INVESTMENT
PROTECTION
Corrocoat products provide engineering structures and equipment with long-term and cost-effective protection against corrosion.
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The maintenance team at a sugar mill in Indonesia were fighting a losing battle against corrosion on the welding joints of their CO₂ pipeline. The purpose of the CO₂ gas at the sugar mill was for carbonation, ultimately improving the quality of the sugar.
In the carbonatation process, the melt is spiked with lime [Ca(OH)2] then CO₂ gas is flowed in the carbonatation vessel, a precipitate of calcium carbonate (CaCO3) is formed which absorbs/binds impurities, including reducing dyes so that the acidic pH dissolves again. The source of CO₂ gas comes from boiler gas which has been purified through a scrubber. The carbonation process is carried out in two stages: 1. Add lime as much as 0.5% brix together with flowing CO₂ equivalent to the amount of lime added 2. At the end of the carbonator completes the reaction with CO₂ flow until the pH drops to around 8.3, then the liquor is filtered in a pressure filter (leaf filter) to produce filter liquor and mud.
At that time, the plant was using SS304 & SS316L stainless material for their pipework. But, after just six months in service, the pipework was suffering leaks on the welding joints areas.
Over 220m of pipework was transported to the Corrocoat workshop (in Indonesia), where the team were tasked with providing a long-term solution. Polyglass was the recommended coating system.
So impressed with the result and performance of the Polyglass VE system, once the pipework was put back in to service, the client chose to downgrade their pipework material to carbon steel, and award Corrocoat Indonesia with additional contracts for their expansion and preventive maintenance programs, for further CO₂ piping systems, over the next three years.
Corrocoat USA was recently contacted by a general contractor that constructed a sodium hypochlorite containment for Florida’s largest community-owned electric utility company, serving more than 1 million Northeast Florida residents with electric, water, sewer and reclaimed water services.
The containment required a lining for the concrete floor that met 3 requirements:
As a result of the turnkey nature of the business and ability to provide the required 5-year warranty, Corrocoat USA were chosen for the project.
The surface was first wet abrasive blasted with Chlor*Rid to removal salts and remove laitance. It was then primed with Plasmet ECP; a high-solids, low viscosity, two or three-pack epoxy primer, used to prepare concrete surfaces that are damp, or where levels of moisture are approaching the saturation point of concrete.
Once the primer had cured, the surface was graded towards the sump using Corrocoat Zip E screed; an epoxy glassflake coating with additional fillers, which provides cost-effective, durable protection in aggressive atmospheric conditions and aquatic immersion environments. It has excellent application characteristics, in single applications.
Following cure of Zip E Screed, all transitions and 100% of the sump area were laminated using Corrocoat Epoxy Laminating Resin and fiberglass matting. The surface was abraded to remove nibs and cleaned, then Plasmet AR3 was applied at 48-60 mils DFT, to provide the required protection.
Following the success of the project, Corrocoat USA has completed a second containment for the same contractor, and has a 3rd awaiting approval.
Find out more about out high performance products here.
The largest oil services company in Kuwait, recently contacted our partners in Kuwait, Aja Technological Solutions Co. to provide long term protection to the floor of a containment area, spanning 500m².
Over the years the concrete floor had continued to suffer corrosion as a result of raw hydrochloric acid spills. To try and rectify the issue, the client would constantly re-concrete the floor, which proved both ineffective and extremely costly.
Four applicators from the team in Kuwait completed the project in 24 days; preparing and coating a concrete floor which had been laid 28 days prior to work commencing. Initially, the surface was abrasive blasted to remove surface laitance or weak frangible material. Following the removal of dust and debris and a thorough vacuum cleaning, the prepared concrete was then primed with Polyglass PPA, which was used as a penetrating primer and to strengthen the immediate top layer.
The team then applied a Corrocoat laminating system, prior to the application of Polyglass Standard, to 1500 microns.
Throughout this project the team faced numerous challenges. As the project was undertaken in an open space, considerations and allowances for changing weather were factored in. On alternative days, the team were required to provide a cover for the area, to protect the concrete from absorbing water. Also, as the project was conducted in the South of Kuwait, surrounded by desert, there were also considerations regarding the 40°C summer heat, towards the final stages of the project.
The client was extremely satisfied with the solution provided and the guarantee of long-term cost-effective protection.
Contact a member of the team today to discuss how we can repair and protect your concrete floor.
Last month we had the honour of hosting our international partners, at our Global Corrocoat Conference, at our Head Office, in Leeds. Following the last global conference, which took place 5 years ago (unfortunately prolonged as a result of the global pandemic), it was great to reunite with a number of partners, and also representatives from new operations from our global network.
We welcomed partners from 18 of our overseas operations, over 3 days, sharing case studies, project overviews, showcasing live demonstrations in our engineering and coating workshops and much more, amongst socialising and networking.
The majority of attendees were able to join us the weekend before the conference, with a welcome drinks and reception the first evening, followed by exploring the many acres of land, on a scenic walk at Fountains Abbey and Studley Royal, the next day. The group then unwound with a tour and beverages at the Black Sheep Brewery.
The Corrocoat Global Conference commenced on Monday, 18th September with a welcome from our CEO, Charles Watkinson. Charles recounted his earlier days when he first started the company in 1974, and insightful stories from some of Corrocoat’s first ever clients and projects, and the first Corrocoat overseas operation, in the Netherlands (Corrocoat Benelux). Almost 50 years down the line, Charles spoke of his pride on what Corrocoat has now become and the passion and dedication of the entire Corrocoat Team, both nationally and internationally.
The delegates were taken on a site tour of the engineering and coating workshops, at our Leeds Head Office, gaining insight in to the projects which were currently being completed on-site. Managing Director, Graham Greenwood -Sole, then presented on the new markets and areas of industry which are fast emerging. Sharing his knowledge and expertise, Graham spoke about energy from waste, carbon capture and hydrogen production and the ways in which our services can protect and pro-long the life of capital plant and equipment.
The session was followed by Sergio Teixeira, Corroserve Sales Engineer, who imparted more information on the energy from waste sector. Sergio showcased a number of projects which we have completed here in the UK; repairing and protecting baghouse filters; cells and hoppers, Ducting, Stacks, Waterboxes, fan blades, vessels and much more.
Partners from our overseas operations in the Czech Republic, USA, Korea, Israel, South Africa, India, Qatar, Japan and China presented on everything from pump refurbishment and efficiency engineering to concrete repair, projects in Biomass plants and Power Stations, to repairing process equipment, protecting Flue Gas Desulphurisation systems (FGD), pipe refurbishment, work on isolation joints and overboard scrubbers.
The Head Office team also shared top tips on Sales and Marketing, and carried out a number of practical demonstrations including the application of Fibrecoat; using the small-bore pipe spryer to apply the coating and also highlight Fibrecoat as a high-performance structural lining for the repair of severely corrosion damaged pipes, the Plasmet ZF aerosol and alternative surface preparation methods.
Graham said; “It was a very insightful few days and a celebration of the incredible work Corrocoat carries out across the globe. The Conference pays true testament to the hard work and dedication of everyone who is part of the Corrocoat family, and it’s great to come together with our partners and celebrate this. This, along with our exceptional product, is the very heart of what Corrocoat is all about.
I’d like to take this opportunity to say a HUGE thank you to all who attended and presented, and made the conference extremely memorable and insightful. We’re already looking forward to the next Corrocoat Global Conference in 3 years.”
Long-Term Protection Against Chemical Attack & Erosion
In chemical manufacturing processes, Agitated Nutsche Filters (ANF) are essential equipment for the separation and filtration of solid and liquid components. However, the corrosive nature of the chemical process liquids can pose a challenge to the ANFs, leading to degradation and equipment failure.
A renowned chemical manufacturing company in Maharashtra, India, approached Kirloskar Corrocoat Private Ltd, our partners in India, to provide long term protection against chemical attack and erosion for two ANFs. Each one measured 3m in diameter by 2.25m, and included accompanying components; the vessels, agitators, mesh plates and bottoms.
Due to the size of the ANFs, the project was completed on-site, with the team first dismantling them. The internals were grit blasted to ISO 8501 cleanliness standard Sa2½ and Polyglass PPV was then applied as a holding primer, with a top coat of Polyglass VE. Polyglass VE is perfect for immersion environments where superior resistance to chemical attack is required – this was critical for the longevity of the ANFs, in their corrosive service environment.
The team reassembled the ANFs and they are now fully operational.
Contact a member of our team to find out more on how we can provide long term protection against chemical attack and erosion, for your equipment and machinery.
Our partners in the Czech Republic, Corrotech, recently completed a project at a Power Generation Plant, repairing and protecting the internals of a chemical storage tank.
The 960m² tank (12.5m diameter x 15m height), stored limestone slurry. The previously applied coating was extremely porous and had been poorly applied, which resulted in pitting on the carbon steel substrate. The client turned to Corrotech to provide a coating which would offer long term corrosion protection.
Undergoing the project in Winter, temperature regulating and dehumihttps://www.corrocoat.com/wp-content/uploads/2023/09/Corrosion-chemical-storage-tank-internal.pngdifying equipment was required for blasting, and throughout all of the coating application. The team spent 72 days completing the work carrying out the following:
The client was extremely satisfied with the end results and the way in which the project was undertaken, as well as being very impressed with the full turnkey solution which was provided.
Find out more about the work we carry out in the Power Industry here.
Our partners at Corrocoat Benelux, recently worked on a project to repair a secondary settling tank, which was suffering from severe corrosion. The tank, which had its last inspection over 10 years ago, had been in service at a petrochemical plant, and was in much need of repair, having been subjected to waste sludge.
Following an on-site inspection, during an outage, it was discovered that the 2 outer shells, which were 2.4 metres high, with a diameter spanning 4.5 metres, were severely corroded.
Before transportation to the Corrocoat workshop, the skirt of the tank was dismantled by the Corrocoat team, to allow for easier transportation and repair. Upon arrival, the shells were abrasive blasted, before Corroglass 632 was applied to prime the substrate. Fibre glass matting was then applied to the damaged areas, ahead of 2 layers of Polyglass VEF.
The client was extremely impressed with the finished result, and the team are confident the protective coating would exceed a further 10 years in service.
Find out more about how we can repair and protect tanks with our protective coatings here.
One of the largest and most competitive engineering, procurement, construction and installation contractors of offshore oil and gas projects in the Asia-Pacific region, recently approached our partners in China, to provide leakage prevention for an open drain caisson.
With leakages being a very common problem with this type of equipment, the client had considered repairing the issue as and when it would happen, using diving and injection repair. This approach is fairly common, but is expensive and may cause environmental consequences, with leakage of hazardous material to the sea.
The client decided providing leakage prevention for the open drain caisson; protecting the 52-metre long piece of equipment, and extending its service life form the start, with Corrocoat, was the best and most viable option. As part of the project the client commissioned the team to also protect the internals of an attachment pipeline, which was to be inserted in the caisson.
The team completed the project on-site and selected Polyglass VEF to line the caisson internals, via spray application. The pipe internals were also coated with Polyglass VEF, after first being split in to 2 sections. Once cured, the client welded the pipe sections back together, and a total of 10 pipes were inserted in to the caisson.
When in position, the team re-prepared the field fit weld area and coated over the weld joints with Polyglass VEF to complete the corrosion protection. The conditions in the caisson to complete the final stages of the project were very challenging, with a restrictive workspace as a result of the diameter of the caisson and the inserted pipes.
We recently welcomed Superintendent, Ryan Robertson (Corrocoat USA), Development Manager, Nguyen Minh Hieu and Tran Quang Phuc, Commercial and Services Department Manager (both from Vietnam Gre-Coating Engineering Services JSC), to the Corrocoat UK Head office. The trio were trained in our Composite Structural Rehabilitation System; which uses a combination of specialised laminating resins, interlayered with glass reinforced polymers (GRP) composite laminates to give structural strength to corrosion damaged pipework, and other damaged plant and machinery.
Whilst visiting the UK Head Office, the trio embarked on a full and comprehensive 2 weeks of training. Overseen by our Technical Services Engineer, Douglas Lynch, their visit started with advanced theory-based training, offering a deeper insight in to corrosion, service environments, product specifications and more. They then moved on to practical training, working on a number of projects in the coating and engineering workshop, overseen by Douglas and guided by Engineering Supervisor, Warren Marks – who has been part of the team here at Corrocoat, for almost 30 years.
From disassembling and working on the refurbishment of a large valve, to pipe casting, specialist coating techniques; including spraying and flood and drain, the delegates worked on a number of projects with our expert in-house team.
Douglas also took Ryan, Hieu and Phuc through their Composite Structural Rehabilitation (CSR) training, whilst Engineering Manager, Simon Cappleman carried out specialist pump training and showcased the intricacies of our in-house pump division and specialist proprietary Agmec Pipe spraying equipment.
The visit concluded with Ryan, Hieu and Phuc being presented with their certificates upon successful completion of their training.
Douglas said; “It was a pleasure training Ryan, Hieu and Phuc and I wish them continued success in their roles. I look forward to staying in touch with them and being updated on how their training at head office enhances them in their roles, and they pass on their knowledge to benefit our operations overseas.”
India is the not only the largest consumer of sugar in the world, it is now also the largest producer of sugar, displacing Brazil. The Indian sugar industry is the second largest agro-based industry in India.* With this in mind, our partners in India, Kirloskar Corrocoat, regularly work with clients in the sugar industry, providing refurbishment, repair and corrosion protection for plants and ancillary equipment. Kirloskar Corrocoat have applied Fluiglide E to more than 500 pumps in the sugar industry: providing improved efficiency, along with corrosion protection to considerably extend the life of the pumps.
Fluiglide was featured in the product showcase in the last edition of Corrocoat News (the May 2022 issue). These energy-efficient products maximise the performance of pumping systems used in power generation cooling water systems, water & waste treatment and process industries worldwide. They also provide an effective corrosion barrier, preventing early fall-off in performance due to nodular growth, corrosion and surface roughness.
Kirloskar Corrocoat recently worked with a client/sugar factory in the populous state of Maharashtra. They took on a project to refurbish and protect 5 injection water pumps (ranging from 6” to 16”) with Fluiglide E, with the aim of improving overall efficiency.
The below images show the top and bottom casing and the impeller.
Note, the wear ring portions and bore ID area were totally damaged by erosion & corrosion. The hydraulic portion of casing was in a heavily damaged condition.
For the refurbishment work, the internals were grit blasted in accordance with ISO-8501 to Sa2 ½ surface finish, and then coated using Fluiglide E, applied by brush to a minimum DFT of 1.2mm. The pitting and cavities were filled with Corrocoat EA; a viscous, solvent-free, high build, two pack epoxy coating with excellent erosion resistance, toughness and outstanding anti-corrosive properties. The internals were then spark tested at 10kV.
The externals were also grit blasted to Sa2 ½ surface finish and coated with a standard epoxy paint for aesthetic effect only, as requested by the client. Bearings and wearing rings were replaced, and the pumps were then reassembled using new fasteners, gaskets and fixings.
Assembled pumps awaiting dispatch to the client.
Find out more about how our coatings and services can repair and protect your pump and help improve efficiency, here.
