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Application of Thermal Spraying Technology in the Chemical and Petroleum Industries
Release time:
2020-08-30 14:58
Source:
Application of Thermal Spraying Technology in the Chemical and Petroleum Industries
In the chemical industry, corrosion is particularly severe. It not only causes substantial losses in materials and equipment but also leads to production shutdowns due to corrosion. The losses resulting from safety accidents and environmental pollution are even more difficult to quantify. Prevention... “Leakage, spillage, dripping, and seepage” are among the primary tasks in equipment management for chemical enterprises. Thermal spraying technology—combining multiple process methods and focusing on surface enhancement—can coat virtually all solid engineering materials and boasts excellent chemical stability. As a result, it has been increasingly widely adopted in the chemical industry. Chemical media often contain sulfur and oxygen; therefore, storage tanks for fuels, alcohols, acetic acid, toluene, glycerol, and syrups—as well as original shaft sleeve mechanical seals and impellers—can all be protected against corrosion through thermal spraying. For generally mildly corrosive media, metal thermal spraying with aluminum, zinc, or stainless steel followed by sealing can effectively address corrosion issues. For highly corrosive substances such as strong acids and alkalis, plastic flame spraying using materials like epoxy or polytetrafluoroethylene (PTFE) provides an exceptionally effective solution. The results achieved through thermal spraying in the chemical industry are particularly notable in the following key application areas:
1 , made of low-grade materials Heated spray coatings replace high-end materials such as stainless steel and titanium alloys.
2 It can be used as an anti-corrosion coating for chemical reaction tanks, storage tanks, mixing equipment, and pipelines.
3 It can serve as an excellent repair layer for chipped or damaged enamel-coated equipment.
Thermal spraying has also found widespread application in the petroleum industry. It has been successfully used for the repair and protection of equipment involved in oil exploration and production. Thermal-sprayed coatings have proven effective in providing long-term corrosion resistance for oil pipelines and offshore platforms. The arc-spray technology introduced by the engineering and installation company of a certain downhole operations firm has effectively addressed the challenge of metal corrosion protection, filling a significant gap in metal corrosion prevention in oilfields. Currently, the engineering and installation company has begun applying this technology to wire and plate materials. In profiles and metal equipment, the corrosion resistance of products is enhanced after spraying. 2 More than double.
Current Status of Thermal Spray Technology Applications in the Petroleum and Petrochemical Industry
With the continuous advancement of advanced manufacturing technologies and equipment engineering, the fields of manufacturing and maintenance are becoming increasingly integrated, and the term “maintenance” is now imbued with broader meanings. In 1984, the U.S. magazine “Technology Review” advocated for the refurbishment or remanufacturing of used products, coining the term “remanufacturing.” Remanufacturing requires only about 20% to 60% of the energy needed to produce new items, yet its cost is just 40% to 60% of that for new products. Many worn-out components treated with thermal spraying technology exhibit performance superior to that of new parts. For instance, large-power crankshafts in oil drilling rigs, as well as crankshafts from various heavy-duty vehicles, tractors, and diesel engines used in oilfields, can all be repaired using thermal spraying techniques after wear. For example, 3Cr13 coatings applied via arc spraying or ceramic coatings applied via plasma spraying can be used for such repairs. This approach not only reduces costs but also extends the service life of equipment, particularly addressing repair challenges associated with imported machinery. Thermal spraying can also be employed to restore components that have exceeded machining tolerances or to strengthen the surface layers of wear-resistant parts. Various pump components used in oilfields—such as plungers, cylinder liners, and impellers—can be repaired using multiple thermal spraying methods. For instance, WC-12Co coatings applied via supersonic flame spraying or Al2O3 coatings applied via plasma spraying can be used for repair and reinforcement; alternatively, 1Cr13 steel wires applied via arc spraying can serve as an effective repair solution. Plungers repaired using thermal spraying technology typically have a longer service life than those subjected to surface hardening, though their performance falls slightly short of that of plungers whose working surfaces have been spray-welded with nickel-based alloys. For some large-diameter plungers that have become deformed and thus cannot be repaired by spray welding, thermal spraying emerges as a non-deformation-inducing, low-cost alternative. Recently, a 12-ton plunger was repaired domestically, with the thermal-sprayed coating weighing as much as 33 kilograms. After sealing treatment of the coating, the repaired plunger demonstrated superior performance compared to a new one, while its cost was only one-fourth of that of a new plunger. Additionally, the shafts of electric motors used in oilfield injection pumps and the rotors of high-power motors employed in brine preparation systems can both be repaired using thermal spraying technology on their worn journal areas.
Guangzhou Sanxin Thermal Spraying specializes in the manufacture of various thermal spraying equipment, including plasma spraying equipment, supersonic spraying equipment, arc spraying equipment, zinc-spraying machines, aluminum-spraying machines; flame powder spraying equipment, flame wire spraying equipment, flame plastic-coating equipment, as well as a wide range of thermal spraying coating services, ceramic coating services, and tungsten carbide coating services.
Relevant Information
The complete set of plasma-sprayed equipment has been shipped to the customer’s site in Thailand.
Core spraying equipment: SX-80 plasma spray main unit, with a 15,000℃ flame suitable for multiple materials including zirconia and silicon carbide; powder feeding accuracy of ±1%, and coating thickness tolerance ≤ ±5 μm. Environmental protection support system: Customized soundproof booth + pulse dust collector—effectively addressing spray noise pollution while achieving highly efficient dust recovery, compliant with Thai environmental standards. Automated equipment: 6-axis industrial robot + intelligent spray cart, enabling precise spraying of complex workpieces and automated loading/unloading, boosting production efficiency by 40%.
On-site engineers provide hands-on training, focusing on the core operations of plasma spraying equipment such as the SX-80. Sanxin has customized a complete solution for its customers, including an automated spraying robotic arm, a soundproof booth, and a dust removal system—ensuring both high spraying efficiency and compliance with environmental standards.
Guangzhou Sanxin Thermal Spraying Turntable Shipment
Guangzhou Sanxin Company manufactures single-station and multi-station thermal spray turntables, which can be paired with plasma equipment, supersonic equipment, and arc equipment. We offer rapid, customized production tailored to customer requirements and product dimensions. A thermal spray turntable is a high-precision rotary worktable specifically designed for thermal spraying processes—including flame spraying, plasma spraying, and arc spraying. By providing controllable rotational speed and exceptional stability, it ensures uniform coating thickness on the workpiece surface, thereby enhancing spraying efficiency and quality.
SX-80 plasma equipment is being used at a customer site in Russia.
SX-80 plasma equipment is being used at a customer site in Russia.
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