1. Plasticon Composites International Contracting B.V.
Field Fabricated Fiberglass Tanks
The ultimate solution for your storage of
chemicals

2. • Headquarter in NL, founded in 1952.
• Worldwide presence, production
facilities and sales all over the world.
• More than 700 employees in 16
Production Locations with approx.
80.000 m² size in 13 countries.
• Approx. 1.500.000 hours production
capacity per year.
• Capability of 200.000 h/a to do
Installation projects.
• 15 stationary and 5 onsite winding
machines.
Introduction

3. Characteristics of FRP
• Little to no maintenance is required
• A long product life span, up to 50 years
• High-performance insulation
• Abrasion and corrosion resistant
• Lightweight (1.8 g/cm3)
• High Chemical Resistance
• Delivery time
• GRP replaces expensive alloys like Hastelloy, Super Duplex, Ni, as well
as steel rubber lined components.
• Able to work with temperature limits of approximately – 50°C to 125°C

4. Fire retardance
• Fire retardant resins are tested according the ASTM E 84 (Steiner tunnel test) and
have class 1 flame rating of 25 or less.
• Normal FRP is classified as : DIN 4102 B2 and ASTM E84 class 2
• Bigger wall thickness and 9 x higher heat transfer factor means that the liquid will
not heat up as fast in a steel tank and it will take much more time that the liquid
will start to boil. Boiling liquid is a major problem during an inferno.
• Because of the thicker wall and higher safety
factor (7-10 in case of FRP and 1,5 -2 to steel)
a FRP tank will stay longer.
• The mechanical properties of steel reduces
fast above the 260 °C. ( SS -40% at 260 °C).
The tank will have a uncontrolled collapse.

5. What to store
Fiberglass Components are corrosion and
chemical resistant, so that you can store
different types of (aggressive) fluids such
as:
- Hydrochloric Acid
- Sulphur Acid
- Phosphoric Acid
- Acid solutions
- Other Acids
- Caustic Solutions
- Brines
- Salt solutions
- Chlorides
- Caustic Liquides
- Flue gases
- Lime slurry
- Fuels
- Fertilizers
- Starch solutions
- Vegetable oils
- Water

6. SERVICES
• Design
• Engineering
• Production
• Field fabrication & installation
• Installation
• Maintenance
• Repair
6

7. Generally
• Storage tanks
• Diameter 0 – 6 m Shop fabricated
• Diameter 6 – 21 m Produced onsite with our onsite winding
equipment.
Under certain conditions we are able
to wind up to 30 m in diameter.
• Silo’s
• Process Apparatus & Equipment
• Piping Systems / Pipelines
• Specialty products
PRODUCTS
7

8. Power industry
• Chimney Liner
• Ducts
• Chimneys
• Spray headers
• Tanks
• Recirculation pipes
• Process piping
• Cooling water pipes
PRODUCTS
8

9. Field fabrication
The field fabrication of large diameter fiberglass
components, consist of a few simple steps:
1. Design and Engineering completely executed by Plasticon’s experienced designers
2. Shipment of equipment and raw materials to site, in only a few containers
3. Quick setup of the winding and site facilities
4. Winding of the tank shells with Plasticon’s state-of-the-art proprietary winding equipment
5. Assembly and installation of the tanks by Plasticon’s experienced and trained field crew
6. Quality inspection & testing
7. Demobilization of the site facilities

10. Innovation
Variable mould
 Step-less variation of mould diameter
- 1 mould for 4 – 7,5 m
- 1 mould for 7 – 12,5 m
- 1 mould for 12 – 21 m
 Mould diameter can be changed within a day
 No (new) mould investment for each product
 Economical advantage for projects that require a wide
variety of (large diameter) products i.e. tanks

11. Production

12. GRP Absorber & Tanks
4.500 m3
atmospheric Tank
Carbon steel SS 304 GRP Carbon steel
Rubber lined
SS 316
Corrosion resistance Poor Adequate Excellent Inside: Excellent
Outside: Poor
Excellent
Maintenance High demand Periodic Close to nothing Lining: High
demand,
Periodic
Aging Undistinguished Good Good
No peeling
Approx. all 15
years 100%
replacement of
lining
Close to nothing
Welding points Strong corrosion
on seams
Corrosion on
seams
No corrosion Strong corrosion
on seams
Slight corrosion
on seams
Construction time 4 – 6 month 5 – 7 month 4 – 6 month 6 – 8 month 5 – 7 month
Lifetime without
serious maintenance
5 years 30 years Up to 50 years 15 years Up to 50 years
Appr. cost ratio 100 % 140 % 150 % 200 % 180 %

13. GRP Absorber & Tanks
- The price for installed GRP products does not vary as extreme as for steel and
stainless steel. The price is usually subjected to the normal inflation only.
- Caused by the shorter construction time the EPC is saving money for overhead.
- Longer lifetime and less maintenance cost may be a sales argument towards the
end user.

14. References
• Alstom Power – ESKOM Kusile Power Plant (South Africa)
• 6 x duct with D=8.9m, L=250 m

15. REFERENCES
CS Mining / USA
– 3 x D = 7.450 mm x H = 9.000 mm
• Vinyl ester resin in structural laminate (Derakane 411-350 or a equivalent
• SIC, anti-abrasive additive
in CBL (20%)
– 4 x Settler 7.000 mm x 13.500 x H = 1.200
– 4 X Half-dome roofs for settler tanks 7.000 mm x 13.500

16. REFERENCES
Plasticon Composites has successfully finished all 3 contracts with CS mining, despite a demanding schedule
and navigated through diverse project impediments.
1. Leach Tanks
Three cylindrical tanks have been wound on site, assembled with prefabricated bottom panels and built up by
Plasticon in early October. All internal fixtures and apparatus were installed in a timely manner. Later, preceding
commissioning in the middle of December, the tanks were subjected to hydro-testing.
2. Settler Tanks
Simultaneously works were progressing on rectangular SX Settlers. All four tubs constructed from the very
scratch using flat FRP panels produced by a local US vendor. All tanks were equipped by Plasticon with different
accessories and applications designated for guiding and controlling the flow. Plasticon determined several
internal details to optimize working procedures. The final installation inside all four tanks proceeded parallel, and
thanks to crafty automatization of selected operations, time deadlines set at the end of october could be met.
3. Half-dome roofs for settler tanks
Recognizing Plasticon's professional conduct, CS Mining in the meantime have pondered awarding us with a
contract extension. Using capacity of Winding Machine, Plasticon was requested to wind, fabricate and install
half-dome roofs on all four rectangular tanks. After receiving additional materials and initiating contract formally,
production proceeded swiftly without major hindrances. In different configurations a complete shell has been
wound for each settler tank, to enable accurate tracing and trimming into three separate roof segments. Four
cans have been wound in total, with twelve roof modules individually tailored. The finalization on roofs has been
fulfilled one week before the deadline on December, the 5th.
The project has been completed. The site structures are already demobilized.

17. REFERENCES

18. REFERENCES

19. REFERENCES

20. References
S.E.S. in Wormer, NL
– 12 x D = 9.100 mm x H = 10.000 mm; 600 m3
– Liquid oils and Fats
– Design temp. 90 °C
– Insulated
– Heating Coils inside
– Won against SS

21. - Client: Daelim Industrial Co., Ltd / Sahara Petrochemical Company
- Location: Saudi Arabia
- Project: CA/EDC plant construction
- 245 KTA caustic/300 KTA EDC
- Based on Uhde technology and specs
- Scope: All Piping and fittings
Tanks and apparatus (36 items)
Design and Engineering (stress)
Installation supervision
On-site welding, lamination
Spool building
- Materials: PP/PVC/PVDF/GRP
- Budget: 10 M€
Arabian Chlor Vinyl Project
References

22. Solvay - IKRA Project
- Client: Technip / Rusvinyl
- Location: Nizhny Novgorod
- Project: PVC plant
(Based on Solvay technology and specs)
- Scope: All piping and fittings
All tanks and apparatus
Complete installation scope (with local partner)
Design and Engineering (stress)
Pipe supports
Spool building
- Materials: PP/PVC/PVDF/GRP
- Budget: 13 M€
References

23. References
• Babcock-Noell – Turow (PL)
• 3x chimney liner and ducts with
D = 5.3 m, L = appr. 700 m

24. Power Plant Neurath BoA 2/3
References
Clean gas duct Absorber to cooling tower
(2 lines)
- Diameter 10,0 m / Length 150m + 30m Elbow
- Turnkey incl. Engineering, Prefabrication,
Transport, Lifting, Installation, Supervision and
Quality control.
- Horizontal on site winding machine.
- Project scope M€ 20

25. Innovations (in progress)
Leak Monitoring System (LMS)
• In testing phase at 3 customers
• Including remote diagnostics in CCR or on computer
• Planned maintenance stop instead of unplanned
• Can replace traditional independent safety back-ups like concrete
containment and/or double wall systems

26. THANK YOU!
www.plasticoncomposites.com