Coal Mine – Loctite PC 7255

Case Study: Reinventing Coal Slurry Tank Protection With Loctite® Sprayable Ceramic Coating

The Challenge

A coal processing facility faced frequent equipment failures due to severe corrosion and abrasive wear on the rake arms within their coal slurry thickener tank. Traditional industrial paints failed to provide adequate protection, resulting in costly downtime and decreased operational efficiency.

Henkel’s Solution

Henkel recommended the application of Loctite® PC 7255™ Sprayable Ceramic Coating to prevent further corrosion and abrasive damage on the rake arms. The process included:

Surface Preparation: The tank was drained, and coal debris was removed from the rake arms using high-pressure water. Corroded areas were treated, and the surface was finely finished through grit blasting. Salts and chloride levels were tested to ensure they were below 40 ppm, optimizing coating adhesion.

Coating Application: A two-coat system was applied — first, a grey sprayable ceramic base coat, followed by a green sprayable ceramic top coat — providing a durable and protective barrier.

The Outcome

Enhanced Abrasion Resistance: The Loctite® Sprayable Ceramic created a smooth, low-friction surface, significantly improving wear resistance against harsh slurry conditions.

Superior Corrosion Protection: The long-lasting coating effectively shielded the rake arms from further corrosion damage, extending equipment life.

Improved Operational Efficiency: With the robust protective layer in place, the facility experienced reduced downtime and optimized thickener tank performance, leading to increased productivity and cost savings.

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