Presentation FFFT
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This document provides information about Plasticon Composites International Contracting B.V., a company that produces fiberglass tanks and other products. Some key details: - Plasticon has over 700 employees across 16 production facilities in 13 countries, with an annual production capacity of around 1.5 million hours and installation project capacity of 200,000 hours. - Fiberglass products offer benefits like low maintenance, corrosion resistance, chemical resistance, and lifespan of up to 50 years. - Plasticon produces a range of products including storage tanks up to 30 meters in diameter, silos, process equipment, piping systems, and more for industries like power, mining, and chemicals. -
Presentation FFFT
- 1. Plasticon Composites International Contracting B.V. Field Fabricated Fiberglass Tanks The ultimate solution for your storage of chemicals
- 2. • Headquarter in NL, founded in 1952. • Worldwide presence, production facilities and sales all over the world. • More than 700 employees in 16 Production Locations with approx. 80.000 m² size in 13 countries. • Approx. 1.500.000 hours production capacity per year. • Capability of 200.000 h/a to do Installation projects. • 15 stationary and 5 onsite winding machines. Introduction
- 3. Characteristics of FRP • Little to no maintenance is required • A long product life span, up to 50 years • High-performance insulation • Abrasion and corrosion resistant • Lightweight (1.8 g/cm3) • High Chemical Resistance • Delivery time • GRP replaces expensive alloys like Hastelloy, Super Duplex, Ni, as well as steel rubber lined components. • Able to work with temperature limits of approximately – 50°C to 125°C
- 4. Fire retardance • Fire retardant resins are tested according the ASTM E 84 (Steiner tunnel test) and have class 1 flame rating of 25 or less. • Normal FRP is classified as : DIN 4102 B2 and ASTM E84 class 2 • Bigger wall thickness and 9 x higher heat transfer factor means that the liquid will not heat up as fast in a steel tank and it will take much more time that the liquid will start to boil. Boiling liquid is a major problem during an inferno. • Because of the thicker wall and higher safety factor (7-10 in case of FRP and 1,5 -2 to steel) a FRP tank will stay longer. • The mechanical properties of steel reduces fast above the 260 °C. ( SS -40% at 260 °C). The tank will have a uncontrolled collapse.
- 5. What to store Fiberglass Components are corrosion and chemical resistant, so that you can store different types of (aggressive) fluids such as: - Hydrochloric Acid - Sulphur Acid - Phosphoric Acid - Acid solutions - Other Acids - Caustic Solutions - Brines - Salt solutions - Chlorides - Caustic Liquides - Flue gases - Lime slurry - Fuels - Fertilizers - Starch solutions - Vegetable oils - Water
- 6. SERVICES • Design • Engineering • Production • Field fabrication & installation • Installation • Maintenance • Repair 6
- 7. Generally • Storage tanks • Diameter 0 – 6 m Shop fabricated • Diameter 6 – 21 m Produced onsite with our onsite winding equipment. Under certain conditions we are able to wind up to 30 m in diameter. • Silo’s • Process Apparatus & Equipment • Piping Systems / Pipelines • Specialty products PRODUCTS 7
- 8. Power industry • Chimney Liner • Ducts • Chimneys • Spray headers • Tanks • Recirculation pipes • Process piping • Cooling water pipes PRODUCTS 8
- 9. Field fabrication The field fabrication of large diameter fiberglass components, consist of a few simple steps: 1. Design and Engineering completely executed by Plasticon’s experienced designers 2. Shipment of equipment and raw materials to site, in only a few containers 3. Quick setup of the winding and site facilities 4. Winding of the tank shells with Plasticon’s state-of-the-art proprietary winding equipment 5. Assembly and installation of the tanks by Plasticon’s experienced and trained field crew 6. Quality inspection & testing 7. Demobilization of the site facilities
- 10. Innovation Variable mould Step-less variation of mould diameter - 1 mould for 4 – 7,5 m - 1 mould for 7 – 12,5 m - 1 mould for 12 – 21 m Mould diameter can be changed within a day No (new) mould investment for each product Economical advantage for projects that require a wide variety of (large diameter) products i.e. tanks
- 11. Production
- 12. GRP Absorber & Tanks 4.500 m3 atmospheric Tank Carbon steel SS 304 GRP Carbon steel Rubber lined SS 316 Corrosion resistance Poor Adequate Excellent Inside: Excellent Outside: Poor Excellent Maintenance High demand Periodic Close to nothing Lining: High demand, Periodic Aging Undistinguished Good Good No peeling Approx. all 15 years 100% replacement of lining Close to nothing Welding points Strong corrosion on seams Corrosion on seams No corrosion Strong corrosion on seams Slight corrosion on seams Construction time 4 – 6 month 5 – 7 month 4 – 6 month 6 – 8 month 5 – 7 month Lifetime without serious maintenance 5 years 30 years Up to 50 years 15 years Up to 50 years Appr. cost ratio 100 % 140 % 150 % 200 % 180 %
- 13. GRP Absorber & Tanks - The price for installed GRP products does not vary as extreme as for steel and stainless steel. The price is usually subjected to the normal inflation only. - Caused by the shorter construction time the EPC is saving money for overhead. - Longer lifetime and less maintenance cost may be a sales argument towards the end user.
- 14. References • Alstom Power – ESKOM Kusile Power Plant (South Africa) • 6 x duct with D=8.9m, L=250 m
- 15. REFERENCES CS Mining / USA – 3 x D = 7.450 mm x H = 9.000 mm • Vinyl ester resin in structural laminate (Derakane 411-350 or a equivalent • SIC, anti-abrasive additive in CBL (20%) – 4 x Settler 7.000 mm x 13.500 x H = 1.200 – 4 X Half-dome roofs for settler tanks 7.000 mm x 13.500
- 16. REFERENCES Plasticon Composites has successfully finished all 3 contracts with CS mining, despite a demanding schedule and navigated through diverse project impediments. 1. Leach Tanks Three cylindrical tanks have been wound on site, assembled with prefabricated bottom panels and built up by Plasticon in early October. All internal fixtures and apparatus were installed in a timely manner. Later, preceding commissioning in the middle of December, the tanks were subjected to hydro-testing. 2. Settler Tanks Simultaneously works were progressing on rectangular SX Settlers. All four tubs constructed from the very scratch using flat FRP panels produced by a local US vendor. All tanks were equipped by Plasticon with different accessories and applications designated for guiding and controlling the flow. Plasticon determined several internal details to optimize working procedures. The final installation inside all four tanks proceeded parallel, and thanks to crafty automatization of selected operations, time deadlines set at the end of october could be met. 3. Half-dome roofs for settler tanks Recognizing Plasticon's professional conduct, CS Mining in the meantime have pondered awarding us with a contract extension. Using capacity of Winding Machine, Plasticon was requested to wind, fabricate and install half-dome roofs on all four rectangular tanks. After receiving additional materials and initiating contract formally, production proceeded swiftly without major hindrances. In different configurations a complete shell has been wound for each settler tank, to enable accurate tracing and trimming into three separate roof segments. Four cans have been wound in total, with twelve roof modules individually tailored. The finalization on roofs has been fulfilled one week before the deadline on December, the 5th. The project has been completed. The site structures are already demobilized.
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- 20. References S.E.S. in Wormer, NL – 12 x D = 9.100 mm x H = 10.000 mm; 600 m3 – Liquid oils and Fats – Design temp. 90 °C – Insulated – Heating Coils inside – Won against SS
- 21. - Client: Daelim Industrial Co., Ltd / Sahara Petrochemical Company - Location: Saudi Arabia - Project: CA/EDC plant construction - 245 KTA caustic/300 KTA EDC - Based on Uhde technology and specs - Scope: All Piping and fittings Tanks and apparatus (36 items) Design and Engineering (stress) Installation supervision On-site welding, lamination Spool building - Materials: PP/PVC/PVDF/GRP - Budget: 10 M€ Arabian Chlor Vinyl Project References
- 22. Solvay - IKRA Project - Client: Technip / Rusvinyl - Location: Nizhny Novgorod - Project: PVC plant (Based on Solvay technology and specs) - Scope: All piping and fittings All tanks and apparatus Complete installation scope (with local partner) Design and Engineering (stress) Pipe supports Spool building - Materials: PP/PVC/PVDF/GRP - Budget: 13 M€ References
- 23. References • Babcock-Noell – Turow (PL) • 3x chimney liner and ducts with D = 5.3 m, L = appr. 700 m
- 24. Power Plant Neurath BoA 2/3 References Clean gas duct Absorber to cooling tower (2 lines) - Diameter 10,0 m / Length 150m + 30m Elbow - Turnkey incl. Engineering, Prefabrication, Transport, Lifting, Installation, Supervision and Quality control. - Horizontal on site winding machine. - Project scope M€ 20
- 25. Innovations (in progress) Leak Monitoring System (LMS) • In testing phase at 3 customers • Including remote diagnostics in CCR or on computer • Planned maintenance stop instead of unplanned • Can replace traditional independent safety back-ups like concrete containment and/or double wall systems