Document gbjKQ5KKMBgN6bLOx0LobQmYq

STEEL MILL PRODUCTS DIVISION RESEARCH & DEVELOPMENT DEPT. SEPTEMBER 1973 I Non-Asbestos Profax (a) Plant Experiments An experimental run was scheduled on September 7, 1973 using EP-5273F for Armco-Middletovn boards. Mark III 'E' and '?' macnines were employed for this experimental run. During the experiment, the recipe was changed due to surface roughness by decreasing X2782 content from 1.0Z to 0.75Z and X3580 from 0.25Z to0.19Z. After these changes (made on the 3rd batch), the run was smooch without any technical problems and the boards were acceptable from Quality Control standpoint. Since September 18, 1973, EP-5465 (the new recipe number for EP-S273F modified) became a production accepted recipe for these two accounts. Within two weeks period we experienced, with EP-5465, intermittently excessive foam formation. The foam formation is attributed to X3560 which is not accurately added. EP-5465 was also tested on the 1-Pe machine using tool <7669 for Republic-Canton. The experiment was ran on September 24, 1973 and 30 tops were produced. The preliminary field trial was successful. (b) Laboratory Experiments and Tests EP-5465 (which is non-asbestos and non-paper recipe) is using a new binder, X3579 (PVAc) besides RM-177A(1.2Z) and RM-447 (1.5Z). The transverse strength ranges between 250-290 p.s.l. and the density between 0.75 g/cc (K4), 0.80 g/cc (1-Pe) and 0.32 and 0.88 g/cc (Hark 111). ...Because the total binder content for EP-5465 is higher than Profax 31 (6.25 vs. 5.58), a burning out test was ran comparing Profax 31, EP-5465, EP-5452A and EP-5465 modified (RM-177A replacing X3579). The test results are: --.EP-5465 modified lost 24Z of its initial strength i -- Profax 31 lost 59Z of its initial strength -- EP-5465 lost 79Z of its initial strength ----- EP-5452A lost lOOZofits initial strength. 1682 Steel Mill Produces D\, .sion Research & Development Dept. September 1973 Page -2- The burn-out test was ran for 1-1/2 hours at 550*F. The above results are relevant concernina the superiority of using RM-177A instead of ocher binders. Our further lab experiments showed that EP-5465 needs 30Z less RM-177A chan Profax 31 besides RM-447. RM-447 was replaced in EP-5465 with X3211 (U.F. liquid resin). The replace ment was made at the same percentage despite Che less solid concent of the U.F. liquid used. The friability test showed no differences and the conclusion is chat X3211 gives Che same properties as RM-447. EP-5465 was said to be less permeable in - green -stage -than Profax-31- during_a plant-experiment______ ____________ _____________ We have cried different air pressures for forming and dewatering processes under lab conditions. 2.5, 5, 7.5 and 10 p.s.i. were cried using EP-5465 and Profax 31. Both slurries were made under production procedures and the tests showed that EP-5465 is more permeable chan Profax 31. The dewatering problem was attributed to the tool. (c) Miscellaneous The raw material cost for EP-5465 has initiated a careful investigation, exploring the possibilities of leveling it at Profax 31. The raw material cost analysis showed that there are two main factors which are determinant: ----- 21Z less KM-131D did increase Che raw material cost for EP-5465 with 17.4Z, and ----- the usage of X3679 instead of RM-177A did increase the raw material cost with 6.8Z. The overall cost difference is 21.7Z. Under lab conditions, we found Chat EP-5465 calls for 30Z less RM-177A chan Profax 31 and also X3211 instead of RM-447. In each of the above modifications are considered, the EP-5465 raw materials cost drops to 11.9Z. (Profax 31 raw material cost was considered also in the hypothes chat X3211 is replacing RM-447). Taking into .consideration chat the machine productivity is 5-SZ favorable co EP-5465, Che usage of green and dry scrap is positive, the oven cycle is 10-15Z lower for EP-5465, the overall cost is at least equal co Profax 31 if not favorable co EP-5465. Another important factor which should be taken into consideration is chat EP-5465 is designed and the preliminary results confirmed co replace all ocher Profax type recipes. 1683 Steel Mill Produces Division Research & Development Dept. September 1973 Page -3- In that respect, we will foresee only one or two Profax type recipes in production (considering the non-asbestos paper bearing recipe replacing; Profax 10, EP-3408, EP-3901 S.O) which will assure more accuracy in preparing batches. _ Non-Asbestos Proflex * (a) Proflex Boards and Tops The lab work is under way and ve can foresee, after 2-3 weeks, the -possibility-of developing -a material with-acceptable-flexibility and--less .com-. possibility. (b) Seal-On Rings XS-L5303 has been perfected under lab conditions since June 1973 but we haven't had the opportunity to experiment with it. Replacement of Silica in Profax-Proflex Materials The silica replacement work was revised with some encouraging results. However, the raw material cost for non-silica, non-paper recipe will be twice as much as present Profax 31 recipe raw material cost. Premix Pro fax at Bethlehem-Johnstown The average scrap rate for the month was 0.441 versus 0.497. last month. The transverse strength and density were 277 p.s.l. and 0.37 g/cc compared with 272 p.s.i. and 0.86 g/cc. The data consistency since the production was switched to Mt. Braddock should be pointed out. Bethlehem-Johnstown is using Premix Profax material contain ing the new binder. The material works well with no major technical problems occurring. The leakers and boiling problems, which occurred during the month, are attributed to their castings and molds situation. Miscellaneous During September, we have received two samples of non-asbestos non-paper boards made,, by Ferro Engineering and PMP. "*1 * I These samples contain the same raw materials we are using in EP-5465. This fact probably will force us co accelerate the EP-5465 production implementation. I 1684