Latest Case Studies & White Papers

Slurry transfer system greatly enhanced with Landia pumps at Metcalfe Farms

At its dairy operation in the Yorkshire Dales, the introduction of new separators has given Metcalfe Farms the opportunity to futureproof the pumps it uses to transfer large volumes of slurry from its 2,000 (1,300 dairy) cows.

Separating slurry has undoubted benefits, but putting together a streamlined slurry transfer system covering three tanks, has presented plenty of challenges, especially with the need to feed the site’s 200kWh biogas plant.

Aside from the separators, one of first issues was to address the final pump in sequence that ultimately sends slurry (about 6% to 8% dry matter) about 120 meters (and 10 meters of lift) up to the 3,500m3 anaerobic digester.

Annoying bits and pieces inevitably find their way into slurry, which was enough to make the pump block quite regularly.

“I used to dread coming down here to sort it out,” said Robert Metcalfe, who oversees all things engineering on the dairy side of the business.

“The pump did an okay job when working but wasn’t the best with solids. It wasn’t a pleasant job spending over an hour unblocking it each time; a two-man job, so all very time-consuming, especially having to retrieve it with a pipe because there was no clutch at the bottom.”

That’s all changed now with the old unit replaced by a Chopper Pump made by Landia, who also supplied an integrated guide rail and a bespoke pipework system for easy access and lifting.

‘It is much a better design’

“Everything flows through so much smoother now,” added Robert. “It is much a better design. You don’t have to worry about any sort of pipe bending or extra weight of the added pipe. Generally speaking, the new pump doesn’t block, although just recently a large chunk of rope stopped it! But unlike before, it’s now a job for one person, and on this occasion, only took 20 minutes before simply lowering it back in again.”

‘Digestate from the AD plant

provides significant benefits’

At the biogas plant, which is run by Iona Management Services, a second CHP (combined heat and power) engine has

recently been added, which will help increase the amount of clean energy that is exported to the grid. Metcalfe supplies a slurry-only feedstock to the AD plant, and then buys power back at a discounted rate for its own use. In the winter this is around 300 kilowatt hours, rising to 360 kilowatt hours in the summer. In addition to providing power for the dairy and the sell-on to the grid, the digestate from the AD plant also provides significant benefits, as Robert Metcalfe explains:

“The digestate does wonders for our grassland. We spread a little bit on the crops, but it’s mainly focused on the grass. This year we did five cuts over 1,000 acres. We hardly spend anything on chemical fertilizer now.”

Working closely with Landia to look at how best to integrate the new separators, a 22kW pump was chosen to manage the slurry feeding task, with an existing long-shaft Landia pump moved up from its existing task on another tank.

“We’ve had this pump since 2004,” added Robert Metcalfe, “which has understandably endured plenty of wear, but when tested by Landia engineers during a service, the 20-year-old unit was still happily pumping full pipe, which I have to admit, I was pleasantly surprised by. Now that we have separators, we can remove solid material to reduce our environmental impact.”

To replace the old long shaft unit, a new 7.5kW Landia Chopper Pump has now been installed so that slurry levels don’t rise. Meanwhile, the existing Landia long shaft chopper pumps, which have already been in service for 20 years, since Metcalfe had its first shed, continue to work away.

Very strongly built’

Robert Metcalfe continued: “The pump at the front of the loop system that has been created gets plenty of pain, so no surprise it’s had some repairs over the years, but steadily pumping away, it, with the others, has ensured that the dairy’s channels never fill up. We’ve found that by keeping our channels narrow, the pumps keep them flushed out completely, whereas with wider channels, the whole thing would still need flushing out. Now that we have it all set up on timers, it’s seamless, so far less hassle.

“The Landia pumps are very strongly built things, and I like the fact that they are electric and quite modular, so we don’t have to hook up to a tractor. This very much fits in with what we constantly work towards with fewer engines turning and less burning of diesel. One Landia pump we’ve had now for three years, and it’s never given us a bit of trouble.”

Over in the Metcalfe milking parlour, Robert has been glad to see the back of having to replace small vortex pumps that

blocked or blew completely, even though the liquids are very watery.

He explained: “As soon as any foreign debris or plastics came into play, straining the pump, we were having to buy a new one almost every six months due to burnout or component failure, so as they clearly weren’t up to the job, I called Landia for help. Also, the pump(s) had been installed on winches and over time, blockages and sediment buildup forced us to keep raising the pumps closer to the top of the tank, which in turn meant we ended up with sediment right up to the mouth of the tank.

‘Since we’ve had it installed, we haven’t had to touch it’

“We now have a new 5.5kW Landia pump that just flies through any debris or solids, which are an inevitable part of dairy wastewater/slurry. Nothing settles out with this new, much faster pump. It’s absolutely spot-on, and what’s great is that it is completely automatic. Since we’ve had it installed, we haven’t had to touch it. You can configure it so that in this case it knows we want to keep this tank pumped out and empty. The sensor knows the tank’s dimensions and capacity. It is so much better than what we're doing before.”

Synching the pump operation, together with the investment in separators is just part of how Robert Metcalfe is helping focus

on improvements to help take the diary part of the business forward, but without expanding too quickly. The dairy provides around 45 tonnes of milk per day to Paynes Dairies at Boroughbridge. Exceptionally high animal welfare standards for the Metcalfe cows continue to see a rise in yields.

“Going forward,” said Robert, “everything matters, even the little things. For all its benefits, we’d possibly consider sand bedding, but I don’t think our slurry channels would take it, and there’ such a big wear factor on pumps and machines. The sawdust we use is perfect, apart from the price!

“We’ve also been improving the lighting for our cows, again with some help from an automatic, dimmable system. Previously in hot summer spells, you could see that our cows were uncomfortable, which we don’t want. The milk output would drop. As well as the lighting, we’ve also put up new roof sheets to block out any intensive heat, which has made a big, positive difference.”

He concluded: “In time here we will probably phase out other brands of pumps as they come to the end of their life or cause problems, and just stick with Landia. I think it helps that they focus on pumps, rather than some who try to provide everything, plus we always get very good backup and no problems with the supply of spare parts.”

 

www.landia.co.uk

 

Mitigating Corrosion and Erosion in Waste-Fuelled Circulating Fluidized Bed (CFB) Boilers: A Technical Case Study

The operational challenges of biomass-fuelled Circulating Fluidized Bed (CFB) boilers present complex materials engineering problems, particularly in managing simultaneous corrosion and erosion mechanisms. This case study examines a targeted tube protection strategy implemented at a waste to energy power generation facility.

Initial Diagnostic Assessment

Commissioned in 2008, the CFB boiler rapidly experienced critical tube metal degradation. Preliminary investigations identified two primary degradation pathways: erosive wear from particulate matter in waste-derived fuel streams and chemical corrosion induced by high-temperature gaseous elements.

The initial protective cladding quickly revealed limitations, with accelerated tube wall thickness reduction threatening the infrastructure's long-term operational integrity.

Critical observations included:

  • Rapid material loss rates
  • Non-uniform wear patterns
  • Potential for premature structural compromise

Materials Engineering Solution

The solution chosen was SMARTGardTM; a maintenance philosophy that includes HVTS® (High Velocity Thermal Spray) cladding, engineered to protect CFB boilers from fly ash erosion, fireside corrosion, and fouling.

Integrated Global Services (IGS) applied the cladding system, customised to the process to mitigate the wastage and extend the life of the boiler tubes. To maximise budget utilisation during past outages, a thinner specification cladding was installed in 2015, focusing on the critical areas and ensuring boiler reliability until the 2017 outage.

Performance Validation Methodology: Inspection in 2017

The inspection was carried out together with the third party CFB boiler expert and the plant manager. The cladding was observed to be in excellent condition. This mini outage verified the reliability of the IGS HVTS® cladding. An extensive inspection was completed throughout the entirety of the cladding scope. With the topcoat completely intact, the cladding system was confirmed to be in ‘as-applied’ condition.

Fouling was virtually eliminated in the cladded locations and any adhered fouling was no longer tenacious and was easily brushed away.

 

Maintenance Implementation Timeline

  • 2008 – 3rd party commodity thermal spray coating installed to mitigate expected corrosion within the CFB Boiler.
  • 2015 – Aggressive corrosion-erosion mechanism analysed and customised IGS SMARTGardTM HVTS® cladding solution installed
  • 2018 – 5-year maintenance plan created, prioritising locations based on wastage rates and tube condition.

Technical Considerations

The HVTS® cladding solution demanded a multifaceted engineering approach. Critical design parameters included:

  • Maximising protective layer adhesion
  • Eliminating thermal stress
  • Developing a long-term protective system and ensuring boiler reliability
  • Ensuring compatibility with existing boiler infrastructure

Quantitative Outcome Analysis

The implemented cladding protection strategy demonstrated significant operational advantages including the prevention of large-scale tube panel replacement, reduced maintenance frequency, and optimised outage duration, preventing any unplanned production interruptions.

Operational Economic Considerations

The plant manager commented: "We needed to protect a large area and prevent extensive panel replacements. With outage costs running into tens or hundreds of thousands of dollars daily, the maintenance expenses were minimal compared to potential production losses. Our goal was to reduce annual outage time to under 10 days, which meant we had to be incredibly strategic about addressing critical areas efficiently."

Methodological Insights

The successful intervention underscored several critical engineering principles:

  • Comprehensive initial diagnostic capabilities
  • Customised material engineering solutions
  • Data-driven maintenance approach
  • Predictive wear modelling strategies

Conclusion

Advanced cladding technologies provide a sophisticated intervention for mitigating material degradation in boilers, particularly in challenging combustion environments with complex fuel streams.

The research suggests continued development of predictive wear modelling and adaptive cladding technologies could further enhance long-term infrastructure reliability in waste-to-energy and biomass boiler applications. The case study demonstrates the critical role of innovative materials engineering in extending operational infrastructure lifespans and optimising industrial maintenance strategies.

By integrating comprehensive diagnostic approaches, precise engineering interventions, and systematic performance monitoring, plants can transform potential operational vulnerabilities into sustainable, reliable infrastructure solutions.

To find out more, visit: integratedglobal.com

Hoist & Winch is pillar of support in overhead crane project

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The design and installation by Hoist & Winch Ltd of replacement end carriages for two overhead cranes reached its conclusion recently with the end user expressing complete satisfaction in the outcome. Previously, the 2-ton swl (safe working load) manual overhead cranes were suffering from potentially dangerous crabbing problems due to the original design of the end carriages. Hoist & Winch thus had a responsibility to work expediently and professionally, with the aim of bringing this concerning issue to a safe resolution.

Alongside the supply, installation, hire and load testing of hoist units/cranes for all types of industries, Hoist & Winch also offers lifting equipment refurbishment and rectification services. With each project of this type presenting its own set of challenges, the company comes to the fore in tackling work that competitors often prefer to avoid.

For this project, the relatively high-temperature working conditions and access requirements were a factor due to the basement location of the manual cranes in a large, ageing building in central London. The cranes work over two large gas-fired piston engines that provide heat to neighbouring buildings.

The core objective was to design and install replacement end carriages for the cranes that in the first instance would eliminate the potentially dangerous crabbing issues. Due to this problem, the cranes had not performed correctly since initial installation.

                                                                                                                                                            Continued ……

Crabbing occurred because the original end carriage wheelbase was insufficient for the crane span, exacerbated by insufficient tread depth on the crane wheels. During long travel motion, the end carriage wheels would try and ride up (crab) on to the crane rails, a situation that can potentially lead to crane derailment.

With a solution required urgently, Hoist & Winch performed a detailed site dimensional survey to gather important design information and check the alignment of the existing crane rails. The company then set about designing replacement end carriages with a longer wheelbase and new crane wheels featuring deeper tread. Side-acting crane rail guide rollers at each extent of the end carriages were a further important part of the new design.

Working closely with the customer’s on-site scaffold team, Hoist & Winch carried out a comprehensive installation survey. For the rectification work, the scaffolders agreed to build a temporary tube and board scaffold below each crane, providing both general access and jacking positions to raise and lower the cranes when replacing the end carriages.

Hoist & Winch submitted a Risk Assessment Method Statement (RAMS) for approval by the customer. The RAMS detailed the installation procedure, the required equipment, and the hazards and risks associated with the various tasks and how appropriate actions would mitigate accordingly.

Following a five-week period to manufacture the replacement end carriages, installation took place over four days for both cranes. The work included dynamic load and 125% proof load testing with a certified roller test load for each crane. A series of lifting beams helped to move the test load into the basement area via the use of temporary manual hoist units.

Hoist & Winch issued a Thorough Examination report in accordance with LOLER (Lifting Operations and Lifting Equipment) regulations.

                                                                                                                                                            Continued ……

“The new replacement end carriages served to eliminate the crabbing issues exhibited by the original crane design,” confirms Hoist & Winch Director Andy Allen. “Our customer was very satisfied as they could carry out essential maintenance work on the gas-fired piston engines that was previously delayed. The successful conclusion of this task is yet another example of how Hoist & Winch works with its customers in a professional way to overcome challenging issues and bring genuine added-value to lifting projects.”

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

Polymeric Leading Edge Protection Extends Lifespan of 42 Wind Turbine Blades

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Figure 1. Leading edge protection of wind turbine blade using polymeric technology

                                                                                                                                                                                               
In order to achieve net-zero by 2050, according to a 2023 Report from the world-leading authority on climate science, Climate Action Tracker: ‘wind and solar sources in electricity generation will need to reach 57 - 78 percent by 2030, and 79 - 96 percent by 2050.’ In 2022, this figure sat at 12 percent. Needless to say, a colossal scale-up of these industries is anticipated over the upcoming decades.

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Figure 2. Historical progress toward 2030, 2040 and 2050 targets for share of wind and solar sources in electricity generation (Source: State of Climate Action 2023)

Polymeric Technology Supports Transition to 79 – 96% Renewable Energy by 2050

Given the important role wind power plays in the transition to net zero, it is absolutely critical that windfarms are maintained to an excellent standard. Otherwise, damaged wind power assets may needlessly be decommissioned and replaced; the process of which comes with a hefty carbon footprint as well as considerable financial expenditure.

As such, asset owners are investing in a simple yet extremely beneficial (both from a cost and environmental perspective) solution to extend the lifespan of wind turbines. This solution involves the use of polymeric repair composites and high-performance protective coatings to repair and protect key assets in the wind industry. This includes: turbine blades, nacelles and generating components, turbine bases, towers, transformers, amongst other assets.

The use of this technology is based on a circular economic business model: repairing damaged assets rather than replacing them. In turn, not only does this mitigate the carbon footprint incurred during the replacement process, but it is also enables the asset owner to make significant financial savings as well.

Case Study: 42 Wind Turbine Blades Repaired and Protected

At an onshore Windfarm in Denmark, 42 wind turbine blades were exhibiting signs of severe erosion on the leading edges. Previously, the Customer had used pre-formed shells that were bonded onto the substrate to provide leading edge protection. However, this process proved to be extremely time-consuming and expensive. Therefore, the Customer was seeking an alternative solution which would be financially viable and also ensure optimal operation for many years to come.

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Figure 3. Damaged wind turbine leading edge


Specification of Polymeric Leading Edge Protection System

Based on test results, the ease of application as well as the high-quality finish that can be achieved, the Customer decided to repair and protect the leading edges with a combination of Belzona 5711 and Belzona 5721.

The thixotropic paste, Belzona 5711 is specially designed to be applied in conjunction with the Belzona 5721 protective coating. This solvent-free LEP system is formulated for the in-situ repair and rebuilding of leading edge erosion and impact damage on wind turbine blades.

Simple Application Method

Commenting on the application process, Morten Sivertsen, General Manager at AESSEAL Danmark A/S said: “Surface preparation was carried out on each of the 42 blades, followed by the direct application of 90 kg (198.4 lbs) of Belzona 5711 from self-mixing cartridges onto the blade. The repair area was then contoured using a piece of Belzona mixing board. Once cured, a visual inspection was conducted to ensure the application’s readiness for overcoating with 144 kg (317.5 lbs) of Belzona 5721. Using a short-bristled brush, this system was then applied to the leading edge and left to cure for 30 – 60 minutes. With three rope access technicians carrying out the applications, on average, six – nine turbine blades were completed each day.”

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Figure 5. Morten Sivertsen, General Manager at AESSEAL Danmark A/S

 

In-Situ Repair Ensured Minimum Downtime Was Incurred

As the polymeric systems were applied in situ without the need for specialist tools or equipment, this ensured that a fast and seamless application was carried out. Thus, this enabled the Customer to make considerable financial savings as it mitigated the profit loss that can be incurred through lengthy periods of downtime.

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 Figure 6. Leading edge repaired and protected with Belzona 5711 and Belzona 5721

 

Safeguarding Key Wind Power Assets for the Long Term  

 

The scaling up of the wind power industry is absolutely critical in order to support the transition to renewable energy, in keeping with the net zero by 2050 pathway. By safeguarding key assets within this industry through the use of polymeric technology, asset owners can successfully bypass the environmental and financial costs associated with asset replacement. Therefore, it could be argued that polymeric technology plays an intrinsic role in supporting this energy transition. 

 

About AESSEAL DANMARK A/S:


AESSEAL DANMARK A/S is a subsidiary owned by AESSEAL Plc and is the authorised Belzona Distributor for the Denmark territory. Established in 1999, AESSEAL DANMARK A/S provide industrial repair composites and protective coatings to a variety of industries including petrochemical, mining, power, sugar, pulp and paper, amongst others.  

Please click on the following link for more information about AESSEAL DANMARK A/S.

Electric hoist leaves large distillery in high spirits

The world’s largest producer of spirits is now benefiting from a turnkey package of three Italkrane ATEX-rated electric chain hoists supplied by Hoist & Winch Ltd. Operational within a new extension of the Scotland-based distillery, the 2-ton swl (safe working load) hoists raise and lower sealed vessel lids and baskets containing raw materials used in the production of gin.

Among the challenges of this demanding project was a restriction in the overall height of the new building due to local planning laws. In turn, only limited headroom is available for lifting operations over the vessels. Critical for the application, therefore, was the specification by Hoist & Winch of Italkrane YY series electric chain hoists featuring a low-headroom design. The ATEX specification of the hoists is necessary due to the vapours and fumes produced in the manufacture of alcohol-based products.

Italkrane YY series electric chain hoists feature an Ex d electrical enclosure design to contain any explosions and stop flames, sparks and hot gases from escaping. Full anti-spark features are in place for all components subject to sliding friction, including the brass trolley wheels. Also present is a non-sparking load hook, brass anti-tip device and polycarbonate pendant control ensuring explosion protection up to Zone 1 II B T4 classification.

The power supply to each hoist unit is via a festoon cable track system complete with sliding trolleys and support arms clipped to the top flange of the hoist runway beam. Each hoist unit also features an Italkrane heavy-duty geared top/bottom limit switch and friction-type slipping clutch overload protection device.

                                                                                                                                                            

“Although we provide a full spectrum of lifting equipment services, Hoist & Winch is particularly at home supplying equipment for demanding industries, including the distillery sector,” explains Hoist & Winch Director Andy Allen. “We have extensive knowledge of this industry, where our quality of service and flexible approach ensure the highest levels of customer satisfaction.”

Due to the critical nature of the project and the risk of explosion throughout the high-risk site, it was clear that very stringent planning and close monitoring of working practices would be necessary at all times. In addition, the site work was subject to Construction Design and Management (CDM) Regulations, supported by a requirement for all site engineers to hold a valid CCNSG Safety Passport/CSCS competency certification.

Installation took place over seven days, with a Hoist & Winch CompEX-certified electrical installation engineer completing all connection work. The load testing of each hoist unit and complete runway beam took place using a dynamic test load of 2t + 125% proof load. Additional functional testing using the vessel lids and raw material baskets proved system functionality in line with customer requirements.

Following the issue of a LOLER (Lifting Operations and Lifting Equipment Regulations) Thorough Examination Report for all installation work, Hoist & Winch provided on-site training for the distillery’s operating personnel.

Although providing the optimal solution for this large distillery, Italkrane ATEX-rated electric chain hoists are also suitable for many other applications requiring safe lifting operations in explosion risk environments. In addition, Hoist & Winch can offer ATEX wire rope hoists for longer lifting tasks, heavier loads up to 50t swl and higher duty applications.

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

How to avoid damage during mounting and optimally align machines

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  • Incorrect mounting and dismounting of rolling bearings, as well as imbalances in machine shafts, can result in damage to the bearings and other components
  • Schaeffler’s new white paper provides all you need to know about the correct preparation, installation and removal of rolling bearings, and how to ensure machine shafts are properly aligned.
  • The paper includes basic knowledge, expert tips and guidance, as well as case studies showing how customers are profiting from using the right tools for the job.

Birmingham, UK | August 6, 2024 | Global motion technology company Schaeffler has published a white paper on the mounting and dismounting of rolling bearings and shaft alignment.

Learn from the experts on how to avoid damage during bearing mounting and dismounting, how to simplify mounting work, how to save time and ultimately money by protecting the bearing and optimally aligning your machines. Schaeffler’s practical white paper contains valuable knowledge that you can incorporate directly into your maintenance process.

Our 10-point checklist for safe mounting work will help you avoid premature bearing failures in the future:
    

  • Protect your workspace and the rolling bearing from dust, dirt, and moisture.  
  • Use drawings to familiarise yourself with the design.  
  • Make sure that your bearing matches the specifications on the drawing.  
  • Check the housing bore and the shaft seat for dimensional, shape and positional accuracy, as well as cleanliness.  
  • Ensure that the mounting of the bearing rings on the shaft or in the housing bore cannot be impaired by edges. A slip angle of 10° to 15° is helpful.  
  • Wipe off any corrosion protection on the seat and contact surfaces.  
  • Apply a very thin layer of suitable mounting paste to the cylindrical seating surfaces of the bearing rings.   
  • Do not cool the bearings. Condensation can lead to corrosion in the bearings and bearing seats. 
  • After installation, apply a suitable lubricant to the rolling bearings.   
  • Check the bearing to make sure it’s working properly.

These are just a few of the basic recommendations, though to explore further and delve into things like which tool is suitable for certain bearing or bore types, Download the White Paper here.

Heavily Corroded 872 Metre Oil Pipeline Restored with Composite Wrap

An underground oil pipeline at a Refinery in Spain was suffering from severe corrosion. If left unchecked, the pipeline, 872 metres (2860.8 ft) in length, would have incurred severe metal loss. As a result, disastrous consequences, both financially and also from an environmental perspective, would have ensued.


Figure 1. Corroded pipeline restored with composite wrap

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Solution Sought to Mitigate Cost and Carbon Footprint of Pipeline Replacement   

A prompt repair was required for the carbon steel pipeline, 55.9 cm (22 inches) in diameter, in order to mitigate any further corrosion damage being incurred. In fact, if left unchecked, this would have caused the substrate to completely corrode through and, therefore, serious environmental issues would have ensued.  

A potential solution would have been to completely replace the pipeline. However, considering its mammoth length, this process would have required considerable financial expenditure and, furthermore, would incur a hefty carbon footprint.

For every ton of steel that is produced, 1.85 tons of CO₂ - nearly double the amount - is released back into the atmosphere (Carbon Clean). In addition to this, the process of removing and disposing of the damaged pipeline further ratchets up the carbon footprint of this process.

As well as the environmental impact of replacing the corroded pipeline, this process would also require a considerable period of downtime which would lead to further profit-loss. The combination of these factors, costly in both a financial and environmental sense, led the Customer to seek out an alternative solution to replacing the steel pipeline.  

Expensive Replacement Process Bypassed with Composite Wrap

The Customer decided to repair and protect the pipeline with a combination of polymeric technology in order to bypass the drawbacks associated with replacing the pipeline.

The following systems were specified and applied following an inspection from Elena Expósito Fernández, AMPP (NACE) Certified Coating Inspector Level 2 and Technical-Commercial Delegate at authorised Belzona Distributorship Rodator Composites:  

“The 2-part epoxy paste, Belzona 1111 (Super Metal), was specified to fill in any gaps in the weld seams to ensure the pipeline had a smooth profile. For heavily corroded areas, plate bonding was required using steel plates which were 50 cm x 60 cm (19.9 in x 23.6 in) in size, with a thickness of 5 mm (0.2 in). These were bonded into place using the epoxy structural adhesive, Belzona 7311. To reinforce the pipeline, the composite wrap, Belzona SuperWrap II, was specified. Finally, the anti-corrosion coating, Belzona 5811 (Immersion Grade), was chosen to provide long-term corrosion protection.”   




Figure 2. Elena Expósito Fernández, Technical-Commercial Delegate at Rodator Composites

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Figure 3. Application of composite wrap, Belzona SuperWrap II, to the steel pipeline

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Figure 4. Anti-corrosion coating, Belzona 5811 (Immersion Grade), applied to pipeline

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Polymeric Technology Supports Decarbonisation of Oil and Gas Industry    

The Customer was able to successfully bypass the drawbacks associated with complete pipeline replacement by instead, opting to repair and protect the pipeline with a combination of polymeric technology. As well as making huge financial savings, this solution enabled the Customer to also minimise its environmental impact as well.

As the oil and gas industry continues to decarbonise, this latter point is particularly paramount. Polymeric technology is an extremely viable way in which oil and gas asset managers can make great strides in mitigating the carbon footprint of their facilities. An increased uptake in the use of cold-applied repair composites and protective coatings would help to accelerate the decarbonisation of this industry.

For more information, visit: www.belzona.com

Belzona Repairs Propeller Shaft on Ship Carrying Olympic Torch

On May 8th, 2024, the historic Ship the Belem navigated into the bustling port city of Marseille, marking the arrival of the Olympic torch in France. Over 150,000 spectators gathered to witness as the Ship sailed into the bay, accompanied by over a thousand boats. Last year, Alliatech, one of Belzona’s French distributors, was involved in the restoration of this historical Ship.

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The Belem arriving in Marseilles with the Olympic flame             Credit: Benoit Tessier / Reuters

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Photograph of spectators gathered in Marseilles, taken from the Belem as it arrived. Credit: Nicolas Tucat / AFP

The History of the Belem:

Considered to be the last great French merchant Ship, the Belem is an impressive three-mast Vessel reaching 34 metres (112 ft) tall and 58 metres (90 ft) long. As well as possessing an impressive 22 sails with a huge surface area of 1,200 m2  (1435 yd 2), it has two 575 horsepower diesel engines, blending tradition with modernity. Interestingly, carrying the Olympic flame has not been the first time the Belem has had a fire on board. The Ship caught ablaze during its maiden voyage in 1896, the same year the Olympic games were revived, on its way to Belem, a Brazilian port city and the Ship's namesake, but it was repaired and able to continue its visit.

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The Belem made her maiden voyage in 1896, the same year as the first Olympic games

The Belem’s Olympic Voyage:

On Saturday 27th April, once the Olympic flame was lit in Athens, it began its 2000 km (1242 mile) journey from the port of Piraeus to Marseille. The Olympic flame was watched 24 hours a day to ensure it stayed lit and twelve days later, it reached the French coast. A celebratory event anticipating the arrival of the Ship in France featured 800 luminous drones forming a torch in the air followed by a pyrotechnic show. As the Vessel docked, an Air Force flyover featured planes drawing the Olympic rings and the colours of the French flag as over 150,000 lined the streets of Marseilles.

Case Study: Propellor Shaft Suffering from Heavy Corrosion

The propellor shaft on this 19th Century Naval Ship was severely damaged, suffering from heavy corrosion and pitting. The Customer was keen to preserve the shaft, given its historical significance; replacing it would be extremely costly, and they were reluctant to lose a piece of the original Vessel. It was vital that the chosen solution could reconstruct the damaged areas of the shaft and protect it from future seawater corrosion.

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The propeller shaft showed heavy wear due to seawater corrosion

Alliatech, a Belzona-authorised distributor with over 40 years of experience, was chosen to carry out the repair. The application took place whilst the Belem was in dry dock in the Saint-Nazaire Shipyards as part of the Ship's extensive restorations. After grit-blasting and salt-washing the surface, the damaged propeller shaft needed to be reconstructed back to its original profile. Belzona 1111 (Super Metal), a repair composite for metal repair and resurfacing, was chosen for the rebuilding.

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Propellor shaft rebuilt using Belzona 1111 (Super Metal) after first coat of  Belzona 5821

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Final application with the second coat of Belzona 5821

Two coats of Belzona 5821 were then applied to protect the shaft from future seawater corrosion. This product was specially designed to offer long-term protection from erosion and corrosion under immersion, thus providing excellent defence against the effects of salt water.

The application of these two Belzona products allowed the original 127-year-old shaft to be retained, avoiding the costly replacement, and maintaining a piece of history.

Want to learn more about Belzona in the marine industry?

Please Click Here

High-Performance Coating Protects Tanks at Biopolymer Production Plant

At a chitosan production plant in Scotland, UK, a high-performance, anti-corrosion coating was used to coat the internal lining of three tanks, protecting them against aggressive, acidic substances for the long term. Given the important role the tanks play in the process of turning large amounts of shellfish byproduct into the biopolymer chitosan, it was imperative that these assets were safeguarded against future damage with the use of a high-performance coating.

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Figure 1. High-performance coating required to protect tanks against corrosion

Production of Biopolymer from Shellfish Shell Byproduct

CuanTec has created a circular economic business model designed to mitigate the carbon footprint created from the unnecessary disposal of unused shell within the shellfish industry and converting it into valuable chitosan products.

Indeed, the carbon footprint of food waste is staggering. According to data from the UN, food waste contributes to 8% of global greenhouse gas emissions. This means that if food waste was a country, it would be the third-largest emitting country in the world.

At COP28, negotiators from 200 Parties agreed on the science from the Intergovernmental Panel on Climate Change (IPCC) that global greenhouse gas emissions need to ‘be reduced by 43% by 2030’, in order to limit warming to 1.5°C (2.7°F) by 2050, in line with the Paris Agreement. With this in mind, circular business models such as that offered by CuanTec, play an important role in mitigating carbon footprints and limiting global warming to 1.5°C (2.7°F).

Safeguarding Key Assets

Considering the important role businesses such as CuanTec play in this decarbonisation and upcycling journey, it is absolutely fundamental that key assets within these types of businesses, such as machinery, equipment, buildings and structures, are safeguarded to an excellent standard. Otherwise, damage and wear can jeopardise the integrity of assets, and therefore this can undermine the environmental benefits these types of business models offer.

For example, the carbon footprint of steel is phenomenal: for every tonne of steel produced, nearly double the amount of carbon dioxide (CO2) is released back into the atmosphere. Therefore, if a steel asset becomes damaged, not only can this lead to costly replacement fees, but this process can also incur a hefty carbon footprint as well.

As such, numerous industries invest in industrial repair composites and high-performance coatings in order to bypass this replacement process. In this way, polymeric technology mirrors the circular economic model of businesses like CuanTec, as this technology can repair, protect and even intrinsically improve assets that would otherwise be decommissioned and sent to landfill. Thus, it could be argued that polymeric technology has a critical part to play in the decarbonisation of multiple sectors, supporting a net zero by 2050 pathway.  

Pre-Used Tanks in Need of Rigorous Corrosion Mitigation Measures  

CuanTec wanted to deploy three steel tanks in their process of turning shellfish shell into high quality, traceable chitosan products, made to the exacting technical specifications of their customers. The tanks had already been in use elsewhere, but were otherwise still in good condition. In order to ensure the tanks were capable of withstanding the harsh chemicals they would come into contact with, the Customer decided to invest in some polymeric technology to protect them.

System Specification: High Performance Coating, Belzona 1391T

Following an inspection from Clive Leadbitter, Senior Field Sales Engineer at authorised Belzona Distributorship, Belzona UK, the high-performance coating, Belzona 1391T, was specified. As this system is capable of protecting assets against corrosion in extremely aggressive and acidic environments, this was the ideal solution for the steel substrate for this specific application.

In addition, as Belzona 1391T can be applied in situ without the need for hot work, this would ensure that the application was carried out as quickly as possible, whilst minimising the health and safety risks that can arise when hot work is involved.

Belzona 1391T has undergone direct food contact (FDA) testing, the results can be found here.

 

 

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Figure 2. Tank used in process of creating biopolymer, chitosan

Application Procedure

Commenting on the application procedure, Clive said: “Surface preparation was carried out by grit-blasting. Following this, using a stiff-bristled brush, two coats of Belzona 1391T were applied at a thickness of 450 µm (17.72 mil) per coat. Once the application had cured within the space of 24 hours, the application was complete.”

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Figure 3. Application of high-performance coating, Belzona 1391T

Polymeric Technology Supports Net Zero by 2050 Pathway

Considering the important role businesses like CuanTec play in carbon mitigation, it is absolutely critical that key assets are protected for the long term against damage such as erosion and corrosion. As such, polymeric technology plays an important part in safeguarding these assets, and therefore contributing to the net zero by 2050 pathway.  

www.belzona.co.uk

 

 

Belzona 5811DW2 (DW Immersion Grade) Approved by Flour Mill for Dry Food Contact

Introduction:

In the pursuit of maintaining high standards of safety in the food and drink Industry Belzona is constantly seeking innovative solutions to address challenges related to equipment maintenance and corrosion protection. Recently, after undergoing rigorous tests to ensure its suitability for dry food contact, a breakthrough has been achieved with the successful application of Belzona 5811DW2 (DW Immersion Grade), a cutting-edge protection system, in a Flour Mill in Belgium.

Understanding the Need for Food-Safe Coatings:

The food and drink industry is bound by strict regulations and guidelines to ensure the safety and quality of products. Food comes into contact with many materials and articles during its production, processing, storage, preparation and serving, before its eventual consumption. The European Food Safety Authority state that Food Contact Materials (FCMs) should be sufficiently inert so that their constituents neither adversely affect consumer health nor influence the quality of the food.

Flour mills, being a crucial part of the food supply chain, must adhere to these standards. Equipment used in the milling process, such as storage tanks, hoppers, chutes, and conveyors, is prone to wear, corrosion, and degradation over time. Traditional coating solutions often fall short in providing a long-lasting, food-safe barrier.

What is the EU Food Regulation 10 2011?

EU food contact legislation covers the general rules applicable to all materials and articles intended to come into contact with foodstuffs (Regulation (EC) No. 1935/2004). For specific materials such as plastics, more detailed legislation has been additionally in place for several years.

Regulation (EU) 10/2011 sets out safety requirements for plastic materials and articles intended to co­­­­me into contact with food. This regulation is a specific measure for plastic food contact materials as mentioned in the European Framework Regulation (EU) 1935/2004.

This Regulation applies not only to plastics food contact packaging but to equipment such as food storage tanks, pipes, pumps, containers, conveyer belts, etc.

Belzona 5811DWII (DW Immersion Grade) Approved for use on Large Storage Tank at a Flour Mill

Belzona 5811DW2 (DW Immersion Grade) is a solvent-free coating initially designed for the protection of surfaces operating under potable water immersion or where potable water approval is required.

Reacting to customer demand, Belzona Distributor; Perspect Benelux recently invested in comprehensive testing to evaluate the coating’s suitability for contact with dry foodstuffs.

Their customer, a large Mill in Belgium who specialise in the production and development of physically treated wheat flour and mixes used as cake flour, sought a coating suitable for contact with flour which would provide long term corrosion protection. Building on the success of achieving WRAS approval for contact with drinking water, Belzona 5811DW2 (DW Immersion Grade) was put forward as a possible solution.

Comprehensive Testing:

Confident in the performance of the Belzona, Perspect Benelux opted to have Belzona 5811DW2 (DW Immersion Grade) tested by the Belgian packaging institute; IBE-BVI, who are an accredited independent laboratory according to ISO 17025, recognised throughout Europe. Their results confirmed the coating’s compliance with specific requirements of European Regulations No. 1935/2004 and No 10/2011 for prolonged contact with dry foodstuffs.

Perspect Benelux was able to provide tailored support to the customer, in collaboration with Belzona, by providing sufficient data and evidence to satisfy the customer that Belzona 5811DW2 (DW Immersion Grade) is safe and suitable for their specific needs and service conditions.

The positive results were recognised on completion of the project, by the FAVV (Federal Agency for the Safety of the Food Chain) who confirmed application was completed according to the approved method, using Belzona 5811DW2 (DW Immersion Grade).

The unique formulation of this Belzona coating not only ensures compliance with food safety regulations but also offers outstanding protection against corrosion and abrasion. It has been certified as non-leaching, with no harmful emissions or influences on dry food products and flour based on this customer’s specification.

This future-proof coating was also found to conform to the maximum limits of mineral oil aromatic hydrocarbons (MOAH), mineral oil saturated hydrocarbons (MOSH) and Polyolefin oligomeric saturated hydrocarbons (POSH).

The likelihood of these guidelines becoming a requirement in the near future is significant due to the new EU Food standards coming in place.

The results of the tests were not only promising but exceeded expectations, leading to the green light for the application to the internals of a 6000 sq. metres (7175.94 sq. yards) in total flour storage tank of 30 tanks.

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Original tank substate

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Due to the age of the installation, the original lining was blistering and there was a risk it could contaminate the product to be stored in the tanks. In order for the customer to re-use these old, out of service tanks, a new lining was required. Other linings were tested, however Belzona 5811DW2 (DW Immersion Grade) was the only one approved by the QA-QC department. The alternative would have been to build a new silo complex which would have been extremely expensive.

Application Process:

The application of Belzona 5811DW2 (DW Immersion Grade) in the Flour Mill followed a meticulous process to ensure long-lasting protection. The steel surfaces of the tank to be coated were prepared, cleaned, and blasted to the recommended standard of cleanliness, Swedish Standard Sa 2½, SSPC-SP10 (Near-White Metal) with a minimum profile of 3 mils (75 microns). Two coats were then applied by airless spray in cream, to a Dry Film Thickness of 400µm (15.75 mil).

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Blasted surfaces  
 
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   Completed application of Belzona 5811DW2 (DW Immersion Grade)
 

Benefits of Belzona 5811DW2 (DW Immersion Grade) in Flour Mills:

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Coated tank internals

Tested in Accordance with Parts of the Food Safety Regulations: Belzona 5811DW2 (DW Immersion Grade) meets some of the stringent requirements for materials in contact with dry foodstuffs, providing a reliable solution for compliance with regulatory standards.

Extended Equipment Lifespan: The robust nature of the lining enhances the durability of equipment, reducing the frequency of maintenance and replacement.

Solvent-Free Formulation:  The lining’s solvent-free formulation means it is not only food-safe but also environmentally friendly. This characteristic aligns with the Belzona’s commitment to sustainable practices, prioritising the safety of both workers and the surrounding environment.

Corrosion Resistance:  Belzona 5811DW2 (DW Immersion Grade) acts as a barrier against corrosion, preventing the degradation of equipment and maintaining equipment integrity.

Improved Operational Efficiency: With reduced downtime for maintenance, flour mills can operate more efficiently, contributing to increased productivity and cost savings.

Future Potential for Food Manufactures:

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The successful lining of ten tanks (to date) with Belzona 5811DW2 (DW Immersion Grade) in this Flour Mill highlights the potential of this innovative lining being adopted into the maintenance practices of food manufacturers across Europe. As industries evolve, the implementation of such advanced solutions will become pivotal in ensuring a reliable and sustainable food supply chain.

 

How Can Polymeric Solutions Support a More Sustainable Marine Industry?

The marine industry plays an essential role in steering the course of global commerce the total value of the annual world shipping trade has reached more than $14 trillion (US dollars). According to the United Nations (UN), a staggering 90% of everything we consume is transported by sea. Given the colossal size of the marine industry, it is essential to implement a range of strategies to enhance its sustainability. For example, it is imperative to discover a more sustainable fuel source, and finding solutions that enhance energy efficiency will be crucial.

Of these strategies, advanced coatings and repair composites play a significant role, offering not only the promise of efficiency gains and cost savings but also a seamless alignment with the broader goals of the Blue Economy. The UN iterates that the Blue Economy should “promote economic growth [...], while at the same time ensuring environmental sustainability of the oceans and coastal areas”. By simultaneously reducing costs and fortifying assets, these solutions, such as those produced by Belzona, echo these Blue Economy principles, steering the marine industry towards a more sustainable future.

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Boats new and old repaired and protected with Belzona

What is the Environmental Impact of the Marine Industry?

Climate Action Tracker reports that the maritime sector presently accounts for about 3% of all global greenhouse gas (GHG) emissions. If left unregulated, projections suggest that this figure could surge to 17% by 2050. Thus, there is a pressing need for measures to curb and limit this escalation. Surprisingly, Brazil, the 5th largest country in the world, emits just 2.44%, underscoring the maritime sector's outsized role in global emissions.

To contextualise this further, marine transportation far surpasses both the carbon and total greenhouse gas emissions of international aviation. While aviation, a major emitter, contributes about 600 million tonnes of CO2 (MtCO2) per year, marine transport creates a huge 940 MtCO2 annually. Notably, the maritime industry also emits more than twice the amount of total greenhouse gas.

These statistics reveal the mammoth role of shipping in global emissions compared to other industries. Comprehensive measures are urgently needed to address and mitigate the environmental impact of the marine industry in the pursuit of sustainable practices.

What Strategies Are Being Implemented to Address This?

In recent years, a number of new regulations have been created to reduce and prevent air pollution created by shipping. For example, Annex VI of the MARPOL treaty, set in place by the International Maritime Organization's (IMO) limits the sulphur content of marine fuels and regulates emissions of NOx. 

A chapter of this treaty added in 2011 targets operational energy efficiency measures with the goal of diminishing greenhouse gas emissions. There is a growing emphasis on adopting cleaner alternative fuels, improving energy efficiency, and hull design modifications, to reduce the carbon footprint of the industry. In addition, steps are now being taken to minimise the impact of heavy shipping on sea life. Let's take a look at some of these strategies in more detail:

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Efficiency restored with Belzona for bow thruster of private yacht

The Marine Fuel Dilemma

In the pursuit of environmentally sustainable alternatives to Heavy Fuel Oil (HFO) and Marine Gas Oil (MGO), various options, such as LNG, hydrogen, ammonia and methanol, have been explored - each with its own set of challenges.

Liquefied Natural Gas (LNG) has grown in popularity in recent years; however, it is not a viable alternative as switching to LNG would not create a reduction in total GHG emissions. Although LNG has a lower carbon content, it raises methane emissions, which are 80 times more potent than CO2. In fact, the International Council on Clean Transportation (ICCT), asserts that using LNG as a marine fuel emits over 120% more life cycle GHG emissions than MGO. It therefore must be acknowledged that LNG, despite its lower carbon content, remains a high-emission fossil fuel and falls short as a sustainable alternative.

Sustainably produced hydrogen, ammonia and methanol, when produced from renewable sources, are all good sustainable options but face challenges in availability, storage and flashpoint. For example, Hydrogen encounters storage challenges due to volume. Furthermore, most hydrogen produced today is grey hydrogen (not produced sustainably). If enough green hydrogen could be produced and stored it would make a great sustainable alternative. Ammonia boasts easier storage characteristics but would also need to be produced in a carbon-neutral manner and has a low flash point. Provided a sufficient quantity could be produced, green hydrogen, green ammonia or green methanol offer sustainable options. As the industry grapples with the marine fuel dilemma, it becomes evident that more work is required to find a truly sustainable solution to this complex problem.

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Historical and projected transport demand and GHG emissions from international Shipping| Source: UNEP, World Bank

Marine Cavitation

Thinking beyond greenhouse gas, the blue economy faces a host of other environmental concerns, including underwater noise pollution. Propeller cavitation leads to excess fuel consumption and can generate as much as 180 decibels of underwater radiated noise (URN) which can be heard by marine life over 100 miles away.

Propeller-induced cavitation is the formation and rapid collapse of bubbles, and this is the main source of underwater sound produced by ships. In fact, the propellor is responsible for about 80% of a ship's URN. The EU has already put in place thresholds to cut down on underwater noise and the IMO issued guidelines last year too. The UN has 17 Sustainable Development Goals and Goal 14, Life Below Water addresses the need to protect marine life. A recent study by the University of Victoria showed how beluga whales avoid marine noise even when many miles away as it masks their vocalisations. This can lead to chronic stress and the animals being displaced from their habitat. Reducing underwater noise footprint will help with species conservation.

Cavitation damage also reduces the propulsion efficiency of a propeller, incurring economic loss due to excessive fuel consumption and the requirements of frequent maintenance. It is clear then a long-term solution for propellor cavitation is required.

Case Study

One solution to reduce propellor cavitation, is to repair and protect cavitated propellers with Belzona. In the example below, Belzona 1111 (Super Metal) was used to build up the worst affected areas and then Belzona 1341 (Supermetalglide) was brush applied to provide overall protection. The customer opted for this solution after the failure of welding and inferior coatings. In a study carried out by Leeds University, it was found that Belzona 1341 (Supermetalglide) was fifteen times smoother than polished stainless steel, making it ideal for reducing resistance and noise as well as increasing efficiency. The port now has the confidence to inspect on a less frequent basis meaning the vessel can survey the river for longer periods, saving time and money in a dry dock.

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After 10 years of service the hull of the vessel was suffering from cavitation around the propellor area. 

Engine Chocking

As well as repairing and protecting propellors from cavitation, engine chocking to reduce vibrations is key for noise reduction and safety. The essential role of engine chocks is to ensure the proper alignment and stabilisation of ship engines, promoting overall operational reliability.

This is crucial as, left unaddressed, loose bolts can lead to heavy engine vibration, misalignment, bearing damage, and even crankcase explosion. Vibrations may also loosen torque on foundation bolts in crucial components like main engines, turbines, diesel-electric drives, gearboxes, and thrust blocks. Furthermore, if an engine is misaligned or chocks are incorrectly fitted, the overall life span is reduced, and replacement is costly from both an environmental and financial perspective.

Historically, metal has often been used for chocking, however, polymeric resin chocks prove to be a superior alternative. Compounds such as Belzona 7111 (Marine Grade), provide precise alignment with non-shrinking properties and, high impact and high compressive strength, saving time and manpower compared to conventional methods. Specifically designed to endure the physical and thermal shock common to marine environments. This makes it ideal for pouring foundations of heavy ship propulsion systems and other heavy equipment where alignment, and anchorage are essential.

Approved by the American Bureau of Shipping and Lloyd’s Register Classification, Belzona 7111 (Marine Grade) assures lasting alignment and durability, underscoring its excellence in ensuring safety and longevity in maritime applications. Minimising marine noise and extending asset life through solutions, such as those offered by Belzona, are effective and cost-efficient methods for reducing the negative impacts of shipping.

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Belzona 7111 (Marine Grade) used to realign the main engine on a fishing boat with 500 tons of storage

Conclusion

A plethora of strategies will be necessary to achieve sustainable shipping. The quest for a sustainable fuel alternative, reducing underwater noise pollution, increasing efficiency, and the revolutionary use of coatings and composites are all integral strategies. Advanced polymeric solutions such as those produced by Belzona not only address critical issues such as cavitation and engine chocking but also offer a unique opportunity to revolutionise the industry. By simultaneously reducing capital expenditure, maintenance time and greenhouse gas emissions, these innovations play a pivotal role in steering the maritime sector towards a more sustainable and efficient future.

Using coatings and composites can revolutionise the maritime industry by simultaneously reducing capital expenditure and greenhouse gas emissions. Prioritising for the sake of the Blue Economy will propel the maritime industry into an era of environmental responsibility and economic resilience. Embracing these transformative solutions becomes not only a strategic imperative for the maritime industry but also a key enabler in realizing the holistic vision of a thriving Blue Economy that balances prosperity with responsible resource management.

Want to learn more about Belzona in the marine industry?

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