CA1174534A - Corrosion resistant coated articles which include an intermediate coating layer of thermosetting polymer and non-siliceous filler - Google Patents

Corrosion resistant coated articles which include an intermediate coating layer of thermosetting polymer and non-siliceous filler

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Publication number
CA1174534A
CA1174534A CA000378247A CA378247A CA1174534A CA 1174534 A CA1174534 A CA 1174534A CA 000378247 A CA000378247 A CA 000378247A CA 378247 A CA378247 A CA 378247A CA 1174534 A CA1174534 A CA 1174534A
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CA
Canada
Prior art keywords
coating layer
mils
thickness
coated article
admixture
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA000378247A
Other languages
French (fr)
Inventor
William R. Slama
Robert B. Washburn
Dale J. Semanisin
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SPX Corp
Original Assignee
General Signal Corp
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Filing date
Publication date
Application filed by General Signal Corp filed Critical General Signal Corp
Application granted granted Critical
Publication of CA1174534A publication Critical patent/CA1174534A/en
Expired legal-status Critical Current

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16LPIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L58/00Protection of pipes or pipe fittings against corrosion or incrustation
    • F16L58/02Protection of pipes or pipe fittings against corrosion or incrustation by means of internal or external coatings
    • F16L58/04Coatings characterised by the materials used
    • F16L58/10Coatings characterised by the materials used by rubber or plastics
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/14Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/50Multilayers
    • B05D7/56Three layers or more
    • B05D7/58No clear coat specified
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2202/00Metallic substrate
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/08Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain an anti-friction or anti-adhesive surface
    • B05D5/083Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain an anti-friction or anti-adhesive surface involving the use of fluoropolymers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D7/00Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
    • B05D7/22Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to internal surfaces, e.g. of tubes
    • B05D7/222Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to internal surfaces, e.g. of tubes of pipes
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/2495Thickness [relative or absolute]
    • Y10T428/24967Absolute thicknesses specified
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/3154Of fluorinated addition polymer from unsaturated monomers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/3154Of fluorinated addition polymer from unsaturated monomers
    • Y10T428/31544Addition polymer is perhalogenated
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31551Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
    • Y10T428/31565Next to polyester [polyethylene terephthalate, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31551Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
    • Y10T428/31605Next to free metal
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31678Of metal
    • Y10T428/31681Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31678Of metal
    • Y10T428/31692Next to addition polymer from unsaturated monomers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31786Of polyester [e.g., alkyd, etc.]
    • Y10T428/31797Next to addition polymer from unsaturated monomers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/31504Composite [nonstructural laminate]
    • Y10T428/31855Of addition polymer from unsaturated monomers

Abstract

CORROSION RESISTANT COATED ARTICLES
WHICH INCLUDE AN INTERMEDIATE COATING
LAYER OF A THERMOSETTING POLYMER
AND NON-SILICEOUS FILLER

ABSTRACT OF THE DISCLOSURE
A concrete or metal substrate which is normally subject to deterioration in the presence of corrosive substances such as strong acids, particularly sulfuric acid, is rendered corrosion resistant when covered with the improved multi-layered coating of this invention. In particular, a coated article, such as a coated chimney liner or flue duct, which includes a substrate, a primer coating layer of a thermo-setting polymer, one or more inner coating layers of a thermosetting polymer which includes a siliceous filler, an intermediate coating layer of a thermosetting polymer which includes a non-siliceous filler, and a fluoroelasto-meric top coating layer which includes a non-siliceous filler, has improved resistance to the corrosive effects of strong acids. Chimney liners, flue ducts, scrubbers, and the like which have been coated in accordance with this invention are useful in power plants, smelters, and other industrial settings where corrosive environments are present.

Description

1 ~7~53~ ~

CORROSION RESISTANT COA rED ARTICLES
WHICH INCLUDE AN INTERMEDIATE COATING
LAYER OF A THERMOSETTING POLYMER
AND NON-S ILICEOUS FILI.ER
_ FIELD OF THE INVENTION
-This invention relates to novel multi-layered coatinys which are capable of protecting surfaces such as the interior ~urfaces of chimney liners, flue ducts, and scrubbers from 5 the deleterious effects of those corrosive substances which are encountered in many industrial locations such as power plants and smelters.

A combination of factors have changed the conditions under which chimneys and 1ues in many industrial locations, 10 such as power plants and smelters, are operated. These changed ~actors have made the problem of eorrosion, par-ticularly acid corrosion, more criti~al. For example, as the available supply of clean-burning fuels of low sulfur - contents has decrea~ed, lower quality fuels havirlg higher sul~ur ~o~tents have been increasingly utilized. Combus-tion o~ these lower quality fuels results in production offlue gases which contain corrosive substances, especiall~
sul~ur-containing subs~ances, e.g., various oxides of sul~ur. At the same time, utility companies have increased the eficiency of heat utili~ation so that the temperatures o the flue gases produced in their power plants are closer :

~ 1~4~34 to the due points of the corresponding acids. Finally, installations equipped with sulfur dioxide scrubbers produce flue gases which are not only cooler, but also are wetter. Consequently, these installations discharge a corrosive mist into the lower portions of the chimney liners. Because of such changed act~rs, efforts have been undertaken to develop coatings capable of protecting the surfaces of chimney liners, scrubbers, and flue ducts from the effects o~ those corrosive and deterlorating substances which come into contact with ~hese surfaces during the operation of power plants, smelters, and the like.
DESCRIPTION OF THE PRIOR ART

In order to combat the problem of surface corrosion o~
chimney linings, flue ducts, etc., various plastic or polymeric coatings have been developed for use in protecting their interior surfaces. On approach has involved use of a coating layer of a polymeric material such as a polyester or a vinyl ester and a reinforcing filler material such as gl~ss flakes applied over these interior surfaces which are typically composed of steel, concr~te, or brick.

Another approach has involved use of a fluoroelastomer coating. This approach is based in part on such prior ~0 art teachings as those of U.S. Patent No. 3,526,532, which discloses the use of a hydrofluorocarbon coating layer overlaid on a polymeric primer coating to impart corrosion resistance to a coated metal sur~ace. One such c.oating is Colebrand CXL2000, developed by Colebrand Ltd., London, England,and marketed in the United States by Pullman Power Products, Willi~msport, Pennsylvania.
!

1 17~534 S UMMAR'X OF THE INVENTION
_ This invention provides novel, coated article~ such as coated chimney liners, flue ducts, and scrubbers, which possess improved corrosion resistance when placed in contact with corrosive substances such as ~trong acids, particularly sulfuric acid. The multi-layered, coated lQ articles of the present invention comprise a substrate, a primer coating layer, one or more inner coating layers, an intermediate coating layer,and an outer coating layer.

The coated articles are prepared as follows. A primer coating layer of a thermosetting polymer is placed over the surface to be protected. Then, one or more inner coating layers of a thermosettingpoly~ and a siliceous filler are overlaid upon ~he primer coatLng layer. The chemical properties of the thermosetting polym3~ employed in the primer coating lay~r and in the inner coating layer or layers are such that bonding occurs between the primer coating layer and the surface being coated and between the -primer coating layer and the adjacent inner coating layer as well as between contiguous inner coating layers if more than one such layer is present. Over the outermost,inner coating layer th~re is placed a non-siliceously filled, intermediate layer of a thermosetting polymer capable of bonding to the inner coating layer. Finally, an outer coating layer of a fluoroelastomer and a non-siliceous ~iller is applied over the intermediate coating layer. The chemi~al properties of the fluoroelastomer employed are such that,upon curing,a chemical bond forms between the intermediate coating layer and the 1uoroelastomeric outer coating layer.

~17~34 !

In the preferred embodiment of this invention, a coa~ed article is prepared which possesses improved corrosion resistance and comprises a substrate, a primer coating layer of polyester 1-5 mils in thickness, an inner coating layer of glass flake-filled vinyl ester 20-80 mils in thickness, an intermediate coating layer o~ carbon-fi~led vinyl ester 10-15 mils in ~ickness, and an outer coating layer of a carbon-filled fluoroelastomer 10-50 mils in thickness.

It is a principal object of the present invention to provide coated articles such as coated flue ducts, chimney liners, and scrubbers which possess the following desirable physical characteristics: resistance to chemical attack ~y strong acids; resistance to water or chemical transport; resistance to thermal degradation; and resistance to mechanical and abrasion damage.
It is a related object of this invention to provide a method o~ preparing coated articles which possess these desirable physical chacteristics.

It is a ~inal object of this in~ention to provide a method of pro~ecting surfaces such as the steel, concrete, and brick surfaces found in chimney liners and flue ducts from the effects of corrosive substances such as strong acids.
How these and other objects o~ the present invention are accomplish~d will be more readily under~tood upon reading the detailed description of the invention in conjunction with the accompanying drawings and the claims which follow 35 there~fter.

.

- ~ ' .
' BRIEF DESCRIPTION OF THE_DRAWINGS

Fig. 1 is a cross-secti~nal view of a coated article which includes a substrate, a glass flake-filled polymer formed ~rom a vinyl ester as an inner c~atin~ layex,and a carb~n-filled fluoroelastomer as an outer c~ating layer.

Fig. 2 is a coated article which includes a substrate, a first nner coating layer of a silica~-~illed polymer formed from a vinyl ester, a second inner coating layer of a glass flake-filled polymer formed from a vinyl ester, and an outer coating layer of a mica flake-filled fluoroelastomer.
Fig. 3 is a coated article which includes a ~bstrate, a primer coating layer of a polyester, an inner coating layer of a glass flake-~illed polymer formed from a vinyl es~er, and an outer coating layer of a c2rbon-filled fluoroelastomer Fig.4 is a coated article in accordance with thisinvention which includes a substrate, a primer coa~ing layer of p~lyester, a glass flake-filled vinyl ester inner coating layer, a carbon-filled vinyl ester intermediate layer, and a ~arbon-fi~led fluoroelastomer outer coating layer.

DETAILED DEscRIpTIoN or~la~ L333~D EMBODIMENTS

Thls ~nvention provides multi-layered coated artic~es which posse~Q improved corrosion resistance, parti~ularly ~ 17'1~3~

when the articles are in contact with corrosive ~ubstances such as strong acids, especially, concentrated ~ulfuric acid. These coated articles include coated flue ducts, chimney liners, scrubbers, tanks, expansion joints, and the like, all ~f which typically come into contact with corrosi~e ~ubstances during normal usage. They also possess corrosion resistan~e in the presence ~f hydrochloric acid, but have only limited resistance to corrosion caused by contact with nitric acid.

The underlying substrates which are protected may be metals, especially steel, concrete, or brick. At present, the most important applications of the coated articles of this invention are as substitutes or replacements for uncoated chimney liners, ~lue ducts, and scrubbers, all of which come into contact with concentrated suifuric acid during th~ operation of power plants bur~ing fossil fuels which contain sulfur.
When fossil fuels containing sulfur are combusted, the gases produced include sulfur dioxide and sulfur trioxide. These condense at the exhaust temperatures from fuel combustion, typically temperatures up to about 400 to 500F., to produce sul~uric acid at concentrations as high as 90~.

The multi-layered, coated articles of this invention comprise a substrate, a primer coating layer, one or more inner coating layers, an intermediate coating layer, and an outer coating layer. The primer coating layex is ~ polymer ~ormed rom a the.rmosetting polymeric ma~erial, whlch may be the s~me as or dif~erent ~rom ~he ~hermoset~ing polymer in ~he adjacent inner coating layer. It is applied to the sur~ace to be coated prior to application of the inner coating layer or layexs.
The oh2mical properties o the polymer used as the primer coating are such that bonding occurs between `

the primer coati~g, the sur~ace of the coated ~ubstrate, and the adjacent in~er coating layer.

Each inner coating layer is an admixture of a polymer ~ormed fxom a thermosetting polymeric material and a siliceous filler material. The chemical properties of the polymer employed are such that bonding occurs betwe2n the primer coating layer and the innex coating layer with which it is in contact, and such ~hat, if more than one inner coating layer is present, bonding occurs between adjacent inner coa~ing layers.

The intermediate coating layer is an admixture of a thermosetting polymeric material,which may be the same as or different from the polymer present in the inner coating layer or layers or in the primer coatin~ layer, and a non-siliceous filler material. The chemical properties of the polymer are such that it is capable of bonding to the outermost inner coating layer.

Finally, the outer coating layer is an admixture o~ a fluoroelastomer and a non-siliceous filler material.
It is applied over the intermediate coating layer. ~pon curing, the fluoroelastomeric material employed in the outer coati~g layer is capable of forming a chemical bond with the polymer of the intermediate coating layer.

~igs. 1-3 illustrate various multi-layered articles having corrosion r~sis~ance 5uch that the underlying substrate is px~t~c~ed to varying degree~ ~rom deterioration or corrosion in the presence of corrosive substances such as strong acids. ~he prQperties o~ coated artiales lllus~rated in these figures are discusæed more ~ully in the ex~mples.

~ 17453~

Although each of the coated articles 8hown in Pigs. 1-3 possess certain corrosion resistance, they are not as highly resistant as is desirable. The present inventio~
provides coated articles which possess greater corrosion resistance and improved overall Prope.rtie~.

Specifically, Fig. 4 illuætrates a coa~ed article in accordance with the invention having a metal or concrete substratec This coated article includes a primer coating layer o~ a polyester having a dry thickness from about 1 to about ~ mils, an inner coating layer of a glass ~lake-filled polymer formed from a vinyl ester having a clry thickness from about 20 to about80 mils, an intermediate carbon-filled polymer formed from a vinyl ester ha~ing a dry thickne~s from about 10 ~ about 15 mils, and an outer coating layer o~ a carbon-filled fluoroelastomer having a dry thickness from about 10 to abou~50 mils.
As set forth hereinabove, the substrate may be metallic or non-metallic,for example, a steel, concrete or brick surface, the nature o~ the substrate being limited only by the availability of a compatible polymer which will firmly adhere to the surface of the substrate to ~oxm a primer coating layer.

After the surface of the substrate to be protected is cleaned and roughened according to known ~chniyues, ~or example, by acid ~tching or sandblasting, and be~ore any 5ub9tantial oxidation can occur, ~he primer coating layer i~ appli~. In this way, any weak surfaa~ layer is xemoved ~rom the 8ubstrate,permitting stronger adhesi~e bondin~ to be obtained bet~een the coated sur~ace 35 and the ad~acent inner coating layer. Al though the primer ~oating may be any thermosett$ng polymeric material, it is generally preferred that the primer coating layer be an .1 . I

~ ~7~L534 g unsaturated, thermosetting polymer ~uch as a polyeæter or vi~yl ester. The pximer coating may be applied over the prepared substrate surface in any conventional manner to a dry thickness o~ about 1 to about 5 mils.

Each inner coating layer is an admixture of a polymer formed from a thermosetting polymeric material and a siliceous filler material. Although numerous materials are useful, the thermo~etting polymer employed will generally be a vinyl ester, polyester, epoxy, furan, phenolic, or urethane. Of these, a vinyl ester is presently preferred. Preferably, a monomer is used in the inner coating layer to crosslink with ~he polymeric material.
Thus, when ~he polymeric material is a u~saturated, thermosetting polymer such as a vinyl ester, it is pre~erable to include a monomer capable of crosslinking with the Yinyl ester polymer. Examples of useful compounds are styrene, acrylates, and methylacrylates.

The siliceous filler material may be any suitable reinforcing filler which includes silica such as ~lass or mica flakes, silica particles, or glass wool. Glass flakes ~hich are less than about 1/64" long in any dimension are presently preferred.
Such glass flakes axe available from Owens Corning ~iberglass Corp., Toledo, Ohio.

The inner coatlng layer is ~ormed as follows. A ~ormulation is prepared which includes the thenmosetting polymeric matexial. For example, a vinyl e~ter in an amount in the range ~rom about 35~ to about 55% by weight is mixed with a monomex which includes a vinyl group, for example, styrene, in a~ amount from about 40~ to about 25% by weight and a 35 siliceous ~iller, e.g., glass flakes, in an amount ~rom about 15% to about 30~. Also desirabl~ included in the ~ormulation are one or more thixotropic agents, such as ~umed asbestos, ~umed silica, or clay, ln an amount less than about 1%;

, !

.~ .

` ~7~534 glycerin or a ~imil2r polar compound in an amount from abou~
0.04% to about 0.08~; one or more pigmentsr par~icularly metallic oxides, such as titanium dioxide or lead oxide, in an amount from about 1% to about 4%; one or more catalysts, such as a peroxide, e.g., methy}ethyl ketone peroxide, in an amount ~rom about 1% to about 4 ~; one or more promoters, such as amines or metallic soaps, in an amount from about 0.05% to about 0.~%; one or more inhibitors, such as catechols, quinones, and hydroquinones, in an amount from about 0.01% to about 0.1%; and one or more coupling a~ents, such as silane, in an amount less than about 1~.

Within the ~ormulation, polymers are formed from the thermo-setting polymeric material. In this specific example, pol~-mers are formed ~rom vinyl ester and cross-linked with styrene.
The final admix~ure of these materials has a limited "pot"
life, and must be applied to the primed surface within a relatively short time, usually within about 30 minutes to about 2 hours.

The inner coating layer may be applied as a solution or dis-persion in any conventional manner including rolling, brushing, troweling, air-atomized spraying, or airless spraying.
Typically, one coat of about 10 to 40 mils in dry thickness is applied to the primed surface of the substrate, and then a second coat is applied, also 10 to 40 mils in dry thickness, to produce an i~ner coating layer having a dry thickness from about 20 to 80 mils. This range of thickness provides the coated surgace with su~stantial protection from corxosion. Thus, ~he inner coatin~ l~yer provides substan~ial impermeability to sul~uxic acid and w~ter permeability o~ only about 0.001 perm.
inches; Thicknesses less than about lS mil5 do no~ provide ade~uate protection and thicknesses which are too great may result in a coating layer which, over time, tends to crack and ~lake oP~ from the ~oated surface. Thus, it i5 presently pref erred that the thickness of the inner ~ ~7~53 coating layer not exceed about 80 mils~

As set forth hereinabove, more than one inner coating layer may be emp}oyed, each such inner coatins layer having a dry thickness from about 20 to about 80 mils.
Each of the inner coating layers may be identicai or may vary in terms of the poly~er or the siliceous reinforcing filler material present provided only that the layers be compatible with one anot~er.

The intermediate coating layer is formed in generally the same manner as the inner coating layer except that a non-siliceous filler is employed rather ~han a sili~eous filler. Useful non-siliceous ~illers include carbon and inorganic oxides such as aluminum oxide. The intermediate coating layer is applied to a dry thickness from about 10 to about 15 mils.
The outer coating layer is prepared as 40110ws. A formula-tion is prepared which includes a fluoroelastomer, ty~ically one havin~ a molecular weight less than about 2 x 10 since presently available fluoroelastomers of higher molecular weight axe insoluble,and therefore not useful in the practices of this invention. Examples of useful fluoro-elastomers are Viton A-35 and B-50, manufactured by E.I. ~uPont de Nemours & Co., Inc., Wilmington, Delaware, and Fluorel 2175 manufactured by the 3M Company, Minneapolis, Minnesota. Viton i5 the ~rademark for a series of fluoro-elastomers ba~ed on the copolymer of vinylidene fluoride and hexa~luoropropylane. Fluorel is the trademark for a series of fully saturatad,~luorinated pol~mers containing more than 604 ~luorine by weight. The ~ormulation is prepared 3s by mlxins the iluoro~la~1:omer in an amount ~rom about 25i ~, , , ~ ~7~l53 ~

to ~bout 604 by weight with a non-siliceou6~ reinforcing $iller such as carbon or an inorganic oxide, e.g., aluminum oxide, carbon presently being prefer~ed. The size o~ the filler particles should pxeferably not exceed about 1/64 n in any dimension. The non-siliceous reinforcing filler material is present in the fo~nulation in an amount from about lO~ bD ~bout 30% by weight, Also desirably included in the foxmulation are one or m~xe acid acceptors such a~ lead oxide which are capable of reacting with hydro~luoric acid produced during curing of the elastomer.
The acid acceptors are generally present in an amo~t from about 3~ to about 15% by weight. One or more curing agents, such as amines, diamines, peroxides, bis-phenols or azo rompounds, in an amount less than about 10% by weight; one or more pigmen~, such as oxides o~ titanium, in an amount less ~han abou~ 10%;and one orm~rewater reactive compoun~s, such as calcium oxide or magnesium oxide, to react with water produced during curing of the elastomer are a}so desirably included. When the fluoroelastomer is Viton A-35 or B-50 as dessribed above, ~he preferred curi~g agen~ is Diak #3 which is also manufactured by DuPont for use with ~he Viton eries of fluoroelastomers.

The fluoroelast~mer, non siliceous ~iller, and other com-ponents are mixed, ni~led, and pulver~. Solvent is then added. U~eful ~olvents include organic acetates, such a .
~-butyl acetate and amyl acetate, ketones, and este~s.
When th~ ~luoroelastomer used is Viton A-35, a ~olvent mixtux~ o~ n-~utyl acetata and amyl a~etate in the ratio o~ about 4 part8 n-bu~yl aceta~e per part amyl ace~ate i8 par~icula~ly u~ful. m e ou~er coating layex composition 35 80 p~epa~ed is appliad a8 a ~olution or disper~ion over the ~ntermediate coating layer. Typically, ~he outer coa~ing layer i~ appl~ed to a dry ~hickne~s o~ about 10 to about 50 ~7~534 mile using conventi~nal techniques ~uch as th~se de~cr~bed for applying the inner coating layer~

After a period Qf time, typically one day to one week, wherein the solvent i~ released, the e~tire coating may be heat cured at a temperature from about 250~ to about 500F.
for ~t least about 3 hours. Preferably, the heat curing is accomplished at a temperature from about 250 to 300F.
~or a period of at least about 3 hours. Ihe resulti~g, outer fluoroelastomer coating layer is p2rmeable to sul~uric acidO but protect~ the inner coating layer from the corro~ive effects of concentrated ~ulfuric acid. The 15 outer co~ting layer also provides abrasion resis~ance.

Although each of ~he coated articles of Figs. 1-3 have been found to possess some corrosion resistance, the presence of siliceous fillers in the inner ~oating layer or layers results in the premature breakdown of ~he resin/filler - interface, possibly because of attack by hydrofluoric acid produced in the outer coating layer, when the outer coating layer is adjacent an inner coating layer which includes a siliceous filler~
An unfille~ inter~ediate resin layer would provide a longer lasting interface be~ween the thermosetting resin o~ the inner coating layer and the fluoroelastomer of the outer coating layer. However, unfilled, thermosetting resins ~re not meoha~ically stAble when expo.sed to the extreme ~nvironmen~al conditions to which flue ducts and chimney liner~ are ~xpo~ed.

35~
' J . , 5 ~ 4 The present inverltion is based upon the discovery that 5 an intermediate coating layer ~f a thexmosettin~
p~lymeric material and a non-siliceous ~iller provides a layer which is substantially resinous, produces a long-lasting interface with adjacent layers, particularly the fluoroelastomer outer coating layer, and supplies a resin/~iller inter~ace possessing improved resistance to hydrofluoric acid attack.

Specifically, a particular version of the improved coated article of this invention shown in Fig.4 provides better chemical resistance and improved thermal stability when compared with a coated article which does n~t include an intermediate layer of thermosetting polymer and non-siliceous filler.

The ~ollowing examples are set for~h to more clearly illustrate the present invention, but are n~t to be construed as limiting in any way the scope of the invention as set forth in the claims which follow thereafter Example _l A steel panel was sandblasted and then a coating of ~luoxoelastomer was applied over the surface to produce a coating layer having a dry thicknecs of 30 mils. The chemical resi~tance o~ ~he protective coating layer was then evaluated by the Atlas Test Cell Evaluation ~ASTM
Test C 868). ~he coated steel panels were placed in contact with a vapor con~aining distilled water at 180F.

1 ~7~53~

After ~wo weeks the steel panels were removed from contact with ~he ~apor and examined. The coating layer was blistexed and could be readily peeled off the stee~ panel.
The steel panel itself showed visible indications of oxidation.

Example 2 Following the same procedure as in Example 1, steel panels were covered with a coating composition such as i~ shown in Fig. l. Periodically, over a period of several months, the steel panels were removed from contact with th8 water containing vapor and examined. No evidence of blisterin~
or damage to the coa ing layer was found, nor was there any evidence of oxidation o~ the surface of the steel panel .

Example 3 Following the same proceduxe as set forth in Example 1, steel panels were covered with a coating composition such as is shown in Fig. 3,and evalua~ed by the same procedure. During several month~ the panels were periodically removed from contact with the vapor containing distilled water and examined. No evidence of ~listering or peeling of the coating was noted,nor was there any indication of corrosion o~ the steel panel sux~aces.

Example 4 Steel panals which had been covered with a coa~ing compo~i-tion as shown in Fig. 1 were installed as part o~ the chimney lining at a power plant burning ~ossil fuels. In thi~ ~ield te~t, the panels came into con~act with ~he corrosive :3ub9tanc:~e3 p~o~uced during the normal operation o~ the power plant. The panels were periodically examined over ~our months. Some minor bli~ering o~ the coating compo~ition was observed,although the coating composition ,1 , 5 3 ~

continued to adhere to the panels. There was no indication of oxidati~n of the steel panels.

Example 5 Steel panels covered with ~he coating composition shown in ~ig. 3 were also installed at the same power plant as in the preceding example and periodically examined. After four months, no evidence of any bli6tering or other deterioration o the co~ting layer was evident. There was no indication of any corrosion of the steel panels.

Steel panels covered with a coating layer ~f glass ~lake-filled vinyl ester were also installed at the same power plant as in the preceding Fxamples 4 and 5 and periodically examined. A~ter four moAths~ major blistering o~ the coating layer was observed and large patches of coating material could be readily removed from the steel panels.
m ere was significant corrosion of the underlyln~ panels.

Example 7 The water vapor transmission of a carbon-filled fluoroelas-tomer was determined using the water vap~r transmission test (ASTM Test E 96). The average penneability o~E
several samples was dete~nined to be 0.001 perm-inches .
A combination of the same f~lled fluDn~as~x~ and a glass ~lake-filled vinyl ester was then tested. The average pe~neability o~ a ~eries o~ samples was 0.0007 perm-inches indicating a reductionin water vapor per~eability of 30~ .

E_amp~e 8 Steel panels were covered with coa~ings to produce coated artioles as 8hown in ~igs.3 and 4. The chemical resistance o~ t~e proteotive co~ting layer was then eva~uated b5~ par-S 3 4.
--~ 7--tiAlly immersing the panels in concen~rated sulfuric acid.Over a period of several months, visual inspections of these panels showed that the panel wihout the carbon~
f illed vinyl ester in~ermediate coatlng layer began to blister whereas the coated article of this invention remained bonded.

ExamPle 9 Two steel panels were prqx~d as in Example 8 and evaluated by the Atlas Test Cell Evaluation (ASTM Test C868) with deionized water at 160F. Periodically, o~er several months, the panels were removed and examined.
No evidence of blis~ering or damage to the coating with the carbon filled vinyl ester intermediate coating layer was found whereas the panel without ~ s layer began to blister.

Example 10 Two steel panels were prepared as in Example 8. These panels were placed in~o an oven at 400F. and periodically evaluated. After a ~ew months, the panel without the carbon-filled vlnyl ester intermediate layer began to lose adhesion.

As will be obvious to one skilled in the art, many modi-~ications, variations,or alterations can be made in the practice of this invention without deparking from the ~piri~ or scope thereof as set orth in the claims which ~llow.

Claims (11)

The Embodiments Of The Invention In Which An Exclusive Property Or Privilege Is Claimed Are Defined As Follows:
1. A coated article resistant to corrosion or deterioration which comprises:
a substrate;
a primer coating layer in contact with the surface of said substrate, said primer coating layer being a thermosetting polymeric material and having a thickness from about 1 to about 5 mils;
an inner coating layer in bonded contact with aid primer coating layer, said inner coating layer being an admixture of a thermo-setting polymeric material and a siliceous filler material and having a thickness from about 20 to about 80 mils;
an intermediate coating layer in bonded contact with said inner coating layer, said intermediate coating layer being an admixture of a thermosetting polymeric material and a non-siliceous filler material and having a thickness from about 10 to about 15 mils; and an outer coating layer in chemically bonded contact with said intermediate coating layer, said outer coating layer being an admixture of a fluoroelastomer and a non-siliceous filler material and having a thickness from about 10 to about 50 mils.
2. A coated article in accordance with Claim 1 wherein said substrate is a chimney liner, flue duct or scrubber.
3. A coated article in accordance with Claim 1 wherein said thermosetting polymeric material is polyester, vinyl ester, epoxy, furan, phenolic or urethane.
4. A coated article in accordance with Claim 1 wherein said siliceous filler is silica, glass wool, glass flakes, or mica flakes.
5. A coated article in accordance with Claim 1 wherein said non-siliceous filler is carbon or an inorganic oxide.
6. A coated article in accordance with Claim 1 wherein said fluoroelastomer has a molecular weight less than about 2 x 105.
7. A coated article in accordance with Claim 1 wherein said fluoroelastomer is a substantially fully saturated fluorinated copolymer of vinylidene fluoride and hexafluoropropylene.
8. A coated article in accordance with Claim 1 wherein said thermosetting polymeric material of said primer coating layer is polyester or vinyl ester.
9. A coated article resistant to corrosion or deterioration which comprises:
a substrate;
a primer coating layer in contact with the surface of said substrate, said primer coating layer being a polyester and having a thickness from about 1 to about 5 mils;
an inner coating layer in bonded contact with said primer coating layer, said inner coating layer being a polymer formed from vinyl ester and styrene in admixture with glass flakes and having a thickness from about 20 to about 80 mils;
an intermediate coating layer in bonded contact with said inner coating layer, said intermediate coating layer being a polymer formed from vinyl ester and styrene in admixture with carbon and having a thickness from about 10 to about 15 mils: and an outer coating layer in chemically bonded contact with said intermediate layer, said outer coating layer being a fluoroelastomer in admixture with carbon and having a thickness from about 10 to about 50 mils.
10. A method of preparing a coated article in accordance with Claim 1 which comprises:
cleaning and roughening the surface of a substrate to be coated;
covering said cleaned and roughened surface of said substrate with a primer coating layer, said primer coating layer being a thermosetting polymeric material, to a thickness from about 1 to about 5 mils;

covering said primer coating layer with an inner coating layer, said inner coating layer being an admixture of a thermosetting polymeric material and a siliceous filler material to a thickness from about 20 to about 80 mils;
covering said inner coating layer with an intermediate coating layer, said inter-mediate coating layer being an admixture of a thermosetting polymeric material and a non-siliceous filler material to a thickness from about 10 to about 15 mils;
applying an outer coating layer over said intermediate coating layer, said outer coating layer being an admixture of a non-siliceous filler material and a fluoro-elastomer capable of chemically bonding to said intermediate coating layer, to a thickness from about 10 to about 50 mils; and curing the resulting multiple coating layers to produce said coated article.
11. A method of preparing a coated article in accordance with Claim 9 which comprises:
cleaning and roughening the surface of a substrate to be coated;
covering said cleaned and roughened surface of said substrate with a primer coating layer of a polyester to a thickness from about 1 to about 5 mils;

covering said primer coating layer with an inner coating layer of a polymer formed from vinyl ester and styrene in admixture with glass flakes to a thickness from about 20 to about 80 mils;
covering said inner coating layer with an intermediate coating layer of a polymer formed from vinyl ester and styrene in admixture with carbon to a thickness from about 10 to about 15 mils;
applying an outer coating layer over said intermediate coating layer, said outer coating layer being an admixture of carbon and a fluoroelastomer capable of chemically bonding to said intermediate layer, to a thickness from about 10 to about 50 mils; and curing the resulting multiple coating layers to produce said coated article.
CA000378247A 1980-08-14 1981-05-25 Corrosion resistant coated articles which include an intermediate coating layer of thermosetting polymer and non-siliceous filler Expired CA1174534A (en)

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US06/178,168 US4347277A (en) 1978-11-03 1980-08-14 Corrosion resistant coated articles which include an intermediate coating layer of a thermosetting polymer and non-siliceous filler

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US4347277A (en) 1982-08-31
JPH0126339B2 (en) 1989-05-23
AU7117681A (en) 1982-02-18
EP0046362A1 (en) 1982-02-24

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