A major fiberglass manufacturer in the southeastern United States experienced frequent clogs from silica
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This guide compares and discusses the features and advantages of various types of ceramic packing media to improve energy efficiency, increase operational uptime and reduce operating costs
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How would your company withstand the impact of a $33 million fine? That would be the amount in today's dollars (adjusting for inflation) of the $25 million fine against Tonawanda Coke Corporation in New York in 2013 for violating the Clean Air Act and Resource Conservation and Recovery Act.
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Regenerative thermal oxidizers (RTOs) and other types of thermal oxidation systems have proven to be a highly effective and energy- efficient method of abating volatile organic compounds (VOCs) and other pollutants emitted by finishing industry applications
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Knight Material Technologies, a leading provider of custom acid-resistant linings for the chemical process and mining industries, announced today the opening of its new state-of-the-art facility in the Houston area.
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Learn the challenges in designing an autoclave that requires different materials in order to perform in a high-temperature and high-pressure environment.
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In a recent move designed to strengthen its core competencies, Knight acquired Electro Chemical Engineering and Manufacturing Co. (ECM) in Emmaus, PA. Electro Chemical also operates a division in Vancouver, British Columbia, called Superior Dual Laminate Products (SDL). This merger gives customers unparalleled access to the broadest available range of products and services in the corrosion protection industry.
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A leading defense contractor on the U.S. West Coast operates five absorption towers as part of its manufacturing stream to fabricate specialty alloys. The company needed to inspect and repair its processing columns during an annual preventive maintenance period to ensure compliance since many states are tightening air quality and environmental regulations.
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Fertilizer producer Mosaic recently replaced a 40-year-old brick lined drying tower at its unit 10 sulfuric acid plant at its South Pierce facility in Mulberry, Fla. Where the old tower once stood is a new MECS ZeCor®-Z drying tower, which came online last February after a quick 16-day shutdown.
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Knight Materials has been investing for growth, most recently in the form of a new kiln that adds capacity at its local plant in East Canton.
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The addition of robotic automation is one of the many initiatives the company has taken in the past year to meet increasing customer demand for KMT's structured packing media used in corrosive and high-temperature applications found in industrial plants and towers.
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Fertilizer producer Mosaic recently replaced a 40-year-old brick lined drying tower at its unit 10 sulfuric acid plant at its South Pierce facility in Mulberry, Fla. Where the old tower once stood is a new MECS ZeCor®-Z drying tower, which came online last February after a quick 16-day shutdown.
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Semiconductor chemicals and fluids are increasingly coming under higher scrutiny as semiconductor circuitry shrinks to microscopic sizes. What does this mean for sheet linings? Eliminating contamination is key to keeping the purity of the high purity chemicals from production to transport to storage
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Pressure Oxidation (POX) autoclaves have become the main method to recover gold, copper, nickel, zinc and other metals, but they work with corrosive conditions at elevated temperatures and pressure.
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Fluoropolymer linings are a proven cost-effective solution in many corrosive environments. Properly selected, they are less prone to chemical attack and less fragile than other lining options. Fluoropolymer linings can also be repaired and replaced to extend the life span of the equipment they are protecting.
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Although dual laminates have been around since the 1960s, finding a universally agreed upon set of best practices for incorporating these fiber reinforced plastic (FRP) thermoplastic-lined products into your tanks and piping systems is nearly impossible. In fact, the first standards for welding of plastics, including liners, were not even introduced until 2015.
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When you talk about fluoropolymer lining protection against chemical corrosion and permeation, PFA (perfluoroalkoxy) delivers the highest level of resistance. We can thank the strength of the Fluorine-Carbon bond within the PFA polymer chain for its incredible inertness. These bonds are so tight and enduring that they simply do not allow other atoms or molecules to separate them. This makes PFA the strongest of the fluoropolymers for preventing chemical corrosion, permeation, and reaction.
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Since 2005, Electro Chemical Manufacturing has been providing protective fluoropolymer linings for rubber liner repair projects in the Biodiesel Industry. Biodiesel production equipment depends on the use of corrosion-resistant materials. While many plants rely on soybeans to make this sustainable, eco-friendly fuel, an increasing number are using even more corrosive waste oil from the restaurant and foodservices industry as a feedstock.
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Picture yourself as the Plant Manager in one of the many industries that relies on specialty alloys, glass linings, or other corrosion-resistant materials to protect your equipment and keep your production running on schedule. You’ve just gone into shut down for annual maintenance. Your inspection team informs you that your critical process vessel is shot and needs to be replaced. Not what you wanted to hear, obviously.
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When working with chemicals, the job of a lining is to either stop the chemicals from eating through their containment or to stop the container itself from contaminating the chemicals within. In the first case, we’re fighting chemical corrosion and permeation. In the second, we’re protecting chemicals that require ultra high purity to be effective.
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The Dow Chemical Company and Electro Chemical Manufacturing earned the Materials Technology Institute’s (MTI) 2016 Global Value Award for applying Materials Technology Institute (MTI) guidebooks as they collaborated on a scrubber repair project that solved Dow’s corrosion problem while also enabling them to save significant time and money.
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PVDF offers excellent chemical corrosion and permeation protection in a wide variety of applications. It’s very effective against chlorinated and brominated solvents. It’s very malleable and easily shaped. When bound to a substrate, depending on the chemicals involved, it’s thermally stable in temperatures up to 230°F. It comes in a range of sheets and resins and is significantly less costly than other fluoropolymers or exotic metal alloys.
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Lining of a spent sulfuric acid storage tank required repairs to be completed on-site within 2 weeks to avert a plant shutdown. The plant engineers were provided with three options 1) Install spray-on epoxy liner; 2) Remove the tank and have it recoated with a spray-on fluoropolymer or 3) Have the failed lining stripped and a new sheet lining installed in the field.
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A 68” I.D. x 198” straight side “tank container” had been previously coated internally with another manufacturers spray applied system, which had failed to prevent metallic ion contamination of the load. The chosen lining system would not only have to acid resistant but also not impose capacity restrictions because of its weight and be extremely resistant to both the thermal and mechanical shock associated with the container transportation.
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A chemical manufacturer had (6) 300-gal glass lined reactors containing mixtures of hydrochloric acid (HCl), acetic acid (CH³COOH), and various other reactants. Physical shocks frequently caused minor damage in the form of small chips in the glass lining. These chips routinely were repaired with tantalum alloy plugs. The tantalum alloy plugs were ultimately determined to be a contamination source. A decision was made by the production management to keep spare glass-lined vessels on site and to completely replace damaged vessels, rather than repair them with tantalum plugs. The heavy expense of changing out and relining the reactors each time the glass chipped eventually made this option unacceptable to management.
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CCR Refinery, a Glencore company and industry leader in copper refining and precious metals processing, had to shut down one of their two production lines every two to three months to repair the PFA lining. The repair costs as well as lost productivity were a growing problem.
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A large specialty chemical company had experienced multiple equipment failures over a period of several years in a reaction process involving an aqueous hydrogen fluoride (HF) solution. The reactor vessel and internal components were constructed of nonferrous high-nickel alloy. The alloy welds were being chemically attacked, and certain components, such as the agitator experienced life cycles as short as 3 weeks. The extremely high cost of downtime and maintenance over a sustained period drove the process engineers to seek alternative solutions.
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A prominent company’s agricultural chemical division struggled for years with the difficult handling process utilized for loading and unloading a highly corrosive material into small containers. Their process required filling 100 plastic drums with this acidic material which normally took 8-10 hours to complete and tied up more resources than desired. The issues with this process of small container loading caused the project engineers to re-evaluate the situation and consider alternative solutions.
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A leading nuclear facility needed to replace their older chemical water treatment tanks, have new ones installed and utilize a PADEP certified provider to validate the installation. They also needed a proven general contractor to manage the process due to the importance and sensitivity of the project. These chemical water treatment tanks are vital components of a process that controls water chemistry and biological pathogens for the facility’s cooling water system.
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In the summer of 2013, a major semiconductor chipmaker needed someone to haul away its sulfuric acid co-product, a combination of sulfuric acid and hydrogen peroxide (also commercially known as Piranha solution). This material is a highly corrosive liquid and only certain types of trailers are properly equipped to move it safely.
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Technicians at the Buckman Water Reclamation Facility (WRF), JEA’s largest wastewater treatment facility, found that the monolithic ceramic block media within the RTO frequently clogged with silica powder, a byproduct of siloxane found in wastewater.
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Electro Chemical provides a comprehensive welded steel preparation process video describing the required specifications for preparing welded steel tanks, stacks, ducts and other fabricated equipment for fluoropolymer linings.
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Tres empresas especializadas en avanzadas tecnologías para control de la corrosión ahora se han asociado, lo que permite a Knight Material Technologies (KMT) ofrecer soluciones de ingeniería y protección más integrales a la industria de procesamiento de ácido sulfúrico y a los usuarios finales. Esto proporciona a los productores un resguardo 3 en 1 en protección global del ácido sulfúrico al trabajar con tres compañías, cada una con su propia especialidad, bajo un mismo paraguas corporativo. El año pasado, KMT añadió a Electro Chemical (EC) como una nueva división, al mismo tiempo que obtuvo la experiencia en fluoropolímeros de su filial, Superior Dual Laminates, Inc. (SDL). Como resultado, las tecnologías complementarias de estas empresas suministran ahora la más amplia selección de productos y competencias básicas para la protección contra la corrosión durante el proceso de producción, el almacenamiento y el uso de ácido sulfúrico y otras sustancias corrosivas.
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Three companies specializing in advanced corrosion control technologies are now affiliated, enabling Knight Material Technologies (KMT) to offer more comprehensive protection and engineered solutions to the sulfuric acid processing industry and end users. This provides processors the 3 in 1 leverage in global sulfuric acid protection by working with three companies, each with it's own specialty, under one corporate umbrella.
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Durante la conferencia sobre el Azufre, en Berlín, noviembre de 2012, Knight Material Technologies (KMT) fue contactada por Rick Davis, presidente de Davis & Associates Consulting. Rick quería saber si KMT disponía de un método de reparación para una torre de absorción con fugas que había sufrido una liberación incontrolada de energía (explosión de hidrógeno) a principios de 2012. La torre había comenzado a tener fugas sólo algunas semanas después de la puesta en marcha de la planta. El propietario, Noracid, quería una solución temporal hasta que pudiera realizarse la instalación de una nueva torre revestida de ladrillo, la que estaba prevista para dentro de varios meses.
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The Silicon Valley of the early 1900's, Northeast Ohio attracted innovators, leaders and companies from all over the world. Cleveland led the country in patent registrations and had its own stock exchange, while the Mahoning Steel Valley" was one of the most productive industrial centers inter-nationally and Akron served as the global rubber capitol. Our region drove America for decades - until it didn't.
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Knight Material Technologies (KMT) was approached by Davis & Associates Consulting to discuss a repair method for a leaking absorption tower that had an uncontrolled energy release (hydrogen explosion). The tower had started leaking only weeks after the start-up of the plant. The owner, Noracid, wanted a temporary solution until the installation of a new brick-lined tower could take place, which was planned several months down the road.
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Regenerative thermal oxidizing towers (RTOs) depend on the ceramic media within to optimize the tower's performance and efficiency. The selection of ceramic media type can make a significant difference throughout the lifespan of the RTO in terms of time and costs. There are differences and nuances among ceramic media choices. Understanding these differences can help operators and plant managers make a well-informed decision that helps reach target goals for pollutant removal and air quality control while cutting maintenance time and sparing energy expenditures.
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The average lifespan of a regenerative thermal oxidizer (RTO) can vary between ten to 20 years or even more. In fact, a well-designed RTO can outlast the personnel working at the facility. However, suppose you think a 20-year-old piece of capital equipment is outdated and not up to par with current operational demands, regulations or the newest efficiency equipment. In that case, the good news is that there are ways to update the RTO process to meet current trends.
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What is escaping from your regenerative oxidizing tower (RTO)? Wasted energy could release profits while you strive to capture volatile organic compounds (VOCs). A variety of factors can impact the thermal efficiency of your RTO. The choice of RTO packing material for the ceramic bed can play a critical role in optimizing thermal efficiencies. Optimizing thermal efficiencies directly correlates to energy savings—your choice of ceramic media matters.
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Many industries require a regenerative thermal oxidizing (RTO) tower to remove volatile organic compounds (VOCs) to meet environmental compliance standards. The ceramic heat transfer media within the tower acts as an essential element to enable efficient operations. The best tower build or retrofit enables “set it and forget it” operations—requiring little maintenance while supplying trouble-free performance for years to come.
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How to improve dual laminate equipment quality through risk assessment and implementation of ISO 9001:2015. Presented by Gregory O'Brien, VP/GM Superior Dual Laminates (KMT Canada) Ltd.
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Knight Material Technologies (KMT), located in Canton, Ohio, has expanded its production capacity by installing a new kiln to support demand for the company’s anti-corrosive brick and structured media used in corrosive and high-temperature applications found in industrial plants and towers.
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Knight Materials invests in new equipment and the addition of 45 new jobs added to the current 92 positions.
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As a previous part of Koch Industries, the second largest privately held company in the United States, many doors opened while our company was part of the Koch Engineered Solutions group. After a divestiture to High Street Capital in December of 2021, we became a new venture under the name Knight Material Technologies. Yet, our central location has always been in northeast Ohio. This new divestiture has also opened doors for us to expand our offerings in innovative solutions, services, and new infrastructure. We also have a blank slate to develop our unique culture and invest in community outreach. And it all started with our sponsorship of a major event over Labor Day weekend this September.
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See an animated hydrometallurgy autoclave with the essential materials for lining systems.
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The application of hydrometallurgy in the recovery of nickel, copper, gold and other metals continues to grow. The acidic nature and higher temperatures of some of these processes limit the use of alloys, fiberglass or other construction materials for the vessels, but acid brick linings have been proven to provide economical and reliable service.
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Extremely corrosive processing applications, such as those for sulfuric acid production or hydrometallurgy, require resistant interior linings on equipment to help prevent leaks and corresponding hazardous consequences, including environmental contamination or damaged equipment. Knight Material Technologies (KMT) offers its proprietary PYROFLEX® sheet membrane liner as an integral part of its system for corrosion protection in autoclaves, chemical processing vessels and equipment that require materials resistant to sulfuric acid.
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Increase efficiencies, reduce energy costs and avoid unplanned shutdowns by making the right choice of ceramic media in your regenerative thermal oxidizing (RTO) towers. Both random and structured media from Knight Material Technologies supply the industry’s most effective engineered design to absorb heat, ensure low pressure drop and avoid plugging.
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High Street Capital intends to invest in KMT’s technology, innovation plan and infrastructure to grow its market share, relying on its existing management team and employees.
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Electro Chemical and Knight Material Technologies have separate technology and service solutions within the same industries. Together, they are a complete solutions provider.
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See an Absorption Sulfuric Acid Tower constructed in 3D using the full line of Mass Transfer Product Solutions.
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Electro Chemical provides superior fluoropolymer lining services for tanks or all types along with pressure vessels and ISO containers.
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Electro Chemical's helium leak testing service provides superior leak detection
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