Dupont Performance Polymers Industrial & Energy Markets DuPont Performance Polymers Conference May 20th 2010 Albergo Cocca Hotel Sarnico (Bg) Pepa Mayor-Lopez
2 Chemical Industry Food/Pharma Oil & Gas Biofuels Transportation Non-Auto Wire & Cable
3 Segment Table with Key Requirements Requirements Oil & Gas Transportation Non Auto Chemical & Processing Industry Biofuels Food & Pharma Wire & Cable Explosive Decompression Low temp. High temp. Base Acid Lubricants Fuel/Biofuels Additives Steam Polar solvents Pressure FDA & European Equivalents Low permeation Purity (low extractable) Flexibility dynamic Cleaning sterilization
4 Vamac & Viton Applications per Segment Segment Type of sealing parts Example Viton types Example Vamac types Transportation Non Auto Compression seals Molded parts GLT-S DP Ultra IP O-rings Oil & Gas Liner hanger A Needle valve for gas system GF-S ETP-S CPI Coated fabrics A GLS Expansion joints B VM-3110 Peristaltic pumps GBL-S Plate Heat Exchanger gasket GF-S Diaphragm valve ETP-S Hydraulic hoses Biofuels Pumps, valves, mechanical seals, flow meters, hoses, plate heat exchanger gaskets, filtration systems Fuel containment & transportation GBL-S GF-S GFLT-S Not recommended in extensive fuel use Food & Pharma Sanitary seals GF-S Peristaltic pumps tubing ETP-S Diaphragm valve Wire & Cable Oxygen sensor wire insulation for automobile exhaust monitoring Oil drilling instrument wiring HEV/EV battery cables B GF-S ETP-S DP G
5 CHEMICAL INDUSTRY
6 Market Trends Chemicals companies are exposed to high energy cost -> need for efficiency increase and driving operational excellence Emission reduction regulations -> need for new solutions to achieve high performance development of energy-efficient technologies, renewable sourced material processing increases -> need for new materials withstanding those operation conditions is emerging
Applications, Solutions and Opportunities Plate Heat Exchangers (PHE) 7 Application High Performance plate heat exchanger gaskets Material Viton GF-S is preferred grade Benefits Excellent sealing against aggressive fluids Excellent compression set resistance High gasket longevity at high temperatures and pressures -> low maintenance costs Viton GF-S Why Viton? Very good dimensional stability Excellent resistance to aggressive media, like sulfuric acid High temperatures tolerance Ability to produce complex geometry DuPont s registered trade name
Applications, Solutions and Opportunities Flue Duct Expansion Joint 8 Application Light weight elastomeric expansion joint for easy installation Material Viton B, GBL-S, GF-S Benefits Safety and reliability in high temperature operating conditions Withstands aggressive chemical exposure Withstands vibration and pressure Long term service entailing lower maintenance costs Why Viton? Very good hot elongation capability High temperatures tolerance Excellent resistance to wide range of chemicals including sulfuric acids, hydrocarbons DuPont s registered trade name
Hydraulic Hoses Applications, Solutions and Opportunities Application Hydraulic hose for conveying hydraulic fluid to or among hydraulic components, valves, actuators. The systems operate under high peak pressures and harsh operating conditions. 9 Material Vamac Ultra IP, VM-3110 Benefits operating in harsh environment without leakage failure optimal use in applications where lines must flex and bend Why Vamac Ultra? Green strength Good adhesion to textile Good abrasion resistance Good resistance to new synthetic hydraulic fluids Excellent flexibility at low temperatures DuPont s registered trade name
10 BIOFUELS INDUSTRY
11 Global Market Trends & Environmental Legislation Reduce our dependence on fossil fuels Reduce the CO 2 emission (less greenhouse effect) Focus on renewable energy sourced fuels Use of oxygen-containing fuels & Biodiesel that are more aggressive Ethanol E6 & E85 in favor in California, E10 & E85 in rest of USA E10 in Europe, India and China Oxygenates MTBE has been legislated out in the USA, but still used in Europe ETBE and Methanol as well Biodiesel (B5 to B20) Improves diesel fuel emissions bio-degradable and non-toxic product Reduces diesel engine wear (inherent lubricity of FAME s)
12 Viton Product Selection Guide Viton F, GF-S The Standard for Bioalcohols. low volume swell in bioalcohols (e.g. bioethanol and biobutanol) For excellent compatibility with fresh and aggressive contaminated Biodiesels, peroxide cured Viton types with no metal oxides are recommended.. Viton GBL-S The Standard for Biodiesel. Display excellent resistance to aggressive biodiesel. Adequate sealing capability at low temperatures. Viton GLT-S, GFLT-S Improved Low Temperature for Biodiesel. Offers excellent resistance within aggressive biodiesels Excellent performance at low temp.
13 Biofuels Processing Areas and Applications Biofuel Production Process fluids involve fuel, raw ingredients (bio-oil, methanol), catalysts (bases) Ambient (as low as -40ºC) to 100ºC thermal range Pumps, valves, mechanical seals, flow meters, hoses, plate heat exchanger gaskets, filtration systems Biofuel Storage Storage tanks above and under ground with 0ºC to 30ºC thermal range Biodiesel stability limited to 6 months before use Biofuel Distribution Marine, rail and road Biofuel Blending Metering of diverse ingredients: flow meters, hoses Biofuel Dispensing Flow meters, pumps, and dispensing units
Processing Equipment: Components and Parts 14 Valve Seats Automatic dispensing nozzle O-Ring Seals Mechanical seal for rotating shafts Valve stem seal Valve seat Valves UST filling port Cap Seal Check Valve Seal Sump Containment Seal Check valve ball Valve Seats V seals Dispensing hose break-away valve Diaphragm Inner layer veneer Hydrocarbon hose Positive displacement, reciprocating metering pump Pressure regulator Valve Seat Diaphragm pump
15 OIL & GAS
16 Applications Served DRILLING TESTING COMPLETION PRODUCTION Mud pump/motor linings 1 (custom part) Electrical boots/ sensor overmold (custom part) Packer element (custom part) Packer 2 (v-ring) Gate valves (o-rings) 1 Image Copyright Baker Hughes, 2 Image Copyright James Walker Inc Blowout preventer (custom part, o-rings) Artificial lift pumps (bladders) Safety valve (o-rings)
17 Viton Product Portfolio Viton GF-600S The Standard Choice for Oil & Gas FKM sealing applications Improved resistance to hot water and steam Improved resistance to acids and methanol Replaces di-polymer FKM, HNBR Viton GLT-600S The Low Temperature Extreme for Oil & Gas FKM sealing applications Common to all Viton products: High temperature sealing up to 204 o C Broad resistance to hydrocarbons Viton GFLT-600S The Low Temperature Standard for Oil & Gas FKM sealing applications All the benefits of Viton GF- 600S Best-in-class low temperature sealing performance Replaces di-polymer FKM, HNBR Our technical service personnel can help you meet Rapid Gas Decompression requirements with compound formulation recommendations Our Genuine Viton network of Oil & Gas part molders and distributors will help ensure the integrity of the supply chain delivering your seals
18 Rapid Gas Decompression Explosive Decompression Explosive Decompression (ED), also known as Rapid Gas Decompression (RGD), is structural failure in the form of blistering, internal cracking and/or splitting caused when the gas pressure to which the seal is exposed is reduced faster than the gas can diffuse out of the part. This causes internal stresses in the part that can exceed the physical strength limits of the elastomer. Testing in 100% CO 2 environment may be done in our lab at ETC Meyrin, Geneva
19 Fluoroelastomers Selection Guide For Oil & Gas Applications Fluoroelastomer Selection Guide Polymer Requirement A-HV GBL-S GF-S ETP-S TFE/P Strength at High Temperature ++ ++ + NR NR Methanol Resistance NR NR + ++ + Amine Corrosion Inhibitor Resistance NR NR NR ++ ++ Formate Fluid Resistance NR NR NR ++ na Ester Based Fluid Resistance + na NR NR NR ED Resistance (100% CO 2 ) + + ++ ++ NR Compression Set Resistance ++ + ++ + NR Low Temperature Flexibility ++ ++ + + NR ++ Definitely should be considered + Should be considered NR Not Recommended for this service na Not tested Data from paper presented at ACS, Cleveland, OH, in Oct. 2007
20 FOOD/PHARMA
Sealing challenges in food and pharmaceutical industries STEAM CLEAN-IN- PLACE CHEMICALS Sub-optimal sealing material Optimal sealing material Premature Seal Failure Increased Maintenance Cost Risk to Product Quality Lost Capacity Long Lasting Seal Life Minimized Maintenance Cost Product Integrity Improved Up-Time Production 21 PROPRIETARY FLUIDS AT ELEVATED TEMPERATURE Seal materials must be chemically resistant to the product processed
Performance rating for FDA compliant Viton grades Economy 10 9 8 7 6 Low T 5 Org. Swell 4 3 2 1 0 BP-A GF-S GFLT-S TBR-S ETP-S GAL-S 22 Set Steam Hot water Acid Base / Caustic Viton GF-600S and Viton Extreme ETP-600S approved for repeated use in food contact applications, in all food types under all conditions of use, per FCN 00510 and FCN 00539, respectively.
23 Viton GF-600S and Viton Extreme ETP-600S - peroxide-cure terpolymers - monomer composition different than dipolymer FKM superior resistance to steam superior resistance to caustic cleaning fluids. Viton GF-600S and Viton Extreme ETP-600S approved for repeated use in food contact applications, in all food types under all conditions of use, per FCN 00510 and FCN 00539, respectively.
24 Needs for Food & Pharmaceuticals Sealing material Criteria important to Food & Pharmaceutical Applications Resistance to process cleaning solutions Steam resistance Levels of extractable carbon Levels of extractable metal ions Resistance to food- and beverage-related chemicals
25 Process Cleaning Fluids Volume Change for Viton GF-600S and Viton Extreme ETP-600S versus Viton A-401C (Dipolymer FKM) after 1008 hrs/70 C 60 50 Volume Change, % 40 30 20 10 0 CHEMATIC 99 TWEEN 80 CHEMATIC 91 CHEMATIC 9301 CIP 220 CIP 150 A-401C GF-600S ETP-600S
26 Process Cleaning Fluids Volume Change for Viton versus EPDM and Silicone after 1008 hours @ 70 C in Cleaning Fluids 60 Volume Change, % 50 40 30 20 10 0 A-401C GF-600S ETP-600S EPDM SILICONE CHEMATIC 99 TWEEN 80 CHEMATIC 91 CHEMATIC 9301 CIP 220
27 Steam Resistance Steam Cleaning Retention of Tensile Strength after aging in 80 psig (156 C) Steam 150 125 % or Original Tensile 100 75 50 25 0 0 100 200 300 400 500 600 700 800 Aging Time, Hours EPDM Viton GF-600S Viton ETP-600S Silicone
28 Steam Resistance (cont.) Retention of Elongation at Break after aging in 80 psig (156 C) Steam 150 % of Original Elongation 125 100 75 50 25 0 0 100 200 300 400 500 600 700 800 Aging Time, Hours EPDM Viton GF-600S Viton ETP-600S Silicone
29 Attributes of Good Seals Good resistance to: Compression set Process Chemicals Steam and Cleaning fluids But also needs: Low levels of extractable Carbon & Metals to minimize contamination and any potential effect on the flavor of a food process stream
30 Cleanliness - extractable Carbon Total Organic Carbon: EPA Method 415.1* (24 hrs @ 100 C) Viton GF-600S and Viton ETP-600S versus other Sealing Materials 1000 592 Total Organic Carbon, ppm 100 10 82 6 19 3 3 1 EPDM Pt-cure Silicone PTFE "FKM" GF-600S ETP-600S *: combustion or oxidation of HCl-extract
Cleanliness - extractable Metals 31 EPA Method 6010A* 5% Nitric Acid (24 hrs, reflux) Viton GF-600S and ETP-600S versus other Sealing Materials 10000 8198 2774 Total Metals, ppm 1000 100 17 10 4 1 3 1 EPDM Pt-cure Silicone PTFE "FKM" GF-600S ETP-600S *: inductively coupled plasma emission spectroscopy
32 Chemicals as Food & Beverage Flavoring ALIPHATIC & AROMATIC: Alcohols Ketones Organic acids Aldehydes Ethers Esters Terpenes
33 Soft Drink Concentrates Resistance of Sealing materials to Soft Drink Concentrates Weight % Change After 1 Week @ 23 C 150 Weight Change, % 120 90 60 30 0 EPDM VMQ A-410C GF600S ETP-600S Conc.#1 Conc.#2 Conc.#3 Conc.#4 Conc.#5
Physical Property of Viton vs. other Sealing Materials 34 Sealing Material Resistance to Compression Set Resistance to Steam Resistance to Commercial Cleaning Solutions Resistance to a Broad Variety of Types of Chemicals, Fluids Levels of Extractible Carbon Levels of Extractible Metals Viton A-401C Viton GF-600S Viton ETP-600S EPDM Pt-cure Silicone PTFE = Best = Good = Worst
35 Summary Viton GF-600S & Viton Extreme ETP-600S very good resistance to Steam and Caustic solutions good resistance to a wide variety of commercial Cleaning Solutions excellent resistance to a wide variety of Process Chemical & Fluids excellent resistance to a wide variety of Food & Beverage-related Chemicals and Fluids can be formulated to provide very low levels of extractable Carbon & Metal, similar to PTFE approved for repeated use in Food contact applications, in all food types under all conditions of use per FCN 00510 and FCN 00539, respectively
36 Thank you for your attention The information set forth herein is furnished free of charge and is based on technical data that DuPont believes to be reliable and falls within the normal range of properties. It is intended for use by persons having technical skill, at their own discretion and risk. This data should not be used to establish specification limits nor used alone as the basis of design. Handling precaution information is given with the understanding that those using it will satisfy themselves that their particular conditions of use present no health or safety hazards. Since conditions of product use and disposal are outside our control, we make no warranties, express or implied, and assume no liability in connection with any use of this information. As with any product, evaluation under end-use conditions prior to specification is essential. Nothing herein is to be taken as a license to operate or a recommendation to infringe on patents. Caution: Do not use in medical applications involving permanent implantation in the human body. For other medical applications, discuss with your DuPont customer service representative and read Medical Caution Statement H-50103-3. Copyright 2010 DuPont. The DuPont Oval logo, DuPont, The miracles of science, Viton, Vamac, are registered trademarks of E.I. du Pont de Nemours or its affiliates. All rights reserved.
37