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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.

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 5^th 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:

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.

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.

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.

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.

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At a major global blue-chip nickel Mine in Australia, authorised Belzona Distributor, Rezitech, provided a full turnkey solution to combat corrosion under insulation on an ammonium sulphate feed tank. Within the space of 24 hours, the 9.5 metre (31.2 ft) diameter tank (with a height of 2 metres (6.6 ft) from ground level) was repaired and protected against future corrosion with the industrial composite wrap system, Belzona SuperWrap II.

Figure 1. Composite wrap system curbs corrosion under insulation at nickel mine

Protective Coatings and Epoxy Repair Systems Support Transition to Net Zero

The Mine refines granulated nickel matte from their smelter into premium-grade nickel powder and briquettes containing 99.8% nickel. Nickel powder is further processed into nickel sulphate at a Refinery in Australia. Nickel sulphate is an essential ingredient in the lithium-ion batteries that drive electric vehicles (EVs). It could be argued that the increase in sales of EVs is one of the biggest climate wins of 2023. Indeed, according to the 2023 Report from Climate Action Tracker, of the 42 sectors which need

o achieve net zero status by 2050, the only sector which is on track is the share of EVs in lightduty vehicle sales. Considering how road transport currently accounts for 11% of global greenhouse gas emissions, EVs play a vital role in reducing these emissions.

As such, the polymeric technology required to repair and improve assets within the EV industry equally plays a vital role in supporting the transition to net zero. By repairing damaged assets instead of decommissioning and sending them to landfill, this significantly reduces the climate impact that would otherwise be incurred in this process.

Case Study: Feed Tank Suffering from Corrosion Under Insulation & SCC

The Customer’s stainless steel feed tank was suffering from corrosion under insulation and chloride induced stress corrosion cracking. They required a solution that would not only restore the integrity on the substrate, but also protect the asset against future corrosion damage. Not only this, but as the tank operates at elevated temperatures of approximately 70°C (158°F) and processes highly corrosive medium, the repair solution would need to be able to withstand these harsh conditions.

Figure 2. Tank Contents

Rezitech Specifies Belzona Composite Wrap Solution

Having worked with Rezitech over the course of five years, the Customer had complete confidence in the range of Belzona metal epoxy repair composites and industrial repair coatings the Distributorship offers. As such, they decided to contact them again for their advice and system recommendation

Following an inspection by Heath Westell, Sales Engineer at Rezitech, the composite wrap system, Belzona SuperWrap II, was specified.

Commenting on this specification, Heath said: “This composite wrap system is comprised of a fluid-grade resin system, a bespoke hybrid reinforcement sheet, based on fibre glass and carbon fibre, as well as a release film to compact and consolidate the application. The system is specially formulated to restore the strength of holed, weakened and corroded pipe and tank walls, making it the ideal solution for protecting the asset against corrosion under insulation for the long term. In addition, thanks to the cold-curing properties of the composite wrap system, this mitigates the need for hot work, making it a reliable alternative to welding.” 

Application Procedure:

Firstly, all traces of oil and grease contamination were removed using a suitable Rezitech Degreaser. Following this, the surfaces were grit-blasted to provide a surface cleanliness compliant with ISO 8501-1 SA 2½ (ASNZ 1627.4 class 2.5) with a minimum 75 µm (3 mil) rough angular profile.

Once the surface was prepared, the Belzona 9381 reinforcement sheet was measured out and then wetted out with the Belzona resin system. The resin was then systematically applied to the areas to be repaired. Following this, the Belzona reinforcement sheets were then applied to the tank in three layers. The compression film was then added to the top of the application area. Next, using a roller, the Belzona SuperWrap II composite wrap system was then spread, rolled and compressed to the surface of the tank. The system was then left to cure for approximately eight hours.

Figure 3. Stainless steel feed tank repaired and protected with Belzona SuperWrap II

Bypass the Need for Replacement with Polymeric Technology

By investing in the Belzona composite wrap solution, this enabled the Customer to successfully bypass the need to replace the corroded asset, and instead prolong the lifespan of the asset for years to come. Thus, this enabled the Customer to make significant savings in both time and money. In addition, given the important role EVs play in reducing global carbon emissions, it could be argued that polymeric technology also plays a fundamental role in supporting this transition by safeguarding the integrity of key assets within this industry.

Figure 4. Mitigate the need for replacement with polymeric technology

About Rezitech: Established in 1968, Rezitech is the sole Australian Distributor for Belzona. Rezitech offers a comprehensive range of industrial protective coatings and epoxy metal repair composites to many different industries including: oil and gas, mining, power and facilities maintenance, amongst others. For more information, please visit: www.rezitech.com.au/products/belzona

A focus on safety can expand work opportunities and open up a contractor to new and innovative business areas. KM Group, a prominent civil engineering contractor based across Wales and the South West of England, has carved a niche for itself in the industry through its specialisation in multi-utility mains installation, repair, and maintenance. Renowned for its commitment to safe working practices and ethical operations, KM Group partly puts its success down to its longstanding partnership with the supply chain risk management experts, Veriforce CHAS. 

In this case study, Murray Ambler-Shattock, Group Strategic Operations Manager at K M Group, explains how working with Veriforce CHAS has helped KM Group enhance its industry presence. He also discusses their shared objective to enhance safety and efficiency in the civil engineering sector, including through investment in the very latest technology.

CHAS accreditation and market access 

For several years, KM Group has been a proud partner of Veriforce CHAS, which has helped us to showcase our commitment to being a responsible and reliable contractor and enabled us to work with major contractors in our sector. Being accredited to CHAS Elite – which includes the Common Assessment Standard – shows we adhere to high standards across a wide range of risk areas, from health and safety to environmental management to equality, diversity, and inclusion. It also gives us a tool to set standards for our supply chain, so the contractors we work with are typically accredited to CHAS Standard or CHAS Advanced. Like Veriforce CHAS, at KM Group we are strong advocates of the Common Assessment Standard and its potential to improve efficiency and risk management standards in the construction sector. Veriforce CHAS was the first accreditation body to offer the assessment, and we were one of the first companies to complete it.

Accreditation isn't complicated - it's the golden ticket

Achieving accreditation is not a daunting task but a demonstration of our efficient business systems. In our experience, many organisations unknowingly already possess these systems in some form, and accreditation merely involves certifying their functionality.

Veriforce CHAS has been instrumental in conveying this message to our supply chain and supporting our contractors on their accreditation journey. This support is particularly beneficial for our smaller contractors, as CHAS Standard provides an entry-level accreditation that forms a solid foundation for future growth.

We view accreditation as the golden ticket, enabling business expansion and fostering collaboration with reputable employers. It establishes credibility and opens doors to valuable opportunities.

Raising industry standards 

Veriforce CHAS collaborates with clients like us to enhance overall compliance within supply chains. As contractors within our supply chains embark on their accreditation journey, they often aspire to achieve higher levels of accreditation, making them more appealing partners. This increased accreditation assures supply chain partners that these contractors are responsible businesses with effective risk management systems. This helps to raise standards overall and positively impacts the entire sector, creating a more conducive working environment for everyone involved.

Furthermore, there is a substantial effort through the Common Assessment Standard to enhance efficiency. This initiative aims to streamline the accreditation process, eliminating the need for contractors to undergo multiple assessments. Once contractors have completed the Common Assessment Standard through CHAS Elite, their certification becomes accessible through any of the accreditation providers, opening up even more opportunities for them. 

Innovation in utility infrastructure

In recent years, KM Group has embarked on a journey of innovation by investing in Vacuum Excavation, a revolutionary technique transforming the Construction, Utility Infrastructure, and Civil Engineering sectors. This non-destructive digging method uses compressed air and a high-powered vacuum to excavate soil and materials gently. This is safer for operators and avoids the classic challenge of damaging pipes and cables, which can be extremely dangerous, as well as both costly and disruptive to a project. KM Group's adoption of vacuum extraction aligns with the industry trend of adhering to PAS 128 standards, significantly improving utility detection accuracy in the UK.

Pioneering vacuum excavation

KM Plant Hire & Groundworks Ltd, a subsidiary of KM Group, stands out as a leader in innovation within the Utilities Sector. Successfully implementing Vacuum Extraction in various locations, we have been championing safety, efficiency, and reliability in utility detection processes. This forward-thinking approach provides exceptional value to clients and positions KM Group as a pioneer in adopting innovative practices for safer and more efficient operations.

Conclusion

The journey of KM Group serves as a compelling case study in how strategic partnerships, such as our relationship with Veriforce CHAS, can propel a company to new heights. Through accreditation, KM Group has not only gained access to major industry projects but also uncovered hidden efficiencies within our operations. The adoption of Vacuum Excavation further solidifies our commitment to innovation and safety, and we believe it establishes us as a trailblazer in the ever-evolving landscape of utility infrastructure.

Find out more at: http://www.chas.co.uk/ or call 0345 521 9111.

https://km-group.co.uk or call 01633 415321 

Figure 1. US’ first zero emissions, all-electric tugboat, the eWolf

In order to keep the planet on track for achieving net zero carbon emissions by 2050, at COP28, negotiators from 200 Parties agreed on the science from the Intergovernmental Panel on Climate Change (IPCC) that: ‘[…] limiting warming to around 1.5°C (2.7°F) requires global greenhouse gas emissions to peak before 2025 at the latest, and be reduced by 43% by 2030.’

Figure 2. Image: IREANA

Prior to COP28, in July 2023, the UN agency, the International Maritime Organisation (IMO), considerably vamped up its strategy on the reduction of greenhouse gas emissions from ocean freight. The Organisation’s revised targets aim to reduce carbon emissions from international shipping by 40% by 2030, and to achieve net zero by 2050, based on 2008 levels.

The Maritime Industry’s ‘Most Important Mitigation Measure’

One of the fundamental ways in which this sector can achieve this is through ‘scalable zero emission fuels’. According to a 2023 Report from one of the world-leading authorities on climate science, Climate Action Tracker: ‘To achieve full decarbonisation, the shipping sector will need to adopt alternative fuels, otherwise known as scalable zero emission fuels, to power vessels.’ The Report goes on to describe how: ‘This is the most important mitigation measure.’ Scalable zero emission fuels typically refer to hydrogen, ammonia, e-methanol and electric battery.

Considering the seismic reduction in global greenhouse gas emissions required by the maritime industry by 2030, advances in technology, such as the US’ first zero emissions, all-electric tugboat, the eWolf, is a huge step forwards in terms of decarbonising this sector.

The US’ First Zero Emissions, All-Electric Tugboat

Launched in 2023, the 25 metre (82 ft) eWolf is leading the way in terms of mitigating the

climate impact of the maritime sector. Over the first 10 years of its use, the operation of the new ‘eTug' will reduce 178 tons of nitrogen oxide (NOx), 2.5 tons of diesel particulate matter, and 3,100 metric tons of carbon dioxide (CO2), versus a conventional tugboat.

The eWolf is capable of speeds of up to 12 knots, and will be powered by a 6.2 megawatt-hour main propulsion battery and two electric motors. The electricity comes from a charging station that is part of a microgrid facility, equipped with two energy storage containers. Battery modules in each container have a storage capacity of nearly 1.5 megawatt-hours.

Bonding Solution Required for Front Fender

The front fender for the eWolf needed to be bonded together using a strong adhesive that would withstand pushing and pulling forces during the process of adhering the fender to the eTug. Having established confidence in Belzona technology from using their polymeric systems in previous applications, the Customer chose Belzona once again for the application.

System Specification: Elastomeric Primer and Polyurethane Resin

Following an inspection by Micah Heath, Technical Consultant at Belzona Distributorship, Belzona Alabama Belzona Alabama, the fast curing, one-part elastomeric primer, Belzona 2911 (Elastomer QD Conditioner), was specified. This conditioner is optimised for adhesion to a variety of substrates including rubber, as required for this particular application. For the bonding, the polyurethane resin, Belzona 2211, was specified. This flexible rubber repair material is optimised for applications where high build, durability and elasticity are required.

Application Procedure

Commenting on the application procedure, Micah said: “Once the required surface preparation was completed using grinding wheels and MBX Bristle Blaster, the conditioner, Belzona 2911 (Elastomer QD Conditioner), was applied. As soon as the conditioner was touch dry, Belzona 2211 was used to attach the plugs into the fender, and then attach the 3-part fender together. The application team used a manual cable puller to apply the necessary pressure to ensure the various surfaces were sufficiently pressed together. Once completed, the application was left for 36 hours to cure, achieving an excellent mechanical bond.”

 Figure 3. Fender plugs prior to attachment

Figure 4. Polyurethane resin, Belzona 2211, applied to prepared surface

Figure 5. Come-alongs used to hold the sections together during curing process

Policy is Key Driver in Roll-Out of Zero Emissions Technology

Over the past few years, numerous policies have been launched worldwide which have provided huge cash injections for technologies and industries that support the net zero by 2050 pathway. One of the world-leading policies is the US’ Inflation Reduction Act (IRA) Inflation Reduction Act (IRA) which includes $369 billion (US dollars) of investment.

According to the Climate Action Tracker, ‘[…] thanks to the passage of the IRA in the United States, companies are announcing hundreds of clean energy manufacturing facilities, turbocharging battery and electric vehicle production and creating tens of thousands of new jobs.’ A continued investment will continue to ‘[turbocharge]’ advancements in technologies such as the eWolf. In turn, technology like this will help the sector to achieve its decarbonisation targets.

Decarbonising the Marine Sector with Polymeric Technology

In addition to pioneering technology like the eTug, polymeric systems also play a key role in the decarbonisation of this sector. Belzona’s circular economic business model is grounded in the practice of repairing and improving damaged assets, rather than decommissioning and replacing them. Not only does this allow the asset owner to make considerable financial savings, but it also mitigates the carbon footprint incurred during the process of replacing damaged assets. In turn, this supports a net zero by 2050 pathway, in line with the Paris Agreement. Maritime Approvals In addition, Belzona systems are manufactured according to the ISO 9001 quality management systems and are approved by classification societies from all around the world including: Lloyd's Register, American Bureau of Shipping, Bureau Veritas, RINA Services, DNV, China Classification Society and the Korean Register of Shipping.

For more information, please visit: www.Belzona.com

For over 72 years, Belzona polymeric technology has helped numerous asset owners across a myriad of industries to not only make seismic financial savings, but this technology has also enabled them to considerably mitigate their carbon footprints as well. This latter benefit is particularly paramount when considering the drive towards a net-zero by 2050 future for the planet, as outlined in the Paris Agreement.

At the COP28 Summit, negotiators from nearly 200 Parties came together in Dubai with a decision on the world’s first Global Stocktake. The Stocktake recognises the science that indicates global greenhouse gas emissions need to ‘be cut by 43% by 2030 compared to 2019 levels, in order to limit global warming to 1.5°C (2.7°F).’

However, the Stocktake notes that Parties are off track when it comes to meeting their Paris Agreement goals. As such, the Stocktake has called on Parties to take actions towards achieving, on a global scale, a ‘tripling of renewable energy capacity and doubling energy efficiency improvements by 2030.’

The Belzona Solution: a Circular Economic Business Model

Amongst the ever-growing arsenal of carbon mitigation technologies and initiatives, industrial coatings and repair composites can help numerous industries to significantly reduce their carbon footprints, in line with Paris Agreement targets.


Figure 1. Established in 1952, Belzona is a global leader in polymeric technology

With a comprehensive range of polymeric systems such as epoxy repair composites, high-temperature coatings, liquid waterproof membranes, flexible roof coatings and pipe wraps, amongst others, these systems have been proven to not only repair and protect damaged assets across many different industries, but to also intrinsically improve them for the long term as well.

The environmental implications of this circular economic business model are astronomical. By bypassing the need to replace damaged assets and instead actively improving them, industries can make great strides in minimising their environmental impact.

In addition, by investing in these systems, this mitigates the fees that can accumulate in the process of asset replacement. These fees include: the cost of the asset being replaced, the labor required during the removal, disposal and installation process and also the downtime that can be incurred during this procedure. 

For these reasons, an increase in investment into these technologies would help many different industries in the process of ratchetting up their 2030 emissions reduction plans, in line with the net-zero emissions by 2050 scenario, in a way that is also financially advantageous.

Figure 2. Corroded and eroded pump repaired and protected with Belzona 1111 (Super Metal) and Belzona 5821

Conventional Protective Coatings Won’t Survive

At the core of Belzona technology is polymer chemistry. In the Company’s laboratories located in Harrogate, UK and Miami, US, the Company designs, formulates, and manufactures a comprehensive range of polymeric solutions. These systems enable their industrial customers to repair and protect assets that would otherwise be damaged by aggressive service conditions.

For example, slurries and strong chemicals cause abrasion and corrosion as they pass down pipes and through production equipment. Factors such as these as well as elevated temperatures mean that conventional protective coatings won’t survive. As such, companies must turn to a high-performance polymer technology to protect their assets to an appropriate standard.


Figure 3. Pipes in Oil Refinery coated with Belzona 1593

The Evolution of Belzona

The Company was established in 1952. The Founder, Jorgan Svendsen, was fascinated with the mechanisms of corrosion, and how to repair, protect and improve assets against corrosion damage. Initially utilising a flame-spray method to protect fire extinguishers against corrosion, the Business moved away from hot work applications and developed a pioneering cold-applied, zinc-rich corrosion protection technology. This technology could be applied to a variety of steel structures. It worked by creating a polymer-zinc barrier that would resist aggressive corrosion and also protect the integrity of the steel beneath it.

Following on from this, Belzona then developed a range of polymer coatings and repair pastes. The original being Belzona 1111 (Super Metal), which has since been widely replicated over the years. This system was specifically designed for the repair and rebuilding of assets, before then coating and protecting them against any future damage. Applied onto damaged or worn surfaces in thick layers, these Belzona 1000 Series metallic pastes allow the substrate to be reshaped and reformed back to its original profile. The paste then sets, almost like the steel itself, and gives the original asset a new lease of life.


Figure 4. Damaged ship caisson repaired and protected with Belzona 1111 (Super Metal), Belzona 1331 and Belzona 5811 (Immersion Grade)

Since then, Belzona has gone on to develop a range of high temperature immersion linings. These are widely used in the oil and gas industry on structures that are subjected to water, steam, oil, sand, and aggressive chemicals throughout their processing life. Belzona has also developed composite repair systems made from densely woven structural fabrics made from glass fiber or carbon fiber, that can be used to return strength and fortify compromised pipes or other structures.

Figure 5. Desulfurisation unit rebuilt with Belzona 1511 (Super HT-Metal) and protected with high-temperature lining, Belzona 1593

The Company has found the composite repair method to be a rapidly growing market. For that niche, Belzona developed a brand called Belzona SuperWrap, now known as Belzona SuperWrap II. This system is comprised of a fluid-grade resin system and a bespoke hybrid reinforcement sheet, based on fibre glass and carbon fibre. The major benefit of the Belzona SuperWrap II system is its ability to re-instate/restore strength to the original substrate.

When a steel pipe is damaged or corroded, through chemical attack for example, then it will ultimately lose strength and can even leak. This can mean that entire plants or facilities will be shut down for lengthy periods of time. This is clearly a major issue as it could result in millions of dollars being lost every day. In addition, this system can be applied as a composite patch, pad or plate, bringing increased rigidity, corrosion resistance and chemical resistance to the asset.

Figure 6. Pipe strength restored using Belzona SuperWrap II

Design, Develop, Manufacture

Belzona’s Chemists are involved at all stages, through design, development and manufacture. The Chemists work at the metaphorical drawing board, all the way through to supervising the first batch of a new polymer solution being made. As part of the development and manufacturing process, the Company focuses on sourcing materials that are commercially available, can provide the requisite performance, are of the highest quality, and which are as safe and sustainable as possible. By working with different chemical manufacturers, who create the building blocks of these solutions, the Chemists are able to apply their scientific knowledge and expertise, creating an easily appliable, safe, high-performance polymer product.

Testing is another key step in the development process. Belzona has fully equipped testing laboratories at their UK and US sites. These facilities allow the Company to study and characterise the performance of its products, and thereby optimise the formulations. Every solution undergoes an extensive programme of testing, the majority of which is carried out in-house. The testing is defined by the intended end-use for the product; for example, weathering testing for an exterior anti-corrosion coating or abrasion resistance testing for a slurry pump lining. It is Belzona’s investment in this testing capability which sets the Company apart from most competitors.

While the UK and US serve as the two core bases for Belzona’s global operations, the Company also has a global Network of 159 Distributors in over 120 countries. It also has corporate presences in the form of training and support centers in Thailand, Canada and China. Increasingly, Belzona is turning its attention to expanding its portfolio of sustainable solutions.


Figure 7. CEO, Barry Nisill, presenting Belzona solutions at Belzona’s Asia Pacific Office

Polymeric Solutions for a Sustainable Future

Repairing damaged assets instead of replacing them has always been fundamental to Belzona’s philosophy. This is encapsulated in the Company’s strapline ‘Polymeric Solutions for a Sustainable Future’. Originally, though, that philosophy was primarily driven by cost: it’s considerably cheaper to repair an asset than to buy a new one, so the asset owner can make significant financial savings.  

For example, over the course of several years, a Steel Fabricator in the UK’s East Coast managed to save millions of pounds by deploying polymeric repair and protection systems onto more than 2,000 metres of its gas pipeline. This included epoxy repair mortars and stainless-steel protective coatings.


Figure 8. Steel Fabricator saved millions of pounds thanks to Belzona technology

To this day, this philosophy of repair instead of replace remains. However, the need for industries to reduce their environmental impacts is more pressing now than ever before. As such, Belzona polymeric repair materials and protective coatings have an important part to play in supporting this net-zero journey. They can help to reduce the carbon footprint across many different industries such as (amongst others):

Petrochemical, Oil and Gas:
Belzona has a wide range of epoxy-based metal repair composites and high temperature coatings and linings which have been used in the petrochemical and oil and gas industries since the late 1970s. These materials are specifically designed to provide outstanding erosion and corrosion protection, as well as chemical resistance for equipment operating offshore and onshore at various pressures and temperatures.

Belzona systems can be applied in the following areas within the petrochemical and oil and gas industries (amongst others): internal and external of process vessels, pipework, cold bonding, splash zones, storage tanks and secondary containment areas, carbon capture, decommissioning, fenders and hoses, heat exchangers, seawater filters and separator vessels.

Figure 9. Flange protected against corrosion with flange encapsulation system, Belzona 3412

Marine:
Belzona's comprehensive range of cold-curing marine coatings and metal repair composites has been used by the marine industry for over 60 years. These products have been specifically designed to withstand harsh offshore conditions as well as provide exceptional resistance against erosion and corrosion.

Providing metal repair composites to shipyards around the world, long-term protection is proven by years of successful experience with ships and offshore structures. Manufactured according to the ISO 9001 quality management systems, Belzona materials are approved by classification societies from all around the world including: Lloyd's Register, American Bureau of Shipping, Bureau Veritas, RINA Services, DNV, China Classification Society and the Korean Register of Shipping.

Belzona systems can be applied in the following areas within the marine industry (amongst others): rudders, shafts, engines, shimming and chocking applications, rubber components, at sea repairs, storage tanks, exhausts, turbo blowers, stern tubes, auxiliary diesel engines, alternators/generators, tank cleaning systems, oily water separators, steering gears, pumps, heat exchangers, pipework, deck winches, lifeboats and access ladders.


Figure 10. Voith Schneider propulsion unit built up with Belzona 1311 (Ceramic R-Metal) before being overcoated with Belzona 1321 (Ceramic S-Metal)

Mining and Quarrying:
Belzona's wide range of polymeric metal and rubber repair composites and durable protective coatings and linings have been used in the mining and quarrying industry for decades. These materials are specifically designed to provide outstanding erosion, corrosion and abrasion protection, as well as chemical resistance, for equipment operating in highly aggressive environments.

Belzona systems can be applied in the following areas within the mining and quarrying industry: solids handling equipment, fluid and gas handling equipment, mechanical equipment, chocking and shimming applications and facilities maintenance.


Figure 11. Expansion joint repair at Coal Mine using combination of Belzona systems

Steel:
From rolling mills to blast furnaces, critical equipment in the steel industry is susceptible to abrasion, erosion, corrosion and chemical attack. Belzona’s range of metal repair composites, erosion corrosion resistant coatings and durable linings have been engineered to meet the aggressive demands of this industry.

Belzona systems can be applied in the following areas within the steel industry (amongst others): fluid and gas handling equipment, solids handling equipment, storage tank and secondary containment areas, shimming of worn equipment and facilities maintenance.


Figure 12. Tank and concrete saddles fortified with Belzona technology at Steel Production Site

Supporting Renewable Energy Industries  

Not only can Belzona technology help to mitigate the carbon footprint across multiple industries, but these polymeric systems can also safeguard valuable assets within the renewables sector. For example:

Wind:
For both onshore and offshore environments, Belzona solutions for the wind power sector can help to repair and protect assets from these problems, whilst simultaneously making wind farm maintenance procedures more efficient and less time-consuming.

Belzona systems can be applied in the following areas within the wind industry (amongst others): blade restoration and leading edge protection (LEP), nacelle and generating components, rebuild solutions for mechanical components, turbine base and tower, damaged concrete, corrosion resistant encapsulation systems, corrosion and erosion protection for splash zones, surface-tolerant solutions for transformer leaks.


Figure 13. Emergency repair of leaking transformer at Wind Farm with Belzona 1212

Hydropower:
Within the hydropower industry, polymer technology can offer a plethora of benefits including resistance to cavitation, excellent resistance to erosion and corrosion and efficiency enhancement.

Belzona systems can be applied in the following areas within the hydropower industry (amongst others): Francis turbines, Kaplan turbines, wicket gates, inlet valves, switchgears and turbine casings, pipework, penstocks, dams/spillways and facilities maintenance.

Figure 14. Corroded Francis turbine repaired with efficiency-enhancing coating, Belzona 1341 (Supermetalglide)

Biomass and Waste-to-Energy:
Belzona offers a wide range of epoxy-based repair composites and protective coatings to repair and protect biomass and waste-to-energy processing facilities and equipment from common problems occurring in the industry, including: abrasion, erosion, corrosion and chemical attack.

Belzona systems can be applied in the following areas within the biomass and waste-to-energy industry (amongst others): facilities maintenance, pipework, FGD units, chimneys and roofs.    

Range of Systems to Repair, Protect and Improve

For each of these industries and application areas, Belzona has designed high-performance solutions spanning across five product ranges:

Belzona 1000 Series - for the repair and protection of machinery and equipment.
Belzona 2000 Series - for abrasion resistant linings and the repair and protection of flexible components.
Belzona 3000 Series - waterproofing systems for the repair and protection of buildings and structures.
Belzona 4000 Series - for the repair and protection of concrete subject to abrasion, impact, and chemical attack.
Belzona 5000 Series - for protection from physical, chemical, or bacterial attack in a diverse range of environments.
Belzona 6000 Series - Zinc rich epoxy materials for corrosion protection to steelwork.
Belzona 7000 Series – for structural bonding, shimming and chocking.  

Sustainable Solutions

The focus on sustainability and conservation of the planet’s resources is informing much of Belzona’s future endeavors. For example, the Company has been supporting a UK-based Power Distribution Company and their customers whose assets are subject to SF₆ leaks in their transformers. SF₆ is described as the world’s worst greenhouse gas and is 23,500 times more potent than CO2.
 

In early 2022, Belzona created a tailor-made solution to stop leaks on a transformer owned by an electrical distribution operator. After several stages of prequalification, a trial repair was completed and has now been in service for several months. With Belzona’s support, the organisation is now achieving a 90-95% leak reduction rate, with an ambition to reach 100% in the near future.

The SF₆ project reflects an increasingly important mission being adopted by Belzona: creating products that solve industrial problems in a safe and sustainable way.


Figure 15. Belzona created a tailor-made solution to stop leaks on a transformer

Development of Products with High Levels of Renewable Carbon Content

Another important part of Belzona’s sustainability drive is its investigation into the efficacy of bio-based polymer solutions. One of the negative aspects of working with polymers is that the chemical building blocks used throughout the performance coatings sector are derived from oil - this means that an environmental impact is incurred.

However, Belzona has set out to address this challenge through its exploration and development of high-performance polymer solutions that use feed stocks derived from a renewable carbon source: plants. While bio-based chemicals have been available for low-performance solutions such as decorative paints for some time, the use of these types of chemicals has not previously been possible in the heavy industry market.

However, it is increasingly becoming apparent that chemical manufacturers are recognising the need for plant-derived polymers, in order to meet sustainability targets.

It is now possible to achieve very similar performance to oil-derived equivalents. Belzona is passionate about this ongoing change within the chemical industry. As a down-stream producer, the Company intends to work closely with manufacturers to encourage the adoption of more renewable-carbon solutions that don’t compromise on performance or quality.

Polymeric Systems: A Welcome Addition to the Arsenal of Carbon Mitigation Strategies

An increase in investment into industrial protective coatings and repair composites would help countries in the process of ratchetting up their 2030 emissions reduction plans, in order to achieve the net-zero emissions by 2050 target. Not only this, as discussed, these technologies are also instrumental in helping asset-owners across many different industries to make significant financial savings as well.

Indeed, Belzona recognises the critical role polymeric systems play in helping to support a more sustainable future for the planet in a way that is also financially advantageous. As such, they are committed to making ongoing investments into the development of polymeric systems that meet the ever-growing and changing demands of industries as they evolve towards a net-zero future.

About Belzona: Mission and Values

In April 2023, Belzona announced its new values – ‘Investment, Innovation, and Integrity’. These values are encapsulated in all five sectors of the Belzona philosophy - Corporate, Distributors, Consultants, Contractors, and Customers. These sectors work in harmony to provide the best products and services.

‘Investment’, the first of the new values, represents Belzona’s commitment to investing in its people, technology, and infrastructure. This includes investing in its employees’ training and development, as well as in the research and development of new and innovative products. Belzona’s focus on ‘Investment’ ensures that it stays ahead of the competition and continues to provide its customers with the best possible solutions.


Figure 16. Belzona invests in the ongoing training and development of its staff members

‘Innovation’ is the second value that Belzona has adopted. This value represents the Company’s commitment to continuous improvement and finding new and innovative solutions to its customers’ problems. For example, Belzona’s focus on ‘Innovation’ has led to the development of cutting-edge products, such as our range of high temperature linings.

The third and final value that Belzona has adopted is ‘integrity’. This value represents the Company’s commitment to honesty, transparency, and ethical behaviour. Belzona’s focus on ‘integrity’ ensures that it operates with the highest standards of conduct and maintains the trust and respect of its customers and partners. Strong work ethic and education across all areas ensures that the Business gets it, as best they can, right the first time from products to marketing, to technical support.

For more information, please visit: www.belzona.com

With laboratory set up, operational maintenance and the intricacies of daily running, ensuring worker safety, regulatory compliance, and operational efficiency in labs is paramount. Containment of chemical substances is one of the key activities in laboratories and process systems, and at the core of these systems, when maintaining the required pressure and airflow to extract fumes effectively, the responsibility rests with the industrial fan. This makes correct fan selection one of the most important system specifications. Enter our comprehensive specifier white paper: "The Ultimate Guide to Fan Selection in Fume Extraction Systems." ­­

Free to download from the Axair Fans website by scanning the QR code shown, this comprehensive resource, written by the experts in fume fans and air movement for chemical applications, is your roadmap to mastering the process of fan selection in complicated fume extraction systems, ensuring a healthier, safer, and more productive workspace.

Navigating the array of fan options can be overwhelming, especially when faced with the challenging task of managing hazardous fumes and airborne contaminants. That's where our guide comes in. With over 30 years of fan selection expertise, we've condensed the complexities of fan selection into an accessible and easy to understand document, that equips you with the knowledge you need to make informed decisions. Whether from supplier choice, to understanding the questions you’re asked to ensure system compliance, understanding airflow requirements and system compatibility to deciphering the nuances of corrosion resistance and material durability, offering a practical toolkit to guide you through the selection process.

Where static discharge can be a concern in certain environments such as chemical laboratories, we’ll explore the role of carbon loaded ATEX fans that effectively dissipate accumulated static discharge and gain a deeper understanding of the relationship between fan specifications, ductwork design, and effective fume extraction. We’ll explain the importance of EN14986 known as “The design of fans working in potentially explosive atmospheres” and how products must be constructed in compliance with directives to ensure fan components do not act as a source of ignition.  

By the time you've gone through the pages in the guide, you’ll be in a stronger position to write specifications to pass to future stakeholders, to talk to suppliers confidently or to troubleshoot poor system performance, armed with the information you need for fast and efficient decisions.

Who are Axair Fans?

Axair Fans are industrial air movement and fan integration specialists established in 1985 with a singular goal – to help to build better systems, systems that make our customers more successful. Working with specifiers, consultants, OEM’s and contractors at all stages of the specification and buying process in a wide range of chemical applications including laboratory, containment, process, environmental and industrial sectors.

Visit https://www.axair-fans.co.uk/industrial-applications-industrial-fans/the-ultimate-guide-to-specifier-fan-selection-in-fume-extraction-systems/ to download your free copy now.

When it comes to health and safety in food and drink factories, many tend focus on hygiene within production and the threat of contamination to products, as well as possible risks for consumers.

However, the health and safety risks to employees working in these factories are an equally important issue.

2022 HSE statistics show a 28% year-on-year rise in non-fatal injuries in the workplace, with slips, trips or falls, handling, lifting or carrying and being struck by a moving object being the leading causes.

And with more and more people now returning to factories post-Covid, the potential for the numbers to continue to rise exponentially is increasing.

Staff injuries can be particularly detrimental, and not just for the individual, slowing down operations and leading to a decrease in profits along with potential reputational damage. This means that for business owners, being aware of how to minimise the risks is invaluable.

Ian Hart, business development director of adi Projects, an engineering company delivering a multitude of projects within food and drink factories, comments: “The issue of employee safety is one that deserves as much attention as that of contamination within these environments.

“It is a topic of utmost importance. Staff health and safety risks in factories can be overlooked for a number of reasons, and it is vital that these are correctly identified and dealt with for the benefit of employees and overall operations.”

What are the main hazards within food and drink factories?

There are a number of hazards that are common in food and drink factories and that become difficult to manage if the factors posing a threat are not identified and properly dealt with.

“Food factories are inherently full of hazards such as rotating machinery, hot and cold pipes, chemical substances, electrical lines and much more. Humans can become exposed to chemical substances, be required to utilise tools or equipment that are not fit for use, or be subject to slips or falls from height,” says Ian.

“There is a clear element of danger for staff working within these environments. But this doesn’t mean facility owners can become complacent: there are measures and processes that should be put into place to prevent injuries, which can be highly effective.”

According to the HSE, over 30% of food and drink industry injuries are related to manual handling, such as back injuries, causing around 1700 acute injuries each year.

Manual labour including stacking, moving or pushing heavy objects is one of the main causes of injury, and automation of these risky repetitive tasks such as through mechanical handling systems can be instrumental in reducing risks. Yet each individual hazard requires a tailored solution.

Reflecting on the importance of taking a responsible, holistic approach to risk management, Ian comments: "Hazards such as slips, falls and those stemming from workplace transport, moving objects or machinery hazards can't be eliminated altogether: there are certain processes within factories that can't be eradicated yet. But this doesn’t mean that these hazards can't be controlled to reduce risks.”

Designing factories with safety in mind

“Minimising risks starts with factory design, and has it at its core. There are specific considerations to be taken when designing food factories to maximise safety and increase accessibility.

“Factors include limiting points of contact between hazards and humans, such as having hot or cold pipes in the celling void instead of anywhere near people, or ensuring rotating machinery is adequately guarded, so that risk of injury to those in the factory is minimised,” says Ian.

With slips and trips making up for 35% of major injuries in the food and drink sector, being caused by wet floors, uneven surfaces or other obstructions, design factors become particularly important in this context.

Ensuring safe access with proper facility design is equally vital when it comes to falls from height – the third most common cause of fatal injury in the industry.

“There is often a mentality that dictates that slips, falls and similar accidents are common in these environments, and that there isn’t much that can be done. But this mindset can be incredibly detrimental,” adds Ian.

“When designing facilities, it’s important to give some thought to the overall infrastructure, asking questions such as how do you make the factory as dry as possible? How do you prevent contamination of walkways, or ensure there’s enough grip on the floors?

“Something as simple as building factories with the proper flooring or having suitable lighting inside the facility can significantly reduce certain risks.

“Ultimately, it’s about alleviating all the sources of danger and reducing staff exposure to hazards. If the risks are adequately addressed at the design stage, achieving continued high levels of safety becomes easier in the long-term.”

Maintenance as a priority

Manufacturers in the industry often operate from older facilities with outdated equipment, which can constitute a challenge with regards to health and safety. Regardless of whether certain safety measures were put into place at the design stage when factories were built, it is likely that unless proper maintenance has been carried out, the facility is no longer safe.

“Regular health and safety assessment of the production lines and of the equipment are essential in any facility. Many forget that over time, equipment breaks down, or decide to make significant alterations without carrying out proper risk assessments,” says Ian.

“Equipment could be perfectly safe and compliant when it’s first introduced, but that doesn’t mean it will remain safe after years of continued usage. Maintenance needs to be a continuous priority: in a live factory, things are changing all the time, which means that the reassessment of lines is vital.

"There has to be an adequate awareness as to the risks brought on by a certain type of equipment, what its life span is and what investments are needed to enable this equipment to continue to be safe.

“And overall, it’s down to manufacturers to build this vital awareness in order to protect its staff and ensure the smooth running of operations.”

As a division of multidisciplinary engineering business adi Group, five-time winners of the Royal Society for the Prevention of Accidents (RoSPA) Health and Safety Awards, being recognised as one of the few businesses from around the world with impeccably high health and safety standards, adi Projects is best positioned to provide expert health and safety advice to manufacturing businesses.

adi Projects has provided innovative solutions for a number of clients dealing with complex facility design and health and safety challenges, solving each problem at hand with a tailored, strategic approach. To learn more about our services, please visit: https://www.adiltd.co.uk/divisions/adi-projects

Farmers focus on proven stainless steel technology

The Greek agricultural sector has trusted WELTEC BIOPOWER's biogas technologies since 2007 - and this trend is continuing. Most recently, three biogas plants were built, which the German manufacturer designed together with its Greek cooperation partner Tetoros Machinery. Two of these are located in the Epirus region, in northwestern Greece: a 1-megawatt plant in the town of Arta and a 500-kilowatt plant in Ioannina. The third one, a 250-kilowatt biogas plant project, was realized in Serres, in central Macedonia. Here, an upgrade of the CHP plant to 750 kilowatts is also being implemented. The plant in Ioannina will go into production in the fall of 2023.

The region around Epirus is particularly rural. Poultry and cattle production dominate the area. As in many other intensive farming areas, the biomass supply there is higher than the processing capacity of the existing plants. The construction of new biogas plants and the modernization of existing ones are therefore profitable, especially since such projects are supported by subsidies. Thus, not least, the rich substrate supply at the three plant locations was also an important factor for the investment decisions.

At the 1-megawatt plant in Arta, 150 tons of cattle slurry and 50 tons of dry chicken manure are processed daily. At the biogas plant site in Ioannina, the daily input is made up of 100 tons of cattle slurry and 30 tons of dry chicken manure. And in Serres, a substrate mix of 40 tons of cattle manure and 10 tons of energy plants enters the stainless steel digester daily. Here, in addition to his cattle farming, the operator owns land on which corn is grown.

At all three sites, the materials are first sent to a pre-storage tank. Special agitators and pump technology ensures the pretreatment. In the digesters, the proven agitators then mix the substrates for efficient biogas production. The two digesters in Arta each hold 4436 cbm, in Ioannina there is a 3993-cbm digester, and the tank in Serres measures 4905 cbm. "All tanks are made of high-grade stainless steel," specifies the responsible process engineer at WELTEC BIOPOWER, Tobias Peuker. According to him, the fermentation residue from the digester with its high nutrient content can also be used as fertilizer afterwards.

The three biogas projects are an important part of the Greek energy transition. For example, according to a report by DAPEEP S.A., the Greek market operator for renewable energy sources, new biomass, and biogas plants with a total capacity of 7 megawatts came online in the first half of 2022. The Greek Energy and Climate Plan aims to double the share of renewable energy in electricity generation from 30 % in 2021 to 60 % in 2030. WELTEC BIOPOWER has already implemented a total of around 36 biogas plants and projects there since 2007. And the path to decarbonization continues to make progress: In the summer of 2023, Greece's entire one-day energy demand could have been supplied from renewable energy sources for the first time. "This means we are well on our way and will continue to make our contribution to achieving the goal," predicts WELTEC BIOPOWER's Greek sales partner, John Tetoros.