Coro tech thermal insulating coating

Education on Insulating Coatings

CoroTech CompanyJune 2013

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

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

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

Conventional Insulation – The Good & Bad

Pros• Good thermal capability• Works at high temperatures (> 500°F)• Provides good absorptive type energy

retention

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

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

TODAY, NEW TECHNOLOGY SOLVES AGE OLD PROBLEMS

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

Insulating Coatings

LIMITATIONS• Maximum continuing

operating temp of 375°F

11

WHO IS COROTECH?

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

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

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

Service and Support

• Knowledgeable support network

• On-site job visits• Key vendor partnerships

16

Engineering Support

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.

18

SPECIFICS ABOUT INSULATING COATINGS

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

How the Coatings Work

Combination of irregular & sphere shaped particles

that encapsulate air

Conducted heat is transferred across entiresurface and throughout the particles

Reduced temperature with low heat flux

Radiant heat (Reflected)

Radiant heat (Reflected)

Heat Flux Transmissions (Emissivity + Absorptance +

Transmittance) - Power of the heat (amperage – voltage) is reduced

compared to other insulators.

ConductiveThe coating system blocks all aspects

of heat transmission, not just the conductive aspect found in most

conventional insulators.

ReflectiveMascoat uses all of the blocking

agents to reflect heat. Cross section of Heatand Coating

21

How Does Heat Transfer?

• Conduction– Anti-conduction

• Convection– Emissivity– Absorption

• Radiation– Transmittance– Reflectivity

Convection

Conduction

Radiation

Always trying to

reach equilibrium

22

Conventional Insulation Blocking Methods

Anti-conduction

= Insulation Value

Conventional InsulationConvection

Conduction

Radiation

23

Insulation Coating Blocking Methods

Convection

Conduction

Radiation Anti-conduction + Absorptance+ Emissivity+ Transmittance+ Reflection

= Total Insulation Value

Successfully blocking

heat transfer

24

HOW CAN THERMAL INSULATING COATINGS BENEFIT PAPER MILL OPERATIONS?

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


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”

27


28


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

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

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

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

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

WHERE ARE THERMAL INSULATING COATINGS USED?

35

Paper MillsDRYER 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

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

What Does This Mean?

LESS TIME +

LESS MONEY +

LESS ENERGY +

LESS EMISSIONS

= AN INSULATING SYSTEM THAT PAYS YOU BACK

Coro tech thermal insulating coating

Business