CASE STUDY
HIGH-TEMPERATURE TANK COATING
Thermal Insulation with Corrosion and UV Protection for Refinery Batch Tank
Industry: Mining
Application: High Temperature Tank Thermal Insulation, Corrosion and UV Protection
Products: Belzona 5871, Belzona 3211
Customer Location: : WA, Australia
Application Date: Feb 2022
PROBLEM
A high-temperature batch tank at an alumina refinery, used to store a bauxite–caustic slurry, was experiencing significant corrosion and chemical degradation. A solution was needed to apply a protective coating that would restore a safe and reliable operating surface while most importantly, improve the energy efficiency and longevity of the tank. The selected coating system also had to provide UV resistance, moisture sealing, and offer thermal insulation to withstand the demanding operating environment.
Image showing redundant insulation causing CUI at an Alumina refinery
Exisiting condition of batch tank prior to coating
APPLICATION
Belzona 5871 was chosen as the solution. A novel, a two-component, polymeric system that expands up to 3 times to produce a closed-cell foam, providing corrosion protection combined with thermal and subzero “cool-to-touch” insulation properties.
First, the tank surface was abrasive blasted to achieve the required cleanliness standard and to establish a minimum surface profile depth of 75μm to ensure optimal coating adhesion.
Batch tank abrasive blasted and ready for coating
Night-time application of first coat of Belzona 5871
Second coat of Belzona 5871 being applied
Next, two coats of Belzona 5871 were spray-applied during the evening hours to avoid the high daytime temperatures, which ranged between 35°C and 40°C. This timing allowed for improved working conditions and ensured the tank surface temperature remained below 40°C during application.
The first and second coats were applied over two consecutive evenings, with a coat of Belzona 3211 (Lagseal) applied on the third evening to provide ultra-violet radiation protection.
With the batch tank operating at a nominal internal temperature of 90°C to 95°C, an average dry film thickness (DFT) of 4 mm was targeted which would provide sufficient insulation to reduce the external surface temperature to approximately 60°C to 65°C.
First coat of Belzona 5871 completed
Second coat of Belzona 5871 completed
Application of Belzona 3211
Mid-application phase of Belzona 3211
Completed application of Belzona 3211
OUTCOME
A follow up inspection in 2024 showed that the overall condition of the tank was very good. Readings from the side of the coated tank, spool, and flange taken at daytime showed a surface temperature up to 45°C, compared to temperatures of between 45°C and 92°C on adjacent pump discharge pipes feeding the tank.
The customer is highly satisfied with the application and reported that thermal imaging taken during operation at 90°C revealed external temperatures ranging from 63°C to 79°C.
Condition inspection of batch tank two years after coating
Temperature readings of 84°C – 92°C on adjacent pump discharge pipes feeding
the tank
Readings from the side of the coated tank, spool and flange taken at daytime showed a surface temperature up to 45°C
More Information?
For more information about the Rezitech products and services, fill out the form below and one of our staff members will be in touch in 1-2 days.
What is the purpose of thermal insulation?
Thermal insulation reduces the amount of heat transfer through a surface, increasing the efficiency of equipment.
Can Belzona 5871 be spray applied?
Belzona 5871 can be brush or spray-applied, for both small, complex geometries or rapid application over a large area.
Products
Belzona 5871
Belzona 5871 is a two-component, polymeric, 100% solids system providing a thermal insulation barrier with corrosion protection and thermal and sub- zero “cool-to-touch” properties.
Belzona 3211 (Lagseal)
A water-based acrylic emulsion membrane incorporating a polymer bonded glass reinforcing sheet (Belzona 9321) designed to provide seamless, flexible protection to all types of thermal insulation and cladding systems.
About Rezitech
Established in 1968, Rezitech is the sole Australian Distributor for Belzona. Rezitech offers a comprehensive range of industrial protective coatings and epoxy metal repair composites to many different industries including: oil and gas, mining, power, water and waste water, pulp and paper, marine, manufacturing among others.
We value growth and innovation within the maintenance solutions industry
Our Mission
To provide industry with easier maintenance solutions that provide cost effective, efficient and long lasting results for our valued clients. To provide an integrated industry service by striving for Rezitech being a truly complete solutions provider!
Our Values
We value the needs of our clients and place a huge emphasis on providing specialist skills and knowledge.
From engineering to fitting, blasting or coating to sales, administration and customer service, we highly value our organisation and encourage diversity andgrowth to benefit our client and our team of people.
Our Vision
To strive for excellence in our delivery of high quality industrial maintenance solutions. To be our clients’ preferred choice when it comes to solving all of their maintenance and new pump needs while helping to reduce their carbon imprint.
Health and Safety
Rezitech is committed to ensuring the health, safety and welfare of its employees, contractors, visitors and customers who may be affected by Rezitech’s operations. We strive to pursue standards of safety that meet and exceed statutory duties.
Community & Environment
While providing solutions for our clients Rezitech focuses on identifying ways to improve business environmental performance while increasing productivity and reducing costs of production for the benefit our clients and hence the community.
The Future
To continue to strive for excellence! To continue to lead the way in industrial maintenance solutions and services and provide our clientele with high quality, complete and reliable products and services.
Rezitech’s mission is to make its liquid ring vacuum pump expertise available to sugar mills, paper mills and process industries worldwide. We currently export to:
- Fiji
- Thailand
- Mauritius
- Indonesia
- United Kingdom
- Phillipines
- Malaysia
- New Zealand
- Papua New Guinea
We are constantly on the look out for new export opportunities and new countries to export to Rezitech places an emphasis on the development of export business worldwide.
For further information on a Flowtech Distributorship please contact us.
