When it comes to fluid transfer, hoses play a vital role. However, they come in several types, each specific for distinct jobs. Among those, composite hoses excel due to their unique structure and composition. They offer a leak-proof transfer of regular liquids to hazardous fluids. However, many still ask: what is a composite hose, and how does it work?
Knowing this question is crucial for proper usage. What if you pick up a composite hose to transfer chemicals while it is designed to handle cooking oil? It will definitely end up with serious safety risks. Hence, in this article, I will give you a complete understanding of composite hoses and their types and applications. So, let’s get started!
What is a Composite Hose?
A composite hose is a lightweight tube used to transfer different fluids. Unlike regular pipes, composite hoses are equipped with multilayers of various materials. These layers provide extra flexibility and corrosion resistance to handle harsh environments. So this type of hose is known for its durability and strength.
Composition
The composite hoses consist of four main components. First is a core tube or inner lining with which fluid directly comes in contact. It is made with polyethylene, polypropylene, or Teflon to ensure leak-free transfer. The second part is the reinforcement layer. It adds strength and flexibility and is made with nylon or polyester.
The third and most important part is the metal helix. It is made with spiral coils of stainless steel or aluminum. This part prevents the tube from collapsing. However, the last part is the outer covering that saves the hose from weather, abrasion, and UV rays. All these parts work together for the safe transfer of several fluids.
Working Principle
When a fluid enters the hose, the inner lining ensures that the fluid does not react with the hose. This prevents the chemical reaction and contamination. At that time, the reinforcement layer evenly distributes the liquid along the hose walls. This process prevents the pressure buildup and saves from the risk of bursting.
Moreover, the flexibility of this layer also ensures that the hose does not collapse due to waves. As you know, some chemicals can generate static electricity due to over-shaking. This electrical buildup can cause shocks and fire explosions if not discharged. Here, the metal helix acts as a conductor and dissipates the electricity into the ground for safe transfer.
Types of Composite Hoses
Not all the composite hoses are created equal. They come in various designs to cope with specific fluids. So, choosing the proper hose for the correct fluid is crucial to prevent mishaps. Let’s dive in and discuss common types of composite hose with their specifications.
1- Chemical Composite Hoses
As the name suggests, chemical composite hoses are designed to transport aggressive chemicals. These hoses are commonly used in chemical plants and refineries. Because they handle hazardous fluids, they are developed with unique materials. For example, chemical composites are mainly made with polypropylene or Teflon. These materials are chemical resistant and act as an anti-adhesive layer to prevent chemical buildup. One advanced feature of this type is its vapor-tight design. It provides air-tight sealing for volatile organic compounds and toxic fumes to reduce health risks.
2- Petroleum Composite Hoses
This type of composite hose is specially designed to transport petroleum-based products. For example, they transfer crude oil, diesel, kerosene, and diesel. Therefore, petroleum composite hoses are made with Polyvinylidene Fluoride (PVDF). This material cannot degrade even with aromatic fuels that are strong enough to dissolve rubber hoses. These hoses have the highest flexibility for extreme cold weather conditions. Even below -40°C, petroleum hoses prevent petroleum products from freezing.
3- Cryogenic Composite
Cryogenic hoses transport cryogenic substances, which are highly low-temperature liquids. These liquids exist at -200°C and include liquefied natural gas (LNG), liquefied petroleum gas (LPG), and liquid nitrogen (LN2). Thus, cryogenic hoses carefully handle such fluids. These hoses have special linings made with polyamide or polyester to provide insulation. Cryogenic liquid can quickly turn into gas and cause leakage or pressure buildup. Thus, cryogenic composite hoses have vapor barriers that prevent gas permeation.
4- Vapor Recovery Composite Hoses
It is a special type of composite hose used to capture vapors. Fumes and vapors are generated during the loading and unloading of volatile liquids. When exposed to the air, these vapors cause pollution and health risks. Thus, vapor recovery hoses capture vapors and transfer them back to the storage tanks with the help of channels. Volatile vapors are highly explosive. Therefore, these hoses are made with polypropylene to prevent vapor penetration. Moreover, vapor recovery hoses also contain anti-static properties to avoid fire explosions.
5- Food-Grade Composite Hoses
These are specialized hoses used to transfer food-grade liquids. They are highly flexible, lightweight, and made with FDA-approved material. For example, food-grade hoses contain an inner lining of polyurethane. This material is non-sticky and odor-resistant. Thus, the liquids remain fresh and odorless for long distances. Moreover, food-grade polymers in the outer layer prevent fungal or bacterial growth. For alcoholic liquids such as beers and spirits, these hoses also contain stainless steel wire helix. It prevents the static electricity buildup and fire explosion.
6- Biofuel Composite Hoses
Biofuel composite hoses transport biofuels such as ethanol and biodiesel. These liquids contain ester components that can quickly degrade regular rubber. Biofuels can also attract moisture and cause corrosion and swelling inside a hose. However, biofuel composite hoses are specially designed with fluoropolymers. This material resists ester degradation and prevents explosion. Moreover, these hoses comprise “Moisture Barrier Technology.” It involves a moisture-impermeable barrier that prevents moisture from entering hose walls.
7- Steam Composite Hoses
Steam is one of the most challenging substances to handle. It is produced in boilers and power plants by boiling water. This steam is transferred to different areas for energy generation and chemical reactions. So, it is transported with the help of steam composite hoses. These hoses are mainly made with thermoplastic layers that act as insulation. Steam hoses can resist 230°C high temperatures. Moreover, the inner lining of galvanized stainless steel readily withstands high-pressure steam.
Benefits of Composite Hoses
Regular hoses are often prone to leakage, cracks, and failure. Composite hoses, with their extreme durability, are setting a new standard. But what exactly makes them so unique? Let’s take a closer look at the perks they offer.
- High Chemical & Corrosion Resistance: Composite hoses have multilayered materials. Unlike metal hoses, they are made with polypropylene. It is a highly corrosion-resistant and rust-proof material. Moreover, these materials do not degrade with aggressive chemicals.
- Lightweight & Easy to Handle: Composite hoses are 30-50% lighter than rubber and steel. It means they are easy to transfer and store. Moreover, these hoses’ flexible nature makes them easier to handle in deep oceans.
- High-Pressure & Temperature Resistance: As you know, aggressive chemicals build up high pressure. This pressure buildup can degrade typical hoses. However, composite hoses are made with robust materials that can handle heat and high pressure.
- Anti-Static & Fire-Safe Design: Hazardous liquids produce static electricity. This generatic current can cause fire explosion and safety risks. However, composite hoses feature wire reinforcement that dissipates the effect of this electricity.
- Customizable for Applications: Composite hoses can be customized to the needs of industries. For example, they come with various types of inner lining to handle specific liquids. Moreover, you can add extra protective layers for more safety.
Applications of Composite Hoses
Behind every smooth industrial operation, there’s a composite hose at work. They ensure the safe transport of risky liquids, thus becoming necessary for several industries. Let’s explore typical applications of composite hoses.
1- Oil & Gas Industry
Oil and gas industries heavily rely on composite hoses. As I said, they are made with strong, durable materials and can handle high-pressure fluids. Thus, these hoses are used to transfer petroleum-based fluids. For example, they are used in offshore and onshore oil rigs to transfer crude oil. Moreover, composite hoses transport oil, diesel, and petrol from storage facilities tankers.
2- Chemical Industry
Composite hoses are equipped with multilayers of durable materials. So they can easily handle all types of chemicals. For example, these hoses transfer acid into chemical refineries. Composite hoses load and unload solvents from bulk storage facilities to drums. They are also used in research and laboratory facilities to handle corrosive chemicals.
3- Marine & Shipbuilding
As you know, marine environments are salty and rusty. But composite hoses are designed to handle all those harsh conditions. So, they are used in bunkering operations where two ships transfer oil in open oceans. Moreover, composite hoses are used in ship-to-shore operations to transport chemicals. Lastly, these hoses also contribute to bilge and ballast water transfer.
4- Food & Beverage Industry
Composite hoses are made with FDA-approved materials. These materials do not contaminate and reduce bacterial growth. Thus, you can transfer food-grade materials without risk of contamination over long distances. For example, composite hoses transport milk, beer, edible oils, and syrups in the food and beverage industry.
5- Pharmaceutical & Medical Industry
Hygiene is a significant concern in the medical industry. Even a tiny contamination can spoil the medicines and cause health hazards. However, composite hoses are manufactured using non-reactive and non-porous materials. So, contamination cannot react with medicines. So, they are used to transfer vaccines, anesthetic gases, and IV fluids safely.
Questions fréquemment posées
Why are composite hoses better than rubber or metal hoses?
Composite hoses are better than rubber or metal hoses in several aspects. For example, they are lightweight and more flexible than rubber. Unlike metal, their composition involves materials that do not rust in moisture.
Are composite hoses environmentally friendly?
Yes, composite hoses are eco-friendly in many ways. First, they ensure leakage-free transfer of oils and chemicals. This reduces the risk of harmful liquid spills that can contaminate our environment. Moreover, their ability to recover harmful liquids via vapor also reduces emissions.
Are composite hoses safe for flammable liquids?
Yes, composite hoses are safe for flammable liquids. Flammable liquids produce static electricity due to shaking, which can cause a fire explosion if not handled. However, composite hoses contain anti-static wires that dissipate static electricity buildup.
Conclusion
Composite hoses are a special type of hose. They are more flexible and lightweight than regular hoses. I have discussed some composite hoses and their uses in this article. Each type is particular for a specific job. For example, some composite hoses transfer only risky chemicals. However, some are specific for transporting petroleum-based products. Moreover, each type contains a unique material composition to handle specific liquids. Thus, first, you should understand the specifications of each type and choose the right one for the right job.