Energy & Mining International - Fall 2015 - 13


COLUMNS | CORROSION PROTECTION

Fall 2015

can cure in conditions as low as -40F
if required. If it's an exterior coating
application, then UV resistance is
important to ensure the coating system
will not break down.

SUSTAINABILITY AND SAFETY
The mining and energy sectors are
under great scrutiny when it comes to
environmental and safety practices.
Since 2012, the current worth of the
global green coatings market is estimated to be around $60.6 billion. By
2018, the green coatings marketing is
projected to reach $85.7 billion due to
the sheer increase in new environmental regulations and consumer demand.
This means that the availability of
industrial coatings that are sustainable, durable and cost effective have
greatly increased. The characteristics
of a sustainable and safe coating would
be the following:
+ Coating products that do not
produce noxious emissions during
the manufacturing and application
process.
+ 100% solid coating products that
contain no solvents.
+ Coating products that do not
require solvents for the clean-up
process.
+ Coating product that are made with
renewable materials such as plants.
+ Coating products that are not toxic
to dispose of.
+ Coating products that do not have
flashpoints (flammable).
Most manufacturers will provide
clear guidance on what sort of measures
the company needs to make to keep the
worksite safe for all the people involved.

PERFORMANCE
There are many factors that determine
the performance of the coating system.

In atmospheric applications, there
are not as many risk factors, but if the
application involves immersion or
containment, then the coating requirements increase substantially. For
instance, if you have a storage tank that
needs to hold a corrosive liquid, then
chemical compatibility is a primary
concern along with other factors like
temperature range of the liquid. Chemical compatibility can be checked by
referring to the manufacturer's chemical compatibility list or if the mixture
is proprietary, then it can be tested in a
lab environment. Lab results alone are
sometimes sufficient, but it's always
good if there are actual field-installed
applications that are similar in some
way to the proposed application.
If the tank contains mud or slurry,
then the abrasive resistance would
have to be examined. Certifications
such as NSF/ANSI-61 are needed if the
application involves potable water.
If the substrate goes through
expansion, contraction or is subject
to reverse impacts, then good elongation properties are a must. Typical
elongation properties of epoxies are
only about 3 percent and therefore
they do not perform well under those
conditions. It's worth noting that if the
coating is too flexible it may compromise the chemical resistance due to
the permeability of the coating. Pick
your properties carefully because all
of these factors affect the expected
service life of the coating system.

COSTS
The cost is directly related to the
specification. The price of the material per gallon, the amount of material
used to achieve the desired result and
the surface preparation required will
determine the cost of the project. For
instance, some coating systems only

+

require 20 mils to achieve the desired
results, where other coating systems
require 80 mils to achieve the same
objective. It's also good to note what
type of surface preparation is required
on the job. There is a substantial difference in cost between a NACE #1 (no
discoloration) surface prep vs. a NACE
#3 (minor discoloration less than 33%)
surface prep. Some coating systems
also require a primer layer or multiple
coats to achieve the necessary protection. The surface or anchor profile
(roughness) that needs to be achieved
is dependent on adhesion strength of
your coating system.
One other factor to consider is downtime considerations. How much will
it cost you to have the facility or asset
out of service? If it costs you millions
of dollars a day, then a fast cure coating
solution would be a must.
In order to understand the total
cost of the solution, it's important to
understand the ongoing costs involved
with the coating system. The two
areas to consider is the inspection
requirement for the coatings and the
reparability of the coating. If the coating can't be repaired in small sections
in the future, then any damage to the
coating will involve a complete removal of the coating system.
Corrosion is a major issue in mining
and energy-related industries. It could
mean the difference between running a
successful operation and one that loses
money. There are many options out
there, but by being diligent with your
process and working with a qualified
professional, you'll most likely lead to a
successful result. EMI
__
TATSUYA NAKAGAWA is the vice president
of marketing and co-founder of Castagra
Products (www.castagra.com), an industrial coatings manufacturing company.

emi-magazine.com 13


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Table of Contents for the Digital Edition of Energy & Mining International - Fall 2015

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