Introduction
In the chemical industry, ensuring the integrity of equipment is crucial for maintaining safety, minimizing downtime, and optimizing operational efficiency. A leading fertilizer plant in Brandon, Manitoba, recently encountered significant challenges with the performance of their gaskets, particularly the spiral wound/PTFE-filled gaskets that frequently failed. This blog post delves into how the plant overcame these issues by transitioning to Durlon® gaskets, which significantly enhanced both safety and efficiency.
The Challenge
The fertilizer plant, which produces Ammonia, Nitric Acid, Urea-Ammonium Nitrate, and other nitrogen-based products for the Canadian and U.S. farming industries, faced ongoing problems with gasket failures. The existing spiral wound/PTFE-filled gaskets were unreliable, particularly in systems subjected to high temperatures and pressures. These failures led to flange leaks, unscheduled maintenance, potential safety hazards, and increased operational costs.
The Solution
To address these challenges, the plant initiated a trial in November 2018, testing two types of Durlon® gaskets:
- Durlon® 9000: This gasket eliminated 90% of the flange leaks and proved particularly effective in high-temperature applications, such as those involving Ammonium Nitrate Solutions (ANS). However, 10% of the leaks were attributed to issues like flange misalignment and pitting.
- Durlon® Durtec® with 9600 Expanded PTFE Facing and 316SS Core: This gasket was tested in two locations with 56-62% Nitric Acid concentration and delivered exceptional performance, even under challenging conditions such as flange roughness and misalignment. This performance was critical as the pipelines reached their standard operating temperatures.
Customer Findings and Benefits
Following the successful trials, the plant began stocking and using the Durlon® Durtec® with 9600 Expanded PTFE Facing and 304SS Core in January 2020. This gasket met their Nitric Acid 304L pipe specifications and quickly became their preferred solution for Nitric Acid services. The plant also plans to explore its application in other systems.
Key benefits of Durlon® Durtec® gaskets include:
- Blowout Resistance: The metal core provides excellent resistance to internal pressure spikes, enhancing safety.
- Reusability: The core can be refaced with new material, offering a lower cost of ownership over time.
- Superior Core Technology: Improved performance and reduced life cycle costs.
- Ease of Handling: Durlon® gaskets are easy to handle, install, and seal tightly with lower bolt loads.
Conclusion
The fertilizer plant’s switch to Durlon® gaskets has been transformative, reducing leaks, improving safety, and lowering maintenance costs. The success of the Durlon® 9000 and Durlon® Durtec® gaskets in this high-stakes environment underscores the importance of selecting the right gasket materials for specific applications. With their proven track record, Durlon® gaskets continue to set a high standard in the chemical industry, helping companies achieve their safety and efficiency goals.