Restoring Plant Integrity: A Swift and Cost-Effective Solution for Caustic Leak
In the bustling landscape of India’s chemical industry, a prominent caustic plant faced a pressing challenge. They grappled with a caustic leak from a critical tank flange and welding joint, threatening not only their operations but also the integrity of surrounding metal surfaces. Swift action was imperative, and that’s when NESL Belzona Team received an urgent call for help.
Challenge: The primary challenge was to address the caustic leak without the need for a costly and disruptive plant shutdown. The corrosive leak was not only a potential environmental hazard but was also causing further damage to the adjacent stainless steel metal surfaces.
Solution: The NESL Belzona Team, led by a dedicated service engineer, immediately responded to the customer’s call. With a sense of urgency, the team took the necessary steps to begin the restoration process, ensuring minimal downtime.
Surface Preparation: Before the application of Belzona products, meticulous surface preparation was performed. Rust and metal flakes were diligently removed using hand tools, ensuring a clean and well-prepared surface for the subsequent application.
Belzona Products Used: The team applied a combination of Belzona products to restore the flange joint’s integrity:
- Belzona 1212: Best suited for in-situ sealing of oil and fluid leaks. It offered a versatile solution, applicable to a wide range of equipment, including storage tanks, engines, gearboxes, transformers, and sumps.
- Belzona 4301: A chemical-resistant epoxy material, Belzona 4301, played a pivotal role. It protected metal and concrete surfaces from a broad range of chemicals, making it ideal for rebuilding metal and concrete surfaces, protecting against chemical attack, in-situ flange repair, and creating nozzle inserts.
- Belzona 9341: To address the specific issue of sealing the leak, Belzona 9341 was applied. The process involved applying tape coated side down to the repair and wrapping it firmly around the flange joint until the Belzona product sealed the outer surface.
- Belzona 4311: Belzona 4311, known as Magma CR1, was used as a chemical-resistant coating. It provided exceptional resistance to a wide range of chemicals, especially acids and alkalis. This two-part epoxy coating was solvent-free and was applied to protect bund areas, chemical spill areas, concrete tank plinths, and retaining walls.
The in-situ application of Belzona Polymeric Coating saved significant time and cost, as the curing process was swift. The cement plant could continue its operations without the need for a disruptive shutdown, ensuring business continuity while safeguarding the environment.