Furnace Stack High-Temperature Coating
A corroding furnace stack prepared and coated in situ at operating heat, with no shutdown and no cool-down.
A job completed with Belzona. This describes what the Belzona system does and how it goes on, not a record of a specific project by this distributor.
The challenge
A furnace stack corrodes under operating heat, where the hot steel and the flue conditions drive surface attack that thins the shell over time. The metal loss spreads across the stack and weakens the structure that carries the exhaust, and if it is left to run it can force an unplanned outage. The problem is that the unit could not be cooled and shut down for a conventional repair, so any protection had to go on while the stack stayed hot and in service.
The Belzona approach
The stack is treated in place at operating heat rather than waiting for a shutdown the plant could not give. First the hot surface is prepared so the coating has clean, sound metal to bond to. Then a Belzona 5000 Series high-temperature coating formulated to be put on and cured on a hot substrate goes on, sealing the steel against the corrosion that was thinning it. Where the surface had lost metal, a compatible repair brings it back before coating. The stack is worked in stages so the unit keeps running through the job.
- Assess and mapThe hot stack is inspected to map the corrosion and metal loss and confirm the operating conditions so the right high-temperature system is selected.
- Prepare the hot surfaceThe stack surface is cleaned and profiled at operating heat so the coating bonds to sound metal.
- Rebuild lost metalA compatible repair brings thinned and corroded areas back to profile before the coating goes on.
- Apply the high-temperature coatingA Belzona 5000 Series coating formulated for application and cure on a hot substrate goes on, sealing the steel against further attack.
- Cure and return to serviceCure on the hot surface is confirmed and the stack goes back without any interruption to operation.
The result
- Stack protected against further corrosion without a shutdown or a cool-down
- High-temperature coating applied and cured in situ on a hot substrate
- Metal loss rebuilt to profile before coating, with no plate replacement
- Work delivered on the live unit by factory-trained and factory-certified Belzona applicators
In the field
More Petrochemical & Chemical projects
Live Pipe Leak Seal & Composite Wrap
Live leak sealed and a degraded process line reinforced with an engineered composite wrap, no welding and often no shutdown.
Reactor Vessel Chemical-Resistant Relining
Failed reactor lining stripped back, attacked steel rebuilt cold, and a chemical-resistant immersion lining applied to return the vessel to process service.
Acid Pump Casing Erosion Rebuild
Eroded acid pump casing rebuilt cold and lined with a chemical- and erosion-resistant system to restore clearances.
Seeing something like this?
Belzona Houston is the authorized Belzona distributor for South Texas and the Gulf, based in Alvin, Texas, we’ll survey your equipment and recommend the right cold-applied Belzona system, with 24-hour support.