UNIQUE POLYMER SYSTEMS is committed to providing high-performance repair and protection solutions for industrial equipment. This case study details the successful repair of an evaporator tube sheet in a sugar refinery using our UPS 200 EG CERAMIC REPAIR PASTE and UPS 225 HT HIGH TEMPERATURE CERAMIC.

At a sugar refinery, the evaporator tube sheet of a heat exchanger was suffering from severe corrosion. The damage was extensive enough to threaten the operational efficiency of the heat exchanger, and immediate repairs were required to prevent further deterioration and potential failure.

The primary challenge was to repair the heavily corroded tube sheet and protect it from future damage. The solution needed to withstand the high operating temperatures typical in a sugar refinery, ensuring long-term durability and effectiveness.

UNIQUE POLYMER SYSTEMS provided a comprehensive repair and protection solution using UPS 200 EG and UPS 225 HT. The repair process involved the following steps:

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Surface Preparation

All tubes were filled with rubber bungs to protect them during the repair process. The substrate was then abrasive blast cleaned to achieve a surface cleanliness level of Sa 2.5 with a 75-micron profile. This preparation ensured that the repair materials would adhere effectively to the surface.

Application of UPS 200 EG CERAMIC REPAIR PASTE

Areas of pitting on the tube sheet were filled with UPS 200 EG. This step restored the integrity of the corroded sections, providing a smooth and solid foundation for the protective coating.

Application of UPS 225 HT HIGH TEMPERATURE CERAMIC

The entire surface of the tube sheet was then coated with two layers of UPS 225 HT. Both coats were applied by brush on the same day, each at a thickness of 500 microns. This high-performance coating was chosen for its ability to prevent future corrosion and withstand the high temperatures associated with the refinery's operations.

The repair process successfully restored the evaporator tube sheet, protecting it against further corrosion and ensuring it could withstand the high operating temperatures. The application of UPS 225 HT provided a durable, long-lasting solution, extending the service life of the heat exchanger and maintaining its efficiency.

This case study demonstrates the effectiveness of UNIQUE POLYMER SYSTEMS' products in repairing and protecting critical industrial equipment in challenging environments. Our advanced materials and precise application process provided a robust solution that ensured the heat exchanger's continued reliable operation.