Book Estrella 18-9-09 BASSA
Book Estrella 18-9-09 BASSA
Book Estrella 18-9-09 BASSA
Professional Solutions in Glass Lining
Company Profile
2
Estrella AG Switzerland Glass lined process equipment and piping
www.estrella.ch
Professional Solutions in Glass Lining
Estrella has been established in 1946 in Basel, as a steel work company and supplier of glass
lined home products. In the mid sixties the company developed a glass lining technology for
the production of chemical process equipment, glass lined pipes and fittings. In the first years
Estrellas supplies were for the Swiss market only, but soon expanded serving the German
chemistry. In 1976 Estrella went overseas and established an organization, covering the North
American Markets. In early seventies the production capacity was extended to mid size vessels
up to a capacity of 8000 liters. In 1989 Estrella invested in modern technology with a furnace,
that allows to manufacture vessels up to a nominal capacity of 25 m. In the late nineties Estrella
invested a large amount of resources in the research of a piping system that could meet the
demand of GMP conformity and developed a fitting with a reduced void in the gasketing area.
The new flange system not only reduced the void but could also allow the use of gaskets other
than PTFE envelope type ones, reducing by far the leakage rates. In 1999 the new flanging
system has been patented and is so far the safest system present on the market. The system is
not just safe but also easy to install and reduces the maintenance costs. The glass lined piping
for pharmaceutical, food and fine chemical industry has become a reliable system.
Product range:
Glass lined pipes and fittings with Estrellas Safety Flange
Glass lined transportable receivers
Glass lined filters
Glass lined process vessels up to a nominal capacity of 25000 liters
Agitators baffles and temperature probes for glass lined reactors
Covers and accessories for glass lined process equipment, standard or custom designed
Glass lined mushroom type bottom outlet valves
Glass lined dip pipes
Glass lined columns
Glass lined reactors with nominal capacity 63 630 liters
Service range:
Reglassing of glass lined process vessels and accessories
Field service, glass inspection and repairs
Glass
Glass lined vessels, accessories and pipings are frequently used in chemical and pharmaceutical
plants for their chemical and physical properties. The excellent chemical resistance of glass
against acid, basic and neutral organics allows a wide range of applications. The very smooth
surface of glass (Ra 0.05) facilitates cleaning of systems. The hardness of the glass surface
(600 Vickers) is a good protection in case of abrasive mediums. Compared to plastic linings, the
allowable working limits of glasslining regarding pressure (-1/+25 bar) as well as temperature
(-60/ +250C) are remarquable higher. The absolute unpermeability of the glasslining gives also
great advantages for muti-purpose plants compared to the permeable plastic linings. Glasslined
steel is much more resistant against mechanical and thermal shocks than pure glass, due to his
resistant steel wall. This high quality compound material is the result of years of experience and
specific know-how regarding to glass receipt, application techniques, materials selection and
construction details, as well as firing technology.
Steel pieces, built for glasslining, have to be specifically designed and manufactured.
Uniform thicknesses must be used to avoid un-homogenous heating up and cooling down during
firing process of glasslining. Oversized wall thickness of vessels are made, not to withstand the
final working conditions, but to pass several heat treatments at over 800C without important
deformations. Selection of raw materials, under consideration of limited chemical composition,
is done for controlled hydrogen diffusion and best adherence of the lining on his steel support.
Welding procedures and specifications have to be strictly considered. Items to be glass lined
must have minimum radius and an absolutely smooth surface, all nozzles have to be extruded
at temperature to avoid stress and disturb the good progress of lining. After a classical way
of manufacturing, assembly and welding, all welds have to be grinded so that the surface to
be lined is absolutely flat: imperfections in the steel surface must be grinded and smoothed
out to avoid any kind of step. Condition for a perfect glass lining is an absolutely perfect steel
fabrication, including welds without any defect. The final steel construction has to be normalized
at 920C. After this treatment the whole pieces have to be sandblasted once to clean the
surfaces and also to give a certain roughness in order to improve the mechanical adherence of
the glass.
Of course the steel construction is submitted to constant quality controls:
-Check of material certificates as well as control analysis.
-Survey of welding preparation, welding datas and operations.
-Nondestructive testing by LPT, US, or RX.
Glass production
Estrella has his own glass receipt and produces his own glass frits.
The process of glass production is as follows:
After mixing of the raw materials, (Quartz, Soda, Borax, Feldspar, adhesive oxiders and fluidisers)
these are melted in a furnace at 1500C.
The frit is finally obtained by crushing in cold water.
By milling the frit in a ceramic ball mill, including additional set up salts and water, after a final
filtration, we obtain a slurry ready to be used for pouring out or spraying.
Glass lining
Now the slurry and the steel pieces can go into the enameling area to be worked up. The glass
lining consists in several application and firing operations during which the whole layer does
always fuse completely. The first layers (1 to 2 times) are made of ground enamel. This enamel is
specifically prepared to ensure the requested adherence on the steel, first on a mechanical basis
due to the roughness of the steel support, second on a chemical basis due to the oxide film built
up during firing. The composition of the ground enamel will determine the admissible temperature
difference (delta T) due to his buffer function between steel and cover coating. Since the ground
enamel is chemically less resistant than the cover coats, it is very important to limit its thickness
at 0.4 to 0.5 mm. The next layers (5 to 8 times) are made of cover enamel.
This is the real acid / alkali resistant enamel. The total thickness according usual standards
should be 1.0 to 2.2 mm for vessels and 0.8 to 2.0 mm for pipings.
The technical delivery conditions are precisely given in DIN EN15159-1 3 for vessels and
accessories, in DIN 2876 for pipings. Appropriated technologies and extended know-how are
necessary to match the high level of quality requested for these specific products.
Hereby some of the most important working and control steps:
Application of the slurry by spraying on (for easy reachable surfaces ) or pouring out (in worse
reachable areas)
Complete drying of the applicated layer.
Wiping off the surplus, and finalizing the edges before firing.
Loading the pieces on heat resistant firing supports.
Firing the applicated layer at approx. 900C for ground coats and approx. 800C for cover
enamel, using specific firing parameters adjusted to the type and size of the pieces.
Cooling down to ambient temperature (at quiet air or in closed cabins)
Intermediate controls after each firing:
Visual checks (for inclusions, cracks, firing aspect, surface image)
as well as thickness measurements at different areas of the pieces.
Checking the deformations after each layer allows a correction from one firing to the next and
improves a good final result.
From a thickness of 1.0mm (0.8 for pipings) a Sparktesting will be done at 20Kv DC.
This process will be repeated as much as necessary to obtain a product fulfilling the requests of
the standards.
These controls are made on 100% of the produced pieces.
Produced carefully and with adequate competences glass lined articles are safe and high quality
products and the end users can match all needs regarding: chemical, mechanical, abrasion,
temperature and pressure requirements.
Professional Solutions in Glass Lining
Estrellas 2000 Enamel is the result of research and experience, collected serving the European
and Overseas chemical industry. It has been specially formulated to get the same quality in
glassing pipings and process equipment. The glass is consistently homogeneous
and it has a very thin bubble structure.
Chemical resistance
Colors
For more information please download from our website the bulletins:
Chapter 01 : Corrosion table.
Chapter 10 : Heat transfer.
*see download
For engineering information please download from our website the following bulletins:
For the DIN standard.
Chapter 03 : pipes and fittings (DN 350 - DN 700).
Chapter 05 : pipes and fittings (DIN 2873 PN10).
Chapter 5a : jacketed pipes and fittings.
Estrella AG Switzerland Glass lined process equipment and piping www.estrella.ch 9
Professional Solutions in Glass Lining
Professional Solutions in Glass Lining
Glass lined filters
Glass lined filters
Features Technical data
Features Technical data
EstrellasEstrellas
nutschenutsche
filters filters are glass lined
are glass lined with DesignDesign temperature: -10/+200C
temperature: -10/+200C.
with
Estrella 2000 Estrella
. 2000. Design pressure:
Design pressure: -1/+6-1/+6 bar
bar.
The filter The
canfilter
be can be supplied
supplied with with
2 or23orsections.
3 sections. Construction
Construction codecode AD-2000/ /PED.
AD-2000 PED
The openingThe opening
assist is assist is hydraulic a hydraulic
a hydraulic. Available
Available also with
also with ASME,ASME, Chinese and Korean
Chinese
hand operated
hand operated pump.pump. stamp stamp.
and Korean
For engineering information please download from our website the bulletin:
Chapter 8 - 010 : Filters.
For engineering information please download from our website the bulletin:
Chapter 02 : Vessels.
For engineering information please download from our website the bulletins:
Chapter 4 - 001 002: Mixers.
Chapter 4 - 003 : Baffles.
Chapter 4 - 006 : Thermo wells.
Custom designed covers and accessories for glass lined process equipment
Features Technical data
For engineering information please download from our website the bulletin:
Chapter 6 - 004 005: Bottom outlet valves.
For engineering information please download from our website the bulletin:
Chapter 6 - 001 003: Diaphragm valses.
Chapter 6 - 014 : Sight flow indicator.
Chapter 6 - 016 : Sight glass armature.
For engineering information please download from our website the bulletin:
Chapter 4 - 005 : Dip pipes.
For engineering information please download from our website the bulletin:
Chapter 3 - 110 111: Columns.
For engineering information please download from our website the bulletin
For engineering information please download from our website the bulletin : AE reactors.
Descripiton Benefits
We reglass with Estrella 2000. - 100% comparable with a brand new vessel.
We cover all construction codes. - No engineering work needed due to replacement.
In case of larger damage, part of the with a vessel having different standard design
shell or nozzles can be replaced. - Cost and budget saving.
Estrella QA manages the approval - Short delivery time.
procedures with the notified bodies.
Estrella reglasses reaction vessels
and any type of glass lined process
equipment.