Corrosion in ballast tanks Marine Coatings RINA Conference Feb 2010 Presented by: DR M Raouf Kattan - managing director

Doc No. 270CXXXP-RINA Oct ACME = Corrosion Air (Oxygen) Cathode Metal Electrolyte

Doc No. 270CXXXP-RINA Oct New build costs Misc 2% Ohds 28% Labour 19% Paint 2% Pipes etc 7% Equip 22% Main Eng 16% Steel 8%

Doc No. 270CXXXP-RINA Oct The cost of coatings

Doc No. 270CXXXP-RINA Oct The cost of failure Ballast tank refurbishment –$50 - $100 per sqm Total area for a Panamax bulk carrier - 70,000dwt ,000 sqm New build price - $36-48 million Percentage on average of catastrophic failure - 16%of first cost

Doc No. 270CXXXP-RINA Oct Prevention of corrosion Provide a break in ACME –No Air - inert the space, some ballast water treatment systems propose to do this, (but anaerobic corrosion) –No Cathode - same metal to metal problems or non-metals –No Metal - no real alternatives at present –No Electrolyte - treat the water or alternatives, no ballast ships or water alternatives.

Doc No. 270CXXXP-RINA Oct Current solution Create a physical barrier in the form of a coating to break the contact between the ACME elements.

Doc No. 270CXXXP-RINA Oct The solution does work With good Surface preparation and application the Current range of products can create a suitable barrier that can last in theory up to 15 years or more

Doc No. 270CXXXP-RINA Oct Causes of failure Poor design Material selection (paint selection/specification) Production processes control Surface preparation Application In service conditions/planned maintenance Coating chemistry

Doc No. 270CXXXP-RINA Oct Have regulations helped 12 new regulations and guide lines over the last 15 years to do with ballast tanks. Little evidence that they have improved the situation beyond what paint companies may have done to respond to client demand/environmental concerns. Statistics hard to come by.

Doc No. 270CXXXP-RINA Oct Size of the problem Safinah estimate some –7117 bulk carriers and COT –Totalling million dwt –7 - 8 billion sqm of ballast tank afloat –Average vessel age range years

Doc No. 270CXXXP-RINA Oct Expenditure A US Study indicated $8.5 - $11 billion is spent each year –Cost of design measures –Cost of new building measures –Cost of through life Safinah believe these estimates to be very conservative.

Doc No. 270CXXXP-RINA Oct The environment A mix of –Air temp –Steel temp –Cargo temp –Sea temp –Ballast water treatment systems –Vessel design Creates a distorted environment within the tank from outside shell to inside shell

Doc No. 270CXXXP-RINA Oct The solution envelope Design review Design guidelines (lessons learnt) Functional specifications New production technologies Scheduling Understanding the environment Coating strategies HS&E challenges Planned maintenance Education Regulations across the chain of activities

Doc No. 270CXXXP-RINA Oct Get it right - it is cheaper