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PLANT MANAGEMENT


To maximise equipment life and safe production, innovative chemically bonded phosphate ceramic coatings provide durable protection from atmospheric and chemical corrosion


CORROSION PROTECTION FROM


n industrial process facilities, corrosion is the biggest single cause of plant and equipment breakdown, including machinery, vessels, structures, supports and pipelines. Although atmospheric corrosion in the form of air (oxygen), and water (moisture, humidity, vapour, etc.) is the main culprit, environmental factors including high temperatures and pressures as well as harsh substances, chemicals and gasses can also accelerate the corrosion of carbon steel and other metals. Beyond marine environments exposed to salt spray or compounds that cause corrosion, common gaseous industrial air pollutants, such as sulphur dioxide, ozone, and nitrogen dioxide, can be corrosion inducing. So can exposure to industrial chemicals such as chlorides, acetic acid and formaldehyde. “Tere is a huge need for an anti-corrosion coating that can go on in areas where conventional coatings tend


I


to fail,” says Joey Taylor, President of IPI, a US-based paint/coating contractor for commercial and industrial construction. “On certain projects, chlorides need to be removed to meet peak performance. But in most cases, this can be cost prohibitive.” Fortunately, for industrial facilities with


assets prone to environmental corrosion, a new category of tough, chemically bonded phosphate ceramic (CBPC) coatings is helping to stop corrosion, ease application and reduce production downtime.


LONG-TERM ENVIRONMENTAL CORROSION PROTECTION When aluminium is recycled, it is melted to separate the pure metal from the impurities. Te process creates a waste product called salt cake, which contains compounds that can promote corrosion. As a result, typical barrier-type anti-corrosion coatings, such as polymer paints, can fail prematurely.


Tis is particularly true when the paint is scratched, chipped or breached and corrosion promoters enter the gap between the substrate and coating. Ten the coating can act like a greenhouse – trapping the corrosion promoters – that allows the corrosion to spread under the coating. So, when an aluminium recycling


plant in West Virginia required corrosion protection for its operation, it sought a long-term term solution that would not require frequent recoating, according to Taylor, who was involved with the project. “Te recycling plant was not having much luck with conventional anti-corrosion coatings, which only lasted about three or four years,” he says. “Really, anyone trying to protect their assets from corrosion wants their coating to last much longer than that.” To provide long-term corrosion


protection in a tough environment, the plant and Taylor turned to EonCoat, a


EonCoat corrosion protection


36 www.engineerlive.com


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