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Potassium Hydroxide
Organic coatings
Coatings on the basis of reaction resins have attained outstanding importance as
materials for corrosion protection in process engineering plants. This can be attributed to their easy and economic application: after mixing the resin and the hardener
component, and possibly a third component as filler, the mixture can be brought
onto the components by simple technical means such as spraying, rolling or spreading. The mixture then hardens at ambient temperature and after a relatively short
time attains the specified operational properties.
Thermoplastic coatings, particularly those on the basis of fluorothermoplastics,
can also provide effective protection against corrosion. In order to obtain sealed surfaces, relatively high application temperatures are necessary (> 423 K (> 150 C)) so
that coating with these materials has to be carried out in the factory.
Corrosion Handbook Online
Copyright 2008 DECHEMA e.V.
DOI: 10.1002/9783527610433
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136
Potassium Hydroxide
Thin coatings
Thin coating provide adequate protection against corrosion in many practical applications, particularly if no severe stress by abrasion, mechanical force or permeation
from prolonged action of media at high temperatures is involved. They can be produced from powders or from the liquid phase.
Powder coatings
Powder coatings are brought onto metallic components by whirl-sintering or powder
spraying. Depending on the particular process, layer thicknesses in the range from
about 0.1 mm to 0.6 mm per coating step can be achieved.
The coating structure is shown schematically in Figure 41. In most cases a primer is
applied to ensure adhesion of the coating on the substrate. The covering layer or
service layer can be built in one or more passes. Where Figure 41 and subsequent
figures specify layer thicknesses these are to be understood only as rough guidelines
and not as binding stipulations.
Figure 41:
Powder coatings on the basis of PE-LD (modified), PE-HD as well as EVAC and
with a thickness of approx. 0.30.6 mm are resistant to potassium hydroxide solution at 294 K (21 C) and at 333 K (60 C) [448]. The EVAC coatings are soft and
pleasant to touch, the PE coatings are harder and relatively wear proof.
PA 11 and PA 12 coatings are also widely utilized, because these polyamides are
subject to relatively little swelling of medium take up in aqueous media. PA 11 coatings with a thickness of about 0.30.6 mm exposed to alkaline aqueous media (chlorine bleaching liquor, saturated soda solution and concentrated ammonia solution)
showed no change after 18 months at room temperature. The compact PA 11 was
also resistant to 50 % potassium hydroxide solution and 550 % NaOH solution at
293 K (20 C) for 18 months [388]. From the results it is deduced that PA 11 coatings
are resistant to potassium hydroxide solution at room temperature. This is also true
for PA 12 coatings.
Anti-adhesion coatings with thin layer thickness (< 0.1 mm) on the basis of fluoropolymers, e.g. PTFE, are microporous and thus less suitable as corrosion protection.
Apart from the powder coatings based on thermoplastics, ones based on solid
reaction resins, that react to produce thermosetting plastics when heated in the presence of suitable hardeners, are also utilized. Such a powder coating with fatty acid
modified EP resin based on bisphenol A (Araldite G 1999), with o-tolyl biguanide
as hardener and 30 % titanium dioxide as pigment (thickness 0.06 mm) was found
to be resistant to strong alkalis such as 5 % and 30 % NaOH solution at 293 K
(20 C) after 24 months test duration [449]. Similar resistance is to be expected for
potassium hydroxide solution under comparable test conditions.
Liquid thin coatings
Thin coatings applied from the liquid phase (see Figure 41 for the coating build up)
are utilized to a much greater extent than powder coatings. In process engineering
plants, two-component epoxy resin systems consisting of epoxy resin, hardeners
based on polyamines, polyamine adducts or polyamidoamines, fillers, and pigments
as well as additives dominate and in most cases contain approx. 10 % of organic
solvent as thinner. The EP coatings for steel components shown in Table 58 are a
selection of the numerous products offered on the market. The EP coatings are
resistant to potassium hydroxide solution up to approx. 313333 K (4060 C),
whereby the resistance to dilute potassium hydroxide solution is reported to be
lower in some cases than specified for 50 % potassium hydroxide solution. The hot
cured EP coatings listed under b) in Table 58 are resistant to potassium hydroxide
solution up to approx. 353 K (80 C).
Thin layer EP coatings of similar composition are also utilized for protecting concrete surfaces, whereby the corrosion protection is chiefly confined to occasional
wetting and splashing stress. In the case of permanent wetting stress the concrete
substrate must be sealed before coating it, e.g. by applying a sealing layer based on
epoxy resin. Thin layer EP coatings are also frequently utilized as topcoat of floor
coatings (see under Industrial floor coatings).
137
138
Potassium Hydroxide
Layer
thickness,
mm
Concentration
potassium
hydroxide
%
Test
temperature
K (C)
Test
duration
Resistance
Reference
EP/plastic, polyamine
(Icosit-Poxicolor)
approx. 0.2
210 %
NaOH
50 % NaOH
296 (23)
296 (23)
90 days
90 days
+
+
[450]
EP resin/polyamine
(CeRam-Kote 54)
approx. 0.25
20
20
50
311 (38)
327 (54)
344 (71)
90 days
30 days
90 days
[451]
EP resin/polyaminoamide
(Plasguard 7133)
approx. 0.25
10
45
45
311 (38)
311 (38)
339 (66)
6 months
1 year
4 months
+
+
[452]
EP resin/polyamine
adduct
(Plasguard 9060)
0.30.4
550
50
339 (66)
355 (82)
1 year
4 months
[452]
EP resin/polyamine
adduct
(Ceilcote 600 Flakeline)
approx. 0.4
10 and 50
322 (49)
2)
[289]
EP resin/tar/polyamine
adduct
(Ceilcote 661 Flaketar)
approx. 0.4
10 and 50
322 (49)
2)
[289]
Modified EP resin/
polyamine
(Plasguard 9570)
0.30.4
550
50
339 (66)
355 (82)
1 year
1 year
+
+
[452]
EP resin/phenol resin/
polyamine
(Plasguard 9571)
0.30.4
10
10
50
311 (38)
339 (66)
355 (82)
1 year
1 year
1 year
[452]
0.25
50
293 (20)
2)
[453]
Epoxy resin/hardener
(trade name1))
a) Cold hardening coatings
Table 58: Resistance of thin layer EP coatings for steel components to potassium hydroxide solution
In the NACE publication [454] concerning coatings and linings subjected to permanent stress (immersion service) by exposure to chemicals, solvent-containing
coatings of epoxy resin, coal tar and polyamine hardeners with fillers and a solid
Figure 42:
139
140
Potassium Hydroxide
Fluorothermoplastics/
(trade name1))
Layer
thickness,
mm
ECTFE
(Proco-E-CTFE (Halar)
max. 1
saturated
15 % NaOH
50 % NaOH
338 (65)
423 (150)
393 (120)
+
+
+
[455]
ECTFE
(ECTFE Halar)
max. 1
50 % NaOH
394 (121)
[456]
ECTFE
max. 1.5
any
338 (65)
[457]
ETFE
intermediate layer = highmelt-ETFE 0.7 mm, cover
layer =low-melt-ETFE
0.8 mm
(Rhenoguard Jumbo I)
max. 1.5
25
25
48 % NaOH
373 (100)
383 (110)
373 (100)
+
+
+
[458]
PFA/FEP
intermediate layer = PFA
0.7 mm, cover layer = FEP
0.8 mm
(Rhenoguard Jumbo II)
max. 1.5
saturated
413 (140)
[459]
PFA/FEP
intermediate layer = PFA
filled 0.6 mm, cover layer
= FEP filled 0.6 mm,
topcoat = FEP 0.2 mm
(Rhenoguard Jumbo III)
max. 1.8
saturated
433 (160)
[459]
max. 1
saturated
403 (130)
[460]
PFA
(Edlon PFA)
Figure 43:
For the trowel-applied coatings usually two spread layers are applied. The total
coating thickness is about 23 mm. The structure of the layers is shown schematically in Figure 44.
Figure 44:
Spray and trowel-applied coating materials often contain barrier fillers to reduce
their permeability. These are flake fillers having a large area to thickness ratio
(= aspect ratio) e.g. flake glass or mica.
Laminate coatings contain glass fiber mats or glass fiber fabric as reinforcement
material and are able to withstand greater mechanical stress. The layer structure is
shown in Figure 45: On the primer layer follows a laminate layer that is obtained by
saturating one or several glass mats or fabrics with the reaction resin. The final layer
is a fleece layer consisting of 1 or 2 fleeces of C-glass fibers or synthetic fibers. The
total coating thickness is about 23 mm.
Figure 45:
141
142
Potassium Hydroxide
VE coatings
VE coatings are distinguished by a very broad chemical durability, also with respect
to organic solvents and oxidizing substances, high permeation resistance and high
strength. VE coatings have been utilized since several decades as corrosion protection on steel and concrete components, e.g. in chemical industrial plants, in flue gas
desulphurization plants of coal power plants (raw gas and clean gas ducts, in storage
containers, absorber parts) or in sewage water processing plants.
The resistance of the VE resins to potassium hydroxide solution is good, but it
must be taken into consideration that fillers and fibers that are attacked by potassium hydroxide solution impair the resistance of the coatings. Therefore in the
cover layer of laminate coatings synthetic fiber fleeces are often utilized instead of
glass fiber fleeces, or mica or graphite flakes instead of flake glass in sprayed coatings. Subject to these prerequisites, VE coatings can be utilized in contact with
strong alkalis such as potassium hydroxide solution or NaOH solution up to approx.
323333 K (5060 C) [462].
From the resistance specifications of typical VE coatings contained in Table 60 it
is evident that the resistance to potassium hydroxide solution 50 % can be adequate for laminate coatings up to approx. 333 K (60 C) and for sprayed coatings up
to approx. 328 K (55 C). Trowel-applied coatings with flake glass are resistant at
higher temperature only to very dilute potassium hydroxide solution, and otherwise
utilizable only at room temperature.
VE resin/fillers
(trade name1))
Layer
thickness
mm
a) Spray-applied coatings
VE resin/flake glass
(Plasguard 4007)
10
311 (38)
[452]
VE resin/inert flakes
(Plasguard 4100)
0.91.1
550
5
1050
311 (38)
339 (66)
339 (66)
+
+
[452]
0.91.2
10 and 50
311 (38)
[289]
VE resin NOV/mica
(Ceilcote 232 Flakeline)
11.5
10
50
322 (49)
327 (54)
+
+
[289]
VE resin BPA/mica
(Ceilcote 242 Flakeline)
0.91.2
10
50
322 (49)
327 (54)
+
+
[289]
Table 60: Resistance of vinyl ester resin coatings to potassium hydroxide solution
Corrosion Handbook Online
Copyright 2008 DECHEMA e.V.
DOI: 10.1002/9783527610433
Layer
thickness
mm
b) Trowel-applied coatings
VE resin NOV/flake glass
(Keraflake 6 H)
5
1040
1040
343 (70)
293 (20)
303333
(3060)
+
+
+
[463]
5
1040
1040
343 (70)
293 (20)
303333
(3060)
+
+
+
[463]
VE resin/flake glass
(Oxydur Flake)
10
293 (20)
[464]
VE resin/glass mats/
C-glass fleece
(Oxydur VE-L)
approx. 3
10
50 % NaOH
293 (20)
293 (20)
+
+
[464]
approx. 3
10
50
322 (49)
333 (60)
+
+
[289]
approx. 3
10
50
322 (49)
333 (60)
+
+
[289]
VE resin BPA/glass
fleece/cover layer with
carbon fillers
(Ceilcote 6640 Ceilcrete)
approx. 4
10
50
322 (49)
333 (60)
+
+
[289]
c) Laminate coatings
Table 60: Resistance of vinyl ester resin coatings to potassium hydroxide solution
When coatings come into contact with potassium hydroxide solution at higher
temperature, apart from the chemical durability consideration the permeability of
the coating with respect to water vapor is of increasing importance. To reduce their
permeability, VE coatings often contain flake glass or mica as barrier fillers. The
magnitude of the barrier effect of these fillers is shown in Table 61, in which the
permeation coefficient for water vapor is specified for several VE coatings at 343 K
Corrosion Handbook Online
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DOI: 10.1002/9783527610433
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Potassium Hydroxide
(70 C) [17]. The permeation coefficient of the trowel-applied coating is lower by a
factor of about 8 and that of spray coatings is lower by a factor of 2.3, compared with
the permeation coefficient of the VE coating without barrier fillers.
Permeation coefficient for water vapor*)
VE coating
1013x cm3(STP)/cm s Pa
ng/cm h Torr
Perm inch
VE spray-applied coating
with 15 % flake glass (max. 0.4 mm)
166
6.2
0.00092
VE spray-applied coating
with 15 % mica (max. 0.4 mm)
171
6.4
0.00095
VE spray-applied coating
with 17 % flake glass (max. 3.2 mm)
49
1.9
0.00027
389
15
0.0022
Table 61: Permeation coefficient for water vapor in vinyl ester resin coatings at 343 K (70 C) [17]
UP coatings
The resistance of the UP coatings to strong alkalis is good only when UP resins on
bisphenol A basis are taken into consideration [405, 462]. The coatings with other
UP resins are not resistant to strong alkalis, or at best they are resistant at room
temperature. From the durability specifications in Table 62 it is evident that UP
laminate coatings can be utilized up to approx. 333 K (60 C) and UP spray coatings
can be utilized up to approx. 323 K (50 C) in contact with potassium hydroxide solution, if they contain UP resin based on alkoxylated bisphenol A.
UP resin/fillers
(trade name1))
Layer
thickness
mm
Concentration Temperature
K (C)
potassium
hydroxide
%
Continuous
operation
resistance
Reference
a) Spray-applied coatings
UP resin BPA/mica
(Ceilcote 252 Flakeline)
approx.
0.9
10
50
322 (49)
327 (54)
+
+
[289]
UP resin HET/mica
(Ceilcote 262 Flakeline)
approx.
0.9
10 and 50
311 (38)
[289]
UP resin ISO-NPG/mica
(Ceilcote 212 Flakeline)
Layer
thickness
mm
approx.
0.9
Concentration Temperature
K (C)
potassium
hydroxide
%
Continuous
operation
resistance
Reference
10 and 50
311 (38)
[289]
10
50
322 (49)
311 (38)
+
+
[289]
UP resin BPA/glass
fabric/cover layer with
carbon fillers
(Ceilcote 2500 Ceilcrete)
approx. 4
10
50
322 (49)
333 (60)
+
+
[289]
UP resin ISO-NPG/glass
mats/C-glass fleece
(Oxydur UP 410)
approx. 3
10
50 % NaOH
293 (20)
293 (20)
+
+
[464]
b) Laminate coatings
EP coatings
EP coatings are distinguished by curing with almost no shrinking, and good mechanical properties. The chemical durability of the systems that cure at room temperature is above all good when aliphatic amines are utilized as hardener. EP coatings have only limited resistance to oxidizing substances.
The resistance of the EP coatings to potassium hydroxide solution depends
strongly on their composition and recipe. Here too the rule applies that the cover
layer should as far as possible contain fillers or fibers that are resistant to alkalis.
The specifications in Table 63 show that EP spray coatings can be resistant to potassium hydroxide solution 50 % up to approx. 333 K (60 C) and laminate coatings
up to approx. 343 K (70 C).
145
146
Potassium Hydroxide
EP coatings
(trade name1))
Layer
thickness
mm
Test
Concentration
temperature
potassium
K (C)
hydroxide
%
Test
duration
Continuous
operation
resistance
Reference
a) Spray-applied coatings
EP resin/polyamine, low
solvent content
(Icosit 277)
max. 1
1 % NaOH
20 % NaOH
318 (45)
296 (23)
270 d
1 year
+
+
[450]
EP resin/polyamine/
flake filler
(Plasguard 4500), for
steel only
0.81.3
10
20 and 50
322 (49)
327 (54)
1 year
1 year
+
+
[452]
EP novolak resin/
polyamine/flake filler
(Plasguard 4550), only for
steel
0.81.3
10, 20 and 50
327 (54)
1 year
[452]
12.5
2 and 10
10
30 and 50
50
293 (20)
333 (60)
293 (20)
323 (50)
5 years
5 years
5 years
4 years
+
+
+
+
[465]
EP-EP resin/polyamine
adduct/glass mats/synthetic fleece
(Ceilcote 68 Lining)
approx. 3
10 and 50
333 (60)
2)
[289]
EP resin/polyamine/glass
fabric/cover layer with
carbon fillers
(Ceilcote 505 Coroline)
approx. 4
10 and 50
344 (71)
2)
[289]
EP resin/polyamine/glass
mats/fleece
(Asplit 846 laminate)
approx. 3
50
293 (20)
333 (60)
333 (60)
2)
[466]
EP resin/polyamine
hot spray-applied coating
(Permacor 2807/HS-A)
b) Laminate coatings
up to 20
up to 50
PUR coatings
PUR coatings have relatively good resistance to strong and weak alkalis, but they are
utilized only to a limited extent in permanent contact with such media and at temperatures above room temperature. The permeation coefficient for water vapor is
even for highly crosslinked PUR coatings several times as great as that for VE coatings [17], so that at higher temperatures rapid penetration of water into the coating
must be reckoned with.
PUR spray-applied coatings that have very short hardening times and permit
building of layers several millimeters thick in one pass, are also offered on the market. For such a PUR coating (trade name: Disbon 705 Polibrid), that is suitable for
steel and concrete components, resistance to continuous contact with NaOH solution < 30 % at 293 K (20 C) is reported. The coating is conditionally resistant to
NaOH solution of higher concentration (< 70 %) at 293 K (20 C) [467]. These data
are also applicable to potassium hydroxide solutions.
For another quick curing PUR coating (trade name: Icosit TS 687), that is utilized on steel components with a thickness of approx. 0.51 mm, the following data
were determined: Resistant to 1 % NaOH solution at 318 K (45 C) after 270 days
test duration, resistant to 20 % NaOH solution at 318 K (45 C) after 1 year [450].
Similar behavior is to be expected for exposure to potassium hydroxide solution.
FU coatings
FU coatings, that are mostly utilized in the form of glass fiber reinforced laminate
coatings, are distinguished by very good chemical durability, above all with respect
to many organic solvents (chlorinated hydrocarbons, among others), and high
thermal stability. However, the hard brittle character of the furan resins and the relatively large curing shrinkage restrict the possible applications to some extent. The
resistance of the furan resins to potassium hydroxide solution is good, but it is
impaired for the laminate coatings by the utilized glass reinforcement materials.
For an FU coating with two glass mats and one C-glass fleece (trade name:
Korroplast FU 511) resistance to 5 % potassium hydroxide solution up to 313 K
(40 C) and to 1020 % potassium hydroxide solution up to 293 K (20 C) is reported
[463].
Combination linings
The purpose of the combination linings is to withstand the hardest chemical, thermal and mechanical stress situations in chemical and other industrial plants. This
is achieved by combining a layer of plates or bricks embedded and joined in reaction
resin cements with an underlying sealing layer. The sealing layer is provided to prevent penetration of the medium into the component, to compensate mechanical
stress between the plate coating and the substrate, and to bridge over cracks in the
substrate. The lining of plates or bricks shields the sealing layer against the medium, reduces the temperature to which the component and the sealing layer are
Corrosion Handbook Online
Copyright 2008 DECHEMA e.V.
DOI: 10.1002/9783527610433
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Potassium Hydroxide
exposed and is able to take up very high mechanical loads. The layers structure of
combination linings is shown schematically in Figure 46. Combination linings have
also been standardized and are considered, for example, in the Standard DIN
28052-5 [443] and in the AGI work sheets S 10 parts 14 [444].
Figure 46:
Putties
Among the reaction resin putties, the furan resin putties (FU putties) play a leading role
by virtue of their good chemical durability and high temperature resistance. In oxidizing
media vinyl ester resin putties (VE putties) or polyester resin putties (UP putties) are
preferred. Phenol resin putties (PF putties) are also widely utilized, whereas epoxy resin
putties (EP putties) are utilized under moderate chemical stress conditions. To a limited
extent plates and bricks are laid in bitumen. Waterglass putties are utilized when the
components have to be protected against concentrated acids.
The resistance of the putties to potassium hydroxide solution also depends on the
fillers, because these are present in large amounts. Fillers that are resistant to potassium hydroxide solution, such as graphite, petroleum coke or barium sulfate,
increase the durability, whereas for example quartz fillers decrease the durability.
From the data collected in Table 64 it is evident that FU putties with fillers based
on carbon have the highest resistance to potassium hydroxide solution (up to
approx. 403 K (130 C)). Broad resistance to alkalis is reported for the FU putties
also in the NACE publication on corrosion protection materials [454]. The good
resistance of several FU putties to alkalis (FU resins with and without furfural) was
also revealed by immersion tests in which cylindrical test bodies (diameter 20 mm,
height 20 mm) were stored for 42 days in 50 % NaOH solution at 353 K (80 C).
After this stress no loss of compressive strength and a mass change of 0.2 to 2 %
were found [471].
PF putties have slight resistance to potassium hydroxide solution [454] with the
exception PF putties containing furfural as modifier. The latter have good resistance
to alkalis when they have been further hardened with application of heat.
The resistance of the VE, UP and EP putties to potassium hydroxide solution
depends strongly on the recipe; continuous utilization temperatures of 333353 K
(6080 C) can be achieved. Bitumen putties are only conditionally resistant to potassium hydroxide solution of higher concentration, whereas waterglass putties are
strongly attacked already by dilute potassium hydroxide solution.
Putty ingredients
(trade name1))
Concentration Temperature
K (C)
potassium
hydroxide
%
Continuous
operation
resistance
Reference
[466]
a) FU putties
FU resin/carbon fillers
(Asplit FN)
50
Kp
149
150
Potassium Hydroxide
Table 64: Continued
Putty ingredients
(trade name1))
Concentration Temperature
K (C)
potassium
hydroxide
%
Continuous
operation
resistance
Reference
FU resin/carbon fillers
(Sauereisen Resin Mortar No. 21C)
50
Kp
[472]
FU resin/carbon fillers
(Keranol FU 320)
10
20
40
50
393 (120)
373 (100)
353 (80)
333 (60)
+
+
+
+
[470]
FU resin/mineral fillers
(Keranol FU 310)
10
2050
313 (40)
293 (20)
+
+
[470]
60
10 % NaOH
293 (20)
293 (20)
+
+
[473]
PF resin/fillers
(Asplit CV)
50
293 (20)
[466]
50
Kp
[466]
VE resin/mineral fillers
(Keranol VE 311)
5
10
2050
4050
353 (80)
313 (40)
293 (20)
313 (40)
+
+
+
+
[470]
VE resin/mineral fillers
(Asplit VEQ, VEC)
50
293 (20)
[466]
VE resin/quartz fillers
(Sauereisen Vinyl Ester Mortar
No. 400)
55
339 (66)
[472]
VE resin/carbon fillers
(Sauereisen Vinyl Ester Mortar
No. 400C)
55
355 (82)
[472]
c) VE putties
Concentration Temperature
K (C)
potassium
hydroxide
%
Continuous
operation
resistance
Reference
d) UP putties
UP resin/mineral fillers
(Keranol UP 311)
5
10
2050
4050
353 (80)
313 (40)
293 (20)
313 (40)
+
+
+
+
[470]
UP resin/carbon fillers
(Keranol UP 320)
10
20
40
50
353 (80)
333 (60)
323 (50)
313 (40)
+
+
+
+
[470]
UP resin/mineral fillers
(Furadur A, TM)
10 and 60
293 (20)
[474]
EP resin/polyamine/mineral fillers
(Keranol EP 310)
5
10
2050
4050
333 (60)
313 (40)
293 (20)
313 (40)
+
+
+
+
[470]
EP resin/polyamine/mineral fillers
(Asplit ET)
up to 50
up to 20
up to 50
293 (20)
333 (60)
333 (60)
[466]
EP-novolak resin/polyamine/fillers
(Sauereisen Epoxy Novolak Mortar
No. 25, 25LT)
55
355 (82)
[472]
EP resin/polyamine/mineral fillers
(Alkadur K 75)
10, 20 and 50
293 (20)
[475]
up to 50
293 (20)
+2)
[476, 477]
5
10
20
4050
333 (60)
313 (40)
303 (30)
303 (30)
+
+
+
+
[470]
e) EP putties
EP resin/mineral fillers
(PCI-Rigamuls Color, S 30)
f) Bitumen
Bitumen/mineral fillers
(Kerasolith V 80)
151
152
Potassium Hydroxide
Table 64: Continued
Putty ingredients
(trade name1))
Concentration Temperature
K (C)
potassium
hydroxide
%
Continuous
operation
resistance
Reference
[466]
g) Waterglass putties
Waterglass/mineral fillers
(Asplit HB, HES)
50
293 (20)
Sealing layers
Sealing layers consist of either coatings on the basis of the reaction resins described
above, or webs of thermoplastics or elastomers. The thickness of the sealing layers
is approx. 1.53 mm.
In the AGI work sheet S 10 Part 2 the following statements for orientation are
made with regard to the resistance of sealing layers to alkalis such as potassium
hydroxide solution: Coatings on the basis of VE, FU, EP and EP/special tar are resistant, whereas those based on UP, PF, PUR and PUR/special tar are conditionally
resistant. Elastomer webs consisting of IIR, CR, NBR and CSM as well as thermoplastic webs made of PIB and PVC-P are also resistant to alkalis [444].
From the durability specifications contained in the Table 65 it is evident that the
rubber and thermoplastic webs have greater resistance to potassium hydroxide solution than the flexible EP and PUR coatings and can be utilized up to approx. 353 K
(80 C). The hard glass fiber reinforced VE, UP and EP laminate coatings, shown in
the Tables 6063 can be utilized in contact with potassium hydroxide solution up to
approx. 333 K (60 C).
Coatings for water protection against pollution
Coatings for catch troughs, retention rooms and concrete surfaces in plants for storing, filling and transferring water polluting liquids require a general construction
supervisory approval in Germany from the Deutsches Institut fr Bautechnik
(DIBt), certifying permanent bridging of cracks as from a width of 0.1 mm and adequate durability with respect to the encountered water polluting liquids as well as
further required technical characteristics [69].
While for good chemical durability above all a high degree of crosslinking of the
reaction resin is necessary, requiring coatings having greater strength and smaller
rupture elongation, crack bridging is achieved with flexible layers that have a large
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DOI: 10.1002/9783527610433
Sealing layer
(trade name1))
Layer
thickness
mm
Concentration Temperature
K (C)
potassium
hydroxide
%
Continuous
operation
resistance
Reference
a) Coatings2)
23
5
1020
1020
313 (40)
293 (20)
313 (40)
+
+
+
[463]
EP resin/polyamine/
fillers
(PCI-Apoflex TF)
at least 2
20
boiling
[478]
PUR/mineral fillers
(Keracid PU 112)
5
1020
333 (60)
313 (40)
+
+
[463]
1020
50
323 (50)
323 (50)
+
+
[479]
1.5
55
366 (93)
[480]
CIIR/fillers
(Kerabutyl S)
23
550
353 (80)
[463]
CR/fillers
(Kerapren VB)
23
5
1050
353 (80)
333 (60)
+
+
[481]
CSM
(Kerapalon HE)
550
333 (60)
[481]
PIB/carbon fillers
(Rhepanol O.R.G)
approx. 2
10 and 50
353 (80)
[482]
PIB/mineral fillers
(Rhepanol O.R.E)
approx. 2
10 and 50
353 (80)
[482]
1.5
55
Kp
[480]
EP resin/special tar/
polyamine/mineral fillers
(Keracid ES 110)
PUR/asphalt
(Sauereisen Urethane
Membrane No. 87)
b) Rubber webs
c) Thermoplastic webs
Table 65: Resistance of cover layers under plate linings against potassium hydroxide solution
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153
154
Potassium Hydroxide
Figure 47:
layer
4a
6a
9a
Reference
15
Table 66: Chemical durability (42 days/296 K (23 C)) of water protection coatings with general
construction supervisory approval of the DIBt
Corrosion Handbook Online
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DOI: 10.1002/9783527610433
4a
[485]
[486]
[487]
[488]
9a
Reference
Potassium
hydroxide
solution
15
b) Polyurethane systems
Self-leveling coating, thickness 3 mm
(Oxydur UP 82 E-CLF)
[487]
[483]
[489]
[487]
[487]
Table 66: Chemical durability (42 days/296 K (23 C)) of water protection coatings with general
construction supervisory approval of the DIBt
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156
Potassium Hydroxide
Reference
20
293 (20)
[491]
550
boiling
[492]
EP rolling coating
(Disboxid 430)
Reference
50
293 (20)
[493]
EP self-leveling coating
(Keraplan EP 113)
5
1020
4050
333 (60)
303 (30)
293 (20)
+
+
+
[470]
5 20
50
RT
RT
+
+
[492]
5
20
50
RT
RT
RT
+
+
[492]
5
10
4050
333 (60)
313 (40)
293 (20)
+
+
+
[470]
10 and 50
356 (83)
[289]
50
293 (20)
[493]
EP self-leveling coating
(MC-DUR 1200, 1200 AS)
550
boiling
[492]
EP self-leveling or trowel-applied
coating
(Alkadur DFG, K 47, D, DF)
1050
293 (20)
[494]
10 and 45
293 (20)
[495]
10
296 (23)
[496]
EP self-leveling coating
(Rinol Standard)
PUR self-leveling coating
(PCI Pursol 2K)
+ = resistant; += conditionally resistant
1) Trade name not binding
RT = Room temperature
157
158
Potassium Hydroxide
Table 67: Continued
Industrial floor coating
(trade name1))
Reference
5
10
4050
333 (60)
313 (40)
293 (20)
+
+
+
[470]
10
45
353 (80)
293 (20)
+
+
[495]
50
20 % NaOH
50 % NaOH
293 (20)
363 (90)
333 (60)
+
+
+
[497]
10
296 (23)
[498]
10 % NaOH
20 % NaOH
293 (20)
293 (20)
+
+
[499]
VE trowel-applied coating
(Ceilcote 167 Corocrete)
10
50
322 (49)
327 (54)
+
+
[289]
VE broad-cast coating
(Ceilcote 163 Corocrete)
10
50
322 (49)
327 (54)
+
+
[289]
10 and 45
293 (20)
[495]
5
10
4050
333 (60)
313 (40)
293 (20)
+
+
+
[470]
10 and 50
333 (60)
[289]
10
296 (23)
[500]
VE coating
(Rinol Vinylester)
c) Stone floor coatings (thickness > 6 mm)
Expansion gaps cannot be avoided completely in the floor coatings and combination floor coverings with plates or tiles for compensating structural movements of
the building. Details for the technical design of expansion gaps are described in the
AGI Work Sheets of the S-series [444]. Expansion gap compounds or sealants that
are characterized by high deformability are utilized for filling expansion gaps.
However, the chemical durability of the expansion gap compounds is limited. The
AGI Work Sheet S 10 Part 4 contains the results of a ring test of the durability of
expansion gap compounds on the basis of polysulfide, silicone and polyurethane/
tar. As test media 25 % and 50 % NaOH solution were utilized as representative for
strong alkalis such as potassium hydroxide solution. The specified expansion gap
compounds were found to be resistant at 296 K (23 C) with 72 hours exposure time
[444]. However, attack must be reckoned with for longer exposure times.
Organic linings
Rubber linings
Rubber linings are linings with rubber webs or elastomer webs that are bonded to
the steel or concrete parts over their entire surface area with adhesives. The layer
thickness of the rubber webs is approx. 35 mm. For special stress situations, e.g.
exposure to abrasive media, several rubber webs are bonded on top of each other to
give a total thickness that can be greater than 8 mm.
An important application field is constituted by absorbers, pipelines and storage
containers made of steel in flue gas desulphurization plants in which the rubber
linings must withstand aqueous suspensions of limestone and gypsum containing
SO2, HCl and NOx at temperatures of up to 343 K (70 C) [501, 502]. Further applications are concerned with the corrosion protection of containers, pipes, reactors,
basins or channels made of steel or concrete in chemical plants or in sewage water
processing plants, as well as rubber linings in boiler vehicles, tank vehicles or tank
ships, in which chemicals are transported [503].
Corrosion protection with rubber linings in process engineering plants is described
for concrete components in the standard DIN 28052 (Parts 1, 2, 4 and 6) [443] and
for steel components in the standards DIN 28051 [445], DIN 28053 [446] and DIN
28055 (Parts 1 and 2) [504]. For rubber linings in steel containers for storing water
polluting noncombustible liquids, a general construction supervisory approval from
the DIBt is required in Germany [50].
The layers structure of rubber linings is shown schematically in Figure 48. On
top of the primer follow several layers of adhesive, whereby the adhesive is usually
applied to the rubber web as well as to the substrate.
The rubber webs can consist of a single layer or of several different layers, for
example two layer webs consisting of a chemically resistant main layer and an easily
bonded lower layer are often utilized in practice.
Factory rubber linings are applied to steel components that are transportable and
do not exceed a certain maximum size. It is of advantage to utilize non-vulcanized
easily processed rubber webs for this purpose.
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159
160
Potassium Hydroxide
Figure 48:
Construction site rubber linings are applied to very large steel components and
concrete parts on the construction site [505].
Hard rubber linings
Hard rubber linings are highly crosslinked polymer materials with thermosetting
plastic character and no rubber elastic properties at all. The chief rubber for hard
rubber linings is NR, that is often utilized in combination with IR or SBR. The great
hardness and strength are achieved with a relatively large dosage of sulfur (2050
parts/100 parts rubber). Hard rubber linings feature broad chemical durability, e.g.
with respect to acids, alkalis, salt solutions and organic solvents, but their resistance
to oxidizing substances is limited.
The resistance of hard rubber linings to potassium hydroxide solution is generally
considered to be good. From the durability specifications in Table 68 it is evident
that factory rubber linings are resistant to potassium hydroxide solution 50 % up
to about 373 K (100 C), whereas hard rubber linings applied to components on the
construction site by vulcanization with hot water or superheated steam are resistant
to potassium hydroxide solution up to about 333353 K (6080 C). Semi-hard NR
rubber linings that have a hardness of about 50 Shore D are resistant to potassium
hydroxide solution up to about 338 K (65 C).
Chemical basis and hardness of the
hard rubber lining
(trade name1))
Concentration Temperature
K (C)
potassium
hydroxide
%
Continuous
operation
resistance
Reference
+
+
[506]
550
550
353 (80)
373 (100)
Concentration Temperature
K (C)
potassium
hydroxide
%
Continuous
operation
resistance
Reference
550
373 (100)
[506]
NR, 80 Shore D
(Chemonit 3B, 30 and 31)
20, 40 and 80
353 (80)
[507]
2, 20 and 40
353 (80)
[508]
550
363 (90)
[506]
saturated
solution
338 (65)
[454]
25
saturated
solution
366 (93)
338 (65)
+
+
[405]
NR/SBR, 75 Shore D
(Kerabonit HW)
550
333 (60)
[481]
NR, 80 Shore D
(Chemonit 31 HW)
20, 40 and 80
353 (80)
[507]
NR/SBR, 78 Shore D
(Vulcoferran 2194)
2, 20 and 40
353 (80)
[508]
NR/SBR, 75 Shore D
(Vulkodurit 1250)
161
162
Potassium Hydroxide
webs, that can be manufactured only with certain rubbers (e.g. with BIIR or CR),
are vulcanized on the construction site with hot air, hot water or steam within a few
days to weeks.
The resistance of the soft rubber linings to potassium hydroxide solution depends
on the type of rubber. The durability data contained in Table 69 show that soft rubber linings on the basis of the butyl rubbers IIR, CIIR and BIIR achieve the highest
continuous utilization temperaturesof 353373 K (80100 C) in contact with potassium hydroxide solutions 50 %. Then follow the soft rubber linings on the basis of
CSM and CR with a maximum application temperature of about 333353 K
(6080 C). The soft rubber linings on the basis of NR can be utilized in contact with
potassium hydroxide solution up to about 313333 K (4060 C).
Chemical basis/hardness of the soft
rubber lining
(trade name1))
Concentration Temperature
K (C)
potassium
hydroxide
%
Continuous
operation
resistance
Reference
550
373 (100)
[506]
IIR, 55 Shore A
(Vulkodurit 1755)
5- 20
4050
383 (110)
373 (100)
+
+
[506]
25
358 (85)
[405]
IIR/PVC, 55 Shore A
(Vulkodurit WB3)
550
343 (70)
[506]
BIIR, 65 Shore A
(Vulcoferran 2201)
2, 20 and 40
353 (80)
[508]
10 and 25
50
363 (90)
363 (90)
+
+
[507]
BIIR, 57 Shore A
(Vulkodurit 1560)
550
550
353 (80)
373 (100)
+
+
[506]
CSM, 85 Shore A
(Vulkodurit 1691-75)
550
333 (60)
[506]
2, 20 and 40
353 (80)
[508]
10 and 25
50
363 (90)
363 (90)
[507]
IIR
BIIR, 50 Shore A
(Chemoline 4A)
CSM, 85 Shore A
(Vulcoferran 2512)
CR, 55 Shore A
(Chemoline 3 A)
NR, 55 Shore A
(Vulkodurit W2)
Concentration Temperature
K (C)
potassium
hydroxide
%
Continuous
operation
resistance
Reference
550
333 (60)
[506]
25
saturated
solution
377 (104)
377 (104)
+
+
[405]
550
313 (40)
[506]
550
373 (100)
[481]
CIIR, 58 Shore A
(Kerabutyl BS)
550
353 (80)
[481]
CIIR/PVC, 55 Shore A
(Kerabutyl VC)
550
333 (60)
[481]
CSM, 60 Shore A
(Kerapalon HE)
550
333 (60)
[481]
353 (80)
[508]
BIIR, 50 Shore A
(Chemoline 4B)
10 and 25
50
363 (90)
363 (90)
+
+
[507]
BIIR/CR, 50 Shore A
(Chemoline 5B)
10 and 25
50
363 (90)
363 (90)
[507]
CR, 55 Shore A
(Chemoline 3B)
10 and 25
50
363 (90)
363 (90)
[507]
2, 20 and 40
353 (80)
[508]
5
1050
353 (80)
333 (60)
+
+
[481]
BIIR, 60 Shore A
(Vulcoferran 2206)
CR, 65 Shore A
(Vulcoferran 2503)
CR, 60 Shore A
(Kerapren VB)
163
164
Potassium Hydroxide
Rubber basis
Filler
fraction
%
Hardness
Permeation coefficient1)
1013x cm3(STP)/cm s Pa ng/cm h Torr Perm inch
IIR
38
50 Shore A
137
5.3
0.00076
IIR
44
55 Shore A
119
4.6
0.00066
BIIR
44
60 Shore A
111
4.3
0.00062
BIIR
50
65 Shore A
143
5.5
0.00079
CR
53
70 Shore A
975
37.6
0.0054
NR
(hard rubber)
21
75 Shore D
135
5.2
0.00075
Table 70: Permeation coefficient of vulcanized rubber webs for water vapor at 343 K (70 C) [17]
Rubber linings in steel containers for stationary plants for storing, filling and
transferring water polluting substances require a general construction supervisory
approval of the Deutsches Institut fr Bautechnik (DIBt) in Germany, in which the
permanent suitability of the rubber lining is certified [50]. According to the approval
principles for such rubber linings, resistance to alkalis must be verified by a test
with 50 % NaOH solution as test liquid at 313 K (40 C), that then covers the resistance to potassium hydroxide solution 50 % and to other alkalis. If the operating
temperature is higher than 313 K (40 C) the test must be carried out at this higher
temperature. From the durability specifications in the Tables 68 and 69 it is evident
that a durability test at 313 K (40 C) is passed by hard rubber linings as well as by
numerous soft rubber linings without any problems. This is also confirmed by the
relatively large number of rubber linings offered on the market that have a general
construction supervisory approval from the DIBt.
165
166
Potassium Hydroxide
maximum is reported [511]. PVDF linings are not recommended for exposure to
potassium hydroxide solution because of the risk of stress corrosion cracking.
Table 71 contains a price survey of some fluorothermoplastics as inner lining
materials. The specifications are valid for plate material without fabric lining on the
rear side. The relationships for plates with fabric lining that establishes the connection to the glass fiber reinforced plastic laminate are similar [512].
Fluorothermoplastic inner lining Price for plate material
relative price unit/kg
PVDF
ECTFE
1.25
FEP
2.5
MFA
PFA
3.5
The PVC-P linings already mentioned for concrete components are also utilized
for steel components and are resistant to 10 % potassium hydroxide solution up to
323338 K (5065 C) as well as to 35 % potassium hydroxide solution up to
293303 K (2030 C) [509, 510].
Apart from the full surface area bonded fluorothermoplastic webs, that have maximum operating temperatures of 393 K (120 C) because of the limited thermal
stress tolerance of the bonded joint or the adhesive, since a long time loose jacket
linings with fluorothermoplastics are utilized too. The flanges of the containers and
pipe parts usually serve as fixing points for the loose jacket lining. An important
aspect is the back aeration of the lining. By appropriate constructional measures it is
ensured that the small amounts of gases and vapors permeating through the fluorothermoplastic lining do not condense between the steel sheath and the lining and
cause corrosion, but are discharged to the exterior [513, 514].
PTFE and modified PTFE have by virtue of their outstanding properties attained
special importance for loose jacket linings. Examples of applications are for columns, absorbers and reactors that are operated at temperatures up to approx. 473 K
(200 C) [515]. For 4 mm thick linings (trade name: Licuflon) resistance to potassium hydroxide solution of any concentration is reported for a temperature range
from room temperature to approx. 473 K (200 C) [516].
With paste extruded PTFE, linings are carried out with a thickness of up to 8 mm
(trade name: Polyfluron-PTFE) that can also be operated at temperatures of up to
about 473 K (200 C) [517]. With such thick linings measures for rear venting are in
most cases unnecessary.
For exposure to dilute potassium hydroxide solution at high temperatures, apart
from the chemical durability it is also necessary to take the permeation of water
vapor into consideration. As has already been pointed out, a high water vapor perCorrosion Handbook Online
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Figure 49:
Relative permeation rates of fluorothermoplastics for water vapor at 373 K (100 C)
[517]
Metallic materials
A very wide range of different materials is utilized for seals and packings. Information regarding their behavior on exposure to potassium hydroxide solution is contained in the corresponding chapters.
167