Corrosion Management

Challenges and Solutions in Fluoropolymers (PTFE)

Lined Chemical Equipment Corrosion Management
Narendra Thakkar

Abstract
Long term handling of corrosive and hazardous chemicals can expose the equipment to corrosion. To manage
this corrosion, chemical companies use different types of fluoropolymers that can be used at various stages in
a chemical plant. However, it comes with its own set of challenges like limited testing facilities and manufactur-
ing plants and also lack of knowledge. Many companies are now understanding the challenges of fluoropolymers
step-by step and coming up with solutions of their own. The author outlines the various difficulties and solutions
in handling fluoropolymers in this article.

I
ndia has a large chemical industry in Asia Pacific
with a steady growth rate of 7-9% in chemicals,
pharmaceuticals and specialty chemicals with an
overall market size of >US $150 billion making India
6th largest chemical manufacturer in the world.
Larger domestic demand along with growing ex-
port from India would bring a lot of new capital in-
vestment in India which is expected to touch the US
$ 300 billion mark in the next 6-7 years for building
new chemical plants that require a large amount of in- 24 inch PTFE lined piping with 2.8 meter length & elbow for H2SO4
vestment in fixed capital and process equipment (Now handling.
because of COVID crisis, there is some uncertainty on
mm thick) have been used in chemical process equip-
the investments that can take place). Growth comes
ment lining for corrosion management for more than
along with multiple challenges including key raw ma-
50 years. Fluoropolymer linings are used in pipes, fit-
terial availability, new technologies, digitization, safe-
tings, valves, pumps, columns, and tanks, etc. where-
ty concerns, and equipment compatibility to handle
as premature failure leads to increased downtime and
corrosive & hazardous chemicals at an optimized cost.
production losses.
There are multiple solutions to corrosion mitigation
practiced in the chemical industry & every solution Challenges
has its pros and cons. Fluoropolymers like PTFE, PFA, There are a handful of quality fluoropolymers lined
and PVDF, etc. as a barrier lining material (3mm to 12 equipment manufacturers in India and others are

Narendra Thakkar is an engineer with over 19
years of industry experience in polymers, which
includes corrosion management using fluoropoly-
mers. He has worked as sales, business devel-
opment manager for fluoropolymers like PTFE,
PFA, and PVDF etc. in reputed organizations like
Gharda Chemicals, Arkema and DuPont, etc.
>>
Growth comes along with multiple challenges
including key raw material availability, new
technologies, digitization, safety concerns, and
equipment compatibility to handle corrosive & haz-
ardous chemicals at an optimized cost.

Chemical Industry Digest. 2020

 Corrosion Management

catching up. In the last 10 years, the

top key challenges observed in flu-
oropolymers lined process equip-
ments are as follows:
>> Resistotech currently focusing on
complex challenges faced by aggres-
sive chemical handling under full & partial
vacuum systems in industries like paper &
less PTFE liner manufacturing >
400 NB to 2000 NB (16 inches to 80
inches) for heavy process equip-
ments like columns, vessels, scrub-
1) Limited knowledge of the right pulp, specialty chemical, fluorochemicals, bers, etc. which is a proud mo-
selection of raw materials and refineries, pharma API, chloralkali, steel ment for India to become import
consistency. processing, pickling, agrochemical & pes- independent & develop substitutes
ticides manufacturers to find alternative with high-quality fluoropolymers
2) Wrong fluoropolymers grade lined equipment at reasonable cost
solutions to expensive import substitutes
selection without understand- & minimum delivery time.
& exotic metals like titanium, tantalum, and
ing of exposed chemicals & pro-
Hastelloy for selective process equipment’s Expertise in Problem Solving
cess conditions like pressure,
within range of fluoropolymers.
vacuum, temperature, perme- One of the leading compa-
ation performance etc. nies in this field is Resistotech
3) Limited knowledge of manufac- Industries Private Limited, who
turing technologies & many unorganized players. have achieved significant milestones in fluoropoly-
mers lined equipment.
4) Lack of testing facilities as per International Quality
Standards. The company has state of the art manufacturing fa-
cility near Nashik (200 km away from Mumbai) for flu-
5) Manufacturing limitation on larger size fluoropoly-
oropolymers like PTFE, PFA, PVDF processing and lin-
mers lined equipment with limited local option &
ing facility dedicated to offer corrosion protection so-
dependency on imported lined equipment at very
lutions. Such linings have benefits over welded PTFE
heavy cost. For example, large diameter PTFE lined
sheet lining process where delamination could be an
columns > 400 NB (16 inch) under vacuum & high-
area of concern in the longer run.
temperature conditions.
Resistotech has successfully developed India’s larg-
Corrective Steps est diameter seamless extruded PTFE Liner up to 900
Whereas, in the recent past, there multiple efforts NB (36 inch/ 900 mm dia) & 6-meter length after 10
taken by key-value chain players to upgrade overall months of continuous trials and developmental efforts.
quality performance and reliability of fluoropolymers 900 NB PTFE Liner has been lined inside mild steel
lined equipment. Some key corrective actions taken in- tanks for handling corrosive chemicals under partial
clude: vacuum conditions. Currently it is installed and work-
• End-user education and awareness from equip- ing satisfactorily at one of the leading specialty chemi-
ment manufacturers via focused seminars cal manufacturers in India.

• Conferences & exhibitions for global information Many installations with 400 NB (16 inch/ 400 mm
sharing. dia) have also been installed under partial to full vac-
uum conditions at elevated temperature range of 120-
• Active involvement from fluoropolymer materi- 180 Deg.C. The performance of this proprietary tech-
al manufacturers; also engineering process consul- nology has been very sat-
tants have a significant isfactory and the compa-
contribution to the suc- ny is now catering to firm
cessful implementation orders from many reput-
of lined equipment. ed local and international
All the above efforts process equipment man-
have brought a new pos- ufacturers, end-users and
itive drive and helped engineering consultants
equipment manufacturers for larger diameter seam-
to understand the tough less PTFE lined columns,
challenges mentioned vessels, and equipment.
above and brought new They also elaborated that
solutions to include newer there are 30 different pa-
manufacturing technolo- 18 inch dia & 4 meter length: Lined equipment for leading rameters needed to be con-
gies for larger sized seam- Pharma Company trolled for larger diameter

Chemical Industry Digest. 2020

 Corrosion Management

PTFE Liners and 10 of mers lined products

them are most critical in India. Therefore
to get the desired level the company is plan-
of quality performance ning to grow aggres-
as per International sively in future with
Quality Standards like significant investment
ASTM F1545 for PTFE in a new facility for
lined products. Even production, develop-
for bigger sizes like ment and quality con-
1200 NB (1200 mm) to trol for lined equip-
2000 NB (2000mm) dia, ment near Nashik.
this technique can be The company is now
employed. Liners are planning to expand in
also in pipeline of de- the International mar-
velopments which are ket by partnering with
to be used for large- global players in the
sized tanks and col- Middle East & USA to
umn seamless lining. spread their technol-
The company is ogy and expertise for
getting very satisfac- the larger benefit of
tory feedback from the chemical industry
end customers and in corrosion manage-
ment.
eng consultants for ad- 36 inch dia. PTFE lined equipment for corrosive chemical handling.
dressing their specific Resistotech is cur-
appl based needs. Resistotech has thus become one of rently focusing on complex challenges faced in ag-
the preferred partners for the development and sup- gressive chemical handling under full & partial vacu-
ply of complicated & tailor- made quality fluoropoly- um systems in industries like paper & pulp, special-
mers lined products in India. Resistotech mentioned ty chemicals, fluorochemicals, refineries, pharma API,
they are gaining a lot of appreciation from end cus- chloralkali, steel processing, pickling, agrochemical &
tomers & engineering consultants for addressing their pesticides. This is helping manufacturers avoid expen-
specific application-based needs and becoming one of sive imports substitutes & exotic metals like titanium,
the preferred partners for the development and sup- tantalum, and hastelloy.
ply of complicated & tailor-made quality fluoropoly- m

Chemical Industry Digest. 2020