UNIQUE POLYMER SYSTEMS provides specialized protective solutions for industrial structures exposed to harsh environments. This case study details the successful application of a high-acid ceramic coating to protect a chimney stack using our UPS 226 HAC HIGH ACID CERAMIC.

A chimney stack was experiencing corrosion issues due to continuous exposure to sulfur dioxide gas at elevated temperatures of 100°C (230°F). Without adequate protection, the integrity of the chimney could be compromised, leading to potential operational and safety concerns.

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The challenge was to apply a coating that could withstand the highly corrosive environment inside the chimney stack, ensuring long-term protection and durability. The coating needed to resist sulfur dioxide gas at high temperatures, preventing further corrosion.

UNIQUE POLYMER SYSTEMS provided a comprehensive protection solution using UPS 226 HAC. The application process involved the following steps:

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Surface Preparation

- The chimney stack substrate was abrasive blasted to remove existing corrosion and prepare the surface to a cleanliness level of SA 2.5 with a 75-micron profile, in accordance with ISO 8501/4 Standard (SSPC SP10/NACE 2). This step ensured that the coating would adhere effectively to the substrate.

Application of UPS 226 HAC HIGH ACID CERAMIC

- All weld joints were stripe coated with a single coat of UPS 226 HAC at a thickness of 400 microns. While the coating was still wet, the entire surface of the chimneystack was coated using a heated plural feed airless spray with UPS 226 HAC at a thickness of 1mm. This method ensured a uniform and durable protective layer.

Quality Assurance

- After curing, the application was tested for pinholes to ensure the integrity of the coating. Any defects identified were spot blasted, and the affected areas were over-coated with a final coat of UPS 226 HAC by brush, ensuring complete protection.

The application of UPS 226 HAC successfully protected the chimney stack from further corrosion. The high-performance ceramic coating provided a long-lasting solution, capable of withstanding the corrosive effects of sulfur dioxide gas at high temperatures.

This case study demonstrates the effectiveness of UNIQUE POLYMER SYSTEMS' high-acid ceramic coatings in protecting critical industrial structures from harsh environmental conditions. Our advanced materials and precise application process provided a durable solution that ensures the chimney stack remains operational and safe for years to come.