Corotech thermalinsulatingcoating-130710090224-phpapp01
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The document discusses the benefits of using thermal insulating coatings in paper mill operations. It notes that coatings can provide personnel protection by reducing burns and other injuries, while also lowering energy costs through increased energy retention. The document provides examples of where coatings have been used effectively in paper mills, such as on dryer cans and weak liquor tanks, resulting in benefits like increased paper production, more comfortable working conditions, reduced maintenance needs, and savings on energy usage.
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Corotech thermalinsulatingcoating-130710090224-phpapp01
- 2. 2 Main Reasons Insulation is Used • Protect personnel • Reduce energy cost – ROI • Added benefits – Control condensation – Improve process control – Improve facility lifecycle costs – Improve work environment
- 3. 3 Why Insulation is Often Overlooked • Insulation can create added problems – Corrosion Under Insulation (CUI) is one of the biggest maintenance issues in facilities • Poor communication within facility • Unaware of cost saving potential
- 4. 4 Insulation Found in Most Plant Operations – Removable/Reusable Blankets – Calcium Silicate – Perlite – Fiberglass – Closed Cell Foam – Urethane Foam – Ceramic Fiber – Cellular Glass – Insulating Coatings
- 5. 5 Conventional Insulation – The Good & Bad Pros • Good thermal capability • Works at high temperatures (> 500 F) • Provides good absorptive type energy retention
- 6. 6 Conventional Insulation – The Good & Bad Cons • Most absorb moisture, promoting CUI and mold growth • Requires substantial fabrication (2, 3 & 4 part systems) • Shorter lifespan • Consistent maintenance issues • Safety aspects • Diminished performance over time
- 7. 7 NOTE! Facts About Moisture & Insulation • Moisture severely limits performance of conventional insulation • Units running under 316 F (157 C) promote CUI • Conventional insulation systems may require a separate moisture barrier, which degrades over time • Between 10% and 30% of insulation in facilities is missing or damaged* * National Insulation Association
- 8. 8 TODAY, NEW TECHNOLOGY SOLVES AGE OLD PROBLEMS
- 9. 9 Insulating Coatings • Long lifespan with little maintenance needed • Rapid application with minimal man hours • No chance of CUI occurring • Reflects heat back into source, keeping products and processes more manageable • May be applied without shutting down operations
- 10. 10 Insulating Coatings LIMITATIONS • Maximum continuing operating temp of 375 F
- 12. 12 Company Overview • CoroTech was founded in 1974, and headquartered in Grand Rapids, MI. • We are a full service corrosion lining company specializing in: • Engineering • Construction • Field services of lining systems
- 13. 13 Company Overview • Designs, fabricates, installs and maintains custom systems that provide excellent abrasion and chemical resistance • Tile-lined tanks and vessels • Brick and tile tank and floor linings • Various applied lining systems • Single Source capabilities for clients capital and maintenance needs • Excellent Safety Record with a dedicated Corporate Safety Manager • Bondable
- 14. 14 Industries We Serve • Pulp and Paper • Petroleum Refining • Chemical Processing • Sugar Refining • Food/Beverage Processing • Asphalt Plants • Corn Milling • Power Generation Plants • Storage Tanks • Heavy Hauling Trucks • Petro/Gas Transport • Manufacturing • Commercial/Residential Buildings • And just about anywhere else heat and noise are an issue
- 15. 15 Service and Support • Knowledgeable support network • On-site job visits • Key vendor partnerships
- 17. 17 Engineering Support If the Thermal Analysis Report and field experience tells us that the application will not be successful, then we will recommend a more appropriate solution.
- 19. 19 Industrial Coatings Mascoat Industrial-DTI – Personnel protection, energy retention, process stability Industrial-AC – Anti-condensation applications Industrial-HR – Radiant heat gain applications Sound Control-dB – Vibration and noise reduction WeatherBloc – Insulation on buildings and commercial structures Envirotrol CC100 – Personal protection, energy retention, process stability CCX – Similar to CC100, but with maximum operating tempurature of 450 F
- 20. 20 How the Coatings Work Combination of irregular & sphere shaped particles that encapsulate air Conducted heat is transferred across entire surface and throughout the particles Heat Flux Transmissions (Emissivity + Absorptance + Transmittance) - Power of the heat (amperage – voltage) is reduced compared to other insulators. Conductive The coating system blocks all aspects of heat transmission, not just the conductive aspect found in most conventional insulators. Reflective Mascoat uses all of the blocking agents to reflect heat. Cross section of Heat and Coating
- 21. 21 How Does Heat Transfer? • Conduction – Anti-conduction • Convection – Emissivity – Absorption • Radiation – Transmittance – Reflectivity Convection Conduction Radiation Always trying to reach equilibrium
- 22. 22 Conventional Insulation Blocking Methods Anti-conduction = Insulation Value Conventional Insulation Convection Conduction Radiation
- 23. 23 Insulation Coating Blocking Methods Convection Conduction Radiation Anti-conduction + Absorptance + Emissivity + Transmittance + Reflection = Total Insulation Value Successfully blocking heat transfer
- 24. 24 HOW CAN THERMAL INSULATING COATINGS BENEFIT PAPER MILL OPERATIONS?
- 25. 25 Personnel Protection • Thermal insulating coatings can reduce recordable injuries: – Burns – Slip and fall accidents – Hearing loss – Unacceptable working conditions (heat) • This also reduces a facility’s: – Paid time-off for injured employees – Medical costs for injuries on the job – Fines levied by OSHA – Meetings about injuries that have occurred
- 26. 26 Personnel Protection Through a NACE accredited study authored by a independent coatings expert, we have documentation that has shown that thermal insulating coating meets and exceeds the ASTM C1055 & ISO 13732-1 standards, i.e. the “5 second/140˚F rule”
- 29. 29 New World Benefits • Insulation reduces a facility’s CO2 and other polluting emissions output. • When a facility takes steps towards reducing their energy needs, an added advantage is that the facility also lowers the CO2 emissions.
- 30. 30 Reducing CO2 Emissions • A 3rd party test revealed a 35% increase in energy savings when 145 mils (3.25 mm) of Mascoat Industrial-DTI was applied to a test unit compared to an uncoated unit. • This resulted in a 35% reduction in CO2 emissions. Temperature of Contents 148.8 C Ambient Temperature 23.8 C Substrate Geometry Cylindrical Substrate Material Carbon Steel Aspect Ratio [Length/Diameter] 2.4
- 31. 31 Paper Mills • Application – No down time due to shut down – Smaller crews and less time to complete the application – Applicable to tight spaces and on moving equipment. – No risk of overspray, as dry fall is within 3–5 feet
- 32. 32 Paper Mills • Maintenance – Prevents CUI from occurring and removes equipment from CUI programming – Constant inspectability of substrate – Excellent weather resistance – Easily repaired if mechanical damage takes place
- 33. 33 Paper Mills • Return on Investment – Conserves energy – Reduces future maintenance costs – Personnel protection – reduces recordable injuries due to burns (ISO 13732-1) – Coating lasts many years longer than conventional insulation – Helps stabilize internal conditions, reducing energy needs
- 34. 34 WHERE ARE THERMAL INSULATING COATINGS USED?
- 35. 35 Paper Mills DRYER CANS • Problems: Personnel protection from heat surrounding unit, low productivity because of lost energy • Mascoat Benefits: Ease of maintenance, personnel protection, elimination of corrosion, reduction of energy use • Dry Film Thickness: 140 mils (3.5mm) • Results: Unit produced 4 tons more of paper per day after application, working environment much more comfortable
- 36. 36 Paper Mills WEAK LIQUOR TANK • Problems: Personnel protection and energy retention • Mascoat Benefits: Ease of maintenance, personnel protection, elimination of corrosion, reduction of energy use • Dry Film Thickness: 60-80 mils (1.5-2.0 mm) • Results: 20-25% reduction in energy use, no recordable injuries due to burns
- 37. 37 What Does This Mean?