Restoring Corroded Chemical Processing Tank with Belzona 1111 & Belzona 4311
The textile dyeing industry relies heavily on chemical processes that involve highly concentrated substances. This demand for chemical-intensive processes can lead to the corrosion of equipment, such as chemical processing tanks. This case study highlights the successful restoration of a corroded chemical processing tank using the Belzona epoxy coating. The primary objective was to provide a cold repair solution that could effectively restore the tank’s wall surface and withstand the harsh chemical environment.
1. The Problem:
A textile dyeing plant was facing a critical issue with a corroded chemical processing tank. The tank shell’s material had suffered extensive corrosion due to exposure to highly concentrated chemicals used in the dyeing process. The deterioration of the tank’s shell jeopardized its structural integrity and raised concerns about leaks, safety hazards, and operational disruptions.
2. Inspection and Assessment:
Our service engineer inspected the tank and confirmed that the corrosion of the tank shell was a direct result of its exposure to the aggressive chemicals. To address the issue, a cold repair solution was needed to restore the tank’s wall surface and provide long-lasting protection against future corrosion. The pictures show the condition of the tank as found by our service engineer upon inspection.
3. The Belzona Solution:
After careful analysis, it was determined that the most suitable solution for this type of corrosion was the application of Belzona epoxy coating. The Belzona product line is well-known for its high-performance coatings that offer exceptional chemical resistance and durability.
4. Repair Process:
Surface Preparation: Before application of the Belzona coating, the tank’s surface was meticulously prepared. This step involved thorough cleaning, removal of dust, debris and rusted metal flakes using grit blasting technique SA 2.5 and creating a suitable surface profile 75 Micron to ensure proper adhesion of the epoxy coating.
Primary Repair: Belzona 1111, a multipurpose epoxy material with excellent adhesion properties, was applied to repair the damaged tank shell. This product not only restored the tank’s structural integrity but also formed a strong bond with the substrate.
Chemical Resistance Enhancement: To enhance the tank’s chemical resistance, Belzona 4311, a specialized epoxy coating designed to withstand aggressive chemical environments, was applied. This step aimed to provide long-term protection against further corrosion and chemical exposure.
5. Outcome and Inspection:
After two years of the Belzona coating application, a comprehensive reinspection was conducted. The coating was found to be in perfect condition, demonstrating its effectiveness in withstanding the challenging chemical environment. The tank’s structural integrity was restored, and the risk of leaks and associated hazards was mitigated.