Document b5NnBOyBBaYmnGa4RdgpLwOoD

IN'TER-COMPANY AND INTER-DEPARTMENTAL CORRESPONDENCE TO: I'r-r3- ' "~i~irr (Prl.-hiy- ( lTT . from: Robert R. Dzurilla oate: November 9, 1572 I .. ^7*n b*f4 SUBJECT: HfP'.f PATH/T rSsL L.i Li LAUli IE -- cosiT.Niiiinft i..jwLa.ii.Ri. WTDIOALJ *~nrr 23fct/32i--> - - ttkda <*-*. Upon receipt or a sample cf l!cd=r.r. Fundamental Cationic Fibre (HFCF) a number of laboratory experimental teats were conducted in order to deter mine the benefits and range of percentages that HFCr could have in vacer base PUOFLEX-' and PROF/VX* slurries. Tests as.to the compatibility of HFCF with various refractory fillers (page1 S3) without the use of asbestos were very encouraging. The refractory fillers which were tried in our basic PIlOFAX-' 31 included Anthracite coal, olivine, calcium silicate, KagnesiLe, nullice, hycnitc, alumina, grog, chrome magnesite and silica ilcur. All of the fillers formed well and the physical properties 36}* obtained fren the pads were encouraging. The following recipe was used for the filler tests. Haw Material Filler . . HFCF (other designations 1-5236 & X322C) Resin Slag Wool Diatotnitc 76 4 5 11 4 The urgency of the removal of asbestos from hot tops used by REPUBLIC STEEL began in September of 1972. The original PROFLED* G recipes used by REPUBLIC STEEL in their hot top insulator boards and one-piece tops contained 15Z asbestos. The reelpe which was designed to replace the PROFLEX-' G series v;as in the fora of EP-5257/PROFLEX (formerly X514S3B) (fpi 79}. EP-5267/PRTFLSX* Recipe Raw Material 7. SiliJa flour Dlatouitc Resin Alumina Silicate Fiber Fiberglass HFCF Asbestos 49 23 2 10 6 7 1 1319 -2- Tiie li'r'Cr is primarily as a suspension and dispersion agent. Suspension tests were conducted ()iu n1 OOfr* on EP-57.67 vich and without the use of MrCF. The test uses a 1000 ml. graduate which has a height of 14" and is 2-3/S" in diameter. The slurry to be tested is nixed veiland poured to the 1000 nl marker.1 After intervals of time, the solids settle and in some eases rise. The liquid which divides the single or double layer of solids is measured and recorded as 2 water. The formulations which have a tendency to slov;ly rise to the surface are the hotter suspension slurries. The experiment shevci^that the slurry with U?CF did rise and had a betteroverall suspension of 16" water e.s compared to 277, after 15 minutes. Fifteen minutes is Che optimum time used for all slurry suspension teats. Dispersion of the fibers is something that can only be seen and not measured. HFCF in combination with a surfactant disperses fibers sufficiently to.fom . a homogeneous slurry which is necessary for "rood fiber orientation during the forming cycle.on production machines and satisfactory surface texture of the various shaped hot tops. Three production runs totaling over 2,000 hot tops were produced successfully' on production machines from E?-5267/PROFLX^. Hot tops included one, three and four cavity tools. Toe 571 and 572 (napes-3> end-Tg^ were the part numbers produced on Foseco Hark III machines. Physical properties including the Amitec net heat transfer (a*au were all satisfactory. Only the resin level was adjusted no the optimum during the first production run. Verbal reports from the field have indicated yields have increased 22 at REPUBLIC STEEL, Warren, Ohio with the usage of our EP-5267/PR0FLTX'-' hot tnps. The minimum amount of HFCF needed for proper suspension and dispersion of fibers in a PR0FLE>f' and l'ROFAJ^ recipe is 72 09). The range of from 42 to 1007. HFCF was experimented with to water bate slurries (page* 831 03; '00*, 91 The first experiment was tried by using 1002 HFCF slurried in water -(im .ir-OD). The solids concentration was too low and all the slurry passed through the screen. The second test conducted was with 962 HFCF and 42 resin (pane at a higher solids level but again the lurry passed through the screen. Tim* fulluain.r. ^ests were conducted with levels of HFCF at 902. 702, 502 and 302 in a PXOFLZTf* type recipe. The form ing times were affected greatly as thd HFCF was reduced. The forming is consi dered to be Che time it cakes a pad to be formed from the slurry. Forming time is very Important for it is one of the determining factors to whether it can be made at ell or produced economically on a production basis. The best range of HFCF in P30FLEX * is from 72 to approximately 302 because of the satisfac tory physical properties and most important being the farming times. The range from HFCF from 302 to 902 formed satisfactorily but the forming tines were much too high to make It economically feasible to produce even thourh the ocher physical properties such as strength and density were acceptable. 1320