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Coal Handling Hydro-Bin: Combined Corrosion and Abrasion Protection
Coal Facility — U.S.A.
Coal Facility · U.S.A.
The Problem
Simultaneous Chemical Attack and Particulate Abrasion
A carbon steel Hydro-Bin was experiencing significant metal loss from simultaneous chemical attack and particulate abrasion — the same combination of failure mechanisms common to coal handling equipment operating in wet, corrosive environments.
Chemical Attack
Corrosive degradation of the carbon steel substrate from the wet coal environment.
Particulate Abrasion
Continuous abrasive wear from coal throughput against interior wall surfaces.
Specification
Three-Stage Ceramic-Filled Epoxy Novolac System
Application
Hydro-Bin Interior
Substrate
Carbon Steel
Nominal DFT
40 mils
Surface Preparation
Abrasive blasted to SSPC SP-5 White Metal with a 3–4 mil anchor profile.
Stage 1 — Prime Coat
20-mil ceramic-filled epoxy novolac prime coat, spray applied over the full surface.
Stage 2 — Rebuild
Ceramic-filled epoxy rebuilding compound trowel applied over approximately 50% of the surface area to fill pits, stripe welds, and level severely eroded wall sections.
Stage 3 — Topcoat
20-mil ceramic-filled epoxy novolac topcoat, roller applied over the full surface for a total nominal DFT of 40 mils.
The Result
The system was specified for long-term service life based on the ceramic-reinforced coating properties and the dual resistance requirements of the application.
High-performance epoxy systems for industrial repair and protection.
