CASE STUDY
PROCESS VESSEL NOZZLE REPAIR
Repair of Corroded and Holed Nozzle Joints
Industry: Chemical Manufacturing
Application: Nozzle Repair
Products: Belzona 1212, Belzona 5831
Customer Location: : VIC, Australia
Application Date: Oct 2023
PROBLEM
A customer’s process vessel, which contained a hazardous chemical during operation, had suffered severe corrosion around the nozzle joints.
Due to the vessel’s location and strict time constraints, removal or replacement was not a practical option. A full replacement would have resulted in total costs exceeding AUD 200,000.
Severe through-wall corrosion at the base of the nozzles exposed dangerous chemicals during operation
APPLICATION
A Belzona solution was selected as a cost-effective alternative that would significantly reduce repair costs while allowing the customer to maintain production. The previously coated and corroded repair area was mechanically ground and cleaned back to bare metal, exposing the hole at the tank/nozzle interface.
Belzona 1212 was selected to bond and repair the affected area, as site conditions prevented abrasive blasting from being carried out. Using reinforcement mesh and metal mesh to bridge the hole, Belzona 1212 was applied to rebuild and seal the affected area. Once the repair had cured, Belzona 5831 (ST-Barrier) was applied as a protective coating over the repaired area.
Belzona 1212 being mixed in preparation for the repair
Application of Belzona 1212 over repair area before fitting of reinforcement mesh
Application completed with coating of Belzona 5831
OUTCOME
The Belzona repair solution provided the customer with a cost-effective alternative to vessel replacement, allowing the asset to be returned to service with minimal disruption.
By avoiding removal and replacement of the vessel, the customer was able to minimise downtime, maintain production, and achieve substantial cost savings. The repair delivered an estimated saving of approximately AUD 190,000 compared to the cost of full vessel replacement.
More Information?
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Products
Belzona 1212 E Metal
A 2-part surface-tolerant epoxy composite engineered specifically for in-situ application to wet, oil contaminated and underwater surfaces. This multi-purpose solvent-free material exhibits rapid cure and excellent adhesion to manually prepared substrates, where grit blasting cannot be achieved.
Belzona 5831 (ST-Barrier)
A 2-part epoxy coating which once cured forms a barrier coating for the protection of equipment operating under immersed conditions or in contact with aqueous solutions.
Frequently asked questions
How was the corroded process vessel nozzle repaired without replacement?
The corroded nozzle area was mechanically ground and cleaned back to bare metal. Reinforcement mesh and metal mesh were then used to bridge the hole, before Belzona 1212 was applied to rebuild and seal the damaged area. Once cured, Belzona 5831 (ST-Barrier) was applied as a protective coating over the repair.
Why was Belzona 1212 selected for the nozzle repair?
Belzona 1212 was selected because abrasive blasting could not be carried out on site. The product is suitable for in-situ repairs and is designed to bond to manually prepared substrates where grit blasting is not achievable.
What was the main challenge with the process vessel nozzle repair?
The main challenge was severe through-wall corrosion around the nozzle joints on a vessel containing a hazardous chemical during operation. The vessel’s location and time constraints also meant removal or replacement was not a practical option.
How much did the Belzona repair save compared with vessel replacement?
The Belzona repair solution delivered an estimated saving of approximately AUD 190,000 compared with full vessel replacement. Replacement would have resulted in costs exceeding AUD 200,000.
What protective coating was applied after the nozzle repair?
After the Belzona 1212 repair had cured, Belzona 5831 (ST-Barrier) was applied over the repaired area. This provided a protective barrier coating for the vessel operating in contact with hazardous chemical conditions.
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.
