CASE STUDY
INTERCOOLER REFURBISHMENT
Nickel Smelter Intercooler Refurbishment
Industry: Mining
Application: Nickel Smelter Intercooler Refurbishment
Products: Belzona 1511, Belzona 1523
Customer Location: : WA, Australia
Application Date: Nov 2022
PROBLEM
Two intercoolers at a nickel smelter had suffered severe corrosion,resulting in a near-total loss of coating integrity and requiring refurbishment.
The corrosion assessment identified extensive coating failure and significant corrosion of the main shell and internal components, including the cooling system support rails.
Nickel smelter intercoolers
Significant corrosion of the main shell and internal components
APPLICATION
First, pit filling and metal rebuilding were undertaken using Belzona 1511 (Super HT-Metal), a high-temperature repair composite for metal restoration and corrosion protection, applied extensively to the intercooler shells to address widespread pitting and substrate loss.
Widespread pitting and substrate loss in need of repair
Pit filling and metal repairs undertaken with Belzona 1511
Substrate prepared and ready for coating
Once the substrate was adequately prepared and all significant metal loss rebuilt, all welds and hard to reach areas where stripe coated.
This was followed by the spray application of two coats of Belzona 1523, a high-temperature, corrosion- and chemical-resistant coating, to a minimum dry film thickness (DFT) of 500 μm using a heated-line mobile spray unit.
Stripe coating of welds
First coat of Belzona 1523 high temperature epoxy coating applied
OUTCOME
The refurbishment works were undertaken in collaboration with local contractors IND and Reliablee, with continuous operations maintained throughout a tight shutdown window.
The project was successfully completed, with the result a high-quality refurbishment, delivering extended service life under the protection of Belzona’s coating systems.
Final coat of Belzona 1523 applied
More Information?
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Products
Belzona 1511 (Super HT-Metal)
A two-part repair composite based on a solvent-free epoxy resin reinforced silicon with steel alloy. This high temperature repair system is designed for metal repair and rebuilding equipment and provides excellent corrosion protection. Under immersion, Belzona 1511 (Super HT-Metal) is suitable for applications up to 150 °C (302 °F).
Belzona 1523
A 2-part spray-applied epoxy coating designed to provide long-term corrosion and chemical resistance to equipment operating in continuous immersion at temperatures up to 140°C (284°F). This 100% solids coating has a long overcoat window and its cold curing mechanism with full in service cure reduces downtime and ensures rapid return of equipment to service.
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.
