Complete Protective Solution LeBracs Rubber Linings Private ...

Complete Protective Solution

LeBracs Rubber Linings Private LimitedPuducherryIndia

Rubber Lining

Rubber Hoses

Brick Lining

PTFE Lining

Fabrication

COMPLETE PROTECTIVE SOLUTION

Company Profile

Lebracs Rubber commencedmanufacturing activities in 1989 at theirfactory at Puducherry, India. The factoryis spread over four acres of land with acovered area of over 30,000 square feet.

The facilities are integrated for thefabrication and rubber lining of Pipes&Fittings, Tanks & vessels.

Over the years the company hassuccessfully executed many projects tocustomers in the fertilizer / Chlor-alkali/ water treatment / iron orebeneficiation industries in India andAbroad.


IMS Certificate

Lebracs Rubber has over the yearsbeen certified under ISO 9001:2008,ISO 14001:2004 and ISO 18001:2004demonstrating the Management’scommitment to Quality of productand concern for environment andsafety

WHY ?

Lebracs Rubber is the only Rubberlining Company in India with aState-of-the-Art Extruder Machinemanufacturing rubber sheet ofthickness from 2mm to 10mm.Extruder rubber sheets have superiorproperties when compared toCalendared rubber sheets.

EXTRUDER MACHINE


Lebracs Rubber has a large sizeAutoclave of size 5Mtr Ø x 8.5 Mtr long.

Lebracs Rubber has different formulaefor Natural and Synthetic rubbercompounds for various types of rubberlining both hot bonding & cold bonding.

Apart from rubber lining in the factory, wealso execute ‘On Site’ lining of equipment’swhich are too large to be transported.

AUTOCLAVE 5Mtr x 8.5Mtr

WHY ?COMPLETE PROTECTIVE SOLUTION

Business OverviewInternationally operating India-based provider of Surface Protection Solutions

Indian Industry leader for providing Surface Protection services to

• Mineral Processing

• Water Treatment

• Chlor-Alkali

• Fertilizers

• Others


Business OverviewInternationally operating India-based provider of Surface Protection Solutions

Our products include

Surface Protection

• Corrosion Resistant Linings

• Abrasion Resistant Linings

• Desalination

• Water Treatment Linings

• Food Grade Linings

• PTFE Linings

Flexible Hoses / Dredging Hoses

Steel Fabrication


Sectors

CORROSION:

Fertilizer PlantsChlor Alkali PlantsPhosphoric acid plantsETP PlantsDesalination PlantsWater Treatment Plants

ABRASION:

Mining industriesMineral Handling

Industries Dredging


Manufacturing Facilities

KNEADER MACHINE (75 Litres)

3 ROLL CALENDER MACHINE16” X 48”

EXTRUDER MACHINE

2mm – 10mm

MIXING MILL

22” X 60”

Fabrication

The fabrication facilities are geared to meet the requirement of the following standards:American Society for Testing and MaterialsAmerican Petroleum InstituteIndian Standards

Lebracs Rubber has manufactured large tanks and Pressure vessels under Third Partyinspection.

Testing of the equipment includes water fill, DP, Radiography etc.

Carbon steel pipes & fittings of various sizes and manufactured to client specifications.The ends could be either grooved or flanged as specified.

Pipes are hydro tested after fabrication as may be specified.


Fabrication Infrastructure

Site Area : 20,000 M² Shop Floor Area : 10,000 M² Key Equipments:

7 Ton Capacity EOT Crane 8 Ton Capacity Mobile Crane 14 Ton Capacity Mobile Crane Heavy Duty Lathes 25mm thk Plate Rolling Machine 16mm thk Plate Rolling Machine Welding Machines Drilling Machines Grinding Machines(AG7) Flexible Shaft Grinders Pug Cutting Machines

Mineral Processing – Phosphate

In recent years Lebracs Rubber hasfabricated and rubber lined thecomplete Slurry piping for OCP’s ElHalassa Wash plant located in theKhouribga region, Morocco.Approximately 115,000 inch-diameterof piping was fabricated, rubber linedand transported from LebracsRubber’s Puducherry factory to sitein a record 10 months’ time, winningappreciation from the Client and otherInternational competitors forrespecting the delivery schedule andquality.

Mineral Processing – Iron Ore

During 2013-2014, LebracsRubber has executed a largeorder for Iron Ore Plant ofJindal SAW Ltd., inRajasthan. The Order coversfabrication and rubber liningof 32 Tanks and Pipes &Fittings of sizes ranging from50 NB to 400 NB.

Rubber lining was doneusing Soft Natural rubberwith thickness of 6 mm,9mm & 12 mm.

The approximate rubberlined was 1000M²

Mineral Processing – Iron Ore

Lebracs Rubber hassupplied rubber lined pipesand fittings ranging from 50NB to 600 NB to Essar Steelover the years for numerousprojects being executed bythem all over India

Applications

Water Treatment Industries

Wastewater water contains solids and other dissolved effluents which can lead to corrosion of the pipelines, tanks etc. through which they are treated.

We offer an outstanding range of surface protection through Rubber Lining which is also used for corrosive applications in DM plant and ETP’s.

Applications

Water Treatment – Desalination

Lebracs Rubber has offered its rubber liningservices to India’s largest seawater ROdesalination plant, the Nemmeli DesalinationPlant, that supplies water to the city ofChennai

Lebracs Rubber had rubber lined the LimeStone Filters (Size 4.4m Ø X 4.9m Height)with 4.5mm thick Natural Soft Rubber withhot vulcanizing for optimum protectionagainst abrasion

Water Treatment – Seawater RO

Lebracs Rubber has rubber lined 16 PressurizedSand Filters (Size 3.6m Ø X 12.89m Long), withFood Grade Neoprene, 3mm thick Rubber for theChennai Metro Desalination Plant, Chennai, India.

The Pressurized Sand Filters were Rubber Linedwith hot vulcanizing done at our factory underinspection of Bureau Veritas and BefesaInternational, Spain.

The rubber lined area of Food Grade Neoprenerubber covered was 4592M².

Each Pressurized Sand Filter had perforated plateswith 2167 holes to be rubber lined for insertingPolypropylene Nozzles.

Lebracs Rubber has from inception been involved in the rubber lining of equipmentsin Chlor Alkali Projects

The rubber lining of equipments both in our factory and at the site for Aditya BirlaChemicals India Ltd., Renukut, India and of ASM Chemicals Ltd, Bangladesh are recentprojects completed by Lebracs Rubber

Following types of rubber lining have been used in these projectsNatural Soft RubberNatural Hard Ebonite Rubber Butyl RubberHypalon RubberNitrile RubberNeoprene Rubber

Chlor-Alkali Industries

Client : Aditya Birla Chemicals Project : Caustic Soda Project Scope : CS Fabrication and Rubber

Lining of Tanks. Tank Name : NaOH Tank / Receiver Tank /

Pumping Vessels Rubber Compound: Ebonite 75+ 5° Shore “ D “ Rubber Thickness: 4.5 mm Year of Manufacturing: 2011



Client : Karaikal Chlorates Scope : Fabrication and Rubber Lining Equipment Name : Clarifier Rubber Compound : Soft Natural 50 + 5°

Shore “ A “ Rubber Thickness : 5 mm Year of Manufacturing: 2003

Applications

Fertilizer Industries

Over many decades rubber has proved its reliability and cost-effectiveness for this field The metal surfaces of the reaction tanks, agitators, evaporation vessels, storage tanks,

heat exchangers, piping, etc. are effectively protected with rubber The material rubber is well able to satisfy the variety of requirements placed on it in this

field: Resistance to elevated temperatures up to 100°C and higher Resistant to abrasion by particles of solid matter Vacuum tight bond with metal surface Chemical resistance

The size of the different components means that lining with hard rubber and soft rubbermust be carried out on site

Applications

Fertilizer Industries

Client : Uhde

Project : Coromandel

International Ltd, Kakinada

Scope of work : Design, Fabrication and

Rubber Lining

Equipments : Scrubber Vessel &Pre-Fume

Scrubber Vessel

Material of Construction:

Shell and Top Cover: Mild Steel

Internals / Dip Pipe / Filter Plates/ Baffles:

SS 916L, 904L & 316L

Rubber Lining: 5 mm Lebracs BY 50 Butyl

R & D Facilities

• Oscillating Disc Rheometer

• Tensile Testing Machine 5000N

• DIN Abrader Machine

• Electronic Density meter

• Mooney Viscometer.

Specification of Rubber SheetsThe following Table indicates the most commonly used Rubber sheets.Apart from those indicated below Lebracs Rubber has also developed special rubber sheets forindustry specific service condition.

CODE NO TYPE OF RUBBER SERVICE CONDITION HARDNESS RANGE Maximum Design TEMPERATURE

LRL 5060 SM Natural Soft Rubber Phosphoric Acid, HCL, 55 ± 5º Shore ‘A’ 65° C

LRL TRIFLEX Natural Soft RubberPipe Lines for Phosphoric Acid, Any

Dilute Acid50 to 70 Shore ‘A’ 70° C

LRL 6070 S Natural Soft Rubber Phosphoric Acid 65 ± 5ºShore ‘A’ 75° C

LRL BY 50 Synthetic Soft RubberPhosphoric Acid, HCL, Caustic

Storage, Soda Ash55 ± 5ºShore ‘A’ 100° C

LRL CBY 50 Synthetic Soft Rubber Ferric Chloride, Phosphoric Acid 55 ± 5ºShore ‘A’ 115° C

LRL 6070 N Synthetic Soft RubberPhosphoric Acid, Hydro Flousilisic

AcidCL,65 ± 5º Shore ‘A’ 90° C

LRL 8090 Natural Hard Rubber Brine Solution,HCL, Caustic Lye, Dyes 75 ± 5º Shore ‘D’ 70° C

Note: Technical Parameters may be changed due to continuous product development.

Standards being followed

IS – 4682 (Part I)

BS. – 6374 (Part V)

LRL CMS 8090 (Low Ca,Mg,Si)

Natural Hard Rubber HCL & Pure Brine Storage Tank 70 ± 5º Shore ‘D’ 70° C

LRL 6070 SM Natural Soft Rubber Water Treatment, 65 ± 5ºShore ‘A’ 65° C

LRL 6070 N Synthetic Soft Rubber Desalination Plant65 ± 5º

Shore ‘A’90° C

LRL 3545 SM Natural Soft RubberAbrasion Resistance, Launder

and Chute Lining40 ± 5ºShore ‘A’

50° C

LRL 4555 SM Natural Soft Rubber Abrasion Resistance in Acidic Condition

55 ± 5ºShore ‘A’ 65° C

Specification of Rubber Sheets

ON SITE RUBBER LINING – Completed Jobs

CLIENTS NAME DESCRIPTION OF JOB(YEAR) TYPES OF RUBBER LINING AREA

Grasim Industries Ltd Clarifier(2006) Natural Soft Butyl 1110m² 200m²

Sterlite Industries Ltd (Vedanta Group) Phosphoric Acid Tank (2006) Natural Soft 970m² 100m²

Associated Environmental And Engineers Pvt Ltd

Various tanks at M/s Sterlite Industries, Tuticorin(2007) Chloro butyl 900m²

Kanoria Chemicals Ltd Clarifier and Other Tanks at Chlor Alkali Plant (2006) Natural SoftButyl

630m²337m²

Hindustan Dorr-Oliver Ltd Phosphoric Acid Storage Tank at M/s TATA Chemicals Ltd, Haldia Site (2008) Natural Soft

754m²795m²655m²

ASM Chemicals Ltd, Bangladesh

Various Tanks at Chlor Alkali Green field Project (2008) Nitrile Natural Soft 400m²

1900m²


Coromandal International Ltd, Kakinada Phosphoric Acid Day Tank (2007) Natural Soft 715m²

Coromandal International Ltd, Chennai Phosphoric Acid Tank DM Water Tank (2008) Natural Soft

916m²145m²110m²

VatechWabag Ltd Storage Tanks and Degasifiers for Naptha Cracker Project at IOCL Panipat Site (2008) Natural Soft 930m²

DCW Ltd Digesters – 21nos Chloro Butyl 1060m²

TATA Chemicals Ltd, Haldia Rehydration Tank ,Concrete Tank NH3 Conversion Tank (2009) Butyl 1415m²

Aqua Designs India Ltd Various Tanks at M/s Sterlite Industries Ltd, Tuticorin (2009)

Natural SoftChloro Butyl

1490m²460m²

L & T LTD Rubber Lining on Concrete Surface Hindustan zinc ltd Tank (2004) Butyl 6000m²



Llyods India LtdPhosphoric Acid Storage Tanks-4nos At

Amman,Jordan (1996) Natural Soft 10000m²

Madras Fertilizers Ltd, Chennai

Phosphoric Acid storage tank 1500MT, 6000MT and 10000MT (2010) Natural Soft 5750m²

Hindustan Zinc Ltd, Rajasthan M.S.Tanks and Concrete Tanks (2009-10) Butyl 1565m²

Aditya Birla Chemicals (India) Ltd, Uttar Pradesh Various Tanks for Chlor-Alkali Project (2012) Ebonite 3200m²

Grasim Industries Ltd Various Tanks at Chlor Alkali Plant (2006) Ebonite 974m²

Travancore-Cochin Chemicals Ltd HCL Storage Tank (2009) Ebonite 210m²

Travancore-Cochin Chemicals Ltd Filtered Brine Tank (2005) CMS Ebonite 210m²

Gujarat State Fertilizers and Chemicals Ltd,

Gujarat

Digester PA Storage Tank etc (2013) Triflex 1150m²


Uranium Corporation of India Ltd, Kadappa Various Tanks -66Nos (2011) Semi-Ebonite, Butyl, Natural Soft 5747m²

Indian Oil Corporation Ltd, Paradeep Various Tanks -4Nos (2012) Natural Soft 3200m²

Societe Onshore Construction SARL AU, Morocco. Feed Well and accessories(2013) Natural Soft 1000m²

Onshore Construction Company Pvt.Ltd, Mumbai.

Rubber lining of various Tanks at M/s.DCW, SIOP Project, Tuticorin(2013) Butyl 9000m²

Bhushan Power & Steel Ltd, New Delhi

Rubber lining of Pump Boxes & Ducts, Slurry Tanks(2013) Natural Soft 3500m²

Gea Process Engineering (India) Pvt Ltd, Baroda

Rubber Lining of Feed Tank & Intermediate Tank at M/s.DCW Project, Bromo-Butyl 1116m²


CHLOR ALKALI PROJECT TANKS

HCL & HYPO STORAGE TANKS SALT SATURATORS & BRINE CLARIFIER DM WATER TANK

ABRASION RESISTANT LININGS

FABRICATED & RUBBER LINED BENDS PUMP BOXRUBBER LINED PIPES READY FOR DISPATCH

CORROSION RESISTANT LININGS

HCL STORAGE TANK

POLISHED BRINE TANK

INTERMEDIATE CAUSTIC TANK

Products

Hoses Lebracs Rubber Hoses are designed and manufactured to the highest

quality Supplied to a wide range of industry standards Our Hoses ensure maximum reliability & availability for critical applications Standard size ranges from 2”Ø to 48”Ø Can also custom manufacture as per Client’s requirements Hoses are manufactured with the finest grades of rubber compounds,

reinforced with polyester to provide strength and inline movement The spring wire helix construction ensures flexibility and tolerance to

vacuum pressure during service Lebracs Rubber’s hoses are classified into

Slurry Handling Dredging

Slurry Handling HosesUsed in the mineral processing industry, coalrefinement plants, steel and cement industries andother applications where high wear resistancecombined with flexibility and vibration reduction isrequiredA few of the many advantages of opting for Lebracs Rubber Slurry Handling Hoses include

Absorbs system vibration and saves wear on equipment

Compensates for thermal expansion and contraction

Reduces noise Flexible connection for fixed piping misalignment Can be cut on site for immediate installation. No welding necessary. Available with many inner tube compounds to

meet specific material handling needs.

Products

Dredging Hoses

Lebracs Rubber’s dredging hoses arespecifically designed to deliver optimalsuction or discharge in heavy duty dredging.The robust construction is able to handle themost abrasive material including thecorroding effects of marine applications andabrasive slurries

Types include

Suction Hose Discharge Hose

Products

Dredging HosesSuction Hose

This type of slurry hose is very well suited to be used forvery abrasive and sharp edge solids like blasted or precutrock

Reinforced with multiples plies of high tensile cordssuitably impregnated with Rubber

Discontinuous steel rings are provided to take care ofsuction, crush resistance, and avoid kinking and toimprove the sturdiness of the hose

Abrasion resistant, Weather resistant, Sea Water resistantrubber specially compounded outer cover

Mostly used with these hoses are the rubber flange/steelbacking flange and the Double Action flange

Can be supplied in any size, and depending on application,with 100% vacuum capability and high implosionpressures

Products

Dredging HosesDischarge Hose

Specially compounded abrasive resistantrubber hose, suitable for sand & slurry.

Manufactured to very close O.D. tolerancesand in any size as per the Client’srequirement in various lengths andpressure ratings.

Liner thickener applies to the inside of thehose as well as the flanges.

Brick Lining

Lebracs Rubber offers complete integratedservices for supply and application ofrefractories and chemical resistance lining forprojects & revamps. This makes LebracsRubber a complete protective solutioncompany.

SERVICES OFFERED: Design Supply

Detailed Engineering Application

R & D

INDUSTRIAL SECTORS SERVED Zinc

Aluminum

Oil & gas

Cement

Power

Iron & Steel

Copper

Acid Plants

Fertilizers

Chemical

Glass Plants

Brick Lining

PRODUCT RANGE:

Low / Ultra Low Cement CastablesHigh Purity CastablesConventional CastablesInsulating CastablesNon Wetting CastablesHigh Temperature Hot Face Insulating BricksLow Temperature Hot & Cold faceInsulating BricksDense Fire BricksHigh Strength MortarsAcid & Alkali Resistant Bricks / CastablesAcid Resistant MortarsCarbon Bricks / TilesFurane Based Mortars

Brick Lining

PTFE Lining

Offers surface protection against corrosion Excellent resistance to almost all chemicals

Acts as an alternative against use of special alloys Reduces overall cost

Advantages of opting for Lebracs Rubber’s PTFElining High tempering strength Pressure-tight up to 200 bars Universal resistance to chemicals, even to aggressive

acids and alkali Non-corrosive Free of contamination

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