High-temperature industrial settings require effective heat management and corrosion prevention to keep operations running smoothly. Productos Florida S.A. experienced difficulty in repairing feed distribution pipes in the boiler room, where severe heat and humidity caused continuous infrastructure hazards.

Following unsuccessful attempts with competing materials, Productos Florida resorted to CharCoat CTI, a cutting-edge ceramic thermal coating, to decrease heat loss, manage surface temperatures, and eliminate corrosion beneath insulation (CUI). The findings surpassed expectations, demonstrating considerable increases in energy efficiency and durability.

The Challenge

Productos Florida needed a solution to rehabilitate four key test points in the plant’s boiler room:

1. Feed Water Distributor to Boilers: Temperatures between 80–90°C.
2. Steam Main Valve (8” Diameter): Operating at 140–145 psi.
3. Rear Door Coupling Flange of Boiler #2: High-traffic and high-temperature area.
4. Level Control Column of Boiler #1: Steam pressure up to 145 psi.

A prior approach that required 3mm Dry Film Thickness (DFT) proved to expensive and unstable, resulting in adhesion and heat management issues. The aim was to create an effective alternative that could produce outcomes with a reduced application thickness while decreasing energy loss and eliminating corrosion risk.

The CharCoat CTI Solution

CharCoat CTI, a water-based ceramic thermal coating, was chosen for its ability to insulate, resist corrosion, and operate in harsh situations. 

The system involved:

1. Surface Preparation: All pipes were cleaned to eliminate corrosion, oils, and impurities for optimal adhesion.

2. Primer and Coating Application:

• A 25% diluted primer coat of CTI was applied to surfaces over 150°C, resulting in outstanding adhesion. 
• Additional coatings of CTI were used to reach a total DFT of 1.2mm, far less than the unsuccessful rival product.

3. Curing Process: Temperature measurements were obtained to compare coated and uncoated surfaces.

Results and Measurements

Post-application, temperature readings revealed significant improvements:

• Test Point #1:
  • Uncoated: 86.4°C
  • Coated: 81.7°C
  • Temperature Reduction: 12.5%
• Test Point #2:
  • Uncoated: 173.1°C
  • Coated: 129.0°C
  • Temperature Reduction: 21.66%
• Test Point #3:
  • Uncoated: 136.6°C
  • Coated: 110.4°C
  • Temperature Reduction: 23.15%
• Test Point #4 (Steam Zone):
  • Uncoated: 171.5°C
  • Coated: 129.0°C
  • Temperature Reduction: 27.48%

These results demonstrated CharCoat CTI’s ability to reduce surface temperatures significantly, minimize heat loss, and enhance operational efficiency.

Key Benefits of CharCoat CTI

1. Superior insulation performance.

CharCoat CTI’s thermal conductivity ranges from 0.0012 to 0.004 W/m2K, exceeding typical materials such as fiberglass insulation. This results in improved heat retention and lower energy loss, especially in high-temperature applications.

2. Corrosion Resistance.

Unlike standard insulation, CharCoat CTI eliminates CUI by creating a smooth, water-resistant layer that keeps moisture out and preserves the substrate.

3. Simple application and maintenance.

• Suitable for complicated surfaces including flanges, fittings, and valves.
•  Allows for easy localized repairs without requiring equipment shutdowns. 
• Customizable with paint.

4. Long-term durability.

CharCoat CTI is designed to survive tough industrial settings, including humidity, heavy traffic, and adverse weather conditions.

Productos Florida improved heat management by applying CharCoat CTI to boiler room feed distribution pipes. This resulted in up to 27.48% temperature reduction in high-temperature zones, a significant reduction in energy losses, and improved operational safety by lowering surface temperatures, reducing the risk of burns and equipment damage.

The project highlighted CharCoat CTI’s adaptability and efficacy in replacing existing insulation technologies, which are frequently prone to failure and require expensive maintenance.

Why CharCoat CTI is the Best Choice for Industrial Applications

• Environmentally Friendly: Water-based and non-toxic, ensuring compliance with modern sustainability goals.
• High Efficiency: Delivers superior insulation performance with minimal material thickness.
• Versatility: Applicable to a wide range of industrial environments, including food manufacturing, energy plants, and steel production.

Don’t let heat loss and corrosion jeopardize your operations. CharCoat CTI offers a proven, cost-effective solution for insulating pipes and equipment in high-temperature environments.