Aluminizing Coating & Corrosion Protection Coating

Equipment Detail :

• Dalmia Cement Plant Capacity : 8000 TPH
• Make & Designe : FLSmidth
• Coal mill Stack , ESP Stack & RABH Stack (Electrostatic precipitator)
• Size – 2.5 mtr X 65 mtr – Coal mill Stack
• Size – 4 mtr X 65 mtr – ESP Stack
• Size – 5 mtr X 152 mtr- RABH Stack
• Aluminizing by SVCC process (External)
• High temp. & Corrosion protection Coating (Internal)
• Using product XPL- 4410 AL25

Concepts for Coal Mill stack, ESP stack & RABH Stack :

• Electrostatic precipitators (ESP) are used for gas cleaning in almost every section of cement manufacture. Application of ESP is studied, keeping in view Indian conditions. The characterisation of dust emissions has been done for different units, such as rotary kiln and raw mill, alkali by-pass, clinker cooler, cement and coal mill, in terms of exit gas quantity, temperature, dew point, dust content and particle size. It is seen that all these characteristics have a wide range of variance

Demands – Aluminizing & Corrosion protection :

• Coating at Stack is a mainly due to the Corrosion Protection volatiles like Chlorides, alkalies ( Na2O and K2O) and SO3 Bypass and all CMs’s fans in running condition
• Status of E.S.P. Filter “RM & Cooler”&Bag filters of Bypass and all CMs’s fans .The following is an inspection report about the technical status of ESP filter “RM& Cooler” and bag filters of Bypass and all CMs’s fans in running condition.
• According to Central Pollution Control Board (CPCB), process emission need to limit fewer than 50mg/Nm3 in 2015 and it need to limit fewer than 30mg/Nm3 in 2016.
• The cement industry handles billion tones of dust each year and does a good job in keeping dust out of the atmosphere. Over the years, the allowable dust emissions from cement plants have become lower and lower. Particulate Matter (PM) has impacts on climate and it also adversely affects the human health. Currently using process emission control device in cement plant include Electro Static Precipitator (ESP) and various types of bag houses/RABH.

Process Details :

• SVCC Technology : Supersonic Velocity Continuous Combustion Process.
• SVCC Process is one where the material is atomized and /or accelerated under supersonic gas velocities (greater than the speed of sound).
• That produce coating has low permeability and has a homogeneous coating structure.
• Excellent bonding strength and Corrosion protection.
• The customer had invited many choices and decided to go for Aluminizing thru WR-SVCC Technology : Supersonic Velocity Continuous Combustion Process and WR – 100% Solids, solventless coatings using XPL 4410 for high temperature corrosion and erosion resistance.

The process & benefit details are as follows :

• SVCC Technology : Supersonic Velocity Continuous Combustion Process.
• SVCC Process is one where the material is atomized and /or accelerated under supersonic gas velocities (greater than the speed of sound).
• That produce coating has low permeability and has a homogeneous coating structure.
• Excellent bonding strength and Corrosion protection.

Benefits of Aluminizing thru WR-SVCC :

• WR- SVCC Aluminizing is the most effective, long lasting protective coating available today.
• WR-SVCC aluminized coating can outlast any traditional coating by a factor of more than two to one.
• The entire coating process, blast cleaning, metal spraying is completed in one work day depending the cross sectional area.
• It resists chemicals with pH from 4 to 11.
• At elevated temperatures it is effective up to about 1100 deg F (590deg C) for example on the fire side of fossil fuel boiler tubes and other areas exposed to high temperature.
• Zero VOC and no time or temperature to limit application of WR- SVCC aluminizing.
• No risk of heat distortion or weld damage by WR-SVCC aluminizing.

Benefits of X’tra Performance Lining using XPL 4410 AL-25 – Internal :