The Importance of Rubber in Rubber Lining

Natural rubber along with synthetic rubbers are offering a unique opportunity in meeting various demands in rubber lining Synthetic rubber has made it possible for rubber lining to withstand high temperatures and to have a resistance to a large number of chemicals. The main reasons for this are as under :
Natural rubber and synthetic rubber can afford perfect protection against the corrosive action of the great majority of chemicals and chemical solutions in common use such as alkali, acid (except oxidizing acids) as well as inorganic salts etc. whilst some synthetic rubbers offer better protection against specific chemicals and certain organic solvents. Natural rubber is easily available, easily processed, more easily applied because of the tack which gives better products. Its physical properties are very good and a hardness from sponge like soft to hard as ebonite can be obtained. Thus there is a wide range in selection of hardness also.
The modern discovery of synthetic rubber with good resistance to various chemicals has opened a wide field for the use of rubber even at high temperature. Present industrial production schedules and modern techniques have combined to make lining possible for wider uses in various fields. We have very good facilities e.g. a big imported Calendar and even large vulcanisers of approx. 4000 mm. dia x 7000 mm. length Being pioneers in rubber lining with modern equipment in our factory and with experience of 25 years research and manufacturing know-how, we have developed a number of high quality linings for specific applications. Further more, we have a modern laboratory for research and development We are also maintaining quality control 10 assure highest quality ,and uniformity of compounds We give below details of rubber lining carried out by us: -

1)Various sizes of storage tanks
2)Evaporators and Crystallizers 
3)Pumps and impellers and exhaust fans 
4)Ductings, agitators and chutes
5)Centrifugal extractors 
6)Vacuum and pressure filters
7)Bleaching tower 
8)Mercury cells for Caustic Soda Plants
9)Pipes, fittings and valves

Preparation of Metal :

All metal to be rubber lined, is carefully inspected for proper fabrication and thoroughly sandblasted to ensure highest bonding strength and to remove all possible 90 impurities. After shot blasting, the surface of the metals is cleaned by various processes to obtain the highest possible cleaned surface and then a suitable bonding agent is applied. The service life of the lining done will depend on the life of the bonding agents used for getting good bonding between metal and rubber. Failure in adhesion means early failure of the entire lining job. Bonding agents make rubber lining practical and integral. It is also very essential that the surface which are to be covered with rubber should be easily accessible and also free from pits, blow holes and other physical imperfections. Welding spots should be removed and all welds should be ground smooth. Sharp edges should be avoided and rounded off. Welding of the metal should be done in such a way that there is no defect and the metals are suitable for rubber lining. In case of difficulty or for further information our technicians will guide you with regard to the requirements of condition, of metals for rubber lining.

 Application of rubber sheets from Calender

We have a very big Calender of size 610 mm.
dia. x 1700 mm. long a very costly precision machine. The rubber sheets required are drawn out in this calender machine. Uniformly thin rubber sheets are used exclusively to provide utmost durability. The uniform sheets are tailor-made according to requirement. Only sheets prepared on calender are satisfactory. We use ply-up construction of rubber sheets, i.e. if the thickness of lining is 3 mm., 2 plies minimum are used and for 5 mm. thick 3 plies are used. The lining should be free from blisters and other imperfections which would certainly affect performance. Care is also to be taken to have uniform thickness to ensure quality work.

Vulcanisation:

We have fairly big vulcanisers to meet your requirements. Our biggest vulcaniser has a size of 4000 mm. dia x 7000 mm. length and 1600 mm. dia x 15000 mm. length. Rubber-lined equipment is vulcanised under pressure as pressure cure is a better cure and gives satisfactory rubber lining. When a vessel is suitable to go into an autoclave it should be vulcanised under pressure in vulcaniser. If transportation difficulties are involved because of very large size of vessels, vulcanisation should always be carried out on the site where all facilities are available for lining operations and where the final stage becomes merely the last in a continuous process. The time and temperature of vulcanisation are dependent on the size and weight of the vessel and also on the thickness of rubber lining and the compound used for lining.

Testing:
All rubber lined equipment is tested 3 times with 20,000 V high voltage unit to ensure that there is no leakage in the lining. The first test is carried out after preliminary rubber lining and the second test is carried out after partial curing to gauge the shrinkage of the rubber and the final test is carried out when the vessel is taken out from the vulcaniser. We carry out these tests to ensure that only quality lining goes Out of our factory. We also ensure that there are no pin holes, blow-holes, or any minute leakages. The spark test will show even minutest defect in lining, even hair-line gaps and cracks can be detected. We take the utmost care to supply rubber lined equipment which will give trouble-free service for years.

 Inspection:
Both visual inspection as well as high voltage tests are carried out in presence of clients before equipment leaves our factory. This ensures and confirms quality of our products.
Rubber lining means saving :
The advantages of transporting and storing chemicals in bulk carriers and tankers are appreciated by the big chemical manufacturers. not only is it economical but the purity of the chemicals is ensured and the handling of hazardous chemicals becomes much more easy and safe.
These advantages have also been recognized medium and small suppliers and manufactures who transport and store hazardous and corrosive chemicals in rubber lined MS drums which can be handled with more ease and safety than in Glass Carboys. 

Jai Bhawani Industries are the manufacturers of  Rubber Lining which ensures resistance to acid, alkali, temperature, abrasion, etc. We have done rubber lining of bulk carriers, tankers etc. for the following materials: most inorganic acids, such as hydrochloric acid, dilute sulphuric, acid phosphates, alum caustic soda and organic acids such as maleic, most inorganic solutions such as ferrous sulphate, zinc chloride, etc All plating solutions, dye and bleach solutions, abrasive materials such, as grain, rock, sand and ore etc. Temperature limitations are used at 80 degree C for flexible semi hard rubber and 70

 Degree C for soft rubber. However, all these limitations have been exceeded in many cases where high temperature is intermittent or where the solutions are not reactive. In many instances our linings are in operation successfully at 100 degree C. However, where the normal limitations are exceeded, we should have a complete picture of all the details so that our technicians can analyze and give proper guidance.
For specific requirements we are always requesting our clients to fill up the questionnaire forms, which we are supplying on request, where we are asking more details about service conditions, with a view to helping them. 

The Importance of Rubber in Rubber Lining

Natural rubber along with synthetic rubbers are offering a unique opportunity in meeting various demands in rubber lining Synthetic rubber has made it possible for rubber lining to withstand high temperatures and to have a resistance to a large number of chemicals. The main reasons for this are as under :
Natural rubber and synthetic rubber can afford perfect protection against the corrosive action of the great majority of chemicals and chemical solutions in common use such as alkali, acid (except oxidizing acids) as well as inorganic salts etc. whilst some synthetic rubbers offer better protection against specific chemicals and certain organic solvents. Natural rubber is easily available, easily processed, more easily applied because of the tack which gives better products. Its physical properties are very good and a hardness from sponge like soft to hard as ebonite can be obtained. Thus there is a wide range in selection of hardness also.
The modern discovery of synthetic rubber with good resistance to various chemicals has opened a wide field for the use of rubber even at high temperature. Present industrial production schedules and modern techniques have combined to make lining possible for wider uses in various fields. We have very good facilities e.g. a big imported Calendar and even large vulcanisers of approx. 4000 mm. dia x 7000 mm. length Being pioneers in rubber lining with modern equipment in our factory and with experience of 25 years research and manufacturing know-how, we have developed a number of high quality linings for specific applications. Further more, we have a modern laboratory for research and development We are also maintaining quality control 10 assure highest quality ,and uniformity of compounds We give below details of rubber lining carried out by us: -

1)Various sizes of storage tanks
2)Evaporators and Crystallizers 
3)Pumps and impellers and exhaust fans 
4)Ductings, agitators and chutes
5)Centrifugal extractors 
6)Vacuum and pressure filters
7)Bleaching tower 
8)Mercury cells for Caustic Soda Plants
9)Pipes, fittings and valves

Preparation of Metal :

All metal to be rubber lined, is carefully inspected for proper fabrication and thoroughly sandblasted to ensure highest bonding strength and to remove all possible 90 impurities. After shot blasting, the surface of the metals is cleaned by various processes to obtain the highest possible cleaned surface and then a suitable bonding agent is applied. The service life of the lining done will depend on the life of the bonding agents used for getting good bonding between metal and rubber. Failure in adhesion means early failure of the entire lining job. Bonding agents make rubber lining practical and integral. It is also very essential that the surface which are to be covered with rubber should be easily accessible and also free from pits, blow holes and other physical imperfections. Welding spots should be removed and all welds should be ground smooth. Sharp edges should be avoided and rounded off. Welding of the metal should be done in such a way that there is no defect and the metals are suitable for rubber lining. In case of difficulty or for further information our technicians will guide you with regard to the requirements of condition, of metals for rubber lining.

 Application of rubber sheets from Calender

We have a very big Calender of size 610 mm.
dia. x 1700 mm. long a very costly precision machine. The rubber sheets required are drawn out in this calender machine. Uniformly thin rubber sheets are used exclusively to provide utmost durability. The uniform sheets are tailor-made according to requirement. Only sheets prepared on calender are satisfactory. We use ply-up construction of rubber sheets, i.e. if the thickness of lining is 3 mm., 2 plies minimum are used and for 5 mm. thick 3 plies are used. The lining should be free from blisters and other imperfections which would certainly affect performance. Care is also to be taken to have uniform thickness to ensure quality work.

Vulcanisation:

We have fairly big vulcanisers to meet your requirements. Our biggest vulcaniser has a size of 4000 mm. dia x 7000 mm. length and 1600 mm. dia x 15000 mm. length. Rubber-lined equipment is vulcanised under pressure as pressure cure is a better cure and gives satisfactory rubber lining. When a vessel is suitable to go into an autoclave it should be vulcanised under pressure in vulcaniser. If transportation difficulties are involved because of very large size of vessels, vulcanisation should always be carried out on the site where all facilities are available for lining operations and where the final stage becomes merely the last in a continuous process. The time and temperature of vulcanisation are dependent on the size and weight of the vessel and also on the thickness of rubber lining and the compound used for lining.

Testing:
All rubber lined equipment is tested 3 times with 20,000 V high voltage unit to ensure that there is no leakage in the lining. The first test is carried out after preliminary rubber lining and the second test is carried out after partial curing to gauge the shrinkage of the rubber and the final test is carried out when the vessel is taken out from the vulcaniser. We carry out these tests to ensure that only quality lining goes Out of our factory. We also ensure that there are no pin holes, blow-holes, or any minute leakages. The spark test will show even minutest defect in lining, even hair-line gaps and cracks can be detected. We take the utmost care to supply rubber lined equipment which will give trouble-free service for years.

 Inspection:
Both visual inspection as well as high voltage tests are carried out in presence of clients before equipment leaves our factory. This ensures and confirms quality of our products.
Rubber lining means saving :
The advantages of transporting and storing chemicals in bulk carriers and tankers are appreciated by the big chemical manufacturers. not only is it economical but the purity of the chemicals is ensured and the handling of hazardous chemicals becomes much more easy and safe.
These advantages have also been recognized medium and small suppliers and manufactures who transport and store hazardous and corrosive chemicals in rubber lined MS drums which can be handled with more ease and safety than in Glass Carboys. 

Jai Bhawani Industries are the manufacturers of  Rubber Lining which ensures resistance to acid, alkali, temperature, abrasion, etc. We have done rubber lining of bulk carriers, tankers etc. for the following materials: most inorganic acids, such as hydrochloric acid, dilute sulphuric, acid phosphates, alum caustic soda and organic acids such as maleic, most inorganic solutions such as ferrous sulphate, zinc chloride, etc All plating solutions, dye and bleach solutions, abrasive materials such, as grain, rock, sand and ore etc. Temperature limitations are used at 80 degree C for flexible semi hard rubber and 70

 Degree C for soft rubber. However, all these limitations have been exceeded in many cases where high temperature is intermittent or where the solutions are not reactive. In many instances our linings are in operation successfully at 100 degree C. However, where the normal limitations are exceeded, we should have a complete picture of all the details so that our technicians can analyze and give proper guidance.
For specific requirements we are always requesting our clients to fill up the questionnaire forms, which we are supplying on request, where we are asking more details about service conditions, with a view to helping them.