A summer day can be no picnic.

In addition to the outdoor heat and humidity, the direct sunlight beats indiscriminately on everything. Without proper insulation, a metal-roofed building can quickly feel like an oven.

In the late 1980s, Joseph Pritchett was developing an insulation coating in the U.S. Sun Belt and learned that not all his customers were satisfied with the options available at the time, so he thought he’d develop his own product. He knew NASA had experience in thermal testing, particularly in the realm of ceramics, which have several uses for the agency. Ceramics’ heat­ resistant properties make them excellent materials for spacecraft re-entry shields, and their durability is perfect for airplane components. However, as Pritchett later discovered, not all ceramic compounds can work in a coating that’s applied wet and blended with paint. He had to find the right ceramic, and he thought by infusing paints with both insulating ceramic compounds and tough, resilient polymers, he could devise a coating insulation with the best features or both.

Through the Technology Transfer Office at NASA’s Marshall Space Flight Center in Huntsville, Alabama, Pritchett contacted the center’s materials lab. The facility had many ways to test heat-resistant materials, such as a thermal vacuum chamber that simulates the extreme temperature swings in space and a thermomechanical analyzer that measures how a sample expands under heating. When he asked researchers there for compounds that could help him, the scientists provided a list of possible ceramics. When none of those worked in a coating, the Marshall engineers widened their search and came back to Pritchett with more ceramic compounds.

Over a period of six years, Pritchett tested every compound on the lists NASA provided, whittling down the potential compounds until he found the perfect insulation. Pritchett founded Superior Products International II Inc. or Shawnee. Kansas, in 1995. The product, dubbed Super Therm®, is a composite of both ceramic and polymeric materials. The ceramic acts as the primary heat reflector and heat insulation, while the polymer is more of a heat and environmental-resistant binding agent.

In 2011, when tested by the Oak Ridge National Lab for a pilot program for cooling low-income housing, it was confirmed that Pritchett ‘s product would work as suggested and save energy when cooling homes. Pritchett said the engineers at Marshal played a pivotal role in Super Therm®’s development, as their knowledge was key to finding the right ceramic material. In addition to building insulation, the material has been used in industrial applications. such as keeping equipment like tanks and pumps coot on oil rigs. Pritchett said other insulation providers have only recently started looking into the same material components to improve their products, but he’s grateful Super Therm® had the head start.

“It is now a source of accomplishment that I was able to work with NASA to get a start on the study of ceramic compounds when all the others are just now doing it.” Pritchett said. “It gives us a 30-year head start on the study of what works and what does not work.”

Read the NASA article | Full PDF about SPI NASA Journey

SPI NASA Story | NASA Fire Testing Results

The post NASA’s 2024 Spinoff Magazine with Super Therm® appeared first on SPI Coatings.

• Georgia-Pacific wins the EPA ENERGY STAR Award for energy efficiency with HPC® Coating
• HPC® Coating at Naheola paper mill saves $332,000 annually with one digester
• Georgia-Pacific’s commitment to environmental stewardship emphasized exclusively through HPC® Coating
• HPC® Coating reduces heat loss, prevents corrosion, and withstands high temperatures
• Successful HPC® Coating application at Naheola mill leads to broader use in Georgia-Pacific plants
• Potential annual savings across all plants estimated over $20 million
• HPC® Coating dual benefit of insulation and corrosion prevention could save over $40 million per annum
• HPC® Coating insulation coating material gives 13-18 month ROI estimated from savings reported
• Provides exceptional employee personnel protection
• Georgia-Pacific engineers reported completely stops corrosion under insulation
• Groundbreaking insulation technology that revolutionizes industry and environmental benefits

2023 EPA ENERGY STAR Energy Saving Award

Georgia-Pacific has been recognized by the U.S. Environmental Protection Agency (EPA) for its revolutionary application to energy efficiency with HPC® Coating. SPI Coatings innovative high temperature ceramics insulation coating, HPC® Coating was applied to a Naheola paper mill digester tank at Georgia Pacific which saved $332,000 in annual energy costs, winning the EPA ENERGY STAR Energy Saving Award. 

Georgia-Pacific has always shown a commitment to environmental stewardship and continuously improving energy efficiency and identified that HPC® Coating was a clear benefit to all other options in the marketplace. The ENERGY STAR® program recognized the work of Georgia-Pacific, Flint Hills Resources and their parent company Koch Industries for a Top Project at the 2023 ENERGY STAR Industrial Partner Meeting in October 2023. The recognition comes for their efforts to improve energy efficiency, reduce CO2 and reduce corrosion in Koch manufacturing assets.

Innovation of HPC® Coating as a Revolutionary Insulation Coating

Together with Flint Hills Resources, Georgia-Pacific engineers tested a wide range of insulation options to protect manufacturing equipment and found a solution in HPC® Coating that reduces heat loss, prevents corrosion, and can be applied to equipment that operates at temperatures up to 1,200°F / 650°C. HPC is a ceramic based, water-borne insulating coating designed with over seven lightweight, low-density ceramics to insulate in high temperature situations from 100° to 650°C. 

It is a thick, closed film thermal insulation coating that works opposite to traditional open film insulation that uses air to slow heat yet also allows air and moisture to transfer. HPC® Coating as a vacuum (hermetically) sealed insulator coating blocks heat loss, saves energy, reduces maintenance, stops CUI (Corrosion Under Insulation), reduces landfill and personnel protection. HPC can also last over 15 years (without abuse) with maximum benefits during that time.

HPC® Coating was first tested by Georgia-Pacific on a condensate receiver at its Naheola paper mill in Pennington, Alabama. The condensate receiver captured excess steam and condensation produced by a paper machine. Georgia-Pacific then moved forward with coating a full digester at Naheola with HPC® Coating in March 2020. 

Read the Georgia Pacific News

HPC® Coating offers Multiple Critical Benefits

• Significant Energy Savings: A key benefit of using HPC® Coating in industrial settings is the substantial energy savings it offers, leading to significant cost reductions.
• Corrosion Prevention: HPC® Coating effectively blocks corrosion under insulation (CUI), thereby extending equipment life and reducing maintenance costs.
• Enhanced Safety Improvement: It provides burn protection and personnel safety to employees by reducing surface temperatures.
• Operational Efficiency: HPC® Coating can be applied while equipment is operational, avoiding shutdowns.
• Environmental Impact: Reducing energy consumption contributes to lower emissions, aligning with green initiatives and carbon emissions.

The Use of Digesters for Many Industries

Digesters cook wood chips at high temperatures to obtain the pulp fibers used to make paper products. During the process, the wood chips are loaded into the digester, and chemicals added. The temperature is then raised to around 160°C, and the pressure is increased to several atmospheres. This high temperature and pressure helps to break down the lignin in the wood, which acts as a natural glue, allowing the cellulose fibers to separate.

A digester unit in the context of industries like oil, gas, and energy, is typically a vessel or system where biological decomposition of organic material takes place. This process is commonly used in waste management, wastewater treatment, and biogas production. Digesters break down organic matter, often in the absence of oxygen (anaerobic digestion), to produce biogas, which can be used for energy, and digestate, a nutrient-rich substance used as fertilizer. This aligns well with sustainability and energy-efficient goals in various industries.

The Expensive Impact of Corrosion Under Insulation (CUI)

Corrosion can be caused by traditional and commonly used bulk or wrap insulation in industrial equipment like digesters. CUI occurs when moisture becomes trapped between the insulation and the equipment surface. Over time, this moisture can lead to significant corrosion damage, impacting the integrity and safety of the equipment. The cost of CUI can be substantial, often involving expensive repairs, maintenance, and even equipment replacement. Additionally, there are indirect costs in maintenance, placement, production downtime and safety risks. The exact cost can vary widely depending on the extent of the corrosion, the type of equipment, and the industry sector. In some cases, the annual cost of CUI can reach millions of dollars for a single facility. 

HPC® Coating protected the Georgia Pacific digester from corrosion. The Naheola digester had already begun to experience corrosion prior to application, a common issue for digesters of its age. HPC® Coating hermetically sealed the digester to keep out any new moisture, so when some of the HPC® Coating was removed in 2022 to allow for repairs to the digester, there was no evidence of new corrosion.

The choice of operating temperatures for digesters depends on factors like the type of organic material, desired end products, and energy efficiency considerations. For a business like Georgia Pacific focused on sustainability, corrosion control and utilizing HPC® Coating, understanding these temperature ranges is crucial for optimizing insulation performance to deliver energy efficiency. These benefits collectively enhance operational, financial, and environmental performance.

HPC® Coating is Unmatched in Genuine Savings

HPC® Coating ability to save 49% in energy loss and $332,000 annually per unit at a single Georgia Pacific plant underscores its ability to revolutionize the insulation industry. Despite proven benefits in energy efficiency, corrosion prevention, and personnel safety, widespread adoption of the innovative HPC® Coating coating has been slow, due to resistance to change or existing commitments to poor performing traditional insulation. This raises important considerations about the broader industry’s commitment to energy conservation and sustainability, highlighting the need for embracing more effective insulation solutions like HPC® Coating. When new technology is proven, the effort to change is slowed by status quo attitudes, relationships with current suppliers, acceptance by insulation contractors who are given the role of providing the insulation.

Georgia-Pacific is now using HPC® Coating at other mills following the results of this successful pilot. In addition to the energy savings, HPC® Coating ability to protect manufacturing assets from corrosion adds savings potential for Georgia-Pacific and Flint Hills Resources in millions of dollars in equipment replacement costs. HPC® Coating also improved the quality of the cooking process by allowing the digester to better maintain its internal temperature hence energy savings and quality control. 

The potential savings from using HPC® Coating coating at Georgia Pacific could be considerable. If one unit at a Georgia Pacific plant saved $332,000 annually with HPC® Coating coating, and assuming each of the 30 plants has multiple digesters, the total annual savings could be substantial. If we estimate conservatively that each plant has at least one such unit and pipes, the savings across all plants would be 30 x $332,000 = $9.96 million after the single initial investment of application. If more units per plant are considered, or if savings are higher for some units, the total could indeed exceed $20 million annually.

If energy savings are around $9.96 million annually across all plants, the added protection against corrosion could potentially double these savings. This is due to reduced costs in repairs, tear-downs, and replacements. Thus, investing in HPC® Coating not only for insulation but also for its corrosion prevention could lead to total savings exceeding $40 million. The return on investment for HPC® Coating is significant, underscoring its effectiveness in both energy conservation, asset protection and employee protection.

Transforming Industries: Pioneering Energy Efficiency with HPC® Coating

The article highlights Georgia-Pacific’s significant achievements in energy efficiency and environmental stewardship through the use of HPC® Coating (Hot Pipe Coating). The HPC® Coating application at their Naheola mill led to a $332,000 annual energy saving for one digester, contributing to an EPA ENERGY STAR Award. The success with HPC® Coating, which also offers corrosion prevention and safety benefits, points to potential massive savings across Georgia-Pacific’s multiple facilities. It also underscores HPC® Coating potential to revolutionize the insulation industry and the broader commitment needed for sustainable energy solutions.

Read the Georgia Pacific News

The post Revolutionary Energy-Saving Game-Changer: Georgia Pacific’s HPC® EPA ENERGY STAR Win appeared first on SPI Coatings.

Author: Kristen Rindfleisch – Airport Improvement
Published: October, 2023

Harry Reid International (LAS) in Las Vegas regularly sees temperatures of more than 100 degrees Fahrenheit (37°C) throughout the summer, requiring significant energy to cool its passenger boarding bridges. The Clark County Department of Aviation, which operates LAS, has opted to have a reflective ceramic coating applied to bridge exteriors to help keep the interiors more comfortable for passengers. The strategy will also save energy and prolong the life of the airport’s preconditioned air units, as well as the jet bridges themselves.

When temperatures at the southwest desert airport soar, the external surface temperature of its metal boarding bridges can exceed 200 degrees Fahrenheit (93°C), and most of that heat radiates into the boarding bridges. “We wanted not only more efficient preconditioned air units, which we’re looking into, but it was really more about how we could reduce the cooling curve, if you will, to get that temperature down to better ambient temperatures,” says Doug McMahan, managing director for Facilities and Maintenance with the Clark County Department of Aviation. “So, we wanted to look at something innovative.”

Facts & Figures

Project: Solar Heat-Resistant Coating for Boarding Bridges

Location: Harry Reid Int’l Airport in Las Vegas

Scope: About 100 jet bridges

Status: 70 have been coated since 2017; remaining 44 will be treated as they come due for electronic refurbishment in next 2 years

Cost Per Bridge: Similar to standard paint

Product: Super Therm^®, by SPI Coatings

Application Contractor: Southwest Specialty Coatings Inc., sister company of Cor-Ray Painting

Timeline: Application takes 7–10 days per bridge; coating is applied when bridge is taken out of service for electronic refurbishments

Key Benefits: Reduces cooling time & energy consumption; improves passenger comfort; reduces wear & tear on preconditioned air units; extends life of jet bridges

Associated SPI Coatings Products: Enamo Grip topcoat for sides of bridges; Enamo Grip 5000 topcoat for rotating rotunda segments; Rust Grip^® corrosion protection for components showing signs of rust

Testing and Results

McMahan found just that through a construction management consultant who was discussing a coating product (Super Therm^®) while working with other local public entities.

Aviation Department personnel began general testing of Super Therm^®, a reflective ceramic coating manufactured by SPI Coatings, in 2017. For reference, the company offers two kinds of ceramic coatings generally applicable to jet bridges: HPC^® Coating, which is a thick-film, insulating coating applied on the inside to block conductive heat transfer; and Super Therm^®, a thin-film, reflective coating usually applied on the exterior to insulation and repel most of the solar radiation heat.

SPI Coatings Vice President of Business Development and Technology Timothy Cappel explains that Super Therm^® does not absorb heat from the sun. “That’s the benefit,” he remarks. “If it doesn’t absorb the heat, then there is no heat transfer to the inside of the passenger walkways.” 

In 2018, LAS began testing the ceramic coating on passenger boarding bridges that face southwest, because they receive the most radiant heat. Typically, a preconditioned air unit starts cooling the jet bridge 20 to 30 minutes before a flight arrives. It does so by taking hot outside air and chilling it with air between 28 and 34 degrees Fahrenheit. After the aircraft parks at the gate, it is connected with exterior hoses, and the cooling system is switched from bridge mode to aircraft mode so the aircraft can turn off its auxiliary power unit and stop burning fuel to cool the air on board.

NOTE: Laboratory and Field project results as stated here may vary according to different climate conditions.

To test the performance of Super Therm^®, the project team recorded temperatures inside the bridges before starting the preconditioned air units, and also measured the time needed to cool them. McMahan reports that coated bridges were cooler to begin with—staying with a few degrees of ambient temperatures even as the day warmed up—and also cooled down faster. “The bridge was able to maintain a lower setpoint when we switched over to the aircraft mode,” he adds.

Phased Implementation

After extensive testing for the better part of two years, the Clark County Department of Aviation decided to incorporate Super Therm^® into the ongoing refurbishment of all JBT AeroTech boarding bridges at LAS. The coating manufacturer recruited Southwest Specialty Coatings for installation. And in 2019, the contractor began applying Super Therm^® to jet bridges as they were pulled from service to receive updated electronic components and controls.

“We try to take advantage of when those bridges are going to be closed anyways,” McMahan explains.

So far, crews have coated approximately 70 jet bridges; the remaining 44 will be coated over the next two years as they come due for other refurbishment.

McMahan notes that the cost is about the same as repainting bridges with a standard paint product. “It’s obviously well worth that for the benefits we derive,” he says.

The reflective ceramic coating helps drop the interior temperature of the jet bridges to within three or four degrees of the ambient air temperature, but that is still quite hot many days. “Usually on the inside of a metal shell like that, it can climb up to 130 or 140 degrees easily,” says Justin Leavitt, operations manager at Southwest Specialty Coatings.

In general, travelers are unlikely to notice the temperature on a jet bridge unless it’s extremely hot or cold. If passengers at LAS don’t notice extreme heat, that indicates the coating is doing its job. “Even though they may be walking through and not even realize it, it’s more comfortable,” Leavitt notes.

Application Process

Crews apply Super Therm^® onto the roof and exterior sides of the jet bridges and also onto the rotating rotunda segments. Enamo Grip, another product from SPI Coatings, is applied on the sides of the bridges as a topcoat, but the roofs do not need it, Cappel advises. Enamo Grip 5000 is used as a topcoat on the rotunda segments for added protection against the additional movement and wear. Rust Grip^®, a corrosion protection coating from SPI Coatings, is applied to any rails or other components showing signs of rust.

Applying Super Therm^® isn’t as simple as spraying on a fresh coat of paint, McMahan notes. The physical composition and viscosity of the material are unique, requiring special equipment and techniques. Contractors consequently need to be trained and certified by SPI Coatings to ensure quality and guarantee integrity of the product throughout its 10-year general product limited warranty. “SPI Coatings was definitely the firm that just knocked it out of the park for us,” McMahan remarks. “Their quality was phenomenal, and they stand behind their product.”

Naturally, coordination has been crucial during the phased applications at LAS. “We have to communicate well, so the [boarding bridge] is down for as minimal time as possible,” says Leavitt. “It’s really just sequencing—making sure we schedule things correctly with the intricacies of getting in and out of the airport property.”

Each boarding bridge takes about seven to 10 days to coat, and work is completed onsite at LAS. The only preparation for airport personnel is extending the bridge to its full length so technicians can work on the entire structure. Crews from Southwest Specialty Coatings set up a barrier to protect the area around the jet bridge as they work. There is virtually no impact on travelers or airport operations.

Barring extreme weather conditions or bonding problems during application, Super Therm^® can last 25 to 30 years before it may need to be reapplied, says Cappel. When that time comes, a new layer can be applied directly over the previous coating.

Efficiencies and Benefits

Because it takes less time to cool coated bridges, the airport’s preconditioned air units will consume less energy and presumably last longer because they are running for shorter periods of time. Moreover, the ceramic coating is expected to extend the life of the bridges because it is thicker than regular paint, eliminates expansion and contraction of the metal structure and provides a buffer to everyday wear and corrosion.

The coating also benefits maintenance staff and technicians working on the exterior of the jet bridges. “The ones with the coating stay about one to three degrees from what the exterior ambient temperature is outside,” McMahan reports. “That is phenomenal.”

Previously, maintenance and repairs on boarding bridges had to be performed at night, because the structures were simply too hot to touch. Now, technicians can work on the coated jet bridges during the day. “They basically can lay on the surface with their bare skin and never be uncomfortable or burn themselves,” Cappel remarks.

As other infrastructure projects arise at LAS, Clark County Department of Aviation will consider testing and using Super Therm^®, perhaps on buildings or rooftop air-conditioning units. Other southwest U.S. airports, including Tucson International, use Super Therm® on roofs and storage facilities.   

McMahan sees even wider potential, noting that airports in rainy regions could benefit from the product’s rust protection qualities, and SPI Coatings’ interior product could help increase insulation values for jet bridges at cold weather airports. “If you were doing a refurb, getting down to the bare metal, it might be worth looking at,” McMahan suggests.

Read the article – pdf

Read the Airport Improvements article

Other Aviation Heat Management Projects

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A game changer for insulation piping!

On December 13th, 2021, a paper titled Insulative Coatings – Fit for Purpose was published and presented by Arin Shahmoradian at the 2021 SSPC Coatings+ Show in Phoenix, Arizona, USA.

SPI Coatings in cooperation with the largest interstate pipeline operator in the U.S. has developed a ground-breaking insulative coating system. The new solution consists of an acrylic based insulative coating applied over a fusion bonded epoxy, wrapped in proprietary polyester mesh for structural strength, then top coated with a marine grade epoxy to seal the entire surface.

Conventional below grade insulation materials suffer from cathodic shielding. Laboratory and field testing proves HPC + Moist Metal Grip coating system does not cause cathodic shielding. SPI Coatings insulative coating system is now a proven alternative to conventional jacket insulation, providing superior insulation and corrosion protection. This coating system can also be shop applied, making it a game changer for ground piping.

The SSPC presentation also highlights new ways of applying both our thick film (HPC) and thin film (Super Therm) insulative coatings to combat both process heat and solar heat related challenges. Additional case studies applications including above ground pipes, tanks, vessels, are also referenced in the presentation link below. Over the past 20+ years, our global team of distributors have developed new coating systems to protect a variety of assets across multiple industries.

HPC to insulate underground heated pipes for Natural Gas and oil companies to do several things:

1. Insulate the pipes where the wrapping of the pipes cannot insulate very well. Wraps allow moisture to load and contact the pipe surface.
2. By using HPC, the anodes used to control corrosion are able to work correctly. The Standard Wrap type insulations must have metal jacketing or protection around the wrap material. This metal jacket does not allow the anodes to control the electrical currents used by the anodes to protect the pipes from developing corrosion.
3. HPC is over wrapped with our polyester mesh and Moist Metal Grip to protect from water and moisture. This system does not interfere with the electrical currents the anodes need to perform while this system blocks corrosion development.

Presentation pdf >

Report pdf >

Insulative Coatings Fit for Purpose – SSPC Coatings+ 2021 – by Arin Shahmoradian (SPI)

Abstract: Corrosion Under Insulation (CUI) is a very serious problem impacting the oil and gas, petrochemical, power and heavy industries. Due to the high costs associated with CUI, many industries have begun abandoning conventional jacket insulation. Recent advancements in trade association standards have helped engineers select, apply and inspect different types of insulative coatings in lieu of conventional jacket insulation.

New insulative coating standards by NACE are helping to minimize corrosion costs while simultaneously improving insulation efficiency with a side benefit of personnel protection. However not all insulative coatings are made to address the same challenges.

By differentiating between process and solar heat, engineers can correctly specify insulative coatings which are fit for purpose. This distinction can also help determine the correct application thickness, method and cost. The choice of thickness and type of insulative coating is critical for the end users to receive the perceived benefits they wish to achieve. In the quest for insulation optimization, a variety of insulative coatings are now a proven alternative to conventional jacket insulation.

Insulative Coatings Fit for Purpose SSPC Coatings 2021 Presentation Agenda

• Fit For Purpose – Process Heat Vs. Solar Heat
• Conventional Insulation – Corrosion Under Insulation
• BP Review – Insulation Optimization Tactics
• Sample Applications – Thick Film Vs. Thin Film
• Testing Methods – Process Heat Vs. Solar Heat
• New Testing – Cathodic Shielding
• New Applications – Below Grade Piping
• LNG – Boil-off Reduction

PDF Version

For more information contact Arin Shahmoradian at arinshah@spicoatings.com Superior Products International II, Inc. / 10835 W. 78th St, Shawnee KS 66214 USA / +1 (913) 962 4848 www.spicoatings.com

HPC® Coating | Moist Metal Grip | Super Therm

Read the article – PDF

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A long-term lab and field study by Chevron and Workstrings International published by the Society of Petroleum Engineers, tested 18 leading coatings on drill pipes for eight years. Drill pipes are the toughest environment anyone can ever imagine and Rust Grip^® was the top performer. In that paper they highlight the cascading benefits that came from solving the corrosion problem. You solve the corrosion problem, that’s already millions of dollars in savings and then because you’re not having to swap out these drill pipes so often, you’re saving millions in logistics.

“Beyond the goal of eliminating corrosion and pitting-related damages, the introduction of externally coated completion tubulars has facilitated a paradigm shift in the way operators manage rental completion tubulars.”

“This coating system provides a trouble free solution and significant cost savings to the operator and pipe rental company through reduction in pipe repairs and damages; loss of capital assets; and rig time due to pipe issues, fluid issues and corrosion issues.”

“The savings realized in connection repairs alone is estimated to exceed $250,000 per well.”

Read the article – PDF

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