Thick Film Coating Systems Technology Trends. Michael Osborne

Transcription

1 Thick Film Coating Systems Technology Trends Michael Osborne

2 PRESENTATION OUTLINE 1. INTRODUCTION 2. HISTORICAL PERSPECTIVE 3. POLYUREAS VS POLYURETHANES 4. STATE OF THE TECHNOLOGIES 5. PRACTICAL APPLICATIONS 6. WHAT THE FUTURE HOLDS

3 INTRODUCTION THICK FILM COATINGS BASICS A COMPONENT ISOCYANATE & B COMPONENT RESIN PROCESSED AT TEMP AND PRESSURE GEL IN SECONDS TACK FREE IN MINUTES CHEMICAL CURE / NO EVAPORATION MONOLITHIC / FAST APPLICATIONS ADJUSTABLE PHYSICAL PROPERTIES

4 INTRODUCTION THICK FILM COATINGS BASICS Pure Product Formulations are Either: 1. POLYUREAS (1:1 RATIO A TO B) 2. POLYURETHANES 2:1 OR 3:1 RATIOS (A TO B) Hybrid Product Formulations Vary: 1. LEVEL 1 HYBRIDS ARE MODIFIED FOR SPECIFIC PROPERTIES 2. LEVEL 2 HYBRIDS ARE MODIFIED FOR LOWER COSTS Pure formulations when specified correctly and fit for purpose are all acceptable for use when fit for purpose

5 Temp(0 C) INTRODUCTION THICK FILM COATINGS BASICS Price Quality Polyurea & Hybrid 1 Extreme Properties Extreme Conditions Higher Costs Poly Urethanes Hybrid 2 Lower Properties Lower Conditions Lower Costs Moderate Properties Moderate Conditions Moderate Costs Relative humidity

6 INTRODUCTION THICK FILM COATINGS BASICS Features and Benefits of Thick Film Coatings 1. HIGHER PHYSICAL PROPERTIES & PERFORMANCE 2. FASTER APPLICATIONS (FAST GEL AND CURE) 3. MONOLITHIC (NO LAYERING) 4. HIGHER ABUSE ACCEPTANCE WITHOUT DAMAGE 5. VARIABLE PROPERTIES FOR VARIABLE PROCESS CONDITIONS 6. HYDROPHOBIC (DEPENDING ON FORMULATION) 7. NO SOLVENTS OR CATALYSTS (POLYURETHANES USE CATALYSTS)

7 HISTORICAL PERSPECTIVE THICK FILM COATING DEVELOPMENT Thick Film coatings were developed more than 30-years ago in the form of Polyurethane based, plural component rigid elastomeric liquid applied systems. The products unique and desirable 100% solids spray applied, fast cure properties have not changed over this period but all other aspects of the systems have changed dramatically. By 1990 the product group changed dramatically with the development of Polyurea 1:1 ratio coating systems and first generation plural component application equipment systems technologies. By 2000 these thick film coating systems had developed to a level where the manufacturers offered the end-user from 3-5 coating products, that were typically either aromatic or aliphatic, polyurethane or polyurea and differed in physical properties only in elongation, or tensile or shore hardness. Presently, thick film polyurea/polyurethane coating technologies are the fastest growing coating system globally.

8 HISTORICAL PERSPECTIVE Thick Film Pure Polyurea, Polyurethane and Hybrid Coatings Polyurethane Foam and Initial Thick Film Polyurethane Coatings Plural Component Thick Film Pure Polyurea Coatings Plural Component Thick Film Polyurethane Coatings

9 HISTORICAL PERSPECTIVE

10 HISTORICAL PERSPECTIVE

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13 HISTORICAL PERSPECTIVE 2012 Thick Fims with Nano 2020 Industry Paradigm Shift 1940 Polyurethane Foams 1950 Aromatic Polyurethane 2010 Hybrid Systems with Additives 2005 Hybrid Systems Overtake Pures THICK FILMS 1960 Aliphatic Polyurethane :1 Thick Film Polyurethane 2000 Polyurea - Polyurethane Hybrids :1 Ratio Thick Film Equipments :1 Thick Film Polyurea & Polyurethane :1 Thick Film Polyurethane

14 HISTORICAL PERSPECTIVE Thick Film Coatings have developed from their infancy in 1970 to their current state as a commonly specified coating system in a variety of application types. In 1980 Pure Polyurethanes, followed by Pure Polyureas in 1990, followed by Hybrids of the two chemistries from From 2005 Hybrids have been developing at a much higher rate than pure versions and present Hybrids combine the two basic chemistries of Polyurea and Polyurethane with added chemistries providing unique fit for purpose systems. From 2010 the use of Nano chemistries within the Hybrid formulations are providing extremely versatile coatings that potentially can be utilized within a standard low cost thick film chemistry that is adjustable to exact requirements of the end-user

15 POLYUREAS VS POLYURETHANES TWO CHEMISTRIES Generally Thick Film Coatings can be broken down to two chemical groups, polyurethane s and polyureas. Some studies further divide these two groups down into elastomeric and rigid sub-groups. This sub-division is frankly not relevant as the rigidity of either product is determined by formula modification, with degrees of flexibility and rigidity easily modified as part of a specific design to meet specific applications requirements. Polyurethane manufacturers have principally put this sub-division forward as a marketing method to differentiate one product group from another. Rigid polyurethane s display physical properties that are characteristic of formulating towards rigidity and Polyureas can range from rigid to highly flexible therefore this sub-division grouping is not relevant. The truth is that both chemistries are suitable when the specific formulation and its functional properties meet the requirements of the application and process for which they are specified. Neither chemistry is superior to the other, both have intrinsic properties that lend themselves to different application types

16 POLYUREAS VS POLYURETHANES HOW THEY STACK UP Polyurethane chemistry is based on the exothermic reaction between Di, or, Poly-Isocyanates and compounds with hydroxyl end-groups such as Polyol. A basic chemistry chain is illustrated directly below. It is the exothermic nature of this reaction that provides polyurethane s with the fast-setting, coldtemperature curing and unlimited film builds of 100% solids pure polyurethane coatings. Polyurea chemistry is based on a similar exothermic reaction between Di, and Poly-Isocyanates with the key difference being that the polyurea utilizes active hydrogen groups (amines) to form polyurea instead of polyurethane. A basic chemistry chain is illustrated directly abovew. This chemical difference causes a much faster reaction period giving the polyurea group even faster gel, tack and cure times, while providing the desirable cold-temperature applicability and unlimited film builds similar to polyurethane. This basic chemical difference also explains the reason that polyureas resolve the known weaknesses of polyurethanes those being; curing problems in the presence of moisture or highhumidity, low resistance to impact, poor thermal cycling capability, etc.

17 POLYUREAS VS POLYURETHANES HOW THEY STACK UP PROPERTY STANDARDS POLYURETHANE POLYUREA VOLUME SOLIDS ASTM D % 100% VOC ASTM-D 1259A grams 0 grams MIX RATIO NOT APPLICABLE 1:1 1:1 APPICATION RANGE NOT APPLICABLE -10 C to 60 C -30 C to150 C NON VOLATILE CONTENT NOT APPLICABLE < 45% < 25% TEMPERATURE RESISTANCE NOT APPLICABLE 80 C 125 C DESIGN LIFE NOT APPLICABLE 3-7 YEARS 5-20 YEARS CATHODIC DISBONDMENT ASTM G -42A PASS < 10MM PASS < 2 MM CATHODIC DISBONDMENT ASTM G -8A/G-95 PASS < 3MM PASS < 3MM IMMERSION IN WATER AT 40 C EN ISO 2812 PART 2 ASTM-S 870 PASS PASS IMMERSION IN WATER AT 60 C EN ISO 2812 PART 2 ASTM-S 870 MODIFIED FAIL PASS WATER VAPOUR TRANSMISSION ASTM E PERMS 0.02 PERMS ABRASION TABOR C KG,1000 CYCLES ASTM D MG LOSS 14 MG LOSS TENSILE ADHESION ASTM D Mpa >15 Mpa TENSILE ELONGATION ASTM D 2370/D % >350% TENSILE STRENGTH ASTM D-638 >20 Mpa >25 Mpa TEAR STRENGTH ASTM D-638 >65 Kn/m >95 Kn/m SPLIT TEAR STRENGTH ASTM D-470 >35 Kn/m >35 Kn/m IMPACT RESISTANCE ASTM D 2794/ G-14 >40 IN.LBS >160 IN LBS BEND TEST ASTM G10/ EN1S PASS PASS SHORE D HARDNESS ASTM D QUV WEATHEROMETER ASTM G 53,3000 HRS,UVB 313 PROPERTY RETENTION > PROPERTY RETENTION > 90% BULB 90% SALT SPRAY ASTM B 117 PASS PASS THICKNESS (DFT) DIN MIN 1.5MM MIN 1.00.MM RESISTIVITY DIN 30671/ASTM D-618 NO DATA 3.27 x 10 13

18 POLYUREAS VS POLYURETHANES POLYUREA / POLYURETHANE HYBRIDS Modified or Hybrid versions can be formulated to be lower cost, lower performing products which can be utilized in some applications. Modified or Hybrid versions can be formulated to have extremely high properties in specific areas tailored to specific applications. Modified formulations always cost more if they are superior to the pure versions. Modified polyureas and polyurethanes cost less if they are inferior to the pure versions. RESIN/BINDER CHAIN EXTENDER SYSTEM TYPE ISOCYNATE Polyether di/tri amine Amine terminated Polyurea TDI/MDI/HMDI/IPDI or Pre- Polymers. Polyether Polyol or a blend of Polyether amine and Polyol Amine terminated Polyurea-Polyurethane Hybrid TDI/MDI/HMDI/IPDI or Pre- Polymers Polyether amine Glycol terminated Polyurethane-Polyurea Hybrid TDI/MDI/HMDI/IPDI or Pre- Polymers Polyether Polyol Glycol terminated Polyurethane TDI/MDI/HMDI/IPDI or Pre- Polymers

19 POLYUREAS VS POLYURETHANES POLYUREA / POLYURETHANE HYBRIDS Superior hybrid chemistries utilize a small percentage of the more extensive crosslinking of polyurethane polyol side with a high percentage of the more desirable polyurea amine chemistry to provide high performance properties such as acid resistant, erosion or abrasion resistant, fire resistant and even hydrocarbon resistant properties. These formulations are typically used in applications where higher performance is required and higher associated costs are expected. Inferior hybrid chemistries utilize a high percentage of the lower cost polyol chemistries combined with a low percentage of the higher cost amine chemistry providing lower property products at a reduced cost. These products are typically used in applications for that are not subject to adverse environmental conditions, abuse or chemical exposures. Both hybrid and pure formulations have their uses in applications within the Petrochemical industry. Selection criteria of which product to use where, should be determined solely by the products performance capabilities and proven physical properties

20 STATE OF THE TECHNOLOGIES PROVEN FORMULATIONS IN APPLICATIONS After more than three decades of historical project use for polyurethanes and two decades for polyureas, these products have become a standard specification in waterproofing, containment and anti-corrosion. Some of the larger manufacturers have complete technical specifications, method statements, quality assurance programs and test data, including approvals from national and multinational petrochemical and oil and gas firms. All products and manufacturers are not the same and due diligence should be exercised during the procurement and specification process, however, there are strong reputable companies manufacturing a variety of formulations designed for specific application types that have extensive experience in a variety of applications specific to the petrochemical industry, including; external and internal pipeline applications, internal and external coating of tanks, secondary containment for most chemicals and waste situations, etc. Formulations that readily available, which have the requisite credentials include: Chemical containment of acid and alkaline chemistries Anti-corrosion for carbon steel pipelines (External in immersion and non-immersion) Anti-corrosion for carbon steel pipelines (Internal in sweet and sour applications) Potable water linings for carbon steel tanks and pipelines Linings for domestic and industrial waste tanks and pipelines Anti-corrosion for tank external and internal surfaces Blast mitigation for use in personnel protection and structural protection Waterproofing in both roofing and sub grade structure applications

21 STATE OF THE TECHNOLOGIES PROVEN EQUIPMENT SYSTEMS The special coating equipment systems (heat and high pressure plural component systems) required to process these unique coatings have been refined over the past two decades. Presently there are several manufacturers with a variety of equipment types available globally. These systems continue to be refined but presently are at a high state of technology requirement no major enhancements. Special equipment systems have been designed around these coating delivery systems for specific applications that include automated external and internal pipe coating equipment, automated mobile external and internal pipe coating facilities, robotic delivery systems used in automotive industries, etc. The level of development of these systems ranges (depending on the supplier) from basic to high production state of the art. As with the coating technologies, use of these systems is well documented (technical method statements, production standards, quality assurance programs, etc.,) and have the same requisite credentials that can be reviewed and approved for use as part of any analysis or due diligence undertaken. The product delivery equipment and the secondary specific production systems that utilize them as an integral part of a manufacturing or production process are developed to a high standard. These systems continue to be refined to meet ever changing process and production requirements but there are very few limitations that would have an impact on most projects specified in the petrochemical industry today.

22 PRACTICAL APPLICATIONS LINE PIPE APPLICATION EXAMPLES PIPELINE EXTERNAL ANTI-CORROSION (WET OR DRY FILL) PIPELINE EXTERNAL ANTI-CORROSION (BORE PULLS) PIPELINE INTERNAL ANTI-CORROSION (CORROSIVE) PIPELINE INTERNAL ANTI-CORROSION (NON CORROSIVE) PIPELINE EXTERNAL AND INTERNAL GIRTH WELD JOINTS

23 PRACTICAL APPLICATIONS EXTERNAL LINEPIPE PROPERTIES COMPARISON PROPERTY FBE 3LPP 3LPE Tensile Strength 47 kgf/cm2 105 kgf/cm2 111 kgf/cm2 Adhesion to Steel 1 76 kgf/cm2 76 kgf/cm2 76 kgf/cm2 Mandrel Flexibility 2 Pass Pass Pass Max Elongation 3 13% 13% 13% Max High Temperature C 100 C 100 C Cathodic Disbondment mm 5.0 mm 5.0 mm Hot Water Resistance 6 1 Rating Unknown Unknown Thermal Shock 7 Pass Unknown Unknown Impact 8 1.5J 6.2J 7.4J Water Content 9 0.5% Unknown Unknown Compressive Strength kg/cm 3 Unknown Unknown Penetration Dielectric Resistance v 550v 550v Dielectric Strength @1MHz 2.7@1MHz 2.7@1MHz Volume Resistivity x x x Hardness

24 PRACTICAL APPLICATIONS EXTERNAL LINEPIPE COST COMPARISON COATING/COST USD M2 FBE 3LPE 3LPP THICK FILMS PIPE EXTERNAL COATING $ $ $ $ GIRTH WELDS SHRINK WRAPS $ $ $ $ GIRTH WELDS THICK FILMS $ $ $ $ BASED ON INTERNATIONAL STANDARD PRICING FOR COATING WORKS ONLY SHOWN IN USD PER LINEAL METER FOR LINE PIPE SHOWN IN USD PER GIRTH WELD JOINT

25 PRACTICAL APPLICATIONS INTERNAL LINE PIPE PROPERTIES COMPARISON PROPERTY POLYURETHANE HYBRID POLYUREA Tensile Strength 100 kgf/cm2 316 kgf/cm2 499 kgf/cm2 Adhesion to Steel kgf/cm2 229 kgf/cm2 248 kgf/cm2 Mandrel Flexibility 2 Pass Pass Pass Max Elongation 3 510% 450% 325% Max High Temperature C 150 C 165 C Cathodic Disbondment mm 3.0 mm 2.0 mm Hot Water Resistance 6 1 Rating 1 Rating 1 Rating Thermal Shock 7 Pass Pass Pass Impact J 22.0J 27.5J Water Content 9 0.6% 0.5% 0.4% Compressive Strength kg/cm kg/cm kg/cm 3 Penetration Dielectric Resistance v 426v 432v Dielectric Strength @ 1MHz 1MHz Volume Resistivity x x x Hardness

26 PRACTICAL APPLICATIONS INTERNAL LINEPIPE PROPERTIES COMPARISON COATING/COST USD M2 EPOXIES THICK FILMS PIPE INTERNAL COATING $ $ GIRTH WELDS THICK FILMS $ $ BASED ON INTERNATIONAL STANDARD PRICING FOR COATING WORKS ONLY SHOWN IN USD PER LINEAL METER FOR LINE PIPE SHOWN IN USD PER GIRTH WELD JOINT

27 PRACTICAL APPLICATIONS TANK AND BASIN APPLICATION EXAMPLES Thick film coatings are commonly used in both internal and external anti-corrosion systems in primary containment for steel tanks and concrete basins. The excellent thermal cycling properties extend performance when compared to traditional coatings which are hard and have very low elongation properties, which do not perform well when temperature cycles are extreme. There are a variety of specific formulations available to protect internal steel or concrete substrates in internal applications regardless of the chemicals being contained. Aromatic hybrid polyureas are most commonly specified for internal applications, with formulations readily available for; base and alkaline chemistries, crude oil, refined fuels, and process effluents. There are several options available for external applications that are more commonly specified on steel substrates then concrete. Pure and hybrid aliphatic formulations are more commonly specified due to their color retention capabilities.

28 PRACTICAL APPLICATIONS POLYASPARTIC POLYUREA PROPERTIES COMPARISON Polyaspartic Aliphatic Polyurea Physical Properties Solids by volume 100% Volatile Organic Compounds 0 gm/ lit Theoretical coverage@ 100 microns 10m2/ lit Specific Gravity (kg/ liter) A B-1.24 Viscosity at 25 C in cps) S 64 A-2600 B-2000 Shelf 25 C 12 to 15 Months Tensile strength ( ASTM D 412 C ) 16 to 19 Mpa Elongation (ASTM D 412) 25-35% Hardness (ASTM D 2240) Shore D Flexibility 2 mm mandrel (ASTM 1737) Pass Water Vapor Permeability (ASTM E 96) < perm-in Water Absorption -24 hours (ASTM D 471) < 0.5% Tear strength (Die C ASTM 624) (KN/m) Crack C (ASTM C 836), 25 cycles Pass Fire Rating UBC Class 2 Flash point Penske Martin > 93 C The latest polyurea technology, polyaspartic aliphatic, has become a global specification for external steel protection. These systems are the most suitable for long term anticorrosion protection on steel and can be applied without primers, have excellent thermal cycling capabilities, are color fast and chemical resistant, while providing the following properties: Elongation of 50-70% Shore Hardness of D CO2 Resistance Excellent UV Resistance Excellent Color Fast in Direct UV Exposure Chemical Resistant PH 2-11 Airless Spray Applied No Primer Required on Steel with Abrasive Blast Profile of microns present Service temperature Abrasion Resistance (ASTM D 4060) -20 C to 90 C < 35mg loss Taber CS 17 wheel 1Kg/1000 rev

29 PRACTICAL APPLICATIONS TANKS AND BASIN COST COMPARISON TRADITIONAL SYSTEMS THICK FILM SYSTEMS COATING SYSTEM/COST USD M2 EXPOXY PAINT ALIPHATIC PAINT ALIPHATIC HYBRIDS AROMATIC HYBRIDS POLYASPARTIC ALIPHATICS EXTERNAL STEEL TANK COATING $ $ $ $ $ EXTERNAL CONCRETE TANK COATING - $ $ $ INTERNAL STEEL TANK COATING $ $ INTERNAL CONCRETE TANK OR BASIN COATING $ $ BASED ON INTERNATIONAL STANDARD PRICING FOR COATING WORKS ONLY SHOWN IN USD PER SQAURE METER OF SURFACE AREA

30 PRACTICAL APPLICATIONS SECONDARY CONTAINMENT APPLICATION EXAMPLES The common definition of a flexible membrane lining system is; a continuous plastic or rubber sheeting used to cover the sides and/or bottom of ponds, pits, and lagoons for the purpose of containing liquids and preventing seepage. These lining systems are readily available in a wide range of product types, each with unique properties and physical characteristics designed to provide specific benefits to the user. Conversely features that are beneficial in one respect can be detrimental in another, hence the quandary posed to the Specifiers in determining which product is most suitable for their needs. These membrane liner products are currently the system most commonly specified when designing a system to provide long lasting barriers for such applications.

31 PRACTICAL APPLICATIONS CONTAINMENT LINER PROPERTIES COMPARISON Secondary containment, where environmental hazards are stored in basins or where areas are prepared to contain them if primary containment systems fail, are becoming a standard practice as environmental protection regulations increase. All petrochemical process, storage and distribution facilities are required to implement or upgrade existing systems under the latest regulatory standards. Historically the common practices were to use concrete basins and coat or line them with traditional coatings like epoxies or traditional liners like HDPE. Epoxies do not perform well on concrete substrates under thermal cycling conditions, they crack and delaminate. HDPE systems perform well in some cases, but are prone to failure at the seams. PVC systems also perform well in some cases, but again are prone to failure at seams. HDPE and PVC systems are mechanically attached and are roll goods requiring intricate seaming processes. If the systems are not seamed correct they will fail and the failure of one single seam location will undermine the entire installed system, and there are a lot of seams (1000 square meter installation will have lineal meters of seams. Currently an industry standard of creating these containment basins on compacted fill (without concrete) is accepted globally. This is attractive to end-users as the elimination of the structure reduces costs and allows for faster implementation. HDPE and PVC systems are used in these applications but have much higher requirements for soil compaction and fill specification since they are not capable of handling even slight soil settling which will result in failure of seams in these locations followed by total system failure. Thick film composites made of woven geotextile fabric and polyureas or hybrid products perform at a higher level than traditional systems, require less stringent soil compaction and fill specifications and in fact have no seams at all. A 1000 square meter installation will have 0 lineal meters of seams with thick film composites. Seams are the cause of failure in liners systems 99% of the time, elimination of seams thus eliminates 99% of potential failures in this application.

32 PRACTICAL APPLICATIONS CONTAINMENT LINER PROPERTIES COMPARISON PHYSICAL PROPERTY COMPARISONS OF SYNTHETIC LINER SYSTEMS PROPERTY TEST METHOD EPDM PV) HDPE HYPALON POLYUREA COMPOSITE PRINCIPAL THICK BILM BENEFIT TENSILE STRENGTH PLI BREAK ELONGATION % ASTM D ASTM D % 400% 350% 15% 429% VALUE MUCH HIGHER HYPALON NOT PUBLISHED BEST RANGE OF PRIOPERTIES FOR TENSILE, TEAR, DIMENSIONAL STABILITIY ALL DESIRABLE TRAITS IN THIS APPLICATION TEAR STRENGTH PLI PUNCTURE RESISTANCE PSI RESISTANCE TO OZONE LOW TEMPERATURE IMPACT MOISTURE VAPOR TRANSMISSION WATER ABSORPTION % HYDROSTATIC RESISTANCE PSI DIMENSIONAL STABILITY % CHANGE ABRASION RESISTANCE ASTM D VALUE MUCH HIGHER ASTM D ASTM D-1149 PASS - - PASS PASS ASTM D C -29C -75C -40C -50C ASTM E % MAX 2% MAX - - 1% MAX ASTM D-741 8% MAX 2% MAX - - 2% MAX ASTM DF751 (A- 1) VALUE MUCH HIGHER PVC NOT PUBLISHED CRITICAL FACTOR IN EXPOSED APPLICATIONS NOTE THIS TEST IS 7- DAY EXPOSURE ONLY SOME NOT COMPARABLE IN THIS TEST METHOD USED VALUE MUCH LOWER (BETTER) SOME NOT PUBLISHED NUKOTE AND PVC VALUES MUCH HIGHER OTHERS NOT PUBLISHED VALUE MUCH HIGHER HDPE NOT PUBLISHED ASTM E-96 1% MAX 3% MAX 2% MAX - 7% MAX VALUE MUCH HIGHER TABOR ABRASION C17 WHEEL 1000 G GRAM LOSS MAX VALUE HIGH OTHERS NOT PUBLISHED SHORE D HARDNESS ASTM D VALUE HIGH OTHERS NOT PUBLISHED

33 PRACTICAL APPLICATIONS CONTAINMENT LINER GENERAL COMPARISON GENERAL FEATURES COMPARISON OF LINER SYSTEMS CHARACTERISTIC STR (EPDM) CT (PVC) CP (HDPE) TE (HYPALON) POLYUREA COMPOSITE PRINCIPAL THICK FILM SYSTEM BENEFIT SOLD CONTENT 100% N/A N/A N/A N/A YES 100% SOLD AND VOC FREE MONOLITHIC NO LAYERS N/A N/A N/A N/A YES SEAMLESS 100% NO NO NO NO YES APPLICATION SPEED VERY SLOW VERY SLOW VERY SLOW VERY SLOW VERY FAST APPLICATION COMPLEXITY APPLICATION METHOD COMPLEX COMPLEX COMPLEX COMPLEX SIMPLE MANUAL MANUAL MANUAL MANUAL EQUIPMENT NO LAYERING REGARDLESS OF DFT EVEN FOR REPAIRS OR REMEDIATION NO SEAMS PERIOD THE ONLY PRODUCT IN THIS COMPARISION WITHOUT THIS FATAL FLAW 1500 TO 2000 SQUARE METERS PER DAY COMPLETION LEVELS SINGE APPLICATION STEP USING STATE OF THE ART EQUIPMENT ELIMINATES ERRORS/FAILURES APPLICATION VIA PLURAL COMPONENT EQUIPMENT ELIMINATES ERRORS/FAILURES MOISTURE SENSITIVITY ADVERSE ADHESION ADVERSE ADHESION ADVERSE ADHESION ADVERSE ADHESION MOISTURE HAS NO EFFECT ON ADHESION CURING INSENSITIVE OR APPLICATION OF PRODUCTS ADHESION TO CONCRETE NO CHEMICAL BOND NO CHEMICAL BOND NO CHEMICAL BOND NO CHEMICAL BOND > 3. 5MPa BOND STRENGTH TO CONCRETE IS EQUAL TO FAILURE LEVEL OF CONCRETE SUBSTRATE ADHESION TO METALS CHEMICAL RESISTANCE NIL NIL NIL NIL > 20 Mpa MODERATE GOOD GOOD MODERATE EXCELLENT BOND STRENGTH TO STEEL SUBSTRATES IS EXCEPTIONAL RESISTANT TO ALKALINE OR ACID CHEMICALS IN MOST SOLUTION UP TO 30% CONCENTRATION LEVELS SOLVENT RESISTANCE POOR POOR POOR MODERATE EXCELLENT RESISTANT TO MOST SOLVENTS AND OTHER SOLUTIONS CONTAINING HYDROCARBONS ULTRAVIOLET RESISTANCE VERY POOR POOR VERY POOR POOR GOOD UV RESISTANT COLOR WILL FADE BUT PROPERTIES WILL BE MAINTAINED HIGH VALUE CREATES STRESS ON THE SEAMS AND CO EFFICIENT OF THERMAL EXPANSION VERY HIGH HIGH VERY HIGH HIGH LOW REDUCES FABRICS ABILITY TO MOVE WITH GRADE CHANGES CAUSING FAILURES REPAIR AND MAINTENANCE COMPLEX COMPLEX COMPLEX COMPLEX SIMPLE CLEANING BY STEAM OR HIGH PRESSURE WATER THEN CHEM WIPE THEN APPLY PRODUCT TO ACHIEVE SPECIFIED DFT MONOLITHICALLY APPLICATION AT CRITICAL AREAS COMPLEX COMPLEX COMPLEX COMPLEX SIMPLE PENETRATIONS, TERMINATIONS, SEAMS ALL IN THE SAME SIMPLE APPLICATION PROCESS INCLUDING TERMINATIONS DESIGN LIFE 5-YEARS 7-YEARS 7-YEARS 7-YEARS 20-YEARS LONGER DESIGN LIFE DESIRABLE

34 PRACTICAL APPLICATIONS CONTAINMENT LINER PROPERTIES COMPARISON For Specifiers, the primary focus should be to "design by function". Specific project requirements will determine the proper liner to be utilized. Rarely will the lowest priced material be the "best" liner for the job. Compromises are usually made if price is the primary decision making criteria rather than performance and design life. Price should be the decisive factor only when more than one material meets all of the project requirements. Recognizing that there are numerous types of synthetic lining materials on the market today, analysis of the most widely utilized materials in this application type is appropriate. Comparing every liner system in the market is simply not feasible, instead a comparison of these systems generically, by polymer group will provide for a simpler decision making criteria without the sales hype generated by individual brands. Every lining system in the market will fit into one of five generic polymer categories. Each of these generic polymer categories has their own strengths and weaknesses. By understanding these strengths and weaknesses, individual decision makers will be able to determine the most suitable liner system by type for their specific project needs, only then should individual brands be considered and compared and a final supplier selected.

35 PRACTICAL APPLICATIONS SECONDARY CONTAINMENT COST COMPARISON COATING/COST USD M2 HDPE EPOXIES THICK FILMS CONCRETE BUNDING AREAS $ $ $ COMPACTED SOIL BUNDING AREAS $ N/A $ BASED ON INTERNATIONAL STANDARD PRICING FOR LINER WORKS ONLY SHOWN IN USD PER SQAURE METER OF SURFACE AREA PRICES SHOWN COMPARE ONLY MOST COMMON LINER SYSTEMS UTILIZED

36 WHAT THE FUTURE HOLDS TRENDS IN THICK FILM COATING TECHNOLOGIES Thick Film Coatings have been evolving rapidly over the past two decades. Polyurethanes initially, then Polyureas, then Hybrids of the two chemistries. The systems further evolved with the combination of secondary additives to provide specific performance benefits resulting in much wider ranges of formulations to provide fit for purpose products unique to the petrochemical industry. Nano particles were initially ignored by the industry due to their requirement for water as the delivery system. Recent discoveries that bind the nano particles to the primary resin chemistries allow for production of thick film coatings with nano particles bound to and intrinsic with the coating itself not as a surface treatment. Present formulations in Alpha and Beta Testing include nano hybrid polyureas and polyurethanes that provide; permeability levels of zero, complete color stability and ultraviolet resistance in aromatic formulations, anti-corrosion properties, fire resistant properties, heat resistant properties and chemical resistant properties. These properties are resident throughout the coating. These properties can be used utilizing inexpensive aromatic formulations and modified to specific requirements of the customer

37 WHAT THE FUTURE HOLDS ALPHA LEVEL THICK FILM COATING TRENDS Alpha level development is defined as products that have been fully developed, passed initial laboratory testing and currently in process of extensive third party laboratory testing prior to field trials confirming suitability for intended purpose. Current thick film alpha technologies including the following: A polyurea-hybrid coating that provide electrical properties for use in anti-static floors and special manufacturing applications where the transmission of electricity through the coating at controlled parameters is useful or required. The system also shows potential in use as a coating system that generates heat at increasing levels when electrical current is increased, showing potential for use in applications in cold climates. A pure polyurea coating for use blast mitigation (anti blast coating protection or personnel and structures). This system varies from current technologies where fiber reinforcement is added, the new version includes the fiber in the coating system A pure polyurea hybrid that provides structural properties for application on failing concrete structures to stop further corrosion and reinforce the structure itself.

38 WHAT THE FUTURE HOLDS BETA LEVEL THICK FILM COATING TRENDS Beta level development is defined as product that has completed alpha level development and is presently either in process or has recently completed field trials to confirm final suitability for the intended purpose. Current thick film beta technologies include the following: A polyurea-hybrid coating with high fire resistance properties with initial field trials on wooden utility poles (750,000 poles) in a region where brush fires burn through the poles carrying power and phone lines causing major disruptions to services. Field trials and extensive specific testing were completed at third party laboratories and in client laboratories in The target market for this coating is in Class 1 faculties and in fire rated roofing systems. This product has been fully commercially available since Jan A polyurea-hybrid coating for use as a liner to prevent hydrogen damage, sulphide-stress cracking, or stress-corrosion cracking, from exposures in sour gas with hydrogen sulphide and carbon monoxide, or other gases present in the medium.

39 WHAT THE FUTURE HOLDS BETA LEVEL THICK FILM COATING TRENDS A polyurea-hybrid coating with high vapor and gas resistance is in extensive field trials for use in pressure vessels where high pressures and rapid depressurization occur causing delamination of liners and pitting of the substrates. The formulation was designed to decrease the absorption of gas into the liner system. The system has a favorable glass transition range to accommodate the differentials present. A polyurea-hybrid coating designed to perform longer in extreme abrasion and erosion conditions is in extensive field trials for use in mining and hydroelectric power applications. This product is in the final stages of Beta testing and is already being specified extensively due to its better abrasion resistance compared to any other organic coatings. One of the field trials recently completed was in directional bore installation of a 2 meter diameter 3 kilometer long bore pull where HDPE and other systems failed repeatedly. This system is just a few months away from full commercial release in demanding abrasion resistant applications. Other polyurea-hybrids in final stages of Beta development are: single component versions of the fire rated system noted above, but in aliphatic color stable formulations, that can be brush applied, a chemical resistant formulation increasing the resistance to acids (present formulations contain 60% H2S / 20% HCL / 20% FCL) by 15-20% over current formulations

40 WHAT THE FUTURE HOLDS PARADIGM SHIFT IN COATINGS TECHNOLOGIES Presently we design chemistries to function in special ways, providing specific properties for specific application conditions. This in itself was a paradigm shift in coating technologies. Now we are working on a much different coating design, that being a single thick film polymer type, with lowest costs and strong desirable standard properties and binding specific Nano molecules into this chemistry to achieve desirable specific properties. This process is only possible in thick film fast set chemistries since the reaction time is so fast that the product cures in minutes or less effectively binding the nano molecules in the coating film and not allowing it to escape during an extended curing period. The potential is now there for a single desirable elastomer that can be readily modified to specific features that work throughout the life of the coating. For example we can theoretically design a coating that has continuous ultraviolet protection (special nano molecules reverse exposure degradation permanently) while at the same time reversing oxidation of the substrate (on the other side of the film) at the same time. Essentially we could provide a low cost aromatic coating that will never degrade in ultraviolet and continually reverse oxidation on steel substrates. Similar films could be designed that work in chemical resistance, or carbon dioxide resistance, or abrasion resistance. The potential is unlimited and fascinating. This technology will take time to develop but the potential is there to complete revise the way we design, purchase and specify coatings.

41 SUMMARY CONCLUSIONS This presentation has covered the present feasibility for use of these coating systems solutions, including; what system types are currently available for specific use in the oil, gas and petrochemical industries, what level of testing, completed trials and acceptance are in place for these systems, what specific performance properties can be selected and utilized by the end user and finally, what equipment delivery systems are available, for practical use, in both field and production application conditions. This paper has also summarized the latest developments of thick film coatings technology and summarized its potential future impact on the coatings industry. Thick film coating systems presently offer a wider range of unique solutions to end users than any other coating chemistry available. These coatings have many chemical variations (formulations) designed to reach specific physical and performance properties desirable in the oil, gas and petrochemical industries. The application systems available are state of the art, exceeding production speeds, and at a lower cost, when compared to traditional coatings in both containment and pipe coating plant conditions. The coatings lend themselves to Insitu field applications in both external and internal pipe and tanking applications. The end-user can derive lower first costs (initial costs) when utilizing these systems and expect significant reduction in second costs (maintenance) while extending design life and enjoying extended asset longevity through their use. Traditional coatings and linings will remain in use in the marketplace and have specific applications where there continued specification remains viable. Specifiers should become more demanding of the products they select. Times have changed, you can now demand a product that it specifically suited to your specific requirements, rather than specify a product that best meets your requirements.

42 Michael Steven Osborne MSCE / MBA President Nukote Coating Systems International Headquarters Americas Nukote Coating Systems North America Dallas Texas USA / Headquarters Asia Nukote Coating Systems (S) Pte., Ltd Singapore / Headquarters Austral Asia Nukote Distributors Pty Ltd New South Wales Australia / Headquarters South America Nukote Coating Systems Brasil Ltd. Belo Horizonte, Brasil / Headquarters Asean Nukote Industries Ltd. Ho Chi Minh City, Vietnam / Headquarters Africa Nukote Coating Systems (SA) Pty., Ltd. Johannesburg South Africa /