Document rpG0V56QOn6D8yyGZqX79VjJv

r o J C ;'<* it* " c. J ' Mr. H.J. HalloCer. PMO. l>th Februnry, 1973- V.E. Mallows/ D.J. Bloodworth. Mr. J.J. Chappell. Hr. A. Santlghlan. Mr. R.R. Uzurilla. Mr. 0. Butler. Pile. Aebeatoa-froa Insulators - Foaeoo Ino.. U.3.A. Situation at 1/2/1973. 1) Profax 31. Ho further development work was carried out since the last situation report. Further investiffition of tho Alunino Silicate long fibre eystee gave disappointing results in Proflex (it was hoped to coin advantages with this system in Profax) sloes no ocnproolse could bo found between good flexibility and poor formabillty on the one hand (using no X1281) and good formattlity but loss of fleidblllty on the other (using 3(1281). Since Profax (no Asbestos) types contain 30281, the Mumlno Sill cats la too effectively dl ape read-and no advantage can be gained here. Purther oocsaunlcations have been received from Hedaten which again state that the Medean fibre (HCP) is considered to be non health hazardous. Poseeo Inc. have taken the*declslon to use this eieteriel if necessary. No further trlols hove been eade with ffi? at F.I.L. A new material X35&2. has been used with some suceesa at Inc. In Profax and their latest recipe (X3 1494) has been evaluated on a lab soale and on the SAM. AjU details are .ven in a separate report. XS1494 hes been tested successfully during plant trials at Inc. nnd the first field trials are now being carried out - results still sw.iited. XS 1494 has the edventage of low R.M. coat coapared with earlier rcdpei (contains no X}1$8) out still requires the R.M. 117/R.M. X1261 suspension systea, XJ562 esy-aTso be useful in improving the green strength particularly with one piece tops because of its needle like structure. 2) Proflex Gaskets - Ho further work oarrled wit. 3) Proflex Boards. As mentioned above, the idee of using minima pulped Alxslno Sllloete es a source of long fibres failed. Various other formulations based on different Alud.no Sllloete types and combinations with R.K.^46 and 3(2782 were tried but with no suooess either (mainly owing to poor fozmsblllty). A eunoary of the formulations tested is attached. U-) = FOS-0O-8GO0003S2& 14 62 2 The U.3.A. recipe 713 1500 was evaluated on o lab scale and on the SAM. There wae Indention In the board formed on the 3AM. Full details are given In the separate report on the properties of X >562. A steel pour test carried out on XS 1500 gave very poor results, l.e. severe penetration end slagging. Sumary and Conolualona. Asbestos la a nultlfunctional row- Baterla 1J^Insula ton manufactured by the aqueous slurry/pressure forming process. In each of the produet types In which It woe atteapted to replace, asbestos, different aspects of the role of asbeetoe were of aost laportsnoe. 1) Profs* 31. The Bsjor contribution of asbestos to this product la in slurry dispersion and suspension. It was found possible to match thcoo properties by using nooculated bentonite. The new raw material X35& shown promise in this product particularly from tire cost standpoint. XS 1494 or a modification thereof should be a suitable asbestos free Profax 'Jl. 2) Proflex Packets. Asbestos contributes slpiifloently to the oampreaalhlllty of this product type. Although no complete solution was arrived at the experience obtained during.the visit to Foseoo Inc. from 17/S to 2/9/1972 suggested that a reolpe of the 49G type should yield a solution. X55&2 may also offer some advantages In this product If not used as the main filler. 3) Proflex Boards. The.fibre bulk effect of asbestos together with suspension/ . filter sld properties. Is of paramount importance for tins application. Despite Intensive work using glass fibre, elusiino silicate fibre, slag wool singly or in combination It was not possible to match the performance of asbestos. (xivta) Initially Poseco Inc. had hoped to use this material.In a high proportion (95*) *a flUer/f1 bre. This has not been substantiated by subsequent teste which have ahown that X2562 does not Improve forooblUty and has poor refractoriness. (A_formulation containing 20* Alunlno Silicate and 75* X2362 showed even woree refrectorlneao). Therefore further development work Is required here. fros-00.00000e:j927 1463 nxAnii.v.Tio: c- p..r.. x:-i2 vx vo"co me., U.C.A. u: Tnurvo: a::d ____ Introduction: This ic->UTlal has b?an u?ed recently at Foseco Inc. In Profs* ProO.ex (Asbestos free) reelics with sane success os on old to improving the folding- ciwiTcteristlcs of these products. Since It wss thought that It could fulfil the du.nl functions `C fibre end filler to seme extent, t!.e material appeared to be ideal us a s*euns of simplifying tlie existing recipes, and its cheapness could bring about useful reductions in R.M. -costs. The short investigation was carried out to test the properties of the two latest re cl pen received from U.S.A. (l.e. Proflex X3 1-jOO and Profax XS 1*9*) incorporating K.M. X35&2* 1) Profax XS 1*0*. a) La born ton,- Seale Tests. .Small tiles of XS 1*9* and Profax were forced on the Profox hand machine and tho properties of each product compared. Tin recipes and mixing procedures are given in Appendix- 1. (l) Experimental results. Solids content % Suspension (clear liquid after 2* hours standing - 500 "l cylinder) Forma billty Fill time (secs.) Dewatering time (sees.) Tile thickness ' Nature of top surface Finished product Density (&/ck3) Steel pour test Muffle furnace Shrinkage test (1*00C) Profax 31 20 12.0 (clear supernatant) XS 1*9* 23 *3.0 (clear supernatant) 20 15 l" - 2" Flat - no indents 20 30 ii- - 2"'Flat - no indents 0.8l (See Appendix 2) 0.85 shrinkage practically nil in all cases (all samples of equivalent hardness when hot). Fos-ee-QeeeQe^qgg XS 1 A''1 .--ppesreb to he equivalent to Profs x 31 in it:: main properties. Ir. order to fully test Uie slurry for;:inf. pivr-'rtics, the above tests were repeated for >3 1*9* on the SA M. (h) SAM t:.-=t-. * Large boards 1.5 metres x J7 ca were ferase U since these gave the most severe fencing eencJlticr.s. The properties of XT. 1*9* wrrs compared with those ef I'roiax J1 foi-.:rd under similar cendit ions. (i) Experimental results. Solids content % Machine characteristics - Pressure (line) Pump ('fora) time (secs.) Dewater time (aecs.) Tile thicknsss (inches) Formability Creen strength Profax 31 { 18.9 XS 1*9* 30.0 *0 p.s.i. 12.5 15 25 0.9- *5 1.0 Very smooth top surface - very even fill - no cavitation Reasonably smooth top surface - even fill - slitfit. cavlta tion. Good Adequate for board Conclusions. Formability of XS 1*9* was almost as good cs Profax .31. and most of the other prcjv-'rties were equivalent, with the exception of the dewatering time wiiich es lender. XS 1*9* therefore appears to he a satl-afaetory replacement for Frofax 31. 2) Proflex XS 1500. a) Laboratory scale and Sffi tests. XS 1500 was compared with Proflcx CJ using the Hand machine and the SAM as for Pretax. Recipes end mixing procedures are Given 1 Appendix 5'. FQS-"3929 (1) Expert rt'.rtnl resultn. Hand rv>chine SAM .'.'ollds content % oruablllty 1 \l( pump) tl.ee (sees.) swale ring tlsa (sees.) lie tillckrcss orxablllty 91 XS 1500 5.9 - 5.0 - 20 -6 - 20 era Excellent flat Slight surface^- no Indentations Indents. 91 x<3 iyj:i 4.9 * 5.0 20 20 15 20-25 m 10 to. 25 i Flat surface - Ea*.rd no Indents, Indented. iniched product .nsity (a/csO) Icxiblllty/C--r.pressibi lity Good 0.45 Excellent Compressibility Slightly flexible Good 0.4(7 Flexible- am cou.p.'csslbl1 but poor strength tuel pour test 'ot strip (1 hour) Board residue fairly easily removed clean surface Back face glowing red before strip - apparent severe penetration old strip Fairly rough surface with slight bum on Very severe slagging and penetration. a me Fume ce n-inkage Test (1400C) Sample Intact Poorer hot strength than GJ. Arse shrinkage 10.9# Sample remained .. . intact - good hot strength. Area shrinkage >0.75 (11) Conclusions. XS lpOO Is an inferior product to Proflex GJ and :ould be unsatisfactory both for boards and gsshets sines the refractoriness is low. Apert from tills the SAM tests shoved that formabl 11 ty was unsatisfactory, and the dry strength of the cured product was poor. FOS--00~00000035 3 1466 >) 1: `ir. of Further te.--.l--. v.:ra c.'-'-ried out using Xjj2 in previous recipes which had :c:.ti some iirc-sd cs and i:i modifications of XI 1 .CO to try to evcrecRB Its dis-silvanonpar,. a) HeeiiiC i*C lVi. f'.iis was ? board reeJ which had previously plvcn satlsf '.etory format!lity using 11.li. 1J1A as filler but the cured bcniits were too friable. R.M. Xy/SJ. was used as a direct substitute for R.M. l^lA. Recipe: (see Appendix A). Experimental results: (Hand machine). Slurry dispersion - Good. Formabillty - good (flat surface). Cured tile - good compressibility but no flexibility. b) Heelp;S ?3 133 r.nd PB 15S. The resin content of PB 1}4. was reduced in order to Improve flexibility (P3 125 contained 0.r//> 4683, and PB 1}6 1.05 466B). There was no improvement in flexibility w*:i<-.h Indicated that it-was the XJ5&2 rstner than the R.M. 46Cn which was primarily responsible for the low flexibility. (Microscopic examination of the material showed that it consisted of needle like orystals which it is thought probably interlock to form a riGid structure). It was also observed during this test that the excessive fonm proluced caused segregation of fibres and filler. (For recipes sec Appendix *5). c) Recipes P3 377, 1>9 and 139. (Appendix A). Keel pc PB \yi was cade to confirm the apparent "inflexible" properties of R.M. XYi&2. The board was not flexible and strength was poor. The forming properties were also unsatisfactory (* flat but Indented scut-face was obtained). The compressibility was also low.. This test-indicated therefore several deficiencies of X3562. rieclpe ljQ nnd 1'9 were made to try to increase the flexibility of t)ta previous series (PB 1>*-1^5) by using an interardiate X27I-2 content between that used in XS 15 and in PD 1J4-1J5. The results were again disappointing - no improving in flexibility being achieved. d) Recipe PC HO and Hi. (Appendix A). Because of Vie poor refractoriness of 73 1500 these formulations were tested to try to improve this. The foi*sabllity of both nlr.es -..-ns not satisfactory - the boards being Indented. Flexibility was also poor, but refractoriness ns assessed by the Muffle FXimace shrinkage test at ^ .... ... m .. ...... v W-.^, 1 FQS-00-0000003931 1467 ATvvu.'PIX 3A. Hcclrws - Profax 31 and XS lag-*.. (1i*nd machine tests).' 131c * (1310) ft ay ft63a * (177A) 265* 319 ft52 (5ft6) 122* (X1790) X2782 117 X1281 X3562 Pi-nfax 31 ` 75.92 1.37 ft.33 2.09 1.06 IO.63 3.80 - _ _ - X". HTf'i Cl.) 1.0 3.0 - 2.5 0.5 1.0 0.1 30.0 * Sines the original U.S.A. R.H's were not available, the nearest U.K. equivalents were used. Mixing procedure (Masternlx pulper). Profax 31; Solids weight - 3 Kg. Water addition - 12 Kg. Solids - 20.0 1) Pulped R.M. *152 with 6 litres water 1 min. 2) Pulped R.H. J19 + 265A ft litres water nin. 3) Pulped rest cf R.M's (except 122A) 7 mlr.. ft) Pulped R.H. 122* + 2 litres water 15 sees. XS lft9? Solids weight - 3 Kg. Hater addition - 10 Kg. Solids - 23.0 1) Pulped all R.H's except 117, X12S1 and 122* with 10 litres water ^ aln. 2) Sprinkled in R.M. 117 while pulping { nin. 3) + X1281 20 sees. ft) + 122* 10 secs. Fos-0O-a00ae>a3S32 'Tj; * - !*~cfvx '1 r.7\:i XS 1310 hH'f A6SH ' (177A) i?.a\ * (X1750) X27C2 X35^* 117 X1201 131C (1310) 265A 319 5*6 X1790 Rrof.^r. 31 o.es '1.36 - 76. *6 2-91 1.07 10.70 3.82 . XS 1A?H 61.9 1.0 3.0 2.5 0.5 30.0 1.0 0.1 .. - * U.K. equivalent R.M's. Mlxlnr procedure (90 Bill, hydropulper). ' Profax 31? Solids weight - AO Kg. Water iddition - 172 Kg. % Solids - 18.9 1) - Pulped P..M. 4A7, 1:65b, 131C with 8l litres water for 2 mins. 2) Added R.M. 263A. 319, 5*18. plus 6oj litres v;ater - pulped 2 mins. 3) Added R.M. X17S0 pius 30* litres water - pulped 1-2 .tins. XS 1119A : Solids weight - 50 Kg. Vi\er addition 117 Kg. % Solids - 30JS 1) Pulped all R.M's except 117, X12S1, 122A with 110 litres water for $ min. 2) Sprinkled in R.M. 117 during rain, ..Idle pulping. 3) Added X12S1 plus 17 litres *.ter - pulped 13 secs. 4) Added R.M. 122A - pulped 13 sees. FOS--5<522 U69 Arrr.;:DTX ... Prefer. ~)1 r.nd XS lftQA. Steel Pour Ti.r.t. One tile (10M :: ?" l") of each iMtcri.il wen used v.o line two sides of a steel box into which molten steel t ca. lfcOOC i.-^s tce=x*d. After one ho*ir, the box was removed and the tiles atrir.p'.'d from the eastirr,. T/ie surface characteristics of the metal were examined when the casting had cooled. Hot St.-lD (after 1 hour) Profar 31 Tile residue fairly easily removed clean surface. XS l9t Tile more difficult to remove - conslderaole bum on. Cold Strip Fairly s-.-.ooth surface Slight bum on. Smooth surface, no bum on. Tile residue next to metal surface sintered. Easily removed. Hie performance of XS 1*9^ was considered to be equivalent to that of Profax 31 rOS-00-00000e3<534 1A 7 0 hPi'-r.'Hr. Prciccs - Proflcs G3 *nd XS 1 5=0. 1[llcnd rschine tents). X2Y82 y.yjte 4S3a y.1281 1J1D 265A X22S6 Pro Pcx C3 .0 - 2.0 0.5 51.0 15.0 25-5 . X3 ]=( 4.0 94.6 0.8 0.5 0.1 - Kixlnp procedure (Masteraix pulper). Proflcr. 03: Solids weight - 1 Kg. Wnter addition - 15 Kg. J6 Solids - 5-9% 1) Pulped X2782 + X128l for 1 min. (with 7^ litres water). 2) Added R.K. 2G3* 2-<i litres water - pulp 1 min. J) Added rest of R.K's plus 5 litres water, - pulp 1 min. A) Added 5 litres water - pulped ^ min. X5 1500: Solids v:ci-,ht 800 pTin. Water addition - 15 litres. % Solids - 5.0$ 1) Pulpart X27&2 * X128l * 10 litres water - pulp 1 min. 2) Added XJ562. 447 - pulp $ min. 5) Added 5 litres water - pulped 15 secs. Fos-ao-000aae35 35 1471 __Profit** r- '> end X.* 15*M. (MH tcr.tr.l. >12732 X33! nm X1281 1310 265A X22S6 Proflex C3. 6..0 2.0 0.5 51.0 15.0 25.5 XS 1SOO 4.0 94.6 0.8 0.5 0.1 Mlxlnn procedure (Kastenelx pulpar). Pro flex G3: Solids weight Water addition % Solids 20 Kg. 385 litres. *9 1) Pulped X27C2 * X1201 + 121 litres for 2 rains. 2) Added 2oi>A <30 litres water - pulped 1 min. 3) Added rest-of R.M's and 60 litres water - pulped 2 mins. 4) Added rest of water - pulped rain. XS 1500: Solids weight - 10 Kg. Water addition - 190 litres. Solids - 5*0 1) Pulped Xl?Sl * X2YC2 + 110 litres water for 2 rains. 2) '-.ddqd rest of JJ.n!* end itater - pulped 1 rain. r OS-C0-00000(j3q3fe cm 4r6f000000-o&-soj a S33S oC - * ,H'M jay'io psppv (C 53SK cC - X82XX * XQLZX. pappv (2 SODS OX " ww saJ^TT OX n>XC.X P<TM (I XVX Ud sasr oC - *,H*U Jaipo PPPV (2 _______ sao3 OX - *** CPJ^XX Ot * goXCX padWJ (X 01/X Ed *(aadtnd XToua-vctr,)} :anps3o.id priil TO S'O 8*0 0*9 9*21 O'02 T*X " 0*2 - 0*90 0"2X OtrT Bd X82XX ilru 089* 28JJZX 29SCX GSxCx X'O S'O 0*8 B`o 9`c5 Kl ups pod"nd - j8ic.`A swivt S P*PPV upu X r JaaM canTX OX * B25*r E9SCX P=dxry (2 (t 'Kl i u*B ^ p - J0iCi\ 5CJ1TX poppv ut T potfTnd - s.WVI JO'-llo psppy *"1" X - -MU** canVX OX * 28IZX. + X82XX PtXM (C (2 (X (jodxnd XTBuaasM) 6CX 'gt `Sft 'SCX 'KX <! .-sjuposcuc isupcjl-l X'O S'O 0*9 B'O 9'cG SCx O'T o*6 za C'O - 0'2X D`t L'9d 9a C'O - 0'2X S'O 2`4) CCX ' C'O - 0'2X 0'2 2.-S 9 *CX Od ' X92XX hiii 2R/2X 08?* 29SCX IJV t 13* 65.7 2.0 12.0 - 0O 135 07.2 0.5 12.0 - 0.3 136 86.7 1.0 12.0 - 0.3 137 97>-0 1.0 - - 133 92.6 0.0 6.0 0.5 ` 0.1 ig. procedure; (Masteraix pulpcr). -35. 133, 1J9. .pad X1281 X2?82 * 10 litres water - 1 win.` Jed other R.M's - pulped ^ nin. ded 5 litres v:atcr - pulped ^ win. 139 90.6 0.8 s.o 0.5 0.1 Pulped X35&2 + 4S8B 10 litres water i 1 min. Added 5 litres water - pulped nin. X319S .X3562 X2782 4633 . 447 X1231 PB 140 12.0 06.0 - 2.0 141 20.0 72.6- 6.0 0.8 0.5 0.1 Mlxlnc proccdur*; (Mastonoix pulper). 1) Pulped X3193 * 10 litres water - 10 secs. 2) Added oilier ft.M's - 30 -ecs. 1) Pulped X31?S 10 litres water - 10 sees. 2) Added X2702 X128l - 30 sees. 3) Added other R.M's - 30 sees. FOS-OC-0000003937 1473 g, procedure; (Masterssix pulpcr) j5, 138, 1J9. ped X128l + X2782 + 10 litres ter - 1 win. ed other R.M's - pulped ^ nin. led 5 litres water - pulped -jr win. Pulped XJ562 45CB + 10 litres wster 1 win. Added 5 litres water - pulped ^ min. XJ1S3 XJ562 X2782 453il . 447 X1231 PB 140 12.0 06.0 . 2.0 - 141 20.0 72.6- 6.0 0.8 0.5 0.1 Mixing procedure; (Kastcrmix pulper). 1) Pulped XJ193 - 10 litres water - 10 secs. 2) Added oilier R.M's - JO secs. 1) Pulped XJ1?3 10 litres water - 10 sees. 2) Added X2?*fe * X1281 - JO sees. J) Added other R.M's - JO sees. FOS-ao-00000Q3j37 1473 *ri 155 87.2 0.5 12.0 0.5 156 86.7 1.0 12.0 - 0.3 137 93.0 1.0 - - 133 92.6 0.8 6.0 0.5 0.1 _c: (Masterair pulpcr). 59* - XZfBZ + 10 litres water - 1 min.' .M's - pulped oin. s water - pulped -jf min. 159 2 46GB + 10 litres water .res water pulped $ oin. PB 140 12.0 86.0 " 2.0 - 141 20.0 72.6 6.0 0.8 0.5 0.1 : procedure: (Masterwix pulper). Pulped X51?3 * 10 litres water - 10 sees. Added oilier n.M's - >0 aees. rulped X'5193 10 litres water - 10 secs. Added X'Stfci * X1281 - 30 sees. Added other R.K's - 50 sees. FOS-O0-ca00OCj937 _ 1473 ftppn;r~" 5. Muffle Kur.vic* Shrin'-^rc Test at 1 <iQOC. XS lf/PO and Pnv<*\~.-. 0'S - Staples remained Intact after 1 hour a? wiougr. xITTfiO) ws rnoi-e c.ir.ily brehen down. 5 shrinkage (area) - CJ JO.7? XS 1500 10.9JS Recipe IT/ - Melted In contcet with the silicon carbide platr. :r:t to a lesser extent than the fibre clone. Recipe 1^1 - completely melted. X35C? - partial melting in contact with silicon csrbidr pitr. I i* 7 4 FQS-0a-0a000C3<j3o