the pressure to equalize as the pumping proceeded. Open holes allowed for the resin to flow out of the surrounding holes during injection, thereby permitting a practitioner to monitor the extent of resin flow. A red color in the overflow resin indicated the presence of acid. Additional resin was injected until the red color was gone prior to moving to the next injection port.

After initial pumping, the resin was allowed to cure for a minimum of 45 minutes. Following the initial cure, a sounding procedure was performed to determine the presence of hollow spots in the tower. The pumping procedure was repeated at each hollow spot.

FIG. 9 depicts a method 900 for repairing an acid tank, in embodiments. In at least some embodiments, method 900 utilizes devices 400 and 600, for example, to repair an acid tank, such as the shell of a vessel (e.g., a mass-transfer tower). Example 3, above, is an example of method 900 and Figure 3 depicts an example repaired mass-transfer tower after implementation of method 900.

In block 902, at least one port is created in the mass transfer shell. In one example of block 902, thread 54 is inserted in shell 52 of the mass-transfer tower.

In block 904, a resin pump is coupled to one of the created at least one port of block 902. In one example of block 904, device 400 (or device 600) are coupled to the port. For example, zerk 56 may be coupled to thread 54. In blocks 902-904, the port may be different type of connection point at which a resin injector may be connected to the shell. Thus, it should be appreciated that other port-types (e.g., check valves, etc.) may be utilized besides the thread 52 and zerk 56 in Figure 5.

In block 906, resin is incrementally injected into the port (and thus into the gap between the outer metal shell and a mortar layer, middle membrane layer, and/or inner layer of hate mass-transfer tower) from the connected resin pump. In one example of block 906, resin-based component 34 (including any of the above discussed resin composition(s)) is injected into the mass-transfer tower between the outer metal shell 38 and one or more of the mortar layer 44 located between the middle membrane layer 40, the middle membrane layer 40, and the inner layer 42, as shown in Figure 3. The incremental injection may occur with the inlet pressure not exceeding 120 psi; the air volume (of dry air) was maintained at or greater than 6.5 cft./min; and the output regulator of the pump set at a value no greater than 30 psi. The incremental injection allows the injected resin to flow and the pressure to equalize as the pumping proceeds. In certain embodiments of block 906, the extent of resin flow is monitored while incrementally pumping the resin into the port. For example, additional holes may be created around the injection port created in block 902, which allow for the resin to flow out of the surrounding holes during injection, thereby permitting monitoring the extent of resin flow. Acid present in the overflow may be indicated by a different color than the injected resin composition. Thus, block 908 is a decision which determines if acid is present in the surrounding area by the port (e.g., via a different color in the overflow). If so, block 906 is repeated until the acid is no longer present (e.g., until the color of acid is no longer present in the overflow).

In block 910, a decision is made to determine if all created ports have been injected. If not, then method repeats blocks 904-908 until all ports have been injected with the resin compound. In embodiments, iteration of steps 902-910 for various injection ports may occur from a bottom of the mass-transfer tower, upwards, to fill the lower-most corroded portions of the shell first.

In block 912, the injected resin is cured. In block 914, method 900 analyzes the outer shell of the mass-transfer column to identify hollow spots, indicating acid corrosion. In one example of operation of block 914, a sounding procedure (e.g., tapping or other electronic sensing) is implemented to identify hollow spots in the outer shell 38. If a hollow spot is identified, in block 916, then method proceeds with block 902, else method 900 ends. It should be appreciated that blocks 914 and 916 may be implemented at the initialization of method 900.

Claims

1 . A system for carrying out a chemical process, comprising: an acid tower having a wall with an outer metal layer, and an inner layer; and a resin-based composition dispersed in interstices between said metal layer and said inner layer, said resin-based composition comprising: at least one resin component, and at least one rheology modifier.

2. The system of claim 1 , wherein the inner layer comprises a brick layer, and said membrane layer is positioned between said metal layer and said brick layer.

3. The system of claim 1 , wherein the resin-based composition further comprises one or more of: at least one anti-foaming component; at least one curing agent; and at least one additive.

4. The system of claim 1 , wherein the resin component is selected from the group consisting of a vinyl ester resin, an epoxy resin, a urethane resin, and combinations thereof.

5. The system of claim 1 , wherein the resin component is a vinyl ester resin, said vinyl ester resin being Derakane 470-300.

6. The system of claim 1 , wherein the resin component is an epoxy resin, the epoxy resin being selected from the group consisting of Araldite GY 6010, Araldite PY 289,

Araldite PY 313 EpiRez WD-510, Epokukdo YH-300, Docure KH-819, Epokukdo YD-114F, Epokukdo YDPN- 638, and Epokukdo YDF-170/175.

7. The system of claim 1 , wherein the resin component is a urethane resin.

8. The system of any of claims 1 -7, wherein the rheology modifier is fumed silica.

9. The system of claim 8, wherein the concentration of fumed silica is from about 1 % by weight to about 10% by weight of the composition, or more particularly, about 1 .6% or about 9% by weight of the composition.

10. The system of claim 1 , wherein the resin-based composition further comprises an anti-foaming component, wherein the anti-foaming component is BYK-310, BYK-330, BYK- A-530, BYK-S 732 or BYK 066N depending on requirements or a combination of these.

11. The system of claim 1 , wherein the resin-based composition further comprises an anti-curing agent, wherein the curing agent is selected from the group consisting of Aradur 2975, Aradur 265, Aradur 77, Aradur 450, Docure KH-819 and Epikure 3072.

12. The system of claim 1 , wherein the resin-based composition further comprises an additive, wherein the additive is selected from the group consisting of Schwego fluor 6536, Dow additive 163 Wedron 730/480, Wedron 430, Best 1220, glass flakes and silica sands.

13. The system of any one of claims 1-12, wherein the resin-based composition does not comprise a catalyst or an initiator.

14. The system of any one of claims 1-13, wherein none of the components in the resin-based composition are cross-linked to one another.

15. The system of claim 1 , wherein the resin-based composition comprises: one or more epoxy resins; one or more diluents; an antifoaming component; and a curing agent.

16. The system of claim 15, wherein the resin-based composition comprises: an epoxy novalac resin; a bisphenol F epoxy; sorbitol polyglycidyl ether; neopentyl glycol diglycidyl ether; foam sub; and a cycloaliphatic amine modified curing agent.

17. The system of claim 16, wherein the resin-based composition comprises: about 34.4 wt% to about 44.4 wt% epoxy novalac resin; about 9.5 wt% to about 19.5 wt% bisphenol F epoxy; about 3.0 wt% 9.0 wt% sorbitol polyglycidyl ether; about 3.0 wt% 9.0 wt% neopentyl glycol diglycidyl ether; about 0.4 wt% to about 1 .2 wt% foam sub; and about 28.3 wt% to about 38.3 wt% cycloaliphatic amine modified curing agent.

18. The system of claim 16 or 17, wherein the resin-based composition comprises: about 39.4 wt% epoxy novalac resin; about 14.5 wt% bisphenol F epoxy; about 6.0 wt% sorbitol polyglycidyl ether; about 6.0 wt% neopentyl glycol diglycidyl ether; about 0.8 wt% foam sub; and about 33.3 wt% cycloaliphatic amine modified curing agent.

19. The system of claim 16, wherein the resin-based composition comprises: about 556.02 pounds/100 gal. to about 586.02 pounds/100 gal. epoxy novalac resin; 200.38 pounds/100 gal. to about 220.38 pounds/100 gal. bisphenol F epoxy; about 81.405 pounds/100 gal. 91.405 pounds/100 gal. sorbitol polyglycidyl ether; about 79.405 pounds/100 gal. 89.405 pounds/100 gal. neopentyl glycol diglycidyl ether; about 8.27 pounds/100 gal. to about 14.27 pounds/100 gal. foam sub; and about 466.5 pounds/100 gal. to about 496.5 pounds/100 gal. a cycloaliphatic amine modified curing agent.

20. The system of claim 16 or claim 19, wherein the resin-based composition comprises: about 571 .02 pounds/100 gal. epoxy novalac resin; about 210.38 pounds/100 gal. bisphenol F epoxy; about 86.405 pounds/100 gal. sorbitol polyglycidyl ether; about 84.405 pounds/100 gal. neopentyl glycol diglycidyl ether; about 11 .27 pounds/100 gal. foam sub; and about 481.5 pounds/100 gal. a cycloaliphatic amine modified curing agent.

21. A resin-based composition comprising: an epoxy novalac resin; a bisphenol F epoxy; sorbitol polyglycidyl ether; neopentyl glycol diglycidyl ether; foam sub; and a cycloaliphatic amine modified curing agent.

22. The composition of claim 21 , comprising: about 34.4 wt% to about 44.4 wt% epoxy novalac resin; about 9.5 wt% to about 19.5 wt% bisphenol F epoxy; about 3.0 wt% 9.0 wt% sorbitol polyglycidyl ether; about 3.0 wt% 9.0 wt% neopentyl glycol diglycidyl ether; about 0.4 wt% to about 1 .2 wt% foam sub; and about 28.3 wt% to about 38.3 wt% cycloaliphatic amine modified curing agent.

23. The composition of claim 21 or 22, comprising: about 39.4 wt% epoxy novalac resin; about 14.5 wt% bisphenol F epoxy; about 6.0 wt% sorbitol polyglycidyl ether; about 6.0 wt% neopentyl glycol diglycidyl ether; about 0.8 wt% foam sub; and about 33.3 wt% cycloaliphatic amine modified curing agent.

24. The composition of claim 21 , comprising: about 556.02 pounds/100 gal. to about 586.02 pounds/100 gal. epoxy novalac resin; 200.38 pounds/100 gal. to about 220.38 pounds/100 gal. bisphenol F epoxy; about 81.405 pounds/100 gal. 91.405 pounds/100 gal. sorbitol polyglycidyl ether; about 79.405 pounds/100 gal. 89.405 pounds/100 gal. neopentyl glycol diglycidyl ether; about 8.27 pounds/100 gal. to about 14.27 pounds/100 gal. foam sub; and about 466.5 pounds/100 gal. to about 496.5 pounds/100 gal. a cycloaliphatic amine modified curing agent.

25. The composition of claim 21 or 24, comprising: about 571 .02 pounds/100 gal. epoxy novalac resin; about 210.38 pounds/100 gal. bisphenol F epoxy; about 86.405 pounds/100 gal. sorbitol polyglycidyl ether; about 84.405 pounds/100 gal. neopentyl glycol diglycidyl ether; about 11 .27 pounds/100 gal. foam sub; and about 481.5 pounds/100 gal. a cycloaliphatic amine modified curing agent.

26. A method of repairing a vessel used for carrying out a corrosive chemical process, the method comprising injecting a suitable amount of a resin-based composition into damaged areas of the vessel, said resin-based composition comprising any of the compositions of claims 21-26.

27. A device for injecting a resin-based composition into a wall of a vessel used for carrying out a corrosive chemical process, the device comprising an injection nozzle configured to attach to port in the wall of the vessel, a mixer, a pressurized air source, and at least two reservoir tanks, each storing a component of the resin-based composition, the resin-based composition comprising any of the composition of claims 21-26; wherein the injection nozzle regulates injection pressure to a pressure at or lower than 30 psi.