su r fa c e P r o t e ct i on

Corrosion Protection –
Optimum Solutions for Every Project

www.kch-group.com
 KCH – Your Partner for Industrial Surface Protection
Systems Worldwide

The KCH Company Group has

been specializing in industrial
surface and corrosion protection
systems for 140 years now. Its
operations span the globe. With its
long-standing experience and vast
know-how to draw on, KCH
supplies optimum high-quality
products to cater for virtually all
corrosion protection applications.

KCH’s excellent international

reputation is based on numerous
factors. Not least of these is the
high level of skill and professional-
ism among our workforce, many of
them employees with long service
records. Aided by regular training
programs and direct contacts with
our customers in an advisory role,
our workforce is growing ever more
skilled in solving technical problems
Production
and Sales
Sales Office
while upholding quality standards. production know-how and long-
Intense research and development standing installation experience to
work combine with a high level of complete the picture.

B USINESS A REAS

S URFACE P ROTECTION C OMPOSITES

The product portfolio of KCH
Surface Protection includes rubber
linings and coatings, brick linings
and tiling systems for industrial
surface protection and anti-corrosion
systems. A high level of develop-
ment and production skills combines
with many years‘ installation
experience and close customer
contact to make our range of
products and services so unique.
Needless to say, this range also
includes advice in the planning and
design of anti-corrosion and surface
protection systems, as well as the
proper processing and installation
of our materials and products.
The product portfolio of KCH
Surface Protection includes piping
systems, tanks and process equip-
ment exposed to high chemical,
thermal and mechanical stresses.
These items are manufactured either
from fiber glass-reinforced plastics
with or without an inner liner, or
from fiber-reinforced phenolic resin
materials to ensure reliable and
long-lasting resistance to chemicals.
Besides offering a high level of
materials and production expertise
to its globally active customers,
KCH Composites also provides
comprehensive services such as indi-
vidual advice and planning, as well
as the installation and repair of
these high-tech items, on request.

2

ABOVE: SULFURIC ACID PLANT AT CODELCO/
SALVADOR (LURGI). BELOW: SECONDARY
CONTAINMENT COATING.
Wide-Ranging Applications
for Our Materials
Components in chemical processing
plants are exposed to a wide variety
of stresses, in particular chemical,
thermal and mechanical loads. To
ensure proper performance over the
long term, tanks, process equipment
and other plant components there-
fore need to be given reliable and
long-lasting protection.
KCH supplies an extensive range of
corrosion-resistant materials for the
purpose.
R UBBER L ININGS
Rubber linings are used for protect-
ing highly stressed steel structures
and concrete components exposed
to corrosive stresses. The hard or
soft rubber linings supplied are
based on natural or synthetic
rubbers and installed either in our
workshop autoclave or as on-site
lining at the customer’s premises.
P OLYMER C OATINGS
KCH’s polymer products are ideal
materials for protecting structures
and building components under
high chemical and thermal stress.
Various floor coatings, tank coat-
ings, mortars and specialty materi-
als have given excellent service in
their respective applications.
B RICK L ININGS AND T ILING
S YSTEMS
The main purpose of brick linings
and tiling systems is to protect the
underlying membrane against
mechanical damage and to greatly
enhance the chemical resistance of
the entire corrosion protection
system. We offer acid-proof bricks
and tiles for almost any application.
3
 Our Rubber Material

S PECIAL A DVANTAGES
In industry, in environmental
protection and in other areas,
rubber lining materials are highly
beneficial. This is because these
materials offer particular advan-
tages:

• General corrosion resistance –

the material is almost completely
insensitive to variations in concen-
trations. With all-metal construc-
tions, these variations can lead to
serious damage.
• High resistance to mechanical
stress afforded by the steel base –
pressure vessel designs in accor-
dance with all recognized stan-
dards are possible. The use of
all-plastic construction is restricted
by the mechanical properties in
the case of vessels above medium
size.
• For special applications, KCH
rubber linings are also available
with various official approvals
(e.g. WHG, KTW, FDA).

Rubber linings from KCH can be

installed either in our workshops
(shop lining) or directly on site
(on-site lining). A crucial factor is the
size of the item to be protected.
On-site rubber linings can be used
for high-quality corrosion protection
even on large, immobile steel or
concrete structures.

H ARD AND S OFT R UBBER

L ININGS O UR P RODUCT P ORTFOLIO ABOVE: RUBBER-LINED STORAGE TANK.
BELOW: RUBBER-LINED REACTOR.
The hard or soft rubber linings ®
GENAKOR ABOVE RIGHT: DEMISTER IN A COATED
supplied are based on natural or ®
VULCOFERRAN SCRUBBER HEAD.
synthetic rubbers. The linings are ®
VULKODURIT
manufactured in KCH’s own ®
KERABUTYL
workshops and installed in a ®
KERAPREN
vulcanized or unvulcanized state. ®
KERAPALON
®
KERAFLON
HAWOLINING PVDF (double-layer
rubber/PVDF lining material)

4
 Our Polymer Products

Polymer coating systems are
manufactured by KCH in a large
variety of products. They differ in
the type of base resin, filler and
reinforcement, as well as the
application method. These systems
are ideal for steel and concrete
tanks and equipment.
For special applications, KCH
coating systems are also available
with various official approvals (e.g.
WHG, KTW, FDA).
Depending on the application
method used, a distinction can be
made between the following tank,
vessel and floor coatings:
• Spray-applied/brush-applied
coatings
• Trowel-applied coatings
The range of base resins includes Depending on the type of chemicals
epoxy resin, vinyl ester, novolak involved, KCH employs various
vinyl ester, polyester, epoxy novolac polymer and sodium silicate mortars.
and hybrid novolac.
Chemical-resistant mortars produce O UR P RODUCT P ORTFOLIO :
the horizontal and cross joints in ®
KERAFLAKE
vessel linings composed of a ®
KERAPLAN
membrane layer with a tile or brick ®
KERANOL
covering. They thus provide the ®
KORROPLAST
connection between the semi- ®
KERACID
finished ceramic products and ®
KERAKRET
membrane, and also between the ®
KERAPOX
individual ceramic tiles and bricks.
Wall/pedestal coating with coved profile and connecting Transition zone between wall and coating
substrate
20
Wall finish, available on site

• Laminate coatings
Plaster
• Self-leveling coatings Coating
• Broadcast coatings

minimum 100
Coved profile
Concrete (e.g. Schlüter-DILEX-HKW) Polymer mortar
• Screeds and leveling layers Coating Coating
• Laying and jointing mortar R
35

Their benefits include:

• High chemical resistance Concrete Concrete

• High compressive strength

• High thermal stability
• Large color range
• Short installation times Expansion joint coating in vehical traffic area
Separating sheet PE O-ring seal
• Electrical discharge capability
Soft rubber Permanently elastic jointing mortar

Coating Acid-proof tiles laid in polymer mortar

Concrete Concrete

115 (240) 115 (240)

approx. 125 (250) approx. 125 (250)

5

Acid-Proof Bricks and Tiles
The main purpose of brick linings is
to protect the underlying membrane
– a rubber lining or polymer coating
– against thermal and mechanical
stresses in chemically stressed
vessels, process equipment, piping,
ducts and pits. Brick linings also
increase the chemical resistance
and durability of the corrosion
protection system, as they prevent
direct contact between the aggres-
sive media and the membrane. For
6
good results, the materials used must
be of optimum quality.
MATCHING YOUR NEEDS
Membrane layers, mortars and
bricks are used in all manner of
combinations, depending on the
mechanical, thermal and chemical
stresses involved. The aim is to
provide a durable and hence
cost-effective solution. Whatever
your requirements: By teaming up
Rubber lining or Jointing/
polymer coating laying material
Acid-proof brick Equipment
with KCH you’ll be working
alongside experts right from the time
you select suitable materials.
WELL-ESTABLISHED QUALITY
KCH offers customized solutions
with a long-standing record of excel-
lent performance:
• Chemical resistance, e.g.
against acids, alkalis, solvents
and oxidizing media
• Mechanical load-bearing
capacity
• Thermal stability
The high quality of KCH products is
guaranteed by the company’s own
materials development work on
mortars, and also by controlled
manufacture and careful processing,
either by its skilled workforce or by
installation partners under KCH
supervision.
O UR P RODUCT P ORTFOLIO
• Ceramic bricks
• Carbon bricks
• Graphite bricks
• Fused basalt and granite bricks
• Polymer-based laying and jointing
mortars
• Membrane layers based on
polymers or made of rubber
ABOVE: STRUCTURAL SKETCH OF A TANK BRICK
LINING. LEFT: QUENCHER WITH MULTILAYER
LINING. ABOVE RIGHT: COATING OF A FLUE GAS
DUCT IN A FLUE GAS DESULFURIZATION PLANT.
 Power Industry/Flue Gas
Desulfurization Plants

An acid gas typically produced in
coal-fired power stations during
combustion is sulfur dioxide, which
may react with water to form sulfuric
acid. Depending on the coal’s sulfur
content and the size of the power
station, an annual amount of up to
120,000 tons of this gas is released
into the atmosphere, where it causes
acid rain. Statutory regulations have
therefore been adopted in many
countries of the world to stipulate
the removal of sulfur dioxide from
power station exhaust gases. Most
desulfurization processes used for
this purpose employ limestone and
lime milk or sea water. All power
station components coming into
contact with the sulfurous exhaust
gases during these processes need
to be reliably protected against
corrosion. Such components are the
raw gas ducts with bypass, the
clean gas ducts, the stack and
heat exchanger, as well as the
scrubbing tower with all internals.
The corrosion-resistant materials
specified are rubber linings with
vulcanized or unvulcanized rubber
sheeting for manual installation,
and also brick linings and polymer-
based coatings.

O UR P RODUCT P ORTFOLIO
• Shop and on-site rubber linings
• Polymer coatings (spray-/trowel-applied systems, laminate systems)
• Acid-proof ceramic brick linings

P LANT S ECTION R UBBER L INING C OATING B RICK L INING

Raw gas duct, hot (X)
Raw gas duct, cold X
Raw gas inlet X X
Flue gas scrubber X X (X)
Raw gas duct, upstream of scrubber (X) X
Clean gas duct, downstream of scrubber X
Heat exchanger X
Stack X (X)
Other tanks and equipment items
(emergency storage tanks, gypsum
and slurry tanks, etc.) X X
Piping systems X

EXPERIENCE WITH FGD PLANTS Clean gas Clean gas fan

For more than 30 years now, KCH
has successfully used rubber linings Stack Heat
in flue gas desulfurization (FGD) ex-
changer
plants. Over this period, the
Demister
company has installed more than
Bypass Slurry
1,000,000 m2 of on-site rubber
Absorber Limestone
linings. Flake coatings have been
in use since 1980. Limestone slurry
Boiler Raw gas production and
gypsum processing

Gypsum

7
 Sulfuric Acid Plants/Phosphoric Acid Plants

High sulfuric acid concentrations

Prepared
and the production processes phosphate H3PO4 process
involved in such plants demand rock Digestion equipment 2) 3)4)5)
hardwearing protection against tanks 3) 5) H3PO4
storage Transport 3)
corrosion. This means that ad- tanks 3) 4)5)
equately resistant materials need to
be used in these plants. Drying and
absorption towers, venturi scrubbers
and acid storage tanks in steel are
H2SO4 Sulfuric Sulfur Mineral pyrite
lined with a membrane layer in
storage acid burning1)
rubber sheeting or thermoplastic tanks 3) 4) plant 2) O2
polymers. To protect this layer from
thermal or mechanical stresses and
direct attack by acid, a brick lining
is installed on top, often several 1) Refractory lining
layers thick. The bricks are made 2) Acid-proof brick lining and tiling
from ceramics, carbon, graphite, 3) Rubber lining
silicon oxide, insulating ceramics or 4) Coating and flooring
foam glass. They are embedded in 5) Carbon brick lining
laying and jointing mortars based
on sodium silicate and/or special
polymers.

For the packed towers in sulfuric Spray header

acid production plants, self-support-
ing domed grids have been specially
developed in diameters of up
to 10,000 millimeters. Their key
advantage is that they do not require Membrane layer
Packing
2" Acid-proof bricks
any supporting structure and
therefore considerably reduce the
Cross-partition rings
manufacturing and assembly costs
involved. In addition, the specially Packing
shaped bricks with the cross-parti- 3"
Self-supporting
tion rings placed on top ensure free
domed grid
gas flow through the packed
SO2/SO3 gas
section, i.e. at least 55 percent. (T=200°C)
This ensures that the packed scrubber
has a high efficiency level.
A

H2SO4
94-98%
T=60°C Acid-proof
brick lining

Laying mortar: KERANOL WG311

LEFT: H2SO4 ABSORPTION TOWER.

ABOVE RIGHT: AGITATOR IN A PAPER MILL.
BELOW RIGHT: PICKLING TANK.

8
Other
Application
Fields

STEEL- AND METAL-WORKING
INDUSTRY/PICKLING TANKS
Steel sheets are treated by special
pickling processes before being
electroplated and supplied to the
customer. The corrosion-resistant
materials employed in these
processes depend on the type of
steel to be treated. As a rule,
synthetic rubber linings are used in
combination with a hard-wearing
ceramic or carbon brick lining
embedded in polymer mortar.
The acids used in the pickling
processes gradually degrade and
therefore need to be regenerated.
Regeneration takes place in a system
located downstream of the pickling
tank. Some process sections like the
venturi scrubber and storage tank
are given rubber and brick linings
as well.
PULP AND PAPER INDUSTRY
The ground wood used as a basis
for pulp and paper manufacture is
treated with chemicals in digesters
operated at elevated pressure
and temperature. KCH supplies the
required ceramic and carbon tiles
for embedding in chemically resistant
polymer mortar.
Cellular pulp still contains substanc-
es that need to be treated by
subsequent bleaching. This process
employs various chemicals such as
chlorine, chlorine dioxide, hypochlo-
ride, hydrogen and oxygen. To
protect the components involved in
the process, KCH offers a system
consisting of a vinyl ester resin
laminate combined with ceramic
tiles embedded in polymer mortars.
ORE PROCESSING/STEEL PRO-
DUCTION
Iron ore is melted in blast furnaces to
produce crude steel. The corrosive
and toxic gas constituents produced
in this process are removed in a
scrubbing process. KCH offers well-
tried vinyl ester resin systems and
ceramic brick linings with corrosion-
resistant polymer mortars to protect
the scrubber from corrosion.
Ores containing copper, gold, nickel
or other metals are obtained by
mining. Acids are added to the
rocks, and heat and pressure are
applied in order to extract the
metals from the slurry. The relevant
process tanks are given corrosion-
resistant rubber and brick linings.
The rubber lining both acts as a
membrane layer and affords
hard-wearing protection in certain
process sections. Process sections
exposed to high temperatures are
given a brick lining in addition.

Protective Roller slider

granite ribs in polyester concrete

"A"

Layer build-up:
- Steel
- Rubber lining
- 2 layers of standard bricks
laid in polymer mortar
Partition wall
Stub end build-up:
in acid-proof standard bricks
- Steel
laid in polymer mortar
- Rubber lining
- 1 layer of acid-proof tiles
Detail "A" laid in polymer mortar

9
 Typical Applications

LEFT: PICKLING VAT. RIGHT: ABSORBER WITH

CERAMIC BRICK-LINED FLOOR.

S TATIONARY T ANKS AND P ROCESS E QUIPMENT

Industries Application fields Typical corrosion protection materials
Chemical industry Reactor (phosphoric acid) ®
KERABUTYL V 1) Carbon bricks in ®KERANOL FU 320 4)
H2SO4 storage tank ®
KERABUTYL BS 1) Acid-proof bricks in ®KERANOL WG 311 4)

H3PO4 storage tank ®

KERABUTYL BS 1) Carbon bricks in ®KERANOL FU 320 4)
Pigment reactor ®
GENAKOR 022 1)
HCl storage tank ®
KERABUTYL VC 1)
Wastewater treatment basin ®
KERACID ES 110 3) Acid-proof tiles in ®KERANOL FU 310 4)

Power industry Raw gas duct, hot ®

KORROPLAST VE 310 2)

Raw gas duct, cold ®

KORROPLAST VE 310 2)
Absorber, inlet ®
KORROPLAST VE 310 2) Acid-proof bricks in ®KERANOL FU 310 4)

Absorber ®
VULCOFERRAN 2206 1)
Clean gas duct ®
KERAFLAKE 6R 2)
Stack ®
KORROPLAST VE 310 2)
Slurry tank ®
KERABUTYL BS 1)
Venturi, inlet ®
KORROPLAST VE 510 2) Acid-proof bricks in ®KERANOL WG 3114)
Venturi, spray jets ®
KERAFLAKE 6H 2) Acid-proof bricks in ®KERANOL FU 310 4)
Demister ®
KORROPLAST VE 310 2)
Metal-working HCl pickling tank ®
KERABUTYL VC 1) Acid-proof bricks in ®KERANOL FU 310 4)

industry H2SO4 pickling tank ®

KERABUTYL V 1) Acid-proof bricks in ®KERANOL FU 310 4)

Stainless steel pickling tank ®

KERABUTYL WBC 1)
Carbon bricks in ®KERANOL UP 320 4)
Metal ore Agitator ®
KERABUTYL BB-S 1) Acid-proof bricks in ®KERANOL FU 320 4)

processing Thickener ®
KERABUTYL BS 1) Acid-proof tiles in ®KERANOL FU 310 4)
Reactor ®
VULCOFERRAN 2208 1)
Acid-proof bricks in ®KERANOL FU 320 4)

Pulp and paper Bleaching tower ®

KORROPLAST VE 510 2)
Acid-proof tiles in KERANOL VE 310
® 4)

industry

1) Rubber lining 2) Tank coating 3) Floor coating 4) Mortar

10
 Our Complete Range of Products and Services

ENGINEERING AND SUPERVISION
Once our KCH experts have teamed
up with you to determine the operat-
ing conditions – in particular the
chemical, mechanical and thermal
stresses – and also the geometry of
the components, the best material is
chosen for the job in hand. You stand
to benefit not only from KCH’s wide
range of materials but also from the
company’s development work in the
field of products and processes.
After the best material has been
selected, the product is manufac-
tured as specified and then installed
at the customer’s site on the date
agreed. In doing so, KCH sets great
value on quality and reliability.
If our products are installed by your
own personnel, our specialists can
be made available on request to
supervise proper on-site installation
in good time.
G ENERAL C ONTRACTING
For decades now, KCH has been
working to develop new and
ever more cost-effective technical
solutions. Our aim has always been
to offer you the optimum right
across the board – not just optimum
materials, but also optimum process-
ing and testing of our products. This
is because KCH supplies everything
you need from a single source –
from initial technical advice to quality
assurance of the final product.

C OMPANY C ERTIFICATES

DIN EN ISO Certificate meeting DIN EN ISO 9001:2000

9001
Proof of implementation and maintenance of a Quality Management System for
the development, sale and production of corrosion-resistant linings and coatings,
as well as systems, process equipment and components for the chemical industry,
industrial corrosion protection and environmenal protection

SCC** Certificate on the implementation of a Safety Management System in conformity

with the guiding principles SCC**: 2002 (general certification). The certificate is
valid for: Floorings, transportation, processing and services & installation

KTA 1401 Proof of qualification for the system- and product-related Quality Assurance for
Rule
the planning, manufacture, installation and servicing of process equipment,
pipes and fittings with corrosion-resistant linings, coatings, rubber linings, acid-
VGB Working Group of proof linings and/or tiling systems for nuclear plants
Nuclear Power Station
Operators
WHG Certificate meeting German Water Resources Act (WHG) § 19 I
Proof of acceptance as specialists according to § 19 I WHG for the following
activities: Coatings and rubber linings for vessels, piping, containments, sealing
faces, as well as the installation, maintenance and reconditioning of vessels
and piping made of thermoplastics and thermosets

11
 Locations of Surface Protection
KCH Company Group
KCH Industrial Surface Protection GmbH
Berggarten 1
56427 Siershahn / Germany
Phone: +49 2623 600-900
Fax: +49 2623 600-960
surface-protection@kch-group.com
For further information on industrial
corrosion protection, please contact:
Contact:
Composites
KCH Composites GmbH
Berggarten 1
56427 Siershahn / Germany
Phone: +49 2623 600-600
Fax: +49 2623 600-660
composites@kch-group.com
© KCH Group GmbH, Siershahn, 2008
® registered trademarks of KCH Group companies
The data contained herein represent the current state of our
product knowledge and are intended to provide general informa-
tion on our products and their application spectra. In view of
the variety and large number of application possibilities, these
data should be regarded merely as general information that gives
no guarantee of any specific properties and/or suitability of
those products for any particular application. Consequently, when
ordering a product, please contact us for specific information on
the properties required for the application concerned. On request,
our technical service will supply a profile of characteristics for
your specific application requirements without delay.
SP 900-02/2008e Printed in Germany
www.kch-group.com