Deacon Sealants Case Studies

Fiber Materials Inc. - Deacon 8875-Thin

In 2009, Fiber Materials Inc. was searching for a high temperature sealant and came across Deacon's website. Andrew Dawley needed to seal an access door on two types of industrial ovens that were opened on a routine basis. Previously they were using red silicone and ceramic rope. The red silicone would not last because it was being used above its temperature range of 600F and the ceramic rope was difficult to keep in place and did not have great sealing properties. Dawley needed a product that was able to handle the temperature and pressure without cementing the door in place. On one of the ovens, the temperature was 800F with less than 1 PSI and the process stream was an organic byproduct. The second application was on a pressure oven at 932F and 50 PSI with a tar process stream. Deacon 8875-Thin was used successfully on both applications and the company has been purchasing in bulk quantities every 2-3 months since 2009.

Company A - Deacon 3100

Company A had a warped 8" steel flange and had tried several different types of standard high temperature gasket materials without good success. The flange had a measureable gap at the 6 o'clock position of 1/8" and tapered closed at 8 and 4 o'clock with additional smaller gaps around the entire perimeter of the flange at various locations. Company A needed a product that could fill in the gaps and conform to the uneven surface area. The Customer was advised to use their existing gasket with Deacon 3100 as the gasket dressing. For this application, they could have used a smaller diameter such as 3/16" or 1/14". However, Company A decided to do away with the existing gasket entirely so they were advised to use 3/8" diameter Deacon 3100. That particular diameter was selected after it was recommended to go with 3x the thickness of the largest gap on the flange to ensure the sealant was not just filling a void, but being adequately compressed. Deacon 3100 enabled the customer to achieve a leak free seal the steam application at 400F and negative pressure of 30" hg when nothing else would work on the warped flange.

Industrial Air Tool - Deacon 770-L

Industrial Air Tool had a customer that wanted to find an alternative to Copaltite Liquid because of the smell, cost, and hazardous shipping regulation. The customer needed a product that could seal various high temperature threaded applications in a Texas plant. Applications included 500F on a 450# steam system, DowTherm at 550F with 100 psi, and nitrogen on 1/2" NPT at 650F with 725 psi. Deacon 770-L was selected as the Copaltite Liquid alternative and the customer has continued to purchase regularly for the last 7 years.

nanoComposix - Deacon 3300

In 2012, Andrew Smith of nanoComposix needed a sealing solution for a flanged heating element that operated at 752F with a mix of hydrogen and nitrogen at 30 PSI. The heated chamber needed to be opened 2-3 times per day throughout the week so he couldn't use something that acted like a cement on the joint. Silicone was out of the temperature range and ceramic type sealants they had previously tried got too hard and brittle for the application. Flexibility was crucial so Smith went with Deacon 3300 and has been using 5 feet per week since 2012. nanoComposix's installation procedure involves using the product without a gasket. The sealant is applied at room temperature and the bolts are tightened on the flange. The chamber is heated to 400F then cooled back down to room temperature. A re-torque is performed on the bolts then the heating element is brought up to the maximum operating temperature of 752F over the course of 3 hours. The flange is disassembled and cleaned, and then the procedure is completed 1-2 more times throughout the day.

AFC-Holcroft - Deacon 3300

AFC-Holcroft was having sealing issues on a heat treat furnace flange that was held together by clamps. Mike Blythe said that the standard braided ceramic rope and gasket they used was not working. The flange was on the exit of an endothermic gas generator that operated at 1950F but Mike said the sealant would be exposed to more like 1600F and less than 1 psi. Deacon 3300 was successfully used to seal the process stream that contained CO, N2, CH4, and C02 (known as endothermic gas). Since their initial order, AFC-Holcroft has bought Deacon 3300 as well as Deacon 8875 for other high temperature applications.

The Medical Center Company - Deacon 3100

In 2013, Gary Pekarcsik was having sealing trouble with the manhole gaskets on his water tube boilers. The Medical Center Company was using 12 x 16 x 1.25" spiral wound gaskets for a boiler operating at 140 psi and 365F. It was typically taking three or more attempts to get the manhole covers to seal even though the ring and drum were not in poor condition. At first, Gary thought a paste sealant would be the solution. After discussing his application, we determined that using a smalI diameter of Deacon 3100 with his spiral wound gaskets would be best. The Deacon 3100 would provide an initial seal simply by compressing the material between the mating surfaces, and would conform to any irregularities that were preventing the gasket from seating properly. The product solved Gary's problem and he has been buying 1/8" diameter ever since.

Nirvana Energy Systems-Deacon 8875-T

Nirvana Energy Systems developed an efficient micro-combined heat and power (m-CHP) system to convert natural gas into electricity for water and space heating. The technology called "thermoacoustics" uses sound to turn heat into electric power. The burner assembly that is a key component in the power system needed a high temperature sealant to properly function. NASA Scientist Frank Ritzert was assigned by the federal government to Nirvana Energy Systems to commercialize a NASA Power System Technology and found our company after conducting market research for a high temp sealing solution. Ritzert used the Deacon 8875-T material at several interfaces that continually cycle between 900C and room temperature with pressure. Ritzert stated "Deacon 8875-T is the best solution currently in existence. I'm very glad to have found you and the product as seal interfaces are critical path elements in our system. We have run the current, and most advanced, version of our power system several times and the 8875-T is performing incredibly well." The company plans to move forward with the mass production of their heating units.

Company B - Deacon 3300

In 2013, Company B came to us needing a flexible sealant that could be used from 1200-1300F at 60 psi to seal between two mating surfaces on an amphibious vehicle's exhaust system. High temp RTV could not take the temperature and other high temp sealants became too hard and brittle. The product needed to be able to handle temperatures over l000F, resistant to water I saltwater, and provide a leak free seal under constant vibration to properly seal the exhaust pressure. Deacon 3300 1/4" dia. solved the problem and the company specified the product for use on all newly manufactured units during initial assembly and for repairs of existing units. Company B continues to purchase on a regular basis.

LPR Construction - Deacon 8875-Thin

Zach Martin of LPR Construction was working on a project that called for a high temperature sealant on a kiln exhaust duct flange that operated over 700F. The company was using an 1/8" porous fiberglass tape but needed a sealant as well. Red RTV could not take the heat so we recommended Deacon 8875-Thin be used with the porous gasket. The customer did a weave pattern behind the bolt holes, then applied the fiberglass tape, before applying an additional weave bead on the mating bare flange. The fiberglass tape soaked up the sealant and created a strong leak free seal. The job used 50 gallons of sealant along with 228 caulking tubes. LPR Construction said they would use us for any future job requiring high temperature sealant.

Superior Radiator Coils - Deacon 3300

In 2012, Brian Biskie of Super Radiator Coils contacted us looking for a product that could be used for sealing a cover plate on an exhaust stack that was discharging to atmospheric. Biskie needed to prevent exhaust gas from seeping into their boiler room. He explained they needed a product to seal at 5psi and 1104F. Deacon 3300 was determined to be most suitable for the application so it was applied between the stack and 32" x 8" carbon steel rectangular cover plate. Prior to being put into service, a pneumatic test was to be performed to test for leaks. Biskie questioned if the product would seal at room temperature or if it had to be heat cured beforehand. We explained that simply compressing the sealant material between two mating surfaces would create an initial seal since the product was a putty consistency. During the pneumatic test, the unit would be completely submerged in water so Biskie needed to know if getting the sealant wet before heating presented a problem. We clarified that the only direct water contact would be around the exterior and explained the sealant would not break down or cause any issues by getting wet before heating. To be on the safe side, the customer ran a bead of Deacon 327-RTV (high temp silicone) around the exterior seam of the two mating surfaces. The silicone ensured the pneumatic test would be a success. Once the pressure test was complete, the system was put into service. At 700F, the temperature limitations of Deacon 327-RTV were exceeded and Deacon 3300 was solely responsible for sealing the stack. The application was a success and Superior Radiator has continued to purchase Deacon 3300 for applications above 1000F and Deacon 3100 in other applications below 1000F for the last four years.

 

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