New materials solve the problems of corrosion and dust accumulation in fans in the petrochemical industry on-site

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Note: The anti-corrosion and dust accumulation prevention techniques for the fans mentioned below utilize two different new types of materials in their on-site application. To ensure effective protection for the fans as a whole, it is necessary to develop a reasonable and effective treatment plan based on the specific conditions at the site, and to select appropriate repair materials; this will guarantee the desired results. The brand names of these materials are not disclosed for now. Those who wish to know more details should consult me. I. Corrosion prevention technologies for fans in the petrochemical industry. Traditional methods for addressing corrosion issues in fans used in the petrochemical industry include applying anti-corrosive coatings or carrying out on-site welding; however, both of these methods have their own drawbacks: Coatings such as Teflon typically require installation by specialized manufacturers, resulting in high costs for transportation and maintenance, as well as longer construction times ； In the case where on-site conditions do not permit balancing tests for repair, or when it is not possible to replace the impeller with a new one, patch welding can only be used to repair the severely corroded areas. To address the corrosion issue of fans, they can be protected with coatings on-site using new polymer composite materials. This material is a solvent-free composite with a high degree of cross-linking, composed of high-performance nanomaterials and high-performance resins. It exhibits excellent resistance to high temperatures and sudden temperature changes, is resistant to impact and wear, and has outstanding corrosion resistance. This product can be used for on-site construction and is widely applied in various harsh environments such as high temperatures, strong acids and alkalis, and solvent corrosion. Using polymer materials as anti-corrosion coatings can significantly reduce the repair time and lower the labor intensity. Their excellent performance and low cost enable companies to effectively control maintenance expenses. Description of fan anti-corrosion process: 1. The bonding surface is roughened using methods such as shot blasting or sandblasting for surface treatment ； Remove residual substances from the surfaces to be bonded using methods such as sweeping, blowing, and sucking ； Thoroughly clean the grease from the bonding surface using anhydrous ethanol (analytical grade) ； The surfaces to be bonded must be dry, clean, oil-free, and rough. 2. Ratio and mixing: Most of these polymer composites are two-component products, and the resin and curing agent must be mixed in strict accordance with the volume ratio specified in the product instructions. After mixing evenly, it should be spread out thinly to allow heat to dissipate, and used promptly ； To avoid waste, materials should be prepared according to the required amount and used up within the specified shelf life. 3. The coated mixture can be applied directly to the surfaces to be bonded using a spatula, brush, or other tools; it can also be applied by compression ； 4. The temperature used as a reference for the curing time of this product is 24°C. For every 11°C increase in material temperature, the curing time is reduced by half. The ambient temperature and the temperature of the surfaces to be bonded also affect the curing time. 5. Safety requirements: It is necessary to strictly adhere to the company’s safety regulations, wear protective equipment as required, and maintain a sufficient safe distance from live electrical parts ； After construction, inspect and clean the site to eliminate all potential hazards that could cause accidents. On-site photos: II. Comprehensive solution for preventing dust accumulation in fans When the dust accumulation on the fan impellers reaches a certain level, it is necessary to clean off this dust. Common cleaning methods include manual mechanical cleaning and high-pressure water flushing. Regardless of the method used, most of them are merely temporary solutions that do not improve the accumulation of dust at all. The impeller anti-dust coating is a completely new maintenance approach that has gained recognition internationally in recent years. The principle is to apply a wear-resistant and anti-sticking coating on the surface of the impeller, which can effectively delay the formation of dust accumulation and extend the interval between equipment maintenance by a factor of ten or even more. The G-2 non-stick coating utilizes advanced German industrial technology for non-stick coatings. Its anti-sticking system is a two-layer protection system based on bonded nanoparticles, comprising a primer with anti-erosion properties and the actual non-stick coating, which prevents dust and other dry particulate materials from adhering to flue gas management equipment and devices, as well as to devices used for storing and guiding particulate materials. This coating is a non-stick coating with friction properties, and can be used in low-temperature applications in industrial processes up to 250°C. This product is a two-layer water-based coating (primer layer and functional non-stick coating) that takes 12 to 24 hours to harden at room temperature. This non-stick coating improves the fluidity of dust media, thereby preventing the adhesion of powder and dust. Its tribological properties enhance the frictional characteristics of the separator, thus avoiding the adhesion of dust media. Some slight adhesion may remain, which needs to be removed through gentle cleaning (using an air blowgun). This coating also serves a protective function, preventing corrosion of the substrate. Steps for applying the dust-resistant coating to fans: 1. First, conduct a dynamic balance test on the impeller to ensure it meets the operational requirements ； 2. Surface sandblasting treatment, with no dead corners allowed. The surface should be clean, free of grease, oxide layers, and dust; any residual substances on the surface can affect the adhesion of the coating. The sandblasting standard meets grade SA 2.5 or Ra 0.2~0.3 ； 3. Ensure that the construction area is free of dust during the application and curing processes. Construction environment temperature >15℃/60℉ ； Low humidity and good ventilation are required (to accelerate curing) ； 4. Connect the air supply; the pressure of the paint spray gun should be 2.0~3.0 bar (30~45 psi) ； Airless spraying pressure: 150–200 bar (2000–3000 psi) ； 5. Mix the primer material using a mixer; stir it thoroughly for 5–10 minutes before use ； 6. Adjust the spray gun. The nozzle for paint spray guns is 1.0~1.4 mm, while the nozzle for airless spraying is 0.3~0.4 mm. Ensure the spray gun produces a fine mist; a higher flow rate does not help. 7. The coating thickness of the G2 primer should be no less than 30–40 μm, with a maximum of 60 μm. Please note that the thickness of the coating can be achieved by applying multiple coats, but the total thickness must not exceed the recommended value. If the metal surface of the fan is very rough, a slightly larger amount can be sprayed to smooth it out. Please also pay attention to the operating procedures during application; in any case, avoid applying too much coating in a small area at once, to prevent the coated surface from tearing ； 8. Before applying the second topcoat, allow it to cure at room temperature for 2 hours to dry the surface of the primer ； 9. Apply the G2 topcoat in the same way as the primer (as mentioned above), and evenly cover the surface with the primer material. The thickness of the topcoat layer should be no less than 40–80 μm, with a maximum of 100 μm. Just like with the application of the primer, the coating layer is very thin, and ultimately the entire surface is covered ； After 10 to 12 hours, once it has cured, use a thickness gauge to measure the coating thickness ； 11. Polish the cured surface with a clean cotton cloth. Polishing is necessary to achieve a smooth surface. A smooth coating surface ensures non-stick properties ； 12. Conduct a dynamic balance test again; any defective areas can be repaired using appropriate material. On-site application photos