CoroTech's presentation on Thermal Insulating Coating and how it can help your company with an alternative to traditional insulation!
Contact Kimberlee Hewitt for more information!
khewitt@corotech.com
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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
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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
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Conventional Insulation – The Good & Bad
Pros
• Good thermal capability
• Works at high temperatures (> 500 F)
• Provides good absorptive type energy
retention
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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
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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
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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
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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
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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
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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
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Service and Support
• Knowledgeable support
network
• On-site job visits
• Key vendor partnerships
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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.
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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
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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
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How Does Heat Transfer?
• Conduction
– Anti-conduction
• Convection
– Emissivity
– Absorption
• Radiation
– Transmittance
– Reflectivity
Convection
Conduction
Radiation
Always trying
to reach
equilibrium
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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
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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”
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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.
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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
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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
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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
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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
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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
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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
R-value is determined using the guarded hot plate apparatus. This test is performed in a closed environment at 70F. This doesn’t take any real world situations into account.Basically this means that once an insulation is installed in the real world, it’s r-value is automatically decreased.
The following to be read during the second bulletIncreased energy consumptionIncreased production cost - lower throughput Decreased life of equipmentDecreased work efficiencyPersonnel Protection concerns
Conventional insulation only uses anti-conduction to block heat transfer
Insulating coatings use all blocking methods to inhibit heat transfer
Insulation reduces energy needs, therefore reducing CO2 emissionsConventional insulation is not recommended for tank roofs, where vapor loss (hydrocarbon emissions) occurs. Insulating coatings can be applied to roofs to reduce vapor lossReduction in energy usage is directly correlated to a reduction in CO2 emissionsFor example, a 35% reduction in energy usage equals a 35% reduction in CO2 emissionsMascoat is currently developing lab tests to practically determine energy savings based on a number of factors
Insulation reduces energy needs, therefore reducing CO2 emissionsConventional insulation is not recommended for tank roofs, where vapor loss (hydrocarbon emissions) occurs. Insulating coatings can be applied to roofs to reduce vapor lossReduction in energy usage is directly correlated to a reduction in CO2 emissionsFor example, a 35% reduction in energy usage equals a 35% reduction in CO2 emissionsMascoat is currently developing lab tests to practically determine energy savings based on a number of factors
Insulation reduces energy needs, therefore reducing CO2 emissionsConventional insulation is not recommended for tank roofs, where vapor loss (hydrocarbon emissions) occurs. Insulating coatings can be applied to roofs to reduce vapor lossReduction in energy usage is directly correlated to a reduction in CO2 emissionsFor example, a 35% reduction in energy usage equals a 35% reduction in CO2 emissionsMascoat is currently developing lab tests to practically determine energy savings based on a number of factors
Insulation reduces energy needs, therefore reducing CO2 emissionsConventional insulation is not recommended for tank roofs, where vapor loss (hydrocarbon emissions) occurs. Insulating coatings can be applied to roofs to reduce vapor lossReduction in energy usage is directly correlated to a reduction in CO2 emissionsFor example, a 35% reduction in energy usage equals a 35% reduction in CO2 emissionsMascoat is currently developing lab tests to practically determine energy savings based on a number of factors
Insulation reduces energy needs, therefore reducing CO2 emissionsConventional insulation is not recommended for tank roofs, where vapor loss (hydrocarbon emissions) occurs. Insulating coatings can be applied to roofs to reduce vapor lossReduction in energy usage is directly correlated to a reduction in CO2 emissionsFor example, a 35% reduction in energy usage equals a 35% reduction in CO2 emissionsMascoat is currently developing lab tests to practically determine energy savings based on a number of factors