CASE STUDY
CORROSION UNDER INSULATION REPAIR
Corrosion repair and prevention on an ammonium sulphate feed tank using Belzona SuperWrap II
Industry: Mining
Application: Feed Tank Repair
Products: Belzona SuperWrap II
Customer Location: : WA, Australia
Application Date: January 2024
PROBLEM
A major global blue-chip nickel mine in Australia required a solution to combat corrosion under insulation on a stainless steel ammonium sulphate feed tank which was suffering from corrosion under insulation and chloride induced stress corrosion cracking.
They required a solution that would not only restore the integrity on the substrate, but also protect the asset against future corrosion damage.
Since the tank operates at elevated temperatures of approximately 70°C (158°F) and processes highly corrosive medium, the repair solution would need to be able to withstand these harsh conditions.
Stainless steel feed tank before repairs and after the application of Belzona SuperWrap II
APPLICATION
Following an inspection by Rezitech, the composite wrap system, Belzona SuperWrap II, was specified. This composite wrap system is comprised of a fluid-grade resin system, a bespoke hybrid reinforcement sheet, based on fibre glass and carbon fibre, as well as a release film to compact and consolidate the application.
The system is specially formulated to restore the strength of holed, weakened and corroded pipe and tank walls, making it the ideal solution for protecting the asset against corrosion under insulation for the long term. In addition, thanks to the cold-curing properties of the composite wrap system, this mitigates the need for hot work, making it a reliable alternative to welding. Firstly, all traces of oil and grease contamination were removed using a suitable Rezitech Degreaser. Following this, the surfaces were grit-blasted to provide a surface cleanliness compliant with ISO 8501-1 SA 2½ (ASNZ 1627.4 class 2.5) with a minimum 75 μm (3 mil) rough angular profile.
Once the surface was prepared, the Belzona 9381 reinforcement sheet was measured out and then wetted out with the Belzona resin system. The resin was then systematically applied to the areas to be repaired. Following this, the Belzona reinforcement sheets were then applied to the tank in three layers.
The compression film was then added to the top of the application area. Next, using a roller, the Belzona SuperWrap II composite wrap system was then spread, rolled and compressed to the surface of the tank. The system was then left to cure for approximately eight hours.
Stainless steel feed tank before repairs
Stainless steel feed tank after the application of Belzona SuperWrap II
OUTCOME
Within the space of 24 hours, the 9.5 metre (31.2 ft) diameter tank (with a height of 2 metres (6.6 ft) from ground level) was repaired and protected against future corrosion with the industrial composite wrap system, Belzona SuperWrap II.
By investing in the Belzona composite wrap solution, the customer avoided having to replace the corroded asset, and instead prolonged the lifespan of the asset for years to come. This not only saved a considerable amount of time but also resulted in significant cost savings for the customer.
Products
Belzona’s wide range of polymeric metal and rubber repair composites and durable protective coatings and linings have been used in the mining industry for decades. These materials are specifically designed to provide outstanding erosion, corrosion and abrasion protection, as well as chemical resistance, for equipment operating in very aggressive environments.
Belzona SuperWrap II
Composite repair system, Belzona SuperWrap II, offers a new generation repair solution for restoring the strength of holed, weakened and corroded pipe and tank walls. It is comprised of a fluid-grade resin system, a bespoke hybrid reinforcement sheet, based on fibre glass and carbon fibre, as well as a release film to compact and consolidate the application..
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.
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