Petrochemical Industry: Repair Composites and Coatings
The petrochemical industry is regularly faced with problems such as erosion, corrosion, chemical attack, wear, abrasion and mechanical damage which cause deterioration of infrastructure and equipment over time. Rather than replacing these assets, engineers and plant managers are using Belzona’s epoxy-based metal repair composites, high temperature coatings and linings for reliable, long-lasting maintenance solutions.
Belzona’s solvent-free materials offer solutions for the toughest environments and can be applied in situ to reduce downtime and labour costs, eliminating the need to replace equipment.
Deterioration of pipework
Pipework suffering from erosion and corrosion, including corrosion under insulation (CUI), may experience leaks and loss of containment.
Pipe leaks can be sealed in situ using Belzona metal repair composites, such as Belzona 1212, a surface-tolerant material, which can be applied on to wet, underwater and oily substrates. Where ISO 24817 or ASME PCC-2 compliance is required, Belzona SuperWrap II can be used to return strength to weakened or holed pipes and provide excellent corrosion protection and chemical resistance.
Epoxy coatings, such as Belzona 5851 (HA-Barrier), can be applied on equipment at elevated temperatures to provide corrosion protection and prevent loss of wall thickness. Belzona also offers insulation protection for pipes and other insulated equipment, using fire resistant Belzona 3211 (Lagseal), which is simple to apply and will resist water and UV radiation.
Pipe supports deteriorated by corrosion, wear and galvanic effects can lead to extended forced shutdowns. Belzona's cold-applied composite repair materials can be used to bond new pipe supports, eliminating the requirement for welding.
Corrosion protection for process vessels
Absorber towers and strippers are subject to a number of corrosion problems during their service life. Epoxies are proven to be the optimum lining solution for process vessels as they provide excellent chemical, erosion and temperature resistance.
Belzona high temperature linings, including Belzona 1391T, have a proven track record in aggressive operating conditions and are resistant to problems associated with MEA, MDEA, sulfanol and other stripping agents.
Additionally, Belzona’s solvent-free epoxy coatings have resistance to explosive decompression, steaming out, as well as bacterial and chemical attack. The unique binary curing mechanism allows these coatings to cure in service, thus enabling you to get equipment back into service with the minimum of downtime.
Storage tank and secondary containment area repair and protection
Belzona provides solutions for storage tanks damaged as a result of deterioration, corrosion and adverse weather conditions, including emergency leak sealing and cold metal bonding. Our fast-curing epoxy repair materials, such as Belzona 1212, will eliminate the need for hot work, therefore reducing health and safety concerns.
Tank bases can be sealed with our safe and easy to apply microporous membranes, such as Belzona 3111 (Flexible Membrane), that will allow trapped moisture to escape whilst preventing water ingress at the tank base for long-term protection.
Containment areas and support structures can be protected against chemical attack using Belzona's range of concrete repair composites and coatings. Belzona 4111 (Magma-Quartz) and Belzona 4131 (Magma-Screed) are ideal for the repair and resurfacing of damaged secondary containment areas. Epoxy coatings, such as Belzona 4311 (Magma CR1), are designed to provide long-term chemical protection against a wide range of substances, including acids and alkalis, even at high temperatures and concentrations.
Repair composites and coatings for heat exchangers
Belzona provides a variety of solvent-free metal repair composites and epoxy coatings for repair and protection of heat exchangers damaged by erosion and corrosion on areas such as tube sheets, water boxes, division bars and end covers.
Our cold-curing epoxy products allow for rapid, in-situ application, minimizing downtime whilst providing long-term erosion and corrosion protection. Belzona materials are excellent electrical insulators, which enables them to prevent galvanic corrosion by isolating the dissimilar metals used in heat exchangers.
Our repair composites, high temperature coatings and linings are suitable for other areas including:
- Pump repair and protection
- Insulation protection
- Repair and restoration of valves, including seats, seals and casings
- Conveyor belts and other rubber repairs
- Protective coatings and repair compounds for floors
- Anti-seize for mating compounds