The Problem

The Power Plant at a prominent Big 10 University was grappling with a significant problem of galvanic corrosion and needed a solution, also known as bimetallic corrosion. This phenomenon was not only deteriorating the metals within the plant but also causing tubes to plug, leading to inefficiency and increased energy costs. The University, aiming to reduce these costs and enhance operational efficiency, sought a solution that would provide a smoother surface on the affected metals. Familiar with the expertise of the USI Team from past projects, they entrusted us with this crucial task.

The Substrate

The primary material affected by the corrosion was metal, integral to the structure and functionality of the power plant’s machinery.

The Solution

Unconventional Solutions (USI) devised a meticulous and effective strategy to address the corrosion issue:

• Creating a Controlled Environment: The USI Team set up tents around the work area to create an exhaust and dust-free environment. This was vital for both the safety of the work and the effectiveness of the repair process.
• Preparation and Blasting: Prior to abrasive blasting, the copper tubes were corked to prevent blast media from entering and causing further damage. The team then abrasive blasted the affected areas to NACE 2 specifications, achieving a 2 ½ to 4 mil anchor pattern, crucial for the subsequent repair and coating applications.
• Metal Rebuilding: Lost metal around the tubes was rebuilt using RESIMETAL 201 Ceramic Repair Paste. This product is renowned for its strength and ability to restore metal surfaces to their original integrity.
• Application of Hydrophobic Coating: To finish, two coats of RESIMETAL 203 Superflow Ceramic Repair Fluid were brush applied. The first coat was applied in red and the second in gray. This not only provided a smooth, hydrophobic finish but also served as an indicator for future maintenance: when the red coat becomes visible, it signals the need for reapplication to prevent the recurrence of galvanic corrosion.

The project was a success, resulting in a more efficient and erosion-corrosion-free environment within the power plant. The application of the RESIMETAL products not only addressed the immediate corrosion issue but also provided a long-term solution to reduce energy costs and enhance the efficiency of the plant’s operations. The color-coded coating system also ensured ease of maintenance, allowing for timely preventative measures against future corrosion.

Products Used

• RESIMETAL 201 Ceramic Repair Paste: Used for rebuilding lost metal.
• RESIMETAL 203 Superflow Ceramic Repair Fluid (2 colors): Applied for creating a smooth, hydrophobic surface.

For advanced solutions in combating galvanic corrosion and enhancing operational efficiency in industrial settings, trust Unconventional Solutions. Our expertise in specialized coatings and repair materials ensures your equipment is not just repaired but optimized for long-term performance. Contact us for your industrial repair and coating needs.