HOT SURFACE COATING ®

PROJECT PICTURES       CERTIFICATIONS       APPLICATION

TECHNICAL DATA SHEET

PRODUCT DESCRIPTION:
HOT SURFACE COATING ® (HSC ®) is specifically engineered to control hot surface temperatures ranging between 65°C - 177 °C / 150 °F - 350°F. It is lightweight and smooth in appearance. This is a water-borne system using a special acrylic blend with specific ceramic compounds to provide the non-conductive block against heat transfer without depending upon reflectivity. The coating will dry down on a cold surface by evaporation and can be aided in the dry down by adding heat to the environment. If the surface is already heated, the dry-down process will take care of itself without additional steps required.

HSC ® is water-borne to offer a non-flammable, non-toxic formula for medium heat surface applications over standard steam pipes, oven wall construction and other hot surfaces. This coating was designed for applications whose temperature exposures falls below that which requires HOT PIPE COATING ® ( up to 700°F / 370°C). HSC ® is more easily applied for a smoother finish.

HSC ® can be applied over metal, concrete, wood or all surfaces not glazed or containing polypropylene (having no pores).

FEATURES:
Percent Solid : 77.93% solids by volume \ 50.98% by weight
4.5 pounds per gallon
Dry time: If over 200-300°F, 10-30 minutes per coat or until steaming action has finished. If over a cold surface a minimum of 8 hours.
Elongation: 125%
pH: 8.5-9.0
VOC: 70 grams per liter
U.S.D.A. - Approved

Commercial and Institutional Steam Efficiency:
Checklist for Getting Management Approval

ROCKWOOL/FIBERGLASS WRAP VS. HSC ® FOR HOT PIPES :

Note : The cost comparison between Rockwool/Fiberglass vs. HSC ® coating for hot pipes should be made with respect to the total costs. The total costs include material costs, installation costs, repair costs, frequency of downtime, maintenance costs, labour costs and life span. When all these costs are combined, HSC ® coating is much superior to Rockwool/Fiberglass insulation as evident in the above comparison.

ABSTRACT on CORROSION UNDER INSULATION

TYPICAL CUI ( Corrosion Under Insulation )

BTU LOSS CALCULATION
( These calculations are courtesy of Georgia State University )

In order to calculate cost savings by btu loss prevention ( the Stefan-Boltzmann law ), there are several variables that need to be determined such as the radiating area, the emissivity of the radiating body, the radiating temperature, the surrounding temperature, etc.. Once these variables are known then the CALCULATION of BTU loss per hour can be performed. The total btu loss can then be translated into DOLLARS ie. 1,000,000 Btu's = 1,000 cft of Natural Gas = 1 GJ of electricity.

To assist in the calculation of the radiating area of a pipe here is a chart.

Again these cost savings are IN ADDITION TO THE SAVINGS ON REDUCED DOWNTIME which is by far the most immediate savings given that a shut down can cost a company THOUSANDS or even TENS OF THOUSANDS of DOLLARS per hour. The other benefit is ENVIRONMENTAL as the chart below demonstrates the reduction in fuel burned and the corresponding reduction in GREEN HOUSE GASES.

INSULATE STEAM PIPES
Introduction
Uninsulated steam distribution and condensate return lines are a constant source of wasted energy. Insulation can typically reduce energy losses by 90% and help ensure proper steam pressure at plant equipment. Any surface over 120°F should be insulated, including boiler surfaces, steam and condensate return piping, and fittings.

Insulation frequently becomes damaged or is removed and never replaced during steam system repair. Damaged or wet insulation should be repaired or immediately replaced to avoid compromising the insulating value. Eliminate sources of moisture prior to insulation replacement. Causes of wet insulation include leaking valves, external pipe leaks, tube leaks, or leaks from adjacent equipment.

Operation

Example: In a plant where the value of steam is $4.50/MMBtu, a survey of the steam system identified 1,120 feet of bare 1-inch diameter steam line, and 175 feet of bare 2-inch line both operating at 150 psig. An additional 250 feet of bare 4-inch diameter line operating at 15 psig was found. From the table, the quantity of heat lost per year is:

1-inch line: 1,120 feet x 285 MMBtu/yr per 100 ft = 3,192 MMBtu/yr

2-inch line: 175 feet x 480 MMBtu/yr per 100 ft = 840 MMBtu/yr

4-inch line: 250 feet x 415 MMBtu/yr per 100 ft = 1,037 MMBtu/yr

Total Heat Loss = 5,069 MMBtu/yr

The annual operating cost savings from installing 90% efficient insulation is:

0.90 x $4.50/MMBtu x 5,069 MMBtu/yr = $20,530

CERAMIC TECHNOLOGY USED IN THIS PRODUCT:

Superior Products International has been experimenting with and developing the uses of "insulation and fire protection" ceramics for over 15 years. This category of ceramic functionality is new to the engineering fields. Only in recent years has the idea of insulation been associated with this new breed of ceramics.

Superior Products International knew that this area had not been thoroughly explored before, nor had any extensive documentation been presented for this application. In contrast, many articles and studies have been devoted to the abrasion resistant ceramic compounds and how they can be used in manufacturing and industrial markets.

Insulative ceramics are completely different and separate from those used for abrasion resistance. No extensive studies have been performed to determine which ceramic compounds, either natural or manmade would be best suited for eliminating heat transfer. Some studies have acknowledged the "reflection" of heat by mere radiation of sunlight but since very limited study has been performed, it was thought that reflection was all that this new category of ceramic could provide.

Superior Products International initially worked in the early 1990's with the aid of the ceramic engineers at the Marshall Space Center Laboratories, and it was discovered that no real research had been performed across the broad spectrum of possible ceramic compounds in order to determine the scope of ceramics stopping or slowing "heat conduction" rather than merely radiant heat reflection. It was also decided that Superior Products International would continue the R&D work over the next several years to discover the possibilities of this new design of ceramics. An extensive search was organized and begun to locate all possible types of ceramics compounds in the world market for trial-and-error testing. A system was designed to take each compound through a series of heat conduction tests to find its ability to stop heat conduction. More than 1,500 compounds were received and tested. From this R&D period, eight different compounds were identified as having the ability not only to catch and throw heat away from their surfaces in a manner similar to reflection but also to control heat transfer via conduction.

Superior Products International chose three of these ceramic compounds to develop its insulation coating called SUPERTHERM ®. A fourth ceramic was added in 2000 as part of our continued research in controlling heat transfer. This is a thin film coating that will protect against heat migration equal to six inches of fiberglass batt insulation when applied over surfaces facing the heat source. SUNSHIELD ® is inferior to SUPERTHERM ® but is still superior to any of the cheap imitations on the market. SUNSHIELD ® is less expensive because the Fire ceramic \ resistance and urethane \ toughness have been left out. SUNSHIELD ® does have the same dual acrylics and similar multi ceramic insulation package. EPOXO THERM ® likewise has a similar multi ceramic insulation package but in an Epoxy carrier. Epoxies are required for application to wet substrates such as in the case of extreme condensation.

Seven of the ceramic compounds were also chosen to work in combination with one another in high heat situations. HOT PIPE COATING ® ( up to 700°F \ 370°C ) and HOT SURFACE COATING ® (from 65°C - 177° C / 150°F - 350°F ) were developed to capture surface heat and stop thermal transfer via conduction. OMEGA FIRE (SP 2001 F) ® contains eight different ceramics mixed with glazing materials and hardens to stop flame, smoke or gas penetration and has up to a 3 hour Fire Resistance Rating. As with all of our protective coatings, each one is specifically engineered to solve a particular problem under a wide variety of application requirements and conditions.

LIMITED WARRANTY:
Unless Superior Products provides a written warranty of fitness for a particular use, Superior Product's sole warranty is that the product, as supplied, will meet the current sales specifications and is specific only to return of product found to be defective upon opening of container within one year. Customer's exclusive remedy and Superior's sole liability for breach of warranty is limited to refund of the purchase price or replacement of any product shown to be other than as warranted and Superior Products expressly disclaims any liability for incidental or consequential damages.

IF HEAT GAIN OR LOSS IS A PROBLEM ON ANY STRUCTURE OR EQUIPMENT. . .
WE OFFER AN. . .

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