Paper No.

01339
CORROSION 2001
THE USE OF CARBON/CARBON COMPOSITES AND GRAPHITE IN THE NEW MILLENNIUM

Winn Darden and Gerry Taccini

HITCO Carbon Composites, Inc.
1600 W. 135 th St.
Gardena, CA 90249

Kevin Kelley
SGL Technic, Inc.
21945 Drake Rd.
Strongsville, OH 44149

ABSTRACT

Graphite and carbon have been used to fabricate chemical process equipment and components for
over 50 years due to their excellent corrosion resistance. Recent advances in graphite fabrication
technology have improved the performance of these versatile materials. Carbon/Carbon (C/C)
composites, originally used in the aerospace industry, have the chemical resistance of graphite combined
with the structural properties of metals. Experiences with graphite and C/C composites in the chemical
process industry are detailed.

INTRODUCTION

Graphite and carbon have been used to fabricate chemical process equipment for over 50 years.
They have outstanding corrosion resistance and heat transfer properties, perform well at high
temperatures, can be easily machined and bonded, and are reasonably priced versus other corrosion
resistant materials. In addition, graphite can be made impermeable to permit its use in heat exchanger
tubes and tube sheets.

Carbon/Carbon composites consist of a carbon fiber surrounded by a carbon matrix. The composites
are made by impregnating a carbon fiber with a phenolic resin, pyrolyzing the resin, and then depositing
carbon in the resulting carbon char through chemical vapor infiltration (CVI). This carbon is derived
from the high temperature cracking of methane gas.

Copyright
2001 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole must be in writing to NACE
International, Publications Division, 1440 South Creek Drive, Houston, Texas 77084-4906. The material presented and the views expressed in this paper are
solely those of the author(s) and not necessarily endorsed by the Association. Printed in U.S.A.

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 C/C composites have been used for many years in the aerospace industry. Recently, their use has
been extended to the chemical process industry (CPI). Because of the very high strength of the carbon
fibers, and the inert nature of the carbon matrix surrounding the fibers, C/C products offer the chemical
resistance of graphite, but have the structural properties of a metal. This allows them to be used in
structural applications where the use of graphite can be limited by its physical characteristics.

This paper will discuss graphite technology. In addition, the paper will discuss the manufacture and
properties of C/C composites, and their applications in the CPI.

GRAPHITE PROCESS EQUIPMENT FOR THE CPI

Manufacture of Graphite

Graphite components have been used in the CPI for over 50 years. Graphite's chemical resistance
combined with excellent its heat transfer properties and ease of use leads to its widespread application in
heat transfer equipment (shell and tube, cylindrical block, and plate/frame exchangers). It is also used in
HC1 synthesis plants, and to make column and reactor internals.

The starting materials used in making graphite are low-ash petroleum cokes and a pitch binder.
First, the cokes are calcined. They are then ground and separated into defined particle size fractions.
The various particle fractions are then mixed with pitch to form a blend of high viscosity at moderate
temperatures. This blend is then formed through various processes including extrusion and molding into
tubes, blocks, or cylinders, depending on the final application. These blends are then baked at about
980 ° C. At this temperature, the pitch binder is carbonized; that is, decomposed to form pure carbon.
These formed carbon components are very hard but have low thermal conductivity. Such components
may be used as vessel linings or in applications where abrasion resistance is required.

At this point, more pitch is sometimes added to the carbonized components to reduce the size of the
pores formed during the baking process. These components are heated again to carbonization
temperatures. Finally, the components are graphitized at 2,580 to 2,980 ° C. At these temperatures, the
structure of the carbon is converted to the ordered structure of graphite. It is through this process that
graphite obtains the desirable property of outstanding thermal conductivity while retaining its excellent
chemical resistance. Graphite is also easy to machine and thus lends itself to the fabrication of
intricately machined components.

Manufacture of Graphite Components for the CPI

Formed graphite components are porous. That porosity varies with grade, but typically ranges from
12-16% for the least porous grade to 22-25% for the most porous. Impermeability, which is needed for
nearly all graphite process equipment applications, is obtained by impregnating the graphite with a
synthetic resin, usually phenolic based. The resin is forced into the pores of the graphite with a
vacuum/pressure process. The impregnation process involves precisely controlled time and temperature
cycles to ensure a quality finished product. The resin impregnation step is critical to the life cycle of
graphite process equipment. Proper impregnation increases the strength of the graphite/resin composite
material to a value nearly three times that of the strength of the unimpregnated graphite materials.
Improper impregnation can lead to leakage or to premature mechanical failure.

The impregnated components are usually machined into the final shape using standard machine
tools. Components such as heat exchanger tubes and tube sheets can be joined using a cement system

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 containing a corrosion resistant resin binder, graphite powder, and a catalyst. The cement systems
utilized have the same chemical resistance as the graphite/phenolic resin composite material.

Characteristics and Typical Properties of Graphite Components

Impregnated graphite has properties that enable it to be used in corrosive environments in the
chemical industry. The products offer:
1. Outstanding chemical resistance. Standard graphite products are resistant to most organic and
inorganic chemicals. Graphite equipment is used frequently in the processing of hydrochloric acid,
phosphoric acid, sulfuric acid, and hydrofluoric acid. Strongly oxidizing compounds can attack the
phenolic resin, or in some cases attack the graphite material itself.
2. Good performance over a wide range of temperatures. Standard graphite can be used at
temperatures up to 2,980 ° C in an inert or vacuum environment. Impregnated graphite can be used
in process equipment as long as the wall is maintained at or below 200 ° C.
3. Excellent thermal conductivity. This ranges from 70 W/m °K for tubes to 121 W/m °K for blocks.
These values exceed those of most metals.
4. Good compressive strength. Although graphite has poor tensile strength compared to metals or
composites, its compressive strength is 3-5 times its tensile strength. Resin impregnation improves
the compressive strength even further. This allows graphite, with proper design, to be used in
structural components.
5. Enhanced reliability. For shell and tube heat exchangers, the mechanical failure of tubes can be
greatly reduced by the use of carbon fiber-reinforced tubes. The pretensioned carbon fibers are
wound in a net-like pattern on the outside of the exchanger tubes, which increases the bursting
pressure by 50%. Thermal conductivity of the tube is minimally affected, and effects on necessary
heat transfer area are negligible.

Table 1 shows a partial list of chemicals to which both standard and impregnated graphite are
resistant. Table 2 is a summary of physical properties for a number of metals, C/C composites, and
graphite.

Advantages of Graphite Components

The characteristics of graphite lead to certain advantages in the performance of components used in
the CPI. The excellent thermal conductivity of graphite allows for the construction of economical,
efficient heat exchangers. Because of the nature of the manufacturing process, graphite components are
homogeneous, meaning that heat transfer is uniform throughout the heat exchange unit. The corrosion
resistance of impregnated graphite means that the exchangers can be used in a wide variety of harsh
chemical environments. Graphite heat exchangers can be easily cleaned and repaired, leading to lower
maintenance costs and reduced downtime.

Applications for Graphite in the CPI

The main applications for graphite in the CPI are as components for heat exchangers. Construction
using graphite yields shell and tube heat exchangers with a low pressure drop at high flow rates, reduced
downtime, and an efficient heat exchange profile. Tubes, tube sheets, baffle cages, and headers can be
constructed from graphite, while shells are usually made from a metal. Tubes of varying lengths with
excellent joint strengths can be fabricated using special cements. Tubes are attached to tube sheets
using the same cement. Differences in thermal expansion between the tube bundle and the shell must be
accommodated by using a floating head design.

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 Block heat exchangers can also be made from graphite. Efficient cylindrical block units are utilized
when one corrosive media is present. Compact, modular block units which are suitable for use with
corrosive media on either or both the service and product sides can be fabricated. The thermal
efficiency and opportunity to allow temperature crosses in these heat exchanger designs are also
important in this application. Differences in thermal expansion are again important and must be taken
into account during design.

Corrosion resistant pumps utilizing graphite for the wetted parts have been used successfully in a
variety of acidic environments. Erosion resistance through application of special coatings (chrome
oxide and silicon carbide) allows for a unique erosion/corrosion resistant pumping system.

Finally, a variety of columns and column components can be fabricated from graphite. Columns
made from impregnated graphite are used for absorption of hydrogen halides, purification of acid
mixtures, and for purification of flue gases. Bubble cap trays, sieve trays, and tunnel cap trays can be
made from graphite. Other column internals such as sparger tubes, support plates, and packing can also
be made from graphite.

Case Studies: Examples of the Use of Graphite in the Chemical Process Industry

Case 1: Purification Tower. A major chemical company needed specially machined trays in a
column for the purification of acid at 175 ° C. Impervious graphite trays were utilized in lieu of other
materials, including polymers, because graphite will not sag or deflect at the column temperature. The
tower produces a perfectly clear finished product in which color is crucial. Graphite trays have been
used for 9 years to produce the clear product.

Case 2: Evaporator. The phosphoric acid industry uses carbon fiber-reinforced graphite tubes in
lieu of standard graphite tubes because of the improved mechanical properties imparted by the carbon
fiber. An estimated 60-100 exchangers of this type are in service globally. Tube failure and associated
production losses due to fouling and mechanical failure are greatly reduced.

CARBON/CARBON COMPOSITES IN THE CPI

History of Carbon/Carbon Composites

Composite materials contain a fiber for support and strength and a matrix to hold the fiber in place
and transfer loads to the fibers. Typical fibers include fiberglass, Kevlar, and ceramics. Fabrics can
come in many forms including woven, chopped tow, random fibers and mats. Resins used to
encapsulate the fibers include epoxies, phenolics, polyesters or vinyl esters. Probably the best known
composites in the CPI are FRP products, used to make tanks and piping.

Carbon/Carbon fiber composites were developed in the late 1950's, but were not used in substantial
quantities until the late 1960's and early 1970's. The original C/C structures were used in rocket nozzles
and re-entry components such as missile heat shields, mainly for military use. The original composites
used a low modulus carbon fiber based on rayon and impregnating resins like phenolics and furans.
Advances in carbon fiber technology have led to the use of precursors like polyacrylonitrile (PAN) and
pitch, new techniques for spinning and treating the precursor fibers to yield desirable properties, and
new methods for treating and weaving the carbon fibers themselves to optimize properties for a given
application. C/C materials have excellent specific strength (the ratio of tensile strength to density), good
thermal shock properties, chemical inertness, and are biocompatible. They retain their properties at very

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 high temperatures. As a result, C/C composites are currently used to manufacture parts for a wide
variety of applications, including rocket nozzles, heat shields, aircraft and racing car brakes, biomedical
devices, and now, CPI components.

What are Carbon/Carbon Composites?

Manufacture of C/C Composites. The manufacturing process for C/C begins with the impregnation
of carbon fibers with a phenolic resin. The carbon fibers are usually derived from PAN, since these
have superior physical properties and are less expensive than fibers obtained from other sources. The
choice of precursor is critical, since the mechanical properties of the C/C composite are dictated by the
properties of the fiber. Continuous carbon fibers are usually used, so as to maximize the in-plane
strength and stiffness as determined by the fiber. For components used in the CPI, the carbon fiber is
usually woven into a fabric.

This resin-impregnated fabric is formed around a mandrel to create the desired shape. Mandrels are
usually made of aluminum, since it is strong enough to withstand the pressure required to compact the
composite layers during cure. Unlike metals, the strength of composites is dependent on fiber direction.
In order to maximize the strength of the composite, special techniques specified by the component
designer are used to lay up the prepreg on the mandrel. Multiple layers of fabric are used to build the
thickness of the composite part. The ultimate thickness of the component is determined by the strength
required for the application. Pieces up to several inches thick can be fabricated; usually the components
are between 1 mm and 15 mm thick. There is significant versatility of design with C/C technology. A
wide variety of net shapes can be produced by the appropriate lay-up techniques. This eliminates the
need for copious machining or welding to form shapes that may be required using other materials of
construction. Tubes, cones, I-beams, C-channels, flanged forms, honeycomb or even more complex
shapes can be fabricated. The shaped, phenolic-impregnated fabric is then cured under pressure in an
autoclave at 177 ° C, and is then removed from the mandrel.

The next step in the manufacturing process is carbonization of the phenolic resin to begin formation
of the carbon matrix. The purpose of the carbon matrix is to hold the carbon fibers in place, and to
transfer any applied load to the fibers. Carbonization is accomplished by placing the cured, shaped
component into an inert atmosphere oven with a controlled temperature ramp. This cycle is designed to
start removing hydrogen, oxygen and nitrogen for the phenolic matrix. In the next step, pyrolysis, the
phenolic resin is completely converted into carbon in a vacuum furnace at temperatures exceeding
2,000 ° C. At these temperatures, all of the chemical components of the phenolic resin with the
exception of carbon are volatilized. Typically, phenolic resins used to make C/C composites have
carbon yields of 50-60%.

The composite resulting from the initial carbonization and pyrolysis processes has around 35%
porosity. The porosity arises from the relatively uniform and predictable evolution of volatiles from the
phenolic resin during the heating process. This porous composite is relatively weak. In order to build
the strength of the composite to a suitable level, a second process, called chemical vapor infiltration
(CVI) or chemical vapor deposition (CVD) is used. In this process, methane gas is introduced into a
vacuum furnace that has been heated to 1,000 ° C. At this temperature, the methane cracks to yield
carbon, hydrogen, and hydrocarbons. The carbon generated is deposited into the pores of the composite,
slowly building up the carbon matrix, which is well bonded to the carbon fibers. Deposition continues
until the density of the composite reaches about 1.8 g/cc. The completed composite has a residual
porosity of 3-10%.

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 Characteristics and Typical Properties of C/C. After CVI, the completed C/C composite has
desirable physical, chemical, and thermal properties that make it suitable in a wide variety of
applications. The composites have:
1. The chemical resistance of graphite. C/C composites are resistant to non-oxidizing inorganic acids,
caustic and other bases, organic acids, salts, and most other organic chemicals.
2. The mechanical properties of a metal. It is important to remember that these properties are greatest
in the direction of the fiber, since it is the fiber that provides the strength to the composite.
3. Excellent thermal shock resistance. This can be important in process areas that see wide fluctuations
in temperature in a short time.
4. A low coefficient of thermal expansion. While this is a desirable property for the composite, it must
be taken into account when designing systems in which C/C is to be coupled to another material.
5. Excellent high temperature stability. C/C composites retain their physical properties at temperatures
above 2,500 ° C in non-oxidizing environments. Because of this, they are used as components in
inert atmosphere and vacuum furnaces. In oxidizing environments, C/C can be used at temperatures
up to 450 ° C. Depending on oxidizer concentration at higher temperatures, decomposition can be
quite rapid.
6. Excellent specific strength. The composites have densities ranging from 1.6-1.9 g/cc
7. Good impact resistance.
8. Good mechanical shock resistance. This property can be important in process areas where water
hammer or vibrations occur.

Table 2 gives comparative physical property data for C/C composites and a variety of metals. The
data shows that C/C composites have a tensile strength between that of aluminum and of titanium. Since
C/C is a fiber-based composite material, the greatest tensile strength is in the direction of the fiber.

Table 2 also gives data for graphite. C/C composites and graphite are both carbon-based materials,
and as such, have similar chemical resistance. Because of its superior strength, C/C can be used in
certain structural applications where graphite may not be suitable for use.

Table 3 shows the results of basic chemical resistance tests for C/C. The materials have excellent
resistance to most highly corrosive acids like HF, HC1, HBr, H2SO4 (up to concentrations of about 75%),
and H3PO4. The composites also have good resistance to bases and to salts. C/C composites are not
useful in oxidizing media like HNO3 or chromic acid, and will degrade rapidly in boiling solutions of
these acids. In addition to the products shown in Table 3, C/C composites are also resistant to those
chemicals given in Table 1.

Table 4 gives information on the chemical resistance of C/C from actual applications of C/C or from
laboratory tests run by potential users of the composites. Due to the proprietary nature of certain
chemical processes, it is often difficult to collect precise information on the chemical environment in
which materials of construction are being used. The data in Table 4 offers a glimpse at what might be
the biggest advantage of C/C materials: their ability to withstand corrosive blends without degradation.
This can be a serious shortcoming in metals. For example, tantalum and zirconium withstand HC1, but
cannot tolerate even minute amounts of HF in a chemical blend.

Advantages of C/C Composites

C/C composite materials have advantages over graphite and over metals that are commonly used as
materials of construction. First, the mechanical strength and resistance to mechanical shock of C/C
exceed that of graphite. This can lead to a reduction in component maintenance and replacement costs.

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 Because of the nature of C/C, the material can be used to make components for service in corrosive
blends. Contaminants like halides and metal ions can accelerate corrosion in systems constructed of
metals. Third, C/C composites can often be fabricated into net or near net shapes. This can reduce the
relative cost of C/C versus fluoropolymers or graphite, where complex shapes are often machined from
blocks of the materials, often with substantial waste. Unlike metals, no welds are used to create the
finished shape. Welds are often the weak link in the corrosion resistance of a metallic component.

Applications for C/C Composites

C/C composites are primarily being used to fabricate column and reactor internals. Examples
include trays, tray supports, distillation column packing (both structured and random), sparger or
distribution tubes, inlet tubes, thermowell sheaths, reactor grating, column liners, support fixtures like I-
beams or U-channels, nuts, bolts, and pins for joining components, distributor plates, spray nozzles,
injection ports, and pump impellers.

The main reason for restricting the use of C/C composites to internals has been the permeability of
the finished product. There are, however, methods for rendering the composites impermeable. The
most common of these is to impregnate the composite under vacuum with a phenolic or furan resin.
This technique is commonly used to make impermeable graphite used in heat exchanger tubes and tube
sheets. The drawback to resin impregnation is that the chemical resistance and temperature resistance of
the C/C part are now limited to those of the resin. For example, phenolic resins can be used in HC1
service, but not in HF service. The most promising application for impermeable C/C made using resin
impregnation is in the manufacture of heat exchanger tubes and tube sheets. These techniques are
currently in their infancy as applied to C/C composites; substantial development work needs to be done.

There may be other methods of making C/C composites impermeable. For example, graphite has
been impregnated with fluoropolymer resins. The process for doing so is time consuming and
expensive. The ideal development would be that of using a carbon-based material to impart
impermeability to C/C. This would preserve the best features of using a carbon product, the chemical
resistance and temperature resistance. Here too, substantial development work is needed.

Designing Components with C/C

Designing internals with composites is somewhat different than designing with metal. Design
usually begins with examination, then modification, of existing drawings for the component. In order to
ensure proper design of the composite part, its function along with the chemical and physical
environment and joining requirements of C/C to existing components must be considered to ensure
proper design of the composite part. Critical dimensions and functions of the component are usually not
modified. Non-critical design features and dimensions are often changed to accommodate the change
from a metal to C/C

Case Studies: Examples of the Use of C/C Composites in the Chemical Process Industry

Case 1: Spray Nozzle. A major chemical company had corrosion problems with a spray nozzle.
The nozzle was used at 3t6 ° C in a process stream containing HC1, C12, and trace amounts of
organochlorine compounds. Metal nozzles corroded quickly, requiring frequent replacement. The
nozzle was then constructed from graphite, which offered excellent resistance to the chemicals in the
stream.. Attempts to clean the graphite nozzle during maintenance inevitably led to damage requiring
replacement. Because of its combination of chemical inertness and mechanical strength, a C/C nozzle

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 was chosen to replace the graphite. The C/C product has been in service for over a year with no damage
during maintenance, resulting in substantial savings.

Case 2: Column Liner. A chemical company used a fluoropolymer liner in a 457 mm distillation
column in HF recycle service. The column was operated under vacuum, and service temperatures
approached levels that caused sagging of the liner requiring frequent maintenance. A 25 mm graphite
cylinder offered adequate performance as a support member for the liner. A C/C liner fabricated at a
thickness of 5 mm offered strength superior to that of graphite. In addition, the use of the thinner C/C
liner effectively increased column capacity by 2.2 mm, or 8.8%. The liner has been in service for over
two years with no maintenance problems.

Case 3: Thermowell Sheath. A major chemical company used nickel alloy thermocouples to
monitor temperatures in a process byproduct stream containing HC1 and C12. The high flow rate of the
process stream resulted in erosion corrosion of the expensive thermocouples. A C/C tube, 406 mm long
with a 25 mm inner diameter, was constructed. The tube was plugged at the end with a circular C/C
piece. The good thermal conductivity characteristics of C/C allowed the temperature to be monitored
accurately. In essence, the C/C tube acted as an erosion shield for the thermocouple. The part has been
in service for over a year.

Case 4: Thermal Oxidizer Quench Zone. A supplier of fluorinated products uses a thermal oxidizer
to treat waste streams from their manufacturing process. A byproduct from the oxidizer system is a
concentrated blend of aqueous HF and HC1 acid. This acid is produced by quenching the hot
combustion gases, and absorbing the hydrogen halides in a multi-stage concentrator. Originally, the
quench zone was constructed of a high nickel alloy. While the alloy itself offered good resistance to the
corrosive blend, the welds used to manufacture the cylindrical quench zone were adversely affected.
This required extensive maintenance to repair the welds, resulting in excessive unit downtime.

To increase on-line availability of the oxidizer and acid recovery system, alternative materials for the
quench zone were investigated. A revised quench zone using C/C to replace the alloy was designed by
The T-Thermal Company, Blue Bell, PA. Due to limitations in C/C component size based on furnace
capacity, the part was made in two pieces. It was joined at the midpoint by a pinned lap joint.
Additional fabric build-up was required at the joint in order to improve its strength. Because C/C is not
affected by either of the chemicals in the process stream, no corrosion problems were expected. In
addition, plant operations can increase the concentration of both acids in the recovered byproduct, which
could result in improved unit efficiency. The C/C quench zone was placed in service in September,
2000 with no problems reported to date.

CONCLUSIONS

Graphite continues to be widely used in the CPI as a solution to materials issues in corrosive
environments. Ongoing improvements in the mechanical properties of graphite combined with its
excellent corrosion resistance should ensure that the material continues to be widely used in the future.

Carbon/Carbon composites offer several advantages over other materials of construction in the
manufacture of column and reactor components for corrosive environments in the chemical industry.
Their excellent strength combined with their ability to withstand the most corrosive of chemical blends
have led to the successful introduction of C/C into the industry. More work needs to be done, especially
on developing impervious C/C. This could lead to much larger inroads into the markets for corrosion
resistant components in the CPI.

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 TABLE 1
CHEMICAL ENVIRONMENTS SUITABLE FOR IMPREGNATED GRAPHITE AND
CARBON/CARBON COMPOSITES

N()R(;%NI( ~(III.:MI(".II,N ()R(; % H I ( ('III.:MI('AI,~'

Acids Carboxylic Acids
Arsenic acid Acetic acid
Boric acid Acrylic acid
Hydrobromic acid Benzoic acid
Hydrochloric acid Butyric acid
Hydrofluoboric acid Caprylic acid
Hydrofluosilicic acid Chloroacetic acids
Perchloric acid Citric acid
Phosphoric acid Dichloropropionic acid
Sulfuric acid Formic acid
Sullhrous acid Lactic acid
Aqueous Salts Linoleic acid
Acetates Maleic acid
Chlorides Oleic acid
Fluorides Stearic acid
Nitrates Trifluoroacetic acid
Nitrites Halogenated Hydrocarbons
Sullhtes Allyl chloride
Sulfites Carbon tetrachloride
Miscellaneous Substances Chlorobenzene
Ammonia Chloroform
Carbon disulfide Dichlorobenzene
Hydrogen bromide, gas Ethyl chloride
Hydrogen chloride, gas Methylene chloride
Hydrogen sulfide Vinyl chloride
Phosgene Hydrocarbons
Thionyl chloride Gasoline
Hexane
Kerosene
Mineral oil
Miscellaneous Chemicals
Acetic anhydride
Aniline
Benzene
Butyl acrylate
Cyanuric chloride
Diethyl ether
Ethanolamines
Formaldehyde
Methanol
Nitrotoluene
Phenol
Vinyl acetate

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 TABLE 2
COMPARATIVE PHYSICAL PROPERTIES OF CARBON/CARBON COMPOSITES, GRAPHITE,
AND METALS

Melting point. 1427 640 1678 1850 3662 3652

°C
Tensile strength, 552 179 345 552 9 276
Gpa
Tensile modulus, 207 69 110 97 8 90
Gpa
Compressive . . . . . . . . 303 794 90 207
strength, M P a
Coefficient of
thermal 10 x 10.6 13 x 10-6 6 X 1 0 "6 6 x 10"6 3 X 10 -6 [ X 10 -6
expansion,
cm/cm/°C
Thermal
conductivity, 17 120 17 20 70 34
W/m.k

TABLE 3
CHEMICAL RESISTANCE OF CARBON/CARBON COMPOSITES

Hydrochloric acid, 35% 1 O0 ° C 30 -0.01 (gain) 37,000

Hydrofluoric acid, 35% 90 ° C 30 0 38,000
Sulfuric acid, 70% Boiling 30 0 38,000
Phosphoric acid, 50% 100 ° C 30 0 34,000
Sodium hydroxide. 70% 100 ° C 30 -0.01 (gain) 36,000
Ferric chloride, 50% Boiling 30 0 35.000
Aqua regia 95 ° C 10 0 38.000
Control samples (no 37.000
exposure)

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 TABLE 4
LONG TERM CHEMICAL EXPOSURE OF CARBON/CARBON COMPOSITES

Acetic acid 140 730 (2 years) Coupons tested in pilot

Halides Trace plant acetic acid reactor.
No visible changes seen.

HBr 2O 127 240 Coupon test under lab

Br2 2 conditions. No change
in tensile strength or
visible corrosion noted.
Some discoloration of
coupons seen.
Organobromine 50 54 240 Coupon test under lab
compounds 50 conditions. No change
Ethanol in tensile strength or
visible corrosion noted.
HF 20 100 730 (2 years) Column liner in HF
H2S04 10 recycle column to
support fluoropolymer
lining.
HF I0 75 42 Laboratory galvanostatic
HCI I0 coupling test. No
coupling seen with
Hastelloy

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