Summary

Fortum Waste Solutions A/S extended the lifespan of their surface condensers by up to 25 years using Plastocor’s expertise in engineering and advanced coating solutions. This showcases Plastocor’s capability for tackling complex engineering challenges and ensuring long-term operational efficiency.

Content

> Client Overview
> Challenge
> Solution
> Results

Client Overview

Fortum Waste Solutions A/S, located in Nyborg, Denmark, specialises in managing hazardous waste. Their commitment to environmental sustainability and operational efficiency necessitates reliable, long-lasting, and well-thought-out equipment maintenance and protection solutions.

Challenge

Fortum’s surface condenser, initially constructed in 1989, received plastocor® Cladding in 2004, which provided almost two decades of reliable protection against corrosion and erosion. When the time came to renew the protection in 2021, Fortum’s advantages of continuing with Plastocor were evident based on their positive first experience. Instead of opting for a costly, disruptive, and time-consuming equipment replacement, they recognised the added value of renewing the existing system. The challenge lay in executing this high-level project with the same excellence, ensuring minimal downtime and seamless integration into their operational schedule.

Solution

Fortum Waste Solutions A/S asked Plastocor to not only renew the plastocor® Cladding for protecting the tube sheets but to build an even more comprehensive corrosion protection design, including plastocor® High-Performance Coating for the water boxes, along with the plastocor® DUROCAULK anti-shock upgrade. This solution extends the equipment’s operational life while minimising maintenance interruptions. 

Implementation 

1.  Assessment and Planning: Detailed analysis of the existing conditions and requirements, including the water boxes’ unique design aspects, considering the water quality.
2. Custom Coating Application: In 2021, the tube sheet received plastocor® Cladding, and the water box received the plastocor® High-Performance Coating solution, including customised coating designs for areas possibly creating vulnerability in the system, in particular the separation plates of the water boxes.
3. Efficient Execution: The entire process, executed with precision, was completed in less than ten days, resulting in minimal disruption to Fortum’s operations.

Results

The operation provided the following key benefits. 

• Extended Lifespan: The extended protection is projected to extend the equipment’s lifespan by up to 25 years.
  
• Operational Efficiency: The quick application process minimised downtime, allowing Fortum to maintain its operational schedule with minimal disruption.
• Enhanced Protection: The customised coating solutions ensured robust protection against corrosion and wear, adapting to the unique design features of the water boxes. In addition to plastocor® Cladding for Tube Sheets, the plastocor® DUROCAULK anti-shock upgrade enhanced the system’s resilience, providing crucial protection against mechanical impacts and thermal stresses. This extra layer of defence further safeguarded the equipment integrity, ensuring its reliability and extending its operational life.

Client Feedback

Fortum Waste Solutions A/S expressed high satisfaction with the results, noting the seamless execution and the significant extension of their equipment’s operational life. They highlighted the efficiency and reliability of the Plastocor solutions in maintaining and enhancing their critical infrastructure, which was implemented under an effective risk assessment process and strict quality management system.

Conclusion

The case of Fortum Waste Solutions illustrates the significant impact of the durability of plastocor® Technology in extending the lifespan of industrial equipment. This partnership showcases the efficiency of collaborating with Plastocor.