Belzona Releases Feed Tank Case Study

FRIDAY, MARCH 15, 2024


International manufacturer of industrial protective coatings and composites Belzona recently announced that Rezitech, an authorized Belzona distributor, provided a wrapping to help fight corrosion under insulation on an ammonium sulphate feed tank at a blue-chip nickel mine in Australia.

According to an emailed release, within 24 hours, the 9.5-meter (31.2-foot) diameter tank, with a height of 2 meters from ground level, was repaired and protected against future corrosion with the industrial composite wrap system, Belzona SuperWrap II.

About the Project

Belzona states that the mine currently works to refine granulated nickel matte from their smelter into nickel powder and briquettes with 99.8% nickel. According to the release, the nickel powder is then processed into nickel sulphate at a refinery in Australia.

The release explains that nickel sulphate is a major ingredient in the lithium-ion batteries that drive electric vehicles.

Belzona explained that the refinery's stainless-steel feed tank was experiencing corrosion under insulation and chloride induced stress corrosion cracking. Workers reportedly needed a solution that could restore the integrity on the substrate, while also protecting the asset against future corrosion damage.

Additionally, as the tank operates at elevated temperatures of around 70 degrees Celsius (158 degrees Fahrenheit) and processes highly corrosive medium, the repair solution would reportedly need to be able to handle these harsh conditions.

Belzona decided to contact Rezitech for its advice and system recommendations. After an inspection by Heath Westell, Sales Engineer at Rezitech, composite wrap system Belzona SuperWrap II was reportedly recommended.

“This composite wrap system is comprised of a fluid-grade resin system, a bespoke hybrid reinforcement sheet, based on fibre glass and carbon fibre, as well as a release film to compact and consolidate the application. The system is specially formulated to restore the strength of holed, weakened and corroded pipe and tank walls, making it the ideal solution for protecting the asset against corrosion under insulation for the long term,” said Westell.

“In addition, thanks to the cold-curing properties of the composite wrap system, this mitigates the need for hot work, making it a reliable alternative to welding.”

Belzona explained that the stainless-steel feed tank was experiencing corrosion under insulation and chloride induced stress corrosion cracking. Workers reportedly needed a solution that could restore the integrity on the substrate, while also protecting the asset against future corrosion damage.

To begin, all traces of oil and grease contamination were reportedly removed with a suitable Rezitech Degreaser. Afterwards, the surfaces were grit-blasted to give a surface cleanliness compliant with ISO 8501-1 SA 2½ (ASNZ 1627.4 class 2.5) with a minimum 75 µm (3 mil) rough angular profile.

Next, the Belzona 9381 reinforcement sheet was measured out and then wetted with the Belzona resin system, which was then systematically applied to the areas to be repaired. Following this, the Belzona reinforcement sheets were reportedly applied to the tank in three layers.

Belzona states that the compression film was added to the top of the application area, and, using a roller, the Belzona SuperWrap II composite wrap system was then spread, rolled and compressed to the surface of the tank. The system was then reportedly left to cure for around eight hours.

Belzona states that its composite wrap solution helped the tank owner successfully bypass the need to replace the corroded asset, instead prolonging the lifespan of the structure.

Additionally, Belzona states that the polymeric technology could play a large role in supporting the transition to electric vehicles by safeguarding the integrity of key assets within this industry.

   

Tagged categories: Asia Pacific; Belzona; Case History; Certifications and standards; Coating Application; Coatings; Completed projects; Corrosion; Corrosion protection; EMEA (Europe, Middle East and Africa); Emissions; Environmental Control; Environmental Protection; Greenhouse gas; Latin America; North America; Program/Project Management; Protective Coatings; Tanks; Tanks; Z-Continents

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