Tag: ARC and Ceramic-Polymer Coatings

  • Power Performance for the Power Industry – Chesterton® ARC SD4i Protects Storage Tanks for Ultra-high Purity Water

    Power Performance for the Power Industry – Chesterton® ARC SD4i Protects Storage Tanks for Ultra-high Purity Water

    In thermal power plants, regardless of the type of fuel used, the need for high-purity demineralized water is essential. This water is critical for producing steam to drive turbines and generate electricity. A reliable supply of demineralized water helps ensure the efficient and safe operation of the plant, as it prevents scaling and corrosion in boilers and associated systems.

    This boiler feed and make-up water is treated with various types of chemicals and demineralized to ensure it meets the needs of the boiler system for safe and efficient operation. This treated water is normally stored in large steel tanks before being used in the boiler system. It is imperative that the quality of the water does not deteriorate during storage. Therefore, these steel tanks are usually lined with a suitable material that not only prevents corrosion of the steel tank but also does not leach any unwanted substances into the water.

    ARC SD4i demonstrates outstanding properties and beats competitor products in extensive test series

    Chesterton offers qualified industrial coating products for a wide range of applications in fossil and nuclear power plants, helping our customers to improve productivity and efficiency. In this article, we focus on an outstanding major project – one of our impressive success stories:

     “Back in 2007, a nuclear power plant in Europe was experiencing contamination issues of their ultra-high purity refueling water storage tanks due to deterioration of the rubber lining. Initially the power plant intended to replace the old rubber lining with a new one. However, unacceptable amounts of prohibited substances were discovered during leaching tests of the new rubber liner. Replacing the tanks with new stainless-steel tanks was considered but was deemed to be cost prohibitive.

    The local Chesterton coating partner was contacted and discussed the possible use of a ceramic reinforced coating, ARC SD4i, that had been successfully used by a nuclear power plant in the US in their condensate water storage tanks for over 10 years. A visit to the US power plant was organized and key personnel from the European plant travelled to meet with their counterparts in the US to find out directly about the performance of the ARC coating in the ultra-high purity water storage tanks.

    The power plant also began a series of tests including leaching tests with various different liners and coatings to ensure they met their needs in terms of maintaining water purity and corrosion protection of the tanks. The leaching tests were conducted at 60°C and ARC SD4i was the only coating that passed all the tests.

    This started a project in 2017 to coat all of the safety classified rubber lined tanks with ARC SD4i. Each tank had to be emptied, the existing rubber liner removed, the steel surface prepared to specification and then, application of the ARC SD4i coating using a heated plural component airless sprayer.

    Tank in Nuclear Power plant coated with Chesterton coating

    All of this work had to be completed within a short outage window following strict quality and safety requirements. This challenge was successfully met by the applicator who was able to apply the ceramic reinforced coating on time and to the satisfaction of the power plant. Over the following five years another 10 water storage tanks were lined with ARC SD4i. During this time, the power plant has seen a vast improvement in the purity of the water coming from the ARC lined tanks.”

    Tank in Nuclear Power plant coated with Chesterton coating
    Tank in Nuclear Power plant coated with Chesterton coating

    Reliable long-term performance leads to superior customer experience

    It often takes many years before such large-scale projects can be successfully realized. Especially in a demanding business like the power industry, which only allows qualified coating products in accordance with special standards.

    The 11 tanks in the project described above have been in operation for many years. Our customer is still very satisfied with ARC SD4i – the quality of the water is impeccable, no contamination, no signs of corrosion. It is worth mentioning that in each tank an area of 980m2 was coated in a short period of 11 days! As production downtimes are very expensive in the energy sector, only a very short time frame is specified for each type of maintenance work.

    Conclusion

    When it comes to protecting the quality of water used in thermal power plants, Chesterton ARC coatings have proven that they have the required properties needed to achieve long-term corrosion and water purity requirements. 

    If you would like more information about Coating solutions for your facility, please contact our Expert Desk.

    You can also make a preliminary product selection using our product selector. Our product engineers will gladly assist you in selecting the ideal product for your application.

  • Chesterton® High-Performance Industrial Coating Solutions for Corrosion and Abrasion Challenges in the Pulp and Paper Industry

    Chesterton® High-Performance Industrial Coating Solutions for Corrosion and Abrasion Challenges in the Pulp and Paper Industry

    The pulp and paper sector is a demanding industry. From debarking and wood processing to the chemical processing of paper pulp and the manufacture of finished products – the work steps in this field are complex. The production of paper, cardboard and pulp requires many machines, a lot of water and certain chemicals. Plant operators have major challenges with corrosion and abrasion, which can affect the plants’ operation and performance. Increasing equipment performance, occupational and environmental safety and energy saving are extremely important for manufacturers to be able to reduce costs and increase profitability.

    How can Chesterton help to improve efficiency in pulp and paper production with high-performance industrial coatings?

    The processes used in the production of pulp and paper from wood chips, recycled paper and fibers are associated with high temperatures, high pressures, wear, abrasion, impacts or corrosion, all of which can affect the operation of mechanical equipment in various parts of the plant. High costs are incurred due to the wear of metal and concrete surfaces, erosion or cavitation of pumps, or corrosion caused by contact with chemicals. With Chesterton coatings, not only can new equipment be protected to increase the meantime between repair or failure, but also the repair and reconstruction of already damaged components is possible to increase operating lifetime, reduce spare part inventories and can therefore be extremely cost-efficient.

    wood storage for paper industry

    As in any other industry, the pulp and paper sector has several main targets:

    • Increasing profitability and reliability
      Chesterton offers a comprehensive portfolio of ARC and Ceramic-Polymer Coatings specifically designed for areas where severe abrasion resistance, long-term corrosion protection even in wet chemical applications or high temperature corrosion resistance are required. Whether concrete or steel substrates, the use of Chesterton coatings – also for surface repairs – can help extendthe service life of mechanical equipment.
    • Worker safety and environmental protection
      The long-term performance of Chesterton industrial coatings significantly reduces the need for repair and maintenance work. This not only saves labor costs, but also increases the safety of personnel. The environment benefits, for example, from properly coated secondary containment basins that prevent chemical-containing production water from entering the surrounding area. Repair and protection of operating equipment with Chesterton coatings also contributes to improved environmental performance by reducing the number of new parts that must be kept in inventory.
    • Energy saving
      The application of smooth high performance ceramic coatings to fluid flow equipment such as agitator propellers, cyclones, pipes, and many types of pumps can increase the flow speed of the fluids being handled, reduce power consumption, increase machine efficiency, and thus contribute to energy savings.

    Benefit from our experience in the pulp and paper industry

    Debarking Drums, Log Conveyors and Chippers, Agitators, Cyclones, Fan and Vacuum Pumps, Screws, Pulp Tanks, Press Rolls as well as Wastewater Tanks and Barrier Tanks – all these types of equipment can benefit from increased abrasion and corrosion protection. Chesterton industrial coatings of the ARC and Ceramic-Polymer product lines contribute to a considerably increased service life of the machines and the profitability of the entire plant is significantly improved. Furthermore, unscheduled machine downtimes due to unexpected failure or damage can be effectively prevented.

    Lime kiln in a pulp production plant
    Agitator for Pulp and Paper Mill
    Paper Mill - Pulping department

    The high-performance Chesterton coatings provide long-term protection for metal and concrete surfaces with the following properties:

    • 100% solids
      No evaporating solvents, enhances the safe use
      Resists corrosion and permeation.
    • Maximum Adhesive Strength to Substrate
      Resists disbondment, provide long-term performance.
    • Resists Underfilm Corrosion
      Enables localized repair on small areas.
    • Manufactured Under Vacuum
      Resists permeation through coating – critical for immersion applications.
    • Ceramic and Special Particle Reinforcements
      Resists abrasion, extends equipment life, reduces spare parts, reduces downtime.
    • Abrasion, Erosion/Corrosion, Chemical, Temperature Resistance
      Provides long-term protection of metal or concrete surfaces.
    • Cost effective
      Versus traditional repair methods.
    • Ease of application
      1-layer application by hand tools or airless spraying, saves working time and can often be applied on-site without removal of equipment.
    • Cold curing Technology
      No hot work or welding is required.

    From wood to paper – requirements for coatings to protect the mechanical equipment

    First, the bark is removed from the logs, and they are processed into wood chips. Debarking Drums and Screws Conveyors or Chutes require coatings that are highly resistant to impact and abrasion. 
    Our ARC I BX1(E), for example, is designed precisely for such demanding operating conditions. High impact resistance, hardness, and resistance to sliding wear characterize this product, hence it is also used in the mining sector.

    The ARC BX2(E) is equipped with finer particles and is applied for areas in pulp processing, such as screw presses and agitators, which require moderate abrasion resistance but increased temperature resistance and chemical resistance.

    The thick film coating ARC 858(E) is ideally suited for rebuilding heavily corroded or eroded metal surfaces in pumps or pulp tanks. ARC 855(E) and ARC SD4i(E) are often used as a topcoat for these repaired surfaces. With a thin layer, this system protects metal substrates against abrasion, erosion corrosion and chemical attack.

    Of course, the Chesterton portfolio also includes coatings for the protection of concrete structures, such as wastewater basins, stock, pulp and whitewater chests or secondary containment areas with chemical tanks.

    Talk to us! We will be happy to offer you the optimum coating solution. Please ask our Expert Desk for further information.

    You can also make a preliminary selection using our product selector. Our product consultants will gladly assist you in selecting the ideal product for your application.