Failure analysis of a leaching reactor made of glass-fiber reinforced plastic

•Failure analysis of FRP reactor was carried out.•Various experimental techniques were used together with finite element analysis.•Root cause of the failure was poor adhesion in the joint caused by insufficient grinding.

This paper reports a failure analysis of a leaching reactor in a zinc plant that suffered from a catastrophic failure after less than two years of operation. During normal operation the bottom of the reactor fell out suddenly, releasing the contents, a high-temperature acidic solution, into the surroundings in an uncontrollable manner. The reactor was made of glass-fiber reinforced plastic. Microscopy, thermal analysis, mechanical testing and finite element analyses were employed to investigate the causes of the failure. There were several contributing factors but the root cause was poor adhesion between the bottom and the joint laminate, which was caused by insufficient grinding during the surface preparation stage of the joint.