Research Papers
Multi-Ceramics Thermal Insulation Coatings Help Georgia-Pacific Save Significant Energy and Stopped CUI
S. Strudwick, J.E. Pritchett, G. Allen
Published: November 2024
Australasian Corrosion Association Conference 2024 – Paper number ACA2024-21634
ABSTRACT
The conventional open cell method of insulation aims to slow the heat flowing through materials filled with air such as fibreglass batts, while new coatings that use fillers like aerogel and beads follow the same open cell thermal methods. In this paper we discuss an alternate method of closed cell thermal insulation management with multi-ceramics that block heat and stop air/moisture transfer. These thin and thick heat-block insulation coatings have evolved into a distinct, high-performance formula that far exceeds conventional insulation standards. They also provide energy-savings and carbon emission reductions, while stopping corrosion under insulation and giving additional genuine personnel protection and safety.
This paper discusses results of a recent three-year pilot field study (2020-2023) conducted by Georgia-Pacific, an American pulp and paper company based in Atlanta, Georgia, on a digester tank, where the multi-ceramic heat-block coating was applied. This pilot showed energy loss reductions cut by half, creating annual savings in the hundreds of thousands of dollars for one tank annually. The coatings also prevented corrosion under insulation, reduced CO2 emissions and slashed maintenance costs. This demonstrated how these multi-ceramic coatings help provide a future pathway for industries to achieve substantial energy savings and carbon reduction working towards net zero by 2050 and beyond.
Sustainable High Performance Closed Film Ceramics Thermal Insulation Coatings for Energy, CUI and Personnel Protection
S. Strudwick, J.E. Pritchett
Published: November 2023
Australasian Corrosion Association Conference 2023 – Paper number 0023-20271
ABSTRACT
Ceramic Thermal Insulation Coatings (C-TICs) represent a significant advancement in thermal insulation, challenging conventional insulation paradigms, which introduce the language of “K-values”. C-TICs transcend standard thermal conductivity assessments. This paper addresses the paradigm shift in the perception of Thermal Insulation Coatings (TICs) with specialised ceramics within the industry, emphasising their proven sustainable performance beyond traditional open film conductivity metrics. CTICs establish sealed film barriers that effectively prevent moisture and airflow ingress into the coating film.
This feature significantly mitigates Corrosion Under Insulation (CUI) risks, enhances personal protection well beyond five seconds, ensures energy cost reduction, reduces carbon emissions, and sustains asset performance. Moreover, C-TICs play a crucial role in curtailing the “initial loading of heat” on surfaces, thereby limiting available thermal energy transfer. These closed film C-TICs incorporate meticulously formulated resin systems, developed by a ceramics researcher with extensive experience, including work with NASA from 1989 to 1995. These compounds are tailored to manage temperatures from 40°C to 650°C, ensuring longevity in thermal insulation applications. This paper sheds the light with practical applications of multi-ceramic thermal insulation coatings, reshaping energy management and asset protection paradigms for every industry.
