p.1 

OAR Box 1413 

Prepped by Ollie Stewart 

Document Number: 

69) 11-1-69 

Docket Number: 

A-94-52 

Printed 7/9/2008 3:11:23 PM Sheet 69 of 114 
P.2 

REICHHOLD 

in-i-Grt 

3 0 YEARS Of CHLORINE DIOXIDE SERVICE 

WITH ATLAC 382 BISPHENOL FUMARATE RESIN 

igineers, fabricators and specifiers all look 

>r proven performance in corrosion-resistant 

>osite materials. Nowhere is this more true 

in in pulp and paper mills, which use some 

the most highly corrosive environments faced 

iy material of construction. 

Combine chlorine dioxide with internal temperatures in the 150°F - 160°F range for 30 

years, and you've got an extreme corrosionresistance challenge. 

In 1 996 , Britt Engineering of Birmingham, 

Alabama discovered a remarkable pulp and 

paper seal tank application of Reichhold's 

ATLAC" 382 resin. The company had been 

contacted by a local pulp and paper mill to 

inspect a seal tank that had been fabricated 

with ATLAC* 382 bisphenol fumarate resin 

and was in continuous service since 1966, 

over 3 0 years. 

The seal tank receives spent wash from a chlorine dioxide washer located two stories above 

the tank. It serves to break the seal in fhe long 

vertical pipe which extends from the washer. 

After dropping two stories, high velocity fluid 

enters the side of the lank through a 

tangential nozzle, creating extremely high 

stresses in the tank wall and supports. 

Britt Engineering had been retained by the mill 

to inspect the seal tank, which had no access 

thaf would allow Britt inspectors to see inside. 

Britt advised the mill to cut a 24 " opening in 

me side of tank which would be used as a 

manway if the tank turned out lo be repairable. 

Laminate in Good Condition 

An analysis of fhe cutout indicated that lhe 

laminate was still in good condition with a 

Barcol hardness of 25, even though the C-veil 

portion of the corrosion barrier had been lost. 

Subsequent physical property testing of the 

cutout revealed that after 30 years of service 

the ATLAC 382-05 laminate still retained a 

continued on page 7 

Voli 

TLAC&DIOI 

WHAT'S INSIDE 

~ ICBO I t Sett 

CR/FR Du d 

Standard 

Study 

Demonstrates 

Toughness af 

ATLAC S80-OS A 

Beverly Pacific 

Scrubs Up with 

DION PR* 930 0 A 

DION PR* 770 4 

CR/FR Team 

Expands, 

Reorganises 

Resins Yield ASTM 

1-8 4 Class 1 Flame 

Spread with 

Reduced Antimony 

Content 

Lightning Strikes 

ATLAC A DION* 

Case History 

Contest 

, RPS Meets the 

Challenge's of Flue 

Gas Desulfurlsatlon 

with DION VER 

910 2 
P . 3 

ICBO B SETS Tttt STANDARD fOR CORROSION-RESISTANT f RP DUCT DESIGN 

I

e ICBO Evaluation Service, Inc. (ICBO ES) has long 

sen one of the most reputable and authoritative 

ganizations involved in the accreditation of building 

oducts. Products are able to bear the ICBO ES 

aluation Report Number only after an exhaustive 

t of tests, designed to prove out mechanical and 

fire safety properties, have been successfully completed 

and thoroughly documented. 

To ensure that customers who get all of the value 

they expect, it is necessary for manufacturers to 

develop a detailed quality manual and rigorously 

adhere to the requirements of this manual. They are 

also inspected on a periodic basis by a third party 

quality control inspection agency. The ICBO Field 

Service Group audits the third party agency to ensure 

that they are doing their job in assuring product quality. 

This fastidious attention to careful product design and 

meticulous quality of manufacture cannot be assured 

in equipment that is made "using the ICBO Report 

merely as a guideline," but which does not actually 

carry an ICBO ES Report Number. # 

These claims typically indicate that the stringent testing 

required by ICBO ES has not been performed, often 

because it is very expensive. In fact, the "made to 

ICBO ES standards" claim is misleading, since only 

products bearing the official ICBO ES Report Number 

are subject to ICBO ES review process. 

The ICBO ES material requirements for the "Acceptance 

Criteria for Class V Duct Conveying Non-Flammable 

Corrosive Fumes and Vapors" requires joint vacuum 

and pressure tests, flexural and tensile mechanical 

property testing of FRP laminates and ASTM E-84 

tunnel testing of laminates that are typical of both the 

interior and exterior of the duct. 

The exterior of the duct must demonstrate an ASTM 

E-84 smoke developed index of less than SO. 

These properties have been attained by laminates 

prepared using DION FR* 930 0 flame-retardant vinyl 

ester resin. While demonstrating these properties 

does not, of itself, qualify a fabricator using DION FR 

9300 to attach the ICBO Report 405 5 stamp to their £ 

products, it is the critical first step in this process. 

FRP Specialists (Phoenix AZ) have recently qualified 

their FRP ILS Ducting under the provisions of ICBO ES 

Report 4055 . This is a breakthrough for them and 

for end-users wishing lo buy the highest quality Class 

V ducting. It is also a precursor to additional listings 

currently under evaluation. These listings are based 

on an extensive test program conducted by Reichhold 

Chemicals, Inc. with DION FR 9300 to meet the 

ICBO ES materials requirements. 

Ducting manufactured using DION FR 9300 throughout 

has many advantages compared with metal ducting 

and composite ducting based on phenol-formaldehyde 

(phenolic) resins. Metal ducting requires expensive 

alloys or specialized coatings that are vulnerable to 

abrasion and subsequent corrosion. 

Phenol-formaldehyde-based ducting lacks corrosioncontinued on page 6 

REICHHOLD 
P.4 

STUDY DEMONSTRATES ULTIMATE TOUGHNESS Of ATLAC 580-05 A 

C 

European studies have once again demonthat ATLAC 580 delivers exceptional toughcompared to conventional vinyl ester resins in 

applications. Toughness is defined as the combinaf resilience and strength in a high glass-content 

composite material. 

Linear fracture techniques were used by the Swedish 

Institute for Materials Technology2 to characterize the 

toughness of plastics in terms of critical stress intensity factor, Kc, and the energy per unit area of crack, 

Gc, at fracture initiation. 

Various polyester and vinyl ester resins were tested 

including ATLAC 580-05A urethane-modified vinyl 

ester resin, ATLAC 382-05A bisphenol fumarate 

polyester, Derakane* 41 1-45 bisphenol-epoxy vinyl 

ester, and Derakane 470 novolac vinyl ester. 

Significant differences were discovered, and, as 

shown below, ATLAC 580-05A outperformed all 

of the other materials tested. 

Superior Temperature Performance. ATLAC 580-05A 

boasts an HDT of 244°F - significantly higher than 

conventional vinyl ester resins. Combined with outstanding toughness, this illustrates the unique value 

of urethane-modification. 

Excellent resistance to hot caustic environments. 

Novolac vinyl ester resins offer good temperature 

resistance, but simply cannot perform in hot caustic. 

ATLAC 580-05A has outstanding resistance to 

alkaline conditions. 

No need for exotic catalysts or thixotropic agents. 

ATLAC 580-05A will not foam when used with standard MEKP catalysts. No need for BPO catalyst -

ever. Putties can be easily made using standard 

grades of fumed silica. 

Excellent reinforcement wetout. The unique polymer 

structure of ATLAC 580-05A provides exceptionally 

fast and complete wetout of glass, Kevlar® and 

carbon fiber reinforcements. 

Material Kc (N/mmAl .5) Gc (Nmm/mmA2) 

ATLAC" 580-05 

ATLAC* 382-05 

Derakane* 41 1-45 

Derakane* 470-36 

28.29 

13.04 

22.40 

16.4 

0.144 

0.032 

0.071 

0.045 

Reduction or elimination of cracking is one of the 

most significant benefits thai vinyl ester resins provide. 

The significantly greater toughness demonstrated by 

ATLAC 580-05A gives specifiers and fabricators 

another reason to demand the highest performance 

available in a vinyl ester resin. However, ATLAC 

580-05A provides a host of other unique properties. 

Pre-accelerated. ATLAC 580-05A contains 

DMA. Simply blend in cobalt, then 

catalyst, and fabricate. This eliminates 

the need lo store and measure dimethylaniline co-promoter. 

Strong, tough, temperature-resistant, easyto-use ATLAC 580-05A provides excellent 

corrosion-resistance in demanding applications. If you've got a hot corrosion problem, resist 

with ATLAC 580-05A. 

(1) Williams, J. G. A linear elastic fracture mechanics standard 

(LEFM) for determining Kc and Gc for plastics Imperial College, 

London, 1989. 

(2) Staffan Nystrom* and Peter Vens** Studies of fracture 

toughness of vinyl ester/polyester resin. 'Swedish Institute for 

Materials Technology ** University of Delft Holland. 

% iTLAC&DION 
P.5 

BEVERLY PACIFIC SCRUBS UP WITH DION f R 930 0 & DION FR 770 4 

I

Last year, Beverly Pacific, of Redmond Oregon, was 

tapped to provide five state-of-the-art 60,00 0 cubicfeet-per-minute (cfm) FRP scrubbers for a Hyundai 

semiconductor plant in Eugene, Oregon. The cusB

i e r

 specified that the systems must feature the 

highest quality corrosion-resistant materials. 

Along with the scrubber systems, Beverly Pacific 

provided fans, fan platforms, redundant circulation 

systems, chemical injection systems, secondary sump 

containment and a plethora of control and monitoring 

systems. 

The entire plant covers 500,00 0 square feet on a 

2 0 5 acre site. Overall construction cost was around 

$1.3 billion dollars, and will employ approximately 

1,000 workers once on-line. This was an important 

project for all concerned, and that meant getting all 

aspects right the first time, period. 

To ensure the success of the project, Beverly Pacific 

selected DION FR" 9300 and DION FR* 7704 resins 

from Reichhold for lhe 20 ft tall, 13 ft diameter 

scrubbers. The scrubbers' size mandated that they 

be built on a custom-designed mandrel using the 

two Reichhold resins. 

From inside to out, the shells consist of a 10 mil 

C-veil liner, a 10 mil Nexus liner, and a 100 mil 

resin-rich layer using DION FR 9300, followed by a 

0.5 inch structural layer using DION FR 7704. 

Conductivity and pH levels of the re-circulation 

liquids are constantly monitored and adjusted to 

maintain the most efficient scrubbing process 

possible. The five scrubber systems are installed so 

that mist eliminator assemblies, packing materials 

and other items can be maintained and cleaned 

without shutting down the processes the scrubbers 

support. 

About Beverly Pacific 

Beverly Pacific provides standard horizontal cross 

flow and vertical counlerflow scrubbers ranging in 

capacity from 1,000 cfm lo 60,000 cfm. Custom 

scrubbers are also available. Additionally, the company offers a wide variety of fans, mounts, VFDs and 

other scrubber accessories as well as a full line of 

FRP ductwork to couple the scrubbing systems to 

customers' fabrication tools and to the post 

scrubber/fan exhausf system. 

For more information on Beverly Pacific's capabilities 

and their use of Reichhold's corrosion resistant resins, 

contact Jim Cooper at (541) 548-0810 

REICHHOLD 
P.6 

( 

CR/FR TEAM EXPANDS, REORGANIZES 

hold has made several important changes to 

/FR Team. Richard Martens has been named 

Leader, and assumes overall responsibility for 

activities. Richard has been with Reichhold for 

ars, and has over 12 years of experience in 

rated polyester resin businesses. 

Jerome DeVilbiss has joined Reichhold and serves as 

Market Development Specialist covering the Western 

Region. Jerry's 25 years of engineering experience 

brings a new depth and perspective to the CR/FR 

Team. 

Richard Lewandowski, formerly located in Denver, 

has been relocated to Research Triangle Park, NC to 

focus on the Southeast Region. 

Bob Henrich has joined Reichhold and serves as 

Technical Service Representative specializing in 

iso/tere resins. Bob has 23 years of experience in 

various resin businesses. 

These changes are designed to further improve the 

quality of service Reichhold provides to the corrosionresistant and flame-retardant resin markets. 

Richard 

Lewandowski 

RESINS YIELD ASTM E-8 4 CLASS 1 FLAME SPREAD 

WITH REDUCED ANTIMONY CONTENT 

Fabricators will be pleased to learn that two flame-retardant resins from Reichhold Chemicals yield Class 1 

flame spread with reduced antimony contents, thus lowering the cost of fabricating premium flame-retardant 

FRP products. 

Testing completed by Factory Mutual of Norwood, MA has shown that laminates made using DION FR* 

9300 can provide ASTM E-84 Class 1 flame spread with only 1.5 percent antimony trioxide. This reduced 

level of antimony provides fabricators with a substantial cost reduction when using this premium flameretardant resin, and makes it easier to see and remove air bubbles when rolling out fiberglass laminates. 

DION FR* 7704 fire-retardant resin has also demonstrated ASTM E-84 Class 1 flame spread using significantly 

reduced amounts of antimony synergist. Testing has shown that laminates made using DION FR 7704 can 

provide Class 1 flame spread with only 1.7% antimony trioxide or four percent Nyacol APE 1540. 

"This is good news for fabricators, corrosion engineers, end users and anyone with projects requiring Class 

1 flame spread," says Richard Martens, Team Leader for Reichhold's Corrosion-Resistant and Flame-Retardant 

products. "These refinements have made outstanding producrfeven better." 

For more information on flame-retardant resin systems, call Reichhold's 

Corrosion Hotline at (800) 752-0060 

Rrth H< 

J1AC&DION 
P . 7 

LIGHTNING STRIKES & ATLAC HOLDS 

jre in Reichhold's ATLAC" & DION " literature 

>u find standards on lightning strikes, however 

;yvald, Inc. may have 

re-written the book for us. 

WARNING: Do Not Attempt 

This at Home! 

Red Ewald, Inc. of Karnes 

City, Texas fabricated two 

large tanks to handle highpurity deionized water for a 

semiconductor manufacturer 

in central Colorado back in 

1985. Twelve years later, a 

bit of a problem developed 

when one of the holding 

tanks was struck by lightning. The top of the tank 

experienced a significant 

surface burn and was left 

with two unusual three-foot 

wide streaks where the 

bolt(s) ran to ground. 

The interior side wall and bottom are still in perfect 

condition, and fhe tank is being rehabilitated to handle 

non-critical waste water. A 

new tank will replace the 

original one, now referred 

to as "Lightnin'." 

Reichhold provides several 

resins for FDA and highpurity water applications 

including ATLAC 382-05A, 

ATLAC 4010A, ATLAC 400 

and DION ISO* 6631 . Cure 

and conditioning are important factors, and details are 

provided in the preface of 

the "ATLAC & DION 

Corrosion Guide." 

Also, while it isn't included 

in the most recent edition of 

the guide, lightning-resistance 

is NOT a recommended 

application. 

ICBO continued from page 2 

resistance. This occurs because phenol-formaldehyde 

resins are condensation polymers that cannot attain 

the degree of corrosion resistance exhibited by vinyl 

ester resins. 

One way to protect vulnerable phenol-formaldehyde 

ducting is to use a thin layer of vinyl ester resin on 

the inside of the duct Unfortunately, any small imperfection in the thin vinyl ester layer exposes the underlying phenol-formaldehyde resin to chemical attack. 

Exposure to even a minor fire inside the duct will 

consume this thin corrosion barrier, thus compromising the corrosion-resistance of the entire duct. In addition, the exterior of phenol-formaldehyde duct may 

be attacked by comparatively mild conditions, such 

as heat and humidity. 

Ducting thai incorporates internal sprinklers will 

quickly extinguish minor fires, and preserve the utility 

of the duct In addition, FRP composites manufactured 

using DION* FR 9300 readily withstand the corrosi 

effects of most vapors. By using DION FR 9300 

throughout the duct, customers are assured of the 

highest quality chemical-resistance, and many years 

of trouble-free service. 

For more information on vinyl ester ducting recognized in ICBO ES Report 4055 , please contact 

Reichhold's Jerome DeVilbiss at (360) 733-1942. 

REICHHOLD 
P . 8 

REICHHOLD SPONSORS ATLAC & DION CASE HISTORY CONTEST 

Reichhold Chemicals' CR/FR Team is 

sponsoring a contest to find the best 

case histories on the use of our ATLAC* 

& DION* corrosion-resistant and flameretardant resins. The rules are simple: 

• Write up, in narrative form, fhe best 

application of Reichhold's ATLAC or 

DIO N resins by your company or by 

a customer/client of yours. 

• There are no minimum or maximum 

lengths. 

• Pictures are a must, and color is 

preferred. 

• Value is placed on: 

- length of application's service life 

- extremity of corrosive environment 

- ability to name end-user of the 

CR/FR product 

PRIZES: All bonafide entrants will receive 

an ATLAC & DION premium golf shirt. 

Top entries will be included in a future 

issue of Reichhold's "Corrosion & FR 

News" newsletter. The top three winners 

will be promoted through, press releases 

to their local media cfijd various trade 

publications. %._ /-SKf* |g 

3rd Prize - Premium Pen & Pencil Set 

2nd Prize - A Sony "boom box" with 

AM/F M radio, cassette and CD Player 

1st Prize - A 19" Toshiba color television 

Send entries to: 

ATLAC/DION Contest 

Reichhold Chemicals, Inc. 

P.O.Box 13582 

Research Triangle Park, N C 2770 9 

c / o Richard Martens, Mai l Stop 220-E 

ENTRIES MUST BE RECEIVED 

by March 1,1998. 

Atlac 382 continued from page I 

flexural strength of 16,200 psi, flexural modulus of 

9.1 x IO5 psi, tensile strength of 8,400 psi, and 

tensile modulus of 13.5 x 105 psi. These impressive 

results prompted a decision to re-line the original 

tank using Reichhold's ATLAC 382 resin, of course. _ 

Over three decades of successful performance in 

chlorine dioxide service provides real-world confirmation of studies which have shown that bisphenol 

fumarate resins provide the greatest resistance to 

chlorine dioxide bleach environments. 

Britt Engineering provided a specification to re-line the 

3 0 year-old seal tank and recommended that before 

the corrosion barrier was replaced, Reichhold's 

ATPRIME' 2 composite primer be used to ensure the 

highest quality bond to the existing tank. The lank was 

cleaned, and the old corrosion barrier was removed 

by grinding. All internals were checked and repaired, 

and a new corrosion barrier was applied. 

Prior to shutdown of the tank, the project engineer 

had noted that the tank, which is supported from a 

lower support ring, was being subjected to intermittent dynamic forces that were causing the walls of 

the tank to pulsate. The project engineer also noted 

violent deflections and rocking forces during normal 

operation. To reduce fhe dynamic stress in the wall, 

Britt Engineering added two horizontal trapezoidal 

stiffeners equally spaced on the side wall of the tank. 

After being subjected to 3 0 years of an extremely 

hot, wet, corrosive environment along with intermittent dynamic forces, the 

ATLAC 382 laminate 

performed very well in 

the harsh chlorine dioxide environment and is 

still going strong. 

For more information on 

this and other pbs completed by Britt Engineering, 

call Frank Britt, P.E , at 

(205)951-5691 For 

information on Reichhold 

resins in pulp and paper 

applications, call 

Reichhold's Jerome 

DeVilbiss at (360) 733-

1942 

^ I \( &DION 
P.9 

RPS MEETS IHE CHAUENGES Of f UH GAS DESULFURIZATION WIIH DION VER 9102 

rowing worldwide awareness of the need to 

reduce emissions from coal-fired power plants has 

high demand for efficient, reliable flue gas 

rization (FGD) systems. These systems scrub 

ioxide and other pollutants from the hot, wet 

that are generated by burning large quantities 

of coal. 

The need for high reliability despite the corrosive 

nature of these gases, combined with the breathtaking 

size of FGD systems, creates a need for carefully 

designed and expertly fabricated structures using the 

highest quality corrosion-resistant materials. One 

company that specializes in this exacting work is 

Reinforced Plastics Systems of Mahone Bay, Nova 

Scotia. 

Known as RPS, 

this company has 

dramatically 

expanded the 

range of products 

they provide to 

the FGD market 

through their 

acquisition of 

Composite 

Construction and 

Engineering, Inc. 

(CC&E). 

Custom piping designed and fabricated by RPS using 

DION VER' 9102 provides a key element in controlling 

pollution at French power generating facilities. 

This merger combines the industry-leading field 

fabrication skills of CC&E with RPS's high-quality 

fiberglass pipe manufacturing operation. The result 

is one-stop shopping for power companies seeking 

FRP solutions to highly engineered, corrosion-prone 

FGD equipment. 

The range of skills and expertise at RPS enabled 

them to win major projects at power plants in 

Cordemais and Le Havre, France. For these projects, 

RPS selected DION VER" 9102 vinyl ester resin to 

fabricate their speciality AA-Series Piping, an 

abrasion and corrosion-resistant pipe. 

" W e chose DION VER 9102 because it provides the 

corrosion-resistance we needed for the project, and 

was exceptionally easy to work with in our plant," 

says Robert Hawkins, Manager of Sales and 

Marketing. 

"Reichhold technical service representatives worked 

closely with RPS production staff to create a specially 

modified vinyl ester resin that has very good wetout, 

a controlled exotherm and optimized gel properties. 

W e find that DION VER 9102 works particularly well 

in fabricating small-diameter pipe components 

because of these properties." 

Much of the piping used in these projects handles a 

limestone and gypsum slurry in a distribution header 

inside the header absorption tower. "It's a fairly corrosive environment with hoi flue gas at the bottom of 

the absorber that rises up through a counterflowing 

slurry spray. In addition, design provisions were 

made to take into account possible process excursions 

that would further exacerbate the corrosive nature of 

this hot wet environment," Hawkins explains."These 

were also factors that led to our selection of DION 

VER 9102 for this project." In all, RPS used 110,000 

pounds of DION VER 9102 for the Cordemais and Le 

Havre projects. Pipe was fabricated in Mahone Bay, 

shipped to Europe and installed by a trained RPS 

contractor. 

Employing 25 0 people, RPS manufactures pipe for a 

variety of applications in Mahone Bay, Nova Scotia 

and Minto, Ne w Brunswick, Canada. The CC&E 

group produces huge custom engineered FRP equipment that is field-fabricated because the awesome 

size of this equipment precludes shipment. RPS also 

has a construction division in Bitburg, Germany thai 

performs field fabrication of tanks, process vessels 

and installation of piping. 

For more information on the capabilities of 

RPS/CC&E, contact Robert Hawkins at (800) 343-

9355. Regarding DION VER 9102, please call the 

Reichhold Corrosion Hotline at (800) 752-0060 

For more information, contact CR/FR Team Leader Richard Martens at 919 990-8007 Edited by Phil Bridges, Reichhold Communicaliom. 

REICHHOL D p o Box 13582 • Research Triongle Park, NC 27709-3582 • 800 752 0060 

ft 

9 / 9