What is the Advantage and Disadvantage of special coating
Pros and Cons of Coating Your Rotating Equipment
To coat or not to coat? Rotating equipment owners know protective coatings safeguard against fouling and corrosion, but are they absolutely necessary for every application? Which conditions and/or process media should be considered for coatings? Will coating impact the performance of the equipment positively or negatively? Which coating should be used for which process media? Will coating critical components reduce the need for rotating equipment repairs and downtime? These are the questions rotating equipment owners ask when deciding whether to invest in this practice. The main reason owners look at using coatings is to prolong service life, decrease operation and maintenance costs, and increase equipment efficiency.
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The Advantages of Coatings
Equipment reliability and longevity are the two biggest concerns for industrial facilities and undeniably so, as capital equipment is your largest investment. Depending on the size of the equipment and its usage, the cost of the coating and labor can be paid back in less than a year by an increase in efficiency of just a mere two percent. Other secondary benefits of using coatings are decreased electricity usage and increased performance. Rotating equipment is subjected to harsh conditions with long operational times and abrasive or corrosive process materials. Coatings help protect against the damage caused by wear-prone applications. They have been designed to be wear resistant, reduce friction, protect against caustic/acidic materials and cleaning agents, and increase line efficiencies. Coatings come in two categories – organic and inorganic. Organic coatings range from thermoset and thermoplastic polymers to elastomers. They are the most commonly used and cost effective mode of protection. Inorganic coatings are non-carbon based compounds such as glass, metals, silicones, and ceramics. Choosing one type over the other involves understanding the ease of coating application and whether the service condition is mechanical, thermal, or chemical. Inorganic coatings perform highly in abrasive and corrosive applications and last long, but tend to be more expensive than organic coatings. Check with your equipment manufacturer for coating recommendations.
The Disadvantages of Coatings
Sometimes coatings are not the best solution. Coatings work well for equipment that is stationary and that will not experience high volumes of turbulence or erosion from abrasive particles. Coatings are great short-term solutions in your anti-corrosion strategy. Once a coating has been applied, it immediately begins a degradation process that will require touch-ups, maintenance, or even a complete reapplication. Coatings can also inhibit pump performance by causing obstacles or closing off passes and ports. When these applications begin to throttle your equipment, it moves the machinery farther away from its original design point, thus reducing efficiency and service life. In high velocity services, coatings will be quickly removed and will be less cost-effective in the long run because of constant reapplications.
Coatings for Corrosion and Wear Protection: Pros and Cons
What is the Advantage and Disadvantage of Special Coating
To coat or not to coat your rotating equipment is a decision that involves understanding the specific conditions of your application and the benefits and drawbacks of using special coatings. Protective coatings are known to prevent fouling and corrosion, enhancing the lifespan and efficiency of machinery. However, it's essential to consider if coatings are necessary for every use case and what impact they may have on overall performance and maintenance needs. The key reasons for considering coatings include prolonging the service life of your equipment, reducing operational and maintenance expenses, and boosting efficiency.
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The Advantages of Special Coatings
Improving equipment reliability and longevity is crucial for industrial operations, as these assets represent significant investments. The cost of special coatings and associated labor can be offset within a year due to efficiency improvements as small as two percent. Beyond efficiency, coatings reduce electricity consumption and enhance performance. Rotating equipment often endures harsh conditions and exposure to abrasive or corrosive materials over long periods. Special coatings can protect against such damage, reducing wear and increasing operational longevity. Designed to be wear-resistant, reduce friction, and protect against corrosive agents, these coatings can significantly boost line efficiency.
The choice between organic and inorganic coatings depends on various factors. Organic coatings like thermoset and thermoplastic polymers are cost-effective and widely used. In contrast, inorganic coatings—comprising materials such as glass, metals, silicone, and ceramics—offer superior performance in abrasive and corrosive environments but come at a higher cost. Consulting with your equipment manufacturer can help determine the best type of coating for your needs.
The Downsides of Special Coatings
While special coatings offer numerous benefits, they may not always be the ideal solution. They are most effective for stationary equipment not subjected to high turbulence or abrasive erosion. Special coatings serve as a short-term solution in corrosion prevention, requiring regular maintenance, touch-ups, or complete reapplication as they degrade over time. Additionally, coatings can obstruct pump performance by creating barriers or narrowing passages, which can lead to a decrease in efficiency and service life. In high-velocity applications, coatings may wear off quickly, making frequent reapplications a costly prospect.
Alternative Solutions to Coatings
Composites present a viable alternative to traditional organic and inorganic coatings. These materials offer numerous advantages, including resistance to corrosion and chemicals. Unlike coated metallic components, which can suffer from underlying corrosion as the coating degrades, composites are solid and eliminate such issues. They are also lightweight yet strong, providing energy savings and durability. Composites can withstand stress without permanent deformation and are non-conductive, making them safer for high-voltage operations.
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While composites are advantageous, they require an investment in new components. Deciding between coatings and structural composites involves considering multiple factors to determine the best solution. Though coatings offer an immediate, cost-effective application, composites provide a more permanent, long-term answer. Both methods aim to improve efficiency, reduce energy use, prolong service life, and decrease the need for repairs.
Anticorrosion Coatings Pump Up Efficiency. Industrial Equipment News.
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