Plastics

Corrosion-Resistant Products for Plastics & Polymer Manufacturing

Plastics and polymer manufacturing facilities handle some of the most aggressively corrosive chemicals in industrial processing. Hydrochloric acid is generated as a byproduct in PVC and vinyl chloride production. Concentrated sulfuric acid, caustic soda, and a range of organic solvents are used throughout polymerization, compounding, and reactor cleaning processes. Corrosive fumes, including HCl gas and volatile organic compounds, create harsh atmospheres that attack metallic infrastructure both inside process equipment and throughout the surrounding plant environment.

These combined liquid-side and gas-side corrosion challenges make plastics manufacturing a natural fit for non-metallic, corrosion-resistant materials. Cortrol supplies a complete range of products for both the chemical handling and fume control systems found in plastics and polymer production facilities.

Process & Chemical Handling Piping

Chemical piping in plastics manufacturing carries concentrated acids, caustics, solvents, and process fluids that rapidly degrade carbon steel and many alloy materials. Corrosion in HCl service is a particularly well-documented problem in vinyl and PVC production, where even trace levels of acid in the presence of moisture create aggressive attack conditions.

Cortrol supplies multiple piping solutions for plastics manufacturing applications:

Fiberglass reinforced plastic (FRP) pipe and fittings for acid, caustic, brine, and process water service. FRP pipe offers corrosion resistance, lightweight construction, and long service life in both aboveground and underground installations.
PTFE-lined steel pipe and fittings for aggressive chemical services where the mechanical strength of steel is required along with the near-universal chemical resistance of PTFE. PTFE-lined piping is well suited for concentrated HCl, solvent, and mixed chemical services.
Dual-laminate piping for applications requiring a thermoplastic liner bonded to a fiberglass structural shell.
Thermoplastic pipe and fittings for moderate chemical services where thermoplastic construction meets the temperature and pressure requirements.
Custom-fabricated spools, headers, and nozzles for non-standard transitions and connections throughout the process.

Chemical Storage

Plastics manufacturing requires bulk storage of process chemicals, including hydrochloric acid, sulfuric acid, caustic soda, solvents, and various additives. Tank material must be matched to the stored chemical at its full concentration and operating temperature.

Cortrol supplies FRP tanks, polyethylene tanks, and lined steel tanks for chemical storage in plastics manufacturing. FRP tanks are commonly specified for concentrated acid and caustic storage where temperature and chemical concentration demand a premium resin system. Polyethylene tanks provide a cost-effective option for many standard chemical storage applications.

Cortrol supplies FRP duct from Belco and Ershigs for corrosive air handling and odor control applications. FRP duct provides the chemical resistance needed for continuous hydrogen sulfide and chemical fume exposure while maintaining structural integrity and a smooth interior surface for efficient airflow.

Fume Exhaust & Scrubber Systems

HCl fumes, solvent vapors, and other volatile compounds generated during polymerization and processing must be captured and treated before discharge. The fume collection and scrubbing infrastructure is exposed to the same corrosive gases it is designed to remove, making FRP construction essential for long-term performance.

Cortrol supplies FRP components for fume exhaust and scrubber systems in plastics manufacturing:

FRP scrubber vessels and packed towers from Belco (a division of NOV Fiber Glass Systems), Ershigs (a division of NOV Fiber Glass Systems), and Frontier Plastic Fabricators. Belco is ASME RTP-1 accredited and has manufactured custom FRP scrubbers, towers, and vessels for industrial and chemical applications since 1980. Ershigs is the leading North American supplier of field-wound FRP scrubber shells. Frontier provides contact-molded scrubbers, stacks, and columns through 10′ diameter.
FRP ductwork from Belco and Ershigs for collecting and conveying corrosive fumes from process sources to scrubber systems. FRP duct resists the HCl gas, solvent vapors, and high-moisture conditions that rapidly corrode metal ductwork.
FRP exhaust stacks for discharging treated air. FRP construction resists residual moisture, chemical carryover, and trace corrosive compounds in the exhaust stream.
FRP dampers from Belco for controlling airflow in fume collection and scrubber duct systems. Available types include control and balancing dampers, isolation dampers, and backdraft dampers.

Valves

Valve failures in plastics manufacturing are frequently caused by chemical incompatibility between the process fluid and the valve’s wetted materials. In HCl, solvent, and caustic service, standard metallic valve internals can corrode within months.

Cortrol supplies corrosion-resistant butterfly, ball, plug, diaphragm, and sampling valves with wetted materials selected for compatibility with the specific chemical in service.

Pumps

Chemical transfer in plastics manufacturing involves corrosive, and in some cases hazardous, fluids where leaks and emissions must be minimized. Mechanical seal failures are a common and costly problem in acid and solvent pumping applications.

Cortrol supplies sealless magnetic drive pumps from ANSIMAG and Finish Thompson that eliminate mechanical seals entirely, preventing leaks and fugitive emissions. ANSIMAG pumps feature ETFE-lined wetted components for broad chemical resistance. Finish Thompson offers mag drive centrifugal pumps in multiple configurations and materials.

For waste handling, slurry transfer, and abrasive service, RamParts heavy-duty AODD pumps provide sealless, air-driven operation rated for flows to 380 GPM and temperatures to 300°F.

Supporting Components

Plastics manufacturing facilities include hundreds of flanged connections, equipment interfaces, and flexible transitions across both liquid and gas handling systems. These connection points need the same corrosion resistance as the major equipment.

Expansion Joints

Gaskets

PTFE gaskets provide corrosion-resistant sealing at flanged connections in chemical piping and duct systems.

Hose

Fluoropolymer-lined chemical hoses from PureFlex provide flexible, chemical-resistant connections for process lines, equipment hookups, and areas requiring movement or vibration isolation.

Structural

FRP grating and handrail systems provide corrosion-resistant platforms, walkways, and access around chemical process and fume handling areas where corrosive atmospheres degrade steel structures.

Coatings

Corrosion-resistant floor coatings protect concrete surfaces in chemical storage, containment, and process areas.

Why a Systems Approach Matters in Plastics Manufacturing

Plastics plants present corrosion challenges on both sides of the process: the liquid chemicals used in production and the corrosive gases generated as byproducts. A material strategy that addresses one but not the other will still result in failures, unplanned shutdowns, and environmental risk.

Cortrol’s approach is to evaluate both the liquid handling and gas handling systems together and select materials that are coordinated across the full facility. This includes matching resin systems in FRP piping and tanks, confirming wetted materials in valves and pumps, specifying duct and scrubber construction for the actual fume composition, and extending corrosion protection to structural access and containment areas.

Get System-Level Support for Your Facility

Whether you are building a new plastics production facility, upgrading chemical handling infrastructure, or replacing corroded piping, duct, or equipment, Cortrol can help. Share your process chemicals, operating conditions, and facility layout, and our team will provide guidance on products and materials matched to your application.