HPC® Coating

HPC® Coating: High Temperature Thermal Barrier Coating

 

With HPC® Coating you get heat protection that surpasses conventional insulation.  HPC® Coating is a ceramic-based, water-borne thermal barrier insulation coating designed for extreme heat situations.  It can be applied in multiple coats and built up as needed to achieve the desired level of insulation.

The HPC® insulation coating system (including HPC HT Coating) is designed to coat surfaces that sustain temperatures up to 600°C (1,112°F) .

HPC before and after    (36.9°C=98.4°F)                (463.2°C=865.8°F)

This insulation method is very different than the traditional “wrap” insulation materials which only slow down the loss of heat (heat transfer).  The seven non- conductive ceramic compounds used in HPC® Coating create a thermal barrier to catch and hold heat on the surface of the unit – whether on a pipe, furnace, heated vessel, or boiler, etc.  Unlike wraps that use air as the insulation component, the ceramic compounds in HPC® coating resist absorbing heat radiating from the surface.  HPC® Coating traps and holds the heat onto the surface for more effective insulation performance.

HPC® Coating is applied by spraying directly on operating hot surfaces that have previously been power-cleaned.  As heat actually aids in the curing process, there is no need for a disruptive shutdown.  Since HPC® bonds to the substrate, it also greatly reduces problems associated with corrosion under insulation (CUI).

 

HPC® Coating vs. Traditional Insulation

Traditional hot pipe insulation has many inefficiencies and only slows the conductive heat transfer process because it contains small pockets of air.  With HPC® Coating, heat loss is controlled by the light weight, low-density ceramics which results in more heat being held on the surface and increased temperature/pressure inside the pipe or vessel.  Less energy is required to maintain required temperature/pressure levels results in greater energy savings.

Traditional pipe insulation continuously suffers from costly maintenance in large industrial piping systems. By absorbing air and moisture, traditional pipe insulation systems compress, deteriorate rapidly, lose insulation performance, and cause CUI.  When fiberglass, for example, is exposed to as little as 1.5% humidity, it can lose 1/3 of its effectiveness.  In addition, the inability of traditional pipe insulation to fully cover and seal the valves, joints and elbows of various systems creates gaps in protection for industries that depend on high heat efficiency.

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HPC® Coating Benefits

  • Reduced Maintenance/Easy to Apply – No need for shutdown. Apply directly to hot pipes while operating.  Completely coats and protects areas that are difficult access with much thicker fiberglass insulation such as elbows, joints, and valves.
  • Replaces bulky wraps and jacketing – Easier to repair and maintain. Entire sections don’t need to be replaced for routine inspections or minor repairs.
  • Increased Insulation – Additional coats immediately reduce surface temperature and heat loss.
  • Better Protection – HPC® Coating protects against condensation due to its complete surface bond, and prevents CUI (Corrosion Under Insulation), a common problem with conventional insulation.
  • Long Lasting – Can be top coated for waterproofing, weatherizing, or exposure to harsh environments.  Does not absorb humidity or lose insulation value when over coated.
  • Safe – HPC® Coating is water-based, non-flammable, and non-toxic.
  • Coverage – Can be sprayed to fit over any configuration or shape.

HPC® Coating Uses

  • Reduction of external temperature of hot surfaces, aiding worker safety. Can build layers as needed to reduce the temperature to the desired level.
  • Reduction of heat loss translates into considerable energy savings.
  • Stops condensation in environments with large temperature differences.
  • Stops CUI (Corrosion Under Insulation).
  • HPC® Coating will cover previous coatings, provided they are fully adhered to the surface.

Georgia-Pacific Receives EPA ENERGY STAR and SmartWay Recognitions for Sustainability Work Using HPC® Coating

The ENERGY STAR® program recognized the work of Georgia Pacific (GP), Flint Hills Resources (FHR),and their parent company Koch Industries for a Top Project at the 2023 Energy Star Industrial Partner meeting.  The recognition is for their efforts to improve energy efficiency and reduce corrosion in Koch manufacturing assets using HPC® ceramic insulation coating.  GP tested a wide range of insulation options to protect manufacturing equipment and chose HPC Coating.  This was first tested at its Naheola paper mill in Alabama.

HPC Coating - Georgia PacificThe fully insulated digester reduced heat loss by 49% and saved Naheola an estimated $332,000 in energy costs annually.  It also improved the quality of the cooking process by allowing the digester to better maintain its internal temperature.

HPC hermetically sealed the digester to keep out any new moisture, so when some of the HPC was removed in 2022 to allow for repairs to the digester, there was no evidence of new corrosion under the HPC.

GP is already using HPC at other mills following the results of this experiment. In addition to the energy savings, HPC’s ability to protect manufacturing assets from corrosion could save GP and FHR millions of dollars in equipment replacement costs.

GP has also earned additional recognition from the EPA’s ENERGY STAR programs.  GP’s Leaf River Cellulose mill in New Augusta, Mississippi, is the first paper pulp mill in the U.S. to receive EPA’s ENERGY STAR certification.

You can read full article on GP’s website here:  Read the full article

Need more information?  We look forward to helping you get the best results for your project.

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HPC Formulations

HPC® Standard – Ambient up to 450°F (232°C)

HPC® is water-borne and extremely lightweight in appearance.  It uses a special acrylic resin blend with 7 specific ceramic compounds added to provide a non-conductive block against heat transfer.

HPC Intermediate – 400°F (200°C) up to 1000°F (538°C)

HPC Intermediate (HPCI) is a water-borne and extremely lightweight in appearance.  HPCI Coating uses a special acrylic/silicone resin blend with specific ceramic compounds added to provide a nonconductive block against heat transfer.

HPC® HT – For temperatures up to 1112°F (650°C)

HPC® HT is a two-part hybrid silicone/solvent resin (Part B is flammable) and (Part A is water-based resins) using specific ceramic compound loads for application directly over surface temps up to 1112°F (650°C).  It can be built up as needed to reduce surface temperatures to a level where HPC Intermediate or HPC® Standard can be applied.

HPC® Certifications-Lab Tests

ASTM

ASTM E 84- Class A

ISO8302/ASTM C 177  Thermal Conductivity (0.063W/mK @ 86°F/30° C

ISO 8302- Thermal Conductivity

IMO

IMO- MSC 61(67) Smoke and Toxicity Test

Marine Approvals – American Bureau of Shipping

USDA

USDA Approved

HPC® Documentation

For the most updated HPC, HPC Intermediate, and HPT HT Tech Data Sheet, Application Instructions, and SDS Sheet, please contact us. 

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