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Plastocor® Tube Lining System Shown to Eliminate Heavy Metal Discharge to Cooling Water

A case study has shown that the plastocor® tube lining system eliminates heavy metal discharge to the cooling water while increasing condensers’ lifespans.

plastocor® technologies are environmentally protective, particularly the tube lining system, which eliminates heavy metal discharge from the cooling water, as evidenced by the study.

In plastocor®’s ongoing search for innovative and eco-friendly solutions to common corrosion and erosion problems found along the entire cooling water cycle, reducing the negative impact on the environment that can come from power generation has been of paramount importance.

plastocor® takes great pride in researching and developing products that are sustainable and durable, offering a viable, eco-friendly alternative with regards to repair and maintenance options in all power plants, especially condensers and heat exchangers.

Experts in the protection and repair of corrosion and erosion problems found along the entire cooling water cycle, plastocor-international SA has put environmental considerations at the heart of our 60 plus year long history.

The company appreciates that the key to solving the multiple challenges in condensers and heat exchangers is the selection and use of 100% solids, zero volative organic compounds, non-flammable and solvent-free polymeric epoxy-based materials. plastocor® products are not toxic to the environment and significantly outperform conventional solvent-based and polyurethane coatings.

The original thick layer epoxy plastocor® cladding system for tube sheets offers long-term protection against galvanic corrosion, de-alloying, fouling and erosion and is not only suitable for the protection of new tube sheets, but also for rebuilding both corroded and eroded tube sheets to a new-like condition.

The original thin layer epoxy plastocor® inlet system protects new and repairs old condensers and heat exchanger tubes, from both inlet and outlet end erosion and corrosion, while also eliminating the risk of step-erosion. When used together, these systems offer an optimal lifetime extension of over 20 years at a fraction of the costs involved in retubing.

The original plastocor® tube lining system

However, the original and patented plastocor® tube lining system has had remarkable success in not only extending the lifetime for tubes found along the cooling water cycle, in particular in the condenser and heat exchanger, but also in considerably improving the reduction of heavy metal discharge into the cooling water.

plastocor® tube lining supplies a unique form of recuperating already lost tubes and delaying costly retubing of condensers. Small calibre tubes, around 3mm or 4mm in depth and up to 20m in length, can be lined with a thin film epoxy coating of just 0.05mm to 0.06mm.

Although the coating is thin, tube lining condenser tubes can extend condenser lifespans by more than ten years. Tube Lining System is engineered to withstand extreme erosion, corrosion and fouling conditions, even in different cooling water environments for the latter, such as seawater, brackish water and sweet water.

Case study – CEA PHENIX nuclear power plant, France

When considering its environmental impact, however, plastocor® tube lining stands out in its field, which can be seen in the case study from the CEA PHENIX nuclear power plant, France. Situated on the banks of the Rhone River, the environmental impact of the plant’s activity was a notable concern. After applying plastocor® tube lining, tests conducted by the plant operator showed that plastocor® tube lining applied to the full length of tubes eliminated heavy metal discharge through the cooling water into the Rhone River.

In accordance with ISO 14000 and ISO 14001 environmental standards, the yearly copper discharge decreased by 8.2t, zinc’s dropped by 3.8t and arsenic’s by 7kg. Therefore, the Rhone River’s water quality improved drastically.

In addition, plastocor® tube lining helps prevent fouling, leading to an increase in flow rate as well as eliminating the need for chemical cleaning, which is another environmental advantage of using the system.

Not only does plastocor® tube lining offer credible ecological benefits, but it also results in fewer shutdowns as the study illustrated. The plant avoided two unplanned shutdowns relating to corrosion-induced tube ruptures in a period of approximately 18 months, resulting in an average gain of €5.6m. Furthermore, plastocor® systems allow for greater maintenance planning and scheduling, providing plant operators with a valuable tool when it comes to optimising operational budgets.

Transitioning to a green power generation industry requires innovative, cost-effective and easily applicable solutions that are smart, simple and sustainable. plastocor® pioneer technology offers all of these qualities with its one-stop turnkey solutions, positively impacting the protection of the environment and aiding other economic considerations.

Please contact the company via the enquiry form for more information.

The optimisation of budgets is fundamental in reducing operational and maintenance costs in power plants.
plaster-international offers 60 years of continuous innovation and broad experience in corrosion and erosion protection. 
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