Unique Polymer Systems provides advanced protective solutions designed to withstand the most challenging industrial environments. This case study details the successful protection of sulphuric acid storage tanks using UPS 403 UCU XL ULTIMATE EPOXY NOVOLAC 75 - EXTENDED LIFE.

The client’s sulphuric acid storage tanks were exposed to 98% sulphuric acid, a highly corrosive substance that poses a significant risk to the integrity of the tank structures. To prevent corrosion and extend the life of the tanks, a robust protective coating was required.

The challenge was to apply a coating that could resist the corrosive effects of concentrated sulphuric acid while ensuring long-term durability. The solution needed to be applied efficiently and effectively to cover all internal surfaces of the tanks, including weld joints, to prevent any potential failure points.

UNIQUE POLYMER SYSTEMS provided a comprehensive coating solution using UPS 403 UCU XL ULTIMATE EPOXY NOVOLAC 75 - EXTENDED LIFE. The application process involved the following steps:

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Surface Preparation

- The tank substrate was abrasive grit blasted to a surface cleanliness level of SA 2.5 with a75-micron profile, in accordance with ISO 8501/4 Standard SA2.5 (SSPC SP10/NACE2). This preparation was essential to ensure optimal adhesion of the coating.

Stripe Coating of Weld Joints

- The weld joints were stripe coated with UPS 403 UCU - XL at a thickness of 400 microns, applied by brush. This step provided additional protection to these vulnerable areas.

Application of UPS403 UCU XL ULTIMATE EPOXY NOVOLAC 75 – EXTENDED LIFE

- The entire internal surface of the tanks was coated with 500 microns of UPS 403 UCU 75 - XL, applied using heated plural feed airless spray equipment (Graco XM).

- During application, the base component was heated to 60°C and the activator was maintained at 20°C to ensure a consistent and durable coating.

- After an overnight cure, the coated area was inspected for pinholes and defects, with any necessary remedial work carried out.

- A second coat ofUPS 403 UCU XL in a contrasting colour was then applied at 500 microns, ensuring complete coverage and enhanced durability.

The application of UPS 403 UCU 75 - XL successfully protected the sulphuric acid storage tanks from the corrosive effects of 98% sulphuric acid. The dual-coat system provided long-lasting protection, ensuring the tanks’ structural integrity and extending their service life.

This case study highlights the effectiveness of UNIQUE POLYMER SYSTEMS' advanced coating solutions in protecting critical industrial assets from highly corrosive environments. Our specialised materials and precise application process delivered a reliable solution that ensured the continued safe operation of the sulphuric acid storage tanks.