Polycon Gulf Ltd, which has made a mark as the only company in the UAE to offer rotolining / polyethylene lining technology for corrosion protection, is planning to expand its rotomoulding and rotolining lines in Qatar as well as other business verticals in relevant markets in the near future.

As part of its expansion, the company which brings expertise into the anti-corrosion plant’s operations, now plans to invest in and introduce polytetrafluoroethylene (PTFE) linings for anti-corrosion protection at high temperatures.

With this, the Polycon Gulf aims to serve high-end applications in major industries such as ship building; water treatment plants, chemicals and chemical transportation, oil and gas as well as other industries like petrochemical, fertiliser, thermal power plants, MEP and maintenance and firefighting equipment manufacturers.

Polycon Gulf prides itself in providing unique solutions to its clients is taking its innovation streak beyond its pioneering rotolining technique. In this regard, the company has recently started services for ethylene tetrafluoroethylene (ETFE) lining, polypropylene (PP) lining, and polyvinylidene fluoride (PVDF) lining.

Additionally, the launch of new products such as multi-purpose tanks, slim tanks and conical tanks introduced in different industries has helped broaden the scope of work for Polycon Gulf in the GCC region.

THE CORROSION SPECIALIST

Leakages through corrosion can be a huge problem in industrial operations, affecting adversely the long- term performance of businesses. However, Polycon Gulf says with polymer lining, life of industrial assets like steel assets, pipes and fittings can be extended as it keeps them safe from within.

Polycon products are manufactured using low-density polyethylene – an environmentally compatible hydrocarbon

“Rotolining by Polycon Gulf Limited is an innovative process whereby chemically modified polyethylene and other Fluoropolymers form a bond with metals or other resins. Rotolining enables application of a uniform, seamless layering of polymeric material to the interior surfaces of complex hollow metal structures, metal vessels, tanks and other components,” a senior spokesperson at Polycon Gulf told Gulf Industry.

Rotolining gives a high level of corrosion protection and chemical resistance making the metal structures strong, durable and safe.

Explaining further, he said that Rotolining / Polymer Lining is the best-in-class corrosion protection technology, effective against crude oil, saline water, waste water in addition to the most corrosive

chemicals like acids, alkalis, oxidizers, solvents, and salts. It can be applied on carbon steel pipes, spools, flowlines, fittings, vessels and process equipment etc. in form of a protective layer (internal polymer coating / lining) of 2 to 11mm thickness, enriched with corrosion resistant additives with the wide service temp range.

“The result is fewer breakdowns, significant reduction in the life cycle costing of the assets and reduced maintenance costs. It leads to significantly longer and reliable uptime when compared to other corrosion protection techniques,” he added.

MANUFACTURING FORTE

Part of Al Nasser Industrial Enterprises, a prominent industrial group with manufacturing activities spanning diverse verticals like like steel, polymer, fabrication and industrial intermediates, Polycon Gulf was established in 1993 by Al Nasser Holdings to set up successful industrial ventures and establish a strong presence in the GCC region. Polycon has completed almost three decades as a market leader in the UAE and has a strong presence across Oman, Bahrain and Saudi Arabia through various joint ventures.

Polycon Gulf sets the standard for roto-moulding with an innovative range of products

Focused on quality and service, Polycon has a one-of-a-kind state-of-the-art laboratory and quality testing facility. Besides being TUV and ISO 9001 certified, Polycon is registered as a preferred vendor with many government bodies like OSHAD, SGS, Ministry of Economy, Civil Defence, Chamber of Commerce, ADCE, DEWA, Food Safety Department and with private sector giants like EFECO, Trinity and more, validating its strengths and capabilities when it comes to quality, environment, safety and customer friendliness.

PIONEERING PRODUCTS

Polycon Gulf with a strong commitment to quality and service, sets the standard for roto-moulding with an innovative range of products and services such as water storage tanks, road barriers, portable restrooms, spill containment pallets, pantoon bridges/ marine buoys, dual-face pallets, illuminated planters and polymer lining on interior surface of carbon steel pipes of up to 10 ft diameter with 6 m length and tanks from 35 USG to 10000 USG capacity.

Explaining the manufacturing process of roto moulding, Polycon Gulf’s spokesperson, said: “Rotational moulding, also known as rotomoulding, is a plastics moulding technology which is ideal for making hollow articles. It is a casting technique but unlike most other plastics processes there is no pressure involved. Moulds for the process are relatively inexpensive as they do not have to withstand pressure and therefore relatively short production runs can be made very economically.”

Rotomoulding is used to make a very diverse range of products. The process offers the product designer exceptional freedom as just about any shape can be produced. There is almost no limit to the size of mouldings and there are literally thousands of applications.

The UAE-based brand has the expertise to manufacture custom-designed products, which are approved by top security agencies of the world. These products are preferred and used for marine security in many places across the Middle East and North African (Mena) region.

Polycon products are manufactured using low-density polyethylene – an environmentally compatible hydrocarbon. Polyethylene is a high-grade thermoplastic that has exceptional resistance to both physical and chemical attack and 100 per cent reusable and recyclable.

“Today the industry is heavily dependent on polyethylene (PE) and 97 per cent of rotomoulded products are made from this material. Polyethylene is a versatile, easily mouldable and readily available polymer which has come to dominate the process,” the spokesperson said.

“Rotomoulding is a casting technique in which powder is nearly always used rather than granules, meaning the material must be ground. Polyethylene is relatively easy to grind at ambient temperatures,” he added.

Commenting on the challenges and difficulties the company faces, he said that `meeting quick turnaround times without compromising on quality’ was one of the topmost tasks for the company.

LANDMARK PROJECTS

Polycon’s products are part of various landmark projects that include marine, custom mould products, oil and gas, defence (using the hexagonal military drum) and marine buoys.

The company has successfully executed more than 150 ship projects in a span of two years. For a defence client, the company supplied innovative hexagonal military drums and for a private organization, it supplied the incinerable boxes for the disposal of hazardous waste.

Rotolining was also carried out for Dubai biodiesel supply firm BioD Technology for ETFE lined pipe spools. Rotolining also supports environmentally by supplying ETFE lined spools to Bio-D Diesel, a company in bio-diesel business.