Advances in Thermal Insulative Coatings Due to Two Component Technology MESC 2016 Dubai

Insulative Coatings Benefits  Low Thermal Conductivity  Slows Conduction of Heat  Worker Safety  Energy Savings  Process Temperature Stability  Solar Reflection  Low Condensation Formation  Ability to coat irregular objects  Mitigation of corrosion under insulation

Thermal Insulative Coatings (TIC)  Most consist of WB Acrylic (1-component) or WB Epoxy (2-component) Resin Systems  Contain hollow spheres or aerogel  Apply at 1-10 mm dry film thickness, in multiple coats  Use appropriate corrosion-resistant primer  Most contain 0 or low VOC content

Thermal Conductivity of Common Materials Materialk value* Air Styrofoam/PU foam Insulative Coatings Rock wool insulation Calcium silicate Materialk value* Drywall0.294 Concrete1.730 Stainless steel52 Carbon steel93 Copper694 * BTU/hr-ft-°F

Thermal Conductivity TIC Polyurethane Foam Steel Copper Concrete Insulators Conductors Calcium Silicate Rock Wool

Structural Steel and Blanket are at Same Temperature 140°F (60°C) Why do we burn ourselves on the steel but not the blanket?

R-Value ›R-Value for Insulation and TIC  Used to rate insulative properties, mainly for commercial insulation for buildings  Measure of the resistance to heat flow through a given thickness of material  R value = 1/K value based on testing at 1"

1-component vs. 2-Component ›1-component waterborne TIC  Usually WB Acrylic  Cures by coalescence  Low crosslink density ›2-component waterborne TIC  Reactive Epoxy System  Cures by chemical reaction and coalescence  Higher crosslink density vs. 1-component

Advantages of 2-component ›Improvements:  Adhesion  Hardness Development  Crosslinking  Tensile Strength  Dry Film Thickness per Coat  Water Resistance  Water Fog Blister Resistance  Exterior Weathering  Corrosion Resistant System

Adhesion ›Pneumatic Adhesion (ASTM D4541)  OZ / Epoxy Intermediate / TIC  WB Epoxy Primer / TIC o Both Systems – 2-Comp. TIC results more than double 1-Comp. TIC results ›Knife Adhesion, (ASTM D6677) o 1K vs. 2K – both excellent; 2K stronger

Pneumatic Adhesion, psi

Hardness Development ›Pencil Hardness, ASTM D3363  After 30-day cure: o 1-Component TIC< 6B o 2-Component TIC= B ›Scale, softer to harder: 6B 5B 4B 3B 2B B HB F H 2H 3H 4H 5H 6H 1-Comp.2-Comp.

Durometer Hardness, Shore D ASTM D2240

CrosslinkingImprovement ›Solvent and Chemical Resistance, ASTM D1308  2-component outperformed 1-component for xylene, MEK, 5% NaOH, and 5% H 2 SO 4 ›Tensile Strength, ASTM D638  1-component TIC Commercial Products = psi  2-component TIC Commercial Product = 800 psi (average of 3 samples)

Impact Resistance- ASTM D2794 (in-lbs.)

Application Advantages ›Increased dry film thickness per coat, per pds  1-Component Commercial Products o Most Commercial Products = up to 500 or 625 microns per coat, recoat times vary, up to 24 hours  2-Component Commercial Product o Up to 1 mm per coat, recoat at 5 hours at 24°C ›Improved recoat time ›Can apply higher dft in shorter time frame ›Less application sensitivity, since chemical crosslinking occurs

Water Resistance ›Tap Water Absorption, ASTM D570, 24-hour immersion, average of 3 or 4 samples  1-Comp. Commercial Products (5,250-7,750 microns dft) o % (can vary greatly)  2-Comp. Commercial Product (8,250 microns dft) o 0.998% ›Water exposure testing, ASTM D1308, 48-hr. exposure  1-Component = Softening, no other effects  2-Component = Excellent, no effect

Accelerated Corrosion and Weathering Tests

Accelerated Corrosion Resistance ›Primer required for Corrosion Resistance ›Water Fog Exposure (ASTM D1725) ›Salt Fog Exposure (ASTM B117) ›Cyclic Prohesion / QUV-A, ASTM D5894  For most systems tested: Blistering, rusting, or undercut corrosion started earlier or was more severe in 1-comp. vs. 2-comp. TIC

Water Fog, Sample Exposures 1-Comp. TIC, No primer, 336 hrs. OZ / 1-Comp. TIC, 3408 hrs. OZ / 2-Comp. TIC, 5040 hrs.

Salt Fog, Sample Exposures Zinc-Rich Primer / 1- Comp. TIC, 3408 hrs. 1-Comp. TIC, no primer, 336 hrs. Zinc-Rich Primer / 2- Comp. TIC, 4032 hrs.

Cyclic Prohesion/QUV-A 1-Component TIC (no primer), 360 hrs. Zinc-Rich Primer / 1-Comp. TIC, 3360 hrs. Zinc-Rich Primer / 2-Comp. TIC, 4032 hrs.

Midwest Weathering,ASTM D1014 Approximately 2-year Exposure OZ Primer / 2-Comp. TIC / Topcoat (WB Acrylic, WB Epoxy, WB Urethane)

Carbotherm 551 Fewer coats; faster application FeatureBenefit Epoxy basedDurable; chemical resistant Water-basedSafe to use High film build Temperature resistance-60 to 350°F (-51 to 177°C) Low density; low “k” value Excellent insulation properties 82% solidsExcellent coverage

Summary ›Thermal Insulative Coatings  Provides Benefits ›Technology Advances through 2-Component TIC development  Better Adhesion  Increased Hardness Development  Provides Crosslinking  Higher Tensile Strength  Enhanced Application  Improved Water Resistance  Improved Corrosion Resistance and Weathering System

Carbotherm Product Portfolio ›Carbotherm 3300Water based Modified Acrylic ›Carbotherm 551Water based Insulative Epoxy ›Carbotherm 730Solvent free Epoxy Insulative coating ›Carbotherm 731Solvent free Epoxy Insulative coating ›Carbotherm 735Solvent free Polyurethane elastomer

Advances in Thermal Insulative Coatings & Heat Transfer Questions?