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Acid Resistant Concrete Projects Utilizing KemROK™ Concrete
KemROK™ chemical and acid resistant cement has been succesfully utilized for challenging industrial applications where portland cement concrete has failed due to acid and chemical exposure.
Sulfuric Acid, Secondary Containment
Ardmore, OK April 2013
A petroleum refinery utilized KemROK™ for its acid resistant properties for a secondary acid containment area and sulfuric acid tank pedestals.
Acid tanks contained 93% concentrations of sulfuric acid. In all, 24 cubic yards of KemROK™ acid resistant concrete were placed for containment floor, walls and pedestals. Normally, this type of portland cement based concrete structure would require a protective epoxy coating.
The utilization of KemROK™ acid resistant cement concrete allowed for the elimination of this secondary protective measure saving the owners over twenty thousand dollars in epoxy material and placement costs.
Fertilizer Plant, Nitric Acid Absorber Pedestal Base
Tuscumbia, AL June 2013
A fertilizer plant in Alabama utilized over 30 cubic yards of CeraTech's KemROK™ acid resistant cement concrete for a nitric acid processing tower base where 99% nitric acid is reduced to a lesser concentration.
Nitric acid is especially corrosive to ordinary portland cement concrete and usually requires an epoxy coating to maintain durability. Mico-silica is added to all portland based mixes at this plant to help resist the effects of acid exposure however, this negatively effects workability and set times.
In contrast, CeraTech's KemROK™ acid resistant cement concrete does not present any placement impediments and can be coated with an epoxy if required in just 48 hours.
Battery Manufacturing Facility
Lithonia, Texas December 2011
Trojan Battery is a leading global producer of deep cycle batteries for a wide variety of commercial, industrial and marine applications. The batteries produced at the Lithonia facility are the lead-acid type, and require the use of 31% sulfuric acid as an electrolyte. For Trojan, economics and minimizing life-cycle maintenance costs and the associated down time are key, as their current materials and methods for acid resistance (coatings) on their production and process floors are very expensive and have relatively short service life spans. The test site that was chosen was a battery rack lift was installed to lift batteries to a conveyor. The lift is mounted below finished floor elevation and incorporates an effluent sump. This area sees constant exposure to sulfuric acid and some abrasive activity from the pallet jacks placing the racks on the lift. On 29 December, 2011, Ceratech in partnership with Argos placed 7.5 cu yds of bulk KemROK™ as a test slab for Trojan Battery to evaluate. The truck was positioned and began discharging KemROK™ by 0630 with the placement and final finish including the 2� box inset to accommodate the lift stations being completed by 0815. Since the initial placement the material has seen extensive use and exposure and has performed very well
Paper & Pulp Manufacturing Facility
Secondary Acid Containment
Pine Bluff, Arkansas December 2011
The Evergreen Paper facility is a subsidiary of International Paper. KemROK™ has been specified for use in rehabilitating secondary containment and incidental contact structures. Due to quick turn around times, the mix design required high early strengths, resistance to acid attack and be able to have a protective coating installed in a very short period of time. The required strength for the material was 7000 psi, more so for surface durability as opposed to any type of trafficking. Coating and maintenance activities would need to commence as soon as possible after the concrete achieved final set. For this facility, an epoxy based coating system was utilized to minimize the required maintenance for the containment areas. On 27 December, 2011, CeraTech arrived at Pine Bluff Sand and Gravel to prepare for a placement of ~20 cuyds of bulk KemROK™ and on 28 December batching proceeded for the project. The project went as expected even with temperatures ranging in the low 30s during the cure cycle.
Sulfur Processing Facility
Galveston, Texas February 2010
A chemical processing facility utilized KemROK™ a chemically resistant, high early, non-Portland bulk cement for construction of a 705 foot long flume trench designed to carry molten sulfur for processing. Normally, these flumes would be constructed with high silica fume (micro silica) portland cement concrete and then overlayed with an epoxy resin in order to resist the corrosive effects of molten sulfur and sulfuric acid. (Sulfur temperatures reach 300°F.) CERATECH's KemROK™ green cement was chosen for its chemical & thermal resistance characteristics, no epoxy coating requirement, high early strengths and rapid curing enabling faster return to service. Specifications called for a concrete with a slump of approximately 5 to 7 inches to facilitate pumping and rebar encapsulation and strengths of 4,000 psi in 7 days.
After several years of service, the KemROK™ cement concrete trench shows zero degradation. The customer plans to replace all of their portland cement trenches with KemROK™ thereby eliminating the recurrent costs associated with production downtime, maintainence and rebuilding of corroded flumes.
PetroChemical Facility Sump Pit Re-Lining
Corpus Christi, Texas April 2009
On April 28th, 2009 the Valero Refinery West Plant East Barge Dock Area 75 sump station in Corpus Christi, TX utilized KemROK™ cement concrete to re-line an industrial sump for effluent chemicals. The previous sump pit was constructed from Portland cement concrete was eroded due to corrosion from effluent chemicals. After a thorough cleaning and neutralization the base of the sump was replaced with KemROK™ and when it reached final set, a Sonotube™ form was fitted and blocked in place to maintain proper dimensions. Once in place KemROK™ was poured around the circumference to the existing height of the chemical sump and allowed to cure. The following morning the crew came back on site and removed all form work and the sump was brought back into service 72 hours later.