Phosphoric Acid Reactor Battery
North Africa
The client's existing reactor battery had experienced premature lining failure after just 4 years, resulting in unplanned shutdowns costing $200K per day. They needed a complete replacement system with at least 15 years of reliable service in concentrated phosphoric acid at 80°C with dissolved fluoride compounds.
We designed and fabricated six 200 m³ reactors from carbon steel, each internally lined with a dual-layer EPDM rubber system developed in our GBT Germany compound lab. The compound was formulated specifically for the client's acid chemistry — validated through 10,000-hour immersion testing before application.
Our approach
Compound Development
Our GBT lab in Germany developed a custom EPDM formulation with optimised cross-link density for phosphoric acid resistance. Immersion testing confirmed <2% volume swell after 10,000 hours at 85°C.
Reactor Design
ASME VIII Div 1 pressure vessels with agitator nozzles, acid inlet distributors, and slurry discharge systems. All internals designed for complete rubber coverage.
Lining Application
Dual-layer system — 3mm EPDM bonding layer plus 6mm EPDM wear layer. Applied at our India facility using autoclave curing for maximum bond integrity.
Commissioning
Jasmino field technicians supervised installation and performed final spark testing and hydraulic pressure testing on-site.
Project results
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