Industrial processes often involve handling corrosive chemicals, high temperatures, and abrasive conditions, making the choice of lining material a critical decision for ensuring durability, safety, and cost-effectiveness. Unfortunately, many decision- makers tend to rely on traditional or cost-driven approaches, overlooking the specific technical demands of their processes. Crescent PPG advocates for a paradigm shift, promoting thorough technical assessments as the cornerstone of material selection. Let’s explore this topic through a case study.

A Misstep: Choosing BRICK LINING WITH POTASSIM SILICATE BEDDING AND FURAN POINTING for High Concentration (70% - 98%) Sulfuric Acid environment.

One common misconception is the application of brick lining with potassium silicate bedding and furan pointing in environments exposed to high concentrations of sulfuric acid. (Potassium Silicate Does Not Work With 70% Conc. H2So4 & Furan Pointing Does Not Work With 98% Conc. H2So4).

Brick Lining With Potassium Silicate Bedding And Furan Pointing

With Tentative Cost. As On Today 21 March 2025 - Rs 3500/- Per SQM

While brick lining is a well-established practice, potassium silicate bedding cannot withstand the (water content refer IS 4832 Part -I) and Furan aggressive nature of such a corrosive environment. The chemical interaction leads to degradation, resulting in increased maintenance costs, process downtime, and potential hazards. This serves as a cautionary tale emphasizing why traditional practices are not always suitable.

A thorough evaluation of these parameters provides clarity and ensures long-term reliability.

For environments involving higher (70% to more) concentrated sulfuric acid, the following options align with technical and safety requirements:

• Brick Lining With Polymer Based Bedding And Pointing Material enhances chemical resistance, ensuring compatibility with aggressive acids. This combination offers both durability and cost-effectiveness under challenging conditions.

With Tentative Cost. As On Today 21 March 2025 - Rs 3750/- Per SQM

• Sheet-Based Lining with Polypropylene Polypropylene, a thermoplastic material, exhibits excellent chemical resistance and mechanical strength. It is particularly suitable for industries where strong acids are processed, offering a modern alternative to traditional brick lining.

With Tentative Cost. As On Today 21 March 2025 - Rs 3250/- Per SQM

The choice between these options should be guided by the specific process parameters, including chemical concentration, temperature, and mechanical stress.

While cost considerations cannot be ignored, they should never take precedence over technical suitability. Selecting the wrong lining material could lead to catastrophic failures, jeopardizing both safety and operations. By embracing a data-driven, requirement-specific approach, industries can ensure optimal performance, sustainability, and peace of mind.

Crescent PPG urges industries to challenge outdated norms and adopt a rigorous decision-making framework for lining material selection. Let’s make safety and efficiency the new standard.