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How do you know which “Zone” your equipment is in?

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There is a need to use condition monitoring equipment in many hazardous locations, to measure vibration levels and temperatures of rotating machinery to diagnose faults such as misalignment, unbalance or impending bearing failure. The instruments needed to do the monitoring must therefore be “intrinsically safe” and incapable of igniting an explosive atmosphere.

The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) put the onus firmly on the plant operator to decide which “Zone” the equipment is in and therefore what level of certification is required for any instrumentation used there.

This is because the likelihood of an explosive atmosphere existing is dealt with by the definition of a series of “Zones”. These range from Zone 0, where an explosive atmosphere is likely to be present most of the time, to Zone 2, where it is not likely to occur in normal operation, with Zone 1 the “grey area” in between.

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Deciding which parts of your plant are in which Zone is not easy and may require expensive surveys to determine. However, this is where the true benefit of Zone 0 certification comes in. Basically, you don’t have to think! Because Zone 0 certified devices can be used literally anywhere!

Zone 0 certified devices are typically more expensive due to increased manufacturing costs (e.g. additional safety components and higher levels of redundancy). However, Test Products International (TPI) has achieved a significant Zone 0 cost breakthrough with the very affordable TPI 9085Ex vibration analyser.

The “go anywhere” TPI 9085Ex is certified for Zone 0 IECEx/ATEX with North American approval. This means you simply don’t have to think what potentially explosive atmospheres you might encounter. The 9085Ex is certified to be intrinsically safe for ANY atmosphere WORLDWIDE.

The 9085Ex measures “bearing noise” and displays it in bearing damage units (BDU), which is roughly equivalent to “percentage wear”. In other words, readings above 100 BDU are indicative of a worn bearing. In addition, the 9085Ex uniquely incorporates a directly contacting temperature sensor within its vibration probe. This gives a highly accurate, virtually instantaneous, surface temperature reading for the bearing, simultaneously as the vibration reading is being taken. With a high BDU reading and high temperature you know that what you are seeing really is a worn bearing!

Additionally, a lot of machinery is remotely located (e.g. pumping stations), often in the “middle of nowhere”, requiring highly mobile teams of operatives to access them. However, the compact handheld TPI 9085Ex is extremely affordable and simple to use. It can, and indeed should, be included in every operative’s basic tool kit. Also by using the FREE TPI Bridge App, “routes” and readings can be transferred to and from the 9085Ex anywhere in the world using mobile devices (e.g. smart phone or tablet PC) and then via Bluetooth to and from the 9085Ex.

“Routes” are simply lists of machines showing exactly what readings need to be taken and where to take them. The readings are then automatically time and date stamped by the 9085Ex and saved in the route for automatic transfer to computer-based trending software.

Trending is the cornerstone of condition-based maintenance (CBM). By looking at trends of bearing noise and temperature readings, you can determine well in advance when a bearing will likely need replacing. The TPI 9085Ex comes with powerful, yet simple to use, subscription free trending software, which includes automatic email notification of alarms and report generation, giving you everything you need for a full CBM strategy.

For more information please contact TPI Europe’s head office on +44 1293 530196 or take a look on the website at www.tpieurope.com or email This email address is being protected from spambots. You need JavaScript enabled to view it.

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Quite fast. Active Explosion isolation with Q-Bic

Explosion isolation is essential for comprehensive explosion protection. Without isolation, an explosion safety concept is not only incomplete, but is also a waste of money for operators as.

Isolation systems prevent an explosion from propagating, thereby reducing the effects of the explosion to a minimum. Adjacent system components are optimally protected.

Explosion Isolation System Q-Bic

The explosion isolation system Q-Bic registers the emerging explosion and extinguishes the developing explosion flames within milliseconds by applying the extinguishing powder. The extinguishing powder is optimally distributed in the pipeline via a nozzle system and guarantees reliable isolation. The chemical barrier is particularly well-suited to applications in elevators and spray dryers. 

Fig. 1: Explosion isolation System Q-Bic

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www.rembe.de

 

Ensuring Safety in Hazardous Environments: ATEX Safety Showers

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Introduction

In industries where flammable gases, vapours, and dusts are present, ensuring the safety of employees is of paramount importance. The European Union's ATEX Directive 2014/34/EU, aim to regulate equipment used in potentially explosive atmospheres, requiring companies to implement safety measures that mitigate the risk of ignition and protect personnel.

Background

All chemical manufacturing facilities that handle or specialise in the production of volatile chemicals should adhere to ATEX regulations to protect employees from potential hazards. One of the key aspects of ATEX compliance is the provision of safety equipment, including safety showers and eye wash stations.

The Challenge and Solution

Compliance with ATEX Regulations: The company needs to comply with ATEX Directive 2014/34/EU, which requires the implementation of safety measures to prevent explosions in areas with potentially explosive atmospheres. This includes providing ATEX-compliant safety showers.

Employee Safety: The safety of employees is a top priority. You need to ensure rapid and effective decontamination in case of chemical exposure.

Equipment Selection: Choosing the right ATEX-compliant equipment is essential.  You must evaluate the specific requirements of your facility, including location, potential hazard levels, and the number of showers needed.

The Solution

Get peace of mind knowing that safety showers from Aqua Safety Showers will be manufactured from corrosion resistant materials and come with a two-year warranty, further promoting a safety-conscious workplace culture.

 www.aqua-safety.com

Brilliant Peli Lighting for Hazardous Areas

Only torches and lights that are certified under the ATEX Directive can be used in hazardous areas; where special precautions are required when using electrical equipment due to the presence or chance of explosive atmospheres.

Peli Products (UK) Ltd offer a wide range of ATEX certified, robust safety torches and work area lighting.  Developed and evolved over 30 years, Peli™ professional lighting products are designed for rugged offshore use in the toughest operating conditions. 

 Peli Safety Torches

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The first choice for professionals, Peli torches and headlights are bright, compact, lightweight and exceptionally hard-wearing.  These ATEX certified models are ideal for such hazardous areas as silos, tanks and chambers where an individual may be exposed to a range of potential hazards.

The Peli 3415 Zone 0 right angled torch can be clipped to clothing while the 2755 Zone 0 head torch is secured on a hard hat, using the rubber strap. Peli headtorches also come with hardhat mount and cloth strap. This enables the user to climb a ladder safely using both hands, while still having two light beams directed where required.

 

Peli™ 3335 Zone 0 R

Built tough to perform in the harshest environments, the 3335 Zone 0 is rechargeable and offers 58 hours run time.  There are 3 light modes: High, Low and flashing and a built-in battery level indicator to ensure you never get left in the dark.  A right-angle adaptor is available as an accessory for hands-free use, it allows the head to articulate, directing the light exactly where required.

Beyond its industrial benefits, this model champions environmental sustainability. The rechargeable feature eliminates the need for disposable batteries, minimizing waste and environmental impact. The lithium-ion rechargeable battery offers a life expectancy of over 2000 cycles, 4 times more than the usual amount and the long battery life further contributes to resource conservation, promoting a more sustainable approach to lighting solutions.

Work Area Lighting

Peli Area Lighting provides portable, powerful LED light where there is no mains power. Ideal for maintenance in both on and offshore industries, these rechargeable units deliver a safe, economic and convenient alternative to generator powered lighting.  There are no trailing cables to create a trip hazard, no fumes are emitted and no liquid fuel is required, thus improving worker safety and adding to the environmental benefits of this range. 

The Peli™ 9455 Zone 0 is a portable work light offering wide area illumination in high risk, hazardous areas.  This rechargeable unit is easily carried and can be set up in seconds. It has a retractable mast; the head can be rotated 360° and it also pivots to angle the light directly where required.

A ten-hour run time (economy mode) ensures light duration for a full shift.  Featuring a category leading light output of 1600 lumens and manufactured with a rugged, water resistant (IP54) body; it is ideal for heavy duty, industrial use.

Peli Products (UK) Ltd is an ISO registered company with a nationwide sales team.  Located throughout the UK, the sales team are hugely experienced and can advise on the most suitable lighting and protective packaging options. 

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For more details go to www.peliproducts.co.uk or ring the Peli Products (UK) team: 01457 869999.

Easier Joint Pin Extraction - New Enerpac Hydraulic Pin Pullers

Hydraulic tools specialist, Enerpac, announces the new PPH-Series Hydraulic Pin Puller, providing an efficient, safe, and versatile method for removal of joint pins during the maintenance of heavy machinery. These complete kits use hydraulic power to remove joint pins on vehicles, excavators and heavy machinery used in construction, mining, wind turbine gearbox pins, bogie and truck pin removal for rail and in stationary equipment found in manufacturing facilities.

Until now, operators have relied on pin removal using unsafe methods, such as torching, lancing, or hammering, all of which risk irreparable damage to the joint pin, resulting in extra costs and leading to longer downtime. With a pulling capacity of 40 to 67 metric tonnes, the PPH-Series Pin Puller provides a safer and more efficient removal of joint pins up to 302mm long. It uses a powerful, Enerpac hydraulic cylinder to extract pins with precision and minimal damage, allowing a single operator to remove a multitude of joint pin sizes easily.

Safer Pin Pulling

Supplied in a portable, wheeled carry case, the PPH-Series Pin Puller Kits, PPH40 and PPH66, are ideal for mastering a diverse range of pin-pulling tasks. Each set includes three stacking and locking patented C-Sleeves, with the option of adding an extra two for longer pins up to 508mm long. The C-shape design creates a fitment around the flag of heavy machinery pins, providing a precise and safe pin removal. Improving operator safety, each kit contains a shackle for lifting via a crane or lifting system. The column sections have multiple hoist points, designed to give the user more control over the balance of the tool while it is suspended. The kit also contains a Quick Nut for fast attachment to threaded rods, with alternative thread sizes available to purchase separately.

‘Quick Nut’ for damaged nut threads

With existing solutions using regular threaded nuts, that require time to run down the rod and cannot be used on damaged treads, the PPH-Series kits are engineered to streamline even on the most demanding pin pulling projects. The innovative split Quick Nut makes it easier and faster to manipulate damaged threads. The easy one-handed closure is quick to assemble around a rod and avoids running the nut over damaged threads. 

“Safety on the job site is paramount, which is why these kits offer a safer alternative than old-school, traditional methods involving sparks, heat, hammering, and loose parts. We wanted to provide a safe and efficient way for a single operator to extract pins from construction vehicles that eliminated damage to parts, but also provided a lightweight and potable tool that was practical to move about on-site. The transport and assembly of the PPH-Series Pin Puller Kits is made easier by the robust aluminium construction of the Enerpac Hydraulic Cylinder,” said Ejnar Christensen, National Accounts Manager, Enerpac.

Each PPH-Series Kit includes three column sections that lock together. Multiple column sections can be stacked together depending on the length of the joint pin. Up to maximum 5 Column Sections can be locked together.

For more information on the Enerpac PPH-Series Hydraulic Pin Puller visit www.enerpac.com.

ARCO LAUNCHES WORKING AT HEIGHT EQUIPMENT RANGE

Company’s safety services experts have helped design and develop new own brand offering

Safety specialist Arco has launched its own range of working at height equipment, designed and developed with experts from its safety services division, along with its fall protection manufacturing partners.

The new range introduces an own brand offering to add to the wide selection of fall protection equipment Arco already offers from some of the biggest brands in the safety industry.

The range features 17 products, including safety harnesses; anchorage slings; arrest, restraint and positioning lanyards; and self-retracting blocks, all designed to keep workers safe when carrying out tasks at height and in confined spaces.

The harnesses and lanyard are used together to prevent accidents when there is a risk of a fall from any height. The self-retracting blocks are designed for lower-height applications, instantly locking on impact to prevent falls.  

Arco Professional Safety Services experts are already using the new equipment in the field and when delivering training courses at the company’s five safety centres across the UK.

Mike Clayton, technical lead for working at height at Arco Professional Safety Services, said: “The new Arco working at height equipment range has been designed, developed with help from our own experts to bring total assurance and quality to the safety products market.

“Arco leads the market in working at height expertise with our joined-up safety solutions tailoring the perfect combination of products and services.

“Bringing our own working at height product range to the market furthers this offering, with another avenue for our core purpose, keeping people at work safe.”

Falling from height is the most common cause of death in the workplace, accounting for 36% of fatal injuries in 2023/24, according to recent HSE statistics

As a trusted safety provider with 140 years of experience, Arco offers working at height equipment for sale and hire, as well as safety solutions such as consultancy, training and equipment maintenance services through its Arco Professional Safety Services division.

See the new Arco working at height equipment range

Find out more about Arco Professional Safety Services’ working at height solutions

 For more information, visit www.arco.co.uk

 

 

Cold Bonding Brilliance with Belzona at Two Major Tank Farms

 In the heart of the Netherlands, two large tank farms chose cold bonding to face a daunting challenge: over 1100 brackets needed to be installed on live, fully operational tanks filled with highly flammable liquids. Traditional welding was impossible as taking the site offline and emptying the vessels would have required a costly shutdown which was not a viable option. So, seeking a welding alternative, the Customers chose Belzona’s innovative cold bonding solution.

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Belzona on site, ready for cold bonding

What Was the Problem?

The first Client, a renowned global infrastructure provider, wished to make their operations more sustainable by installing solar panels on the top of their tanks. However, before the panels themselves could be implemented, cable ducts and supports needed to be installed across the entire structure. Such a large number of panels required around 500 brackets be cold bonded on to the live oil tanks, as hot work was out of the question.

The second Client, a global leader in tank terminal operations, required the installation of 660 brackets on to live kerosene tanks. This was required due to recent legislative changes which mandated the installation of extra fire extinguishing pipes. With safety as their top priority, the Client sought a swift and dependable solution. It was crucial that the chosen method could install the required brackets without disrupting the facility's operations or incurring the unnecessary expense of a shutdown.            

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Why Was Belzona Chosen?

For both sites, a hot work permit was out of the question and so a cold bonding solution was required. The kerosene tanks were filled and had an internal coating, meaning hot work was not an option at the first site. Similarly, at the second site the tanks were fully operational, so a welding alternative was also required in this case.

Belzona offered a cold work solution which could be applied whilst the tanks were full and operational. Epoxy composite Belzona 1111 (Super Metal), was chosen for its high adhesion properties, as it can be applied and cured at ambient temperature using simple tools, making it ideal for this in-situ application. In addition to being less hazardous, this method also ensures greater contact across the surface area of the bonded bracket, compared to the limited contact of weld seams.

Application of Belzona 1111 (Super Metal)

First of all, the surface was suitably roughened to Swedish Standard Sa2½ (near white metal finish) with a 3 mil (75 μm) profile in order to achieve maximum adhesion. By utilising ATEX closed-loop vacuum grit blasting, optimal surface preparation was achieved whilst mitigating the hazards of airborne grit and debris. This method not only ensured safety but also maintained operational continuity by eliminating the need for temporary structures like tents and additional scaffolding which would have been required for conventional grit blasting. Therefore, the closed-loop system proved to be the most efficient solution for surface preparation on a live site.

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Belzona 1111 (Super Metal) mixed and applied

Following completion of surface preparation, the team bonded the brackets onto the substrate using Belzona 1111 (Super Metal). Once the product was mixed, a layer was firmly applied to the prepared surfaces of both the tank and the underside of each bracket. The brackets could then be pushed into place with force, secured, and left to cure.

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Belzona 1111 (Super Metal) was used to bond the brackets, then they were left to cure

Cold Bonding Success

Both applications were successful, leaving the Clients thrilled that the brackets had been securely installed without the need for welding, thereby avoiding the expenses and hazards associated with a costly shutdown or dangerous hot work.

The first Client has successfully installed their solar panels after cold bonding over 500 brackets with Belzona 1111 (Super Metal). This application was imperative to their successful implementation, helping the Customer achieve their sustainability goals. Similarly, the second client is now fully compliant with the new fire safety regulations. In each case, choosing Belzona as a welding alternative allowed for a safe and efficient installation, without the need for hot work.

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Successful cold bonding of over 1100 brackets at the two sites

About the Distributor:

Perspect Benelux B.V., based in the Netherlands, has an impressive 29-year history as a Belzona Authorized Distributor. Since its inception, Perspect has expertly utilised Belzona's innovative solutions to repair, protect, and enhance machinery and equipment across a range of industries. With such a wealth of experience, they have a earned a stellar reputation as Belzona’s sole distributor in the Netherlands. To learn more about Perspect Benelux B.V. please visit their website here.

 

Want to learn more about Belzona’s cold bonding solutions?

Learn more about Belzona 7311

Fire-rated vs. Fire-resistant storage: What a lot of people get wrong and why it matters

Mike Brodie, Managing Director of Chemstore UK, outlines the critical differences between fire-rated and fire-resistant storage and emphasises the importance of correctly distinguishing between them.

As the UK experiences increasingly extreme weather patterns and record-breaking temperatures, the importance of proper fire safety measures has never been more critical. 

With rising temperatures and heatwaves becoming more frequent, the risks associated with improper storage of flammable materials are amplified. This makes it imperative to understand the difference between fire rated and fire-resistant storage, as the consequences of getting it wrong can be devastating.

When it comes to protecting valuable or hazardous items, the terms "fire-rated" and "fire-resistant" are often used interchangeably. This common misunderstanding can lead to dangerous consequences, especially when products that require fire rated storage are mistakenly placed in less effective fire-resistant units. To avoid these pitfalls, it’s crucial to understand the differences between the two and why choosing fire-rated storage from trusted experts like Chemstore is essential.

Understanding Fire Rated vs. Fire Resistant Storage

The confusion often starts with the assumption that "fire-rated" and "fire-resistant" are synonymous. Many believe that a fire rating simply means the storage unit can stop the passage of flames. However, the reality is more complex, especially when safety is on the line.

Fire-resistant storage typically refers to materials or structures that can physically resist the passage of flames but this falls well short of the rigorous standards required for fire-rated storage. Fire-rated storage, is designed to not only resist passage of flames but also to control the internal temperature of a storage module, preventing thermal heat transfer that could ignite the contents within.

According to HS(G)51, an essential guideline on fire safety in the workplace, fire walls (and by extension, fire rated storage units) must be imperforate and provide a minimum of 30 minutes of fire resistance in terms of integrity, insulation, and load-bearing capacity where applicable. This means that a fire-rated storage unit must be capable of maintaining its structural integrity, insulating against heat, and bearing loads even under intense fire conditions.

In terms of spotting the difference between a fire-resistant panel and a fire-rated panel, a fire-resistant panel made of single sheet steel is thin, smooth, and solid, often with a shiny or matte finish but lacking visible insulation. Its primary function is to resist flames, but it provides minimal insulation and may warp or fail under intense heat.

In contrast, a fire-rated panel featuring non-combustible insulation such as Rockwool is much bulkier, with insulating material encased between protective layers. This panel offers superior structural integrity and high insulation performance, effectively delaying heat transfer and maintaining a barrier against flames for extended periods. The key differences are in thickness and construction, which impact how each panel performs in fire situations.

The importance of temperature control in fire-rated units

One of the critical benefits of a fire-rated storage unit is its ability to control the temperature inside the unit. This feature is often overlooked but is vital in scenarios where the stored materials are sensitive to heat. In the case of highly flammable substances or lithium-ion batteries, even a slight increase in temperature can lead to disastrous outcomes.

The assumption that stopping flames is enough to protect the contents of a storage unit can lead to tragic mistakes. For instance, a single-skin metal box, which many mistakenly believe to be fire-rated, offers minimal insulation. In direct sunlight or during a fire, such a box can act like an oven, leading to the overheating and possible ignition of the materials inside. This risk is especially pronounced during hot weather when ambient temperatures can already push the limits of what stored items can safely endure.

It is good practice to maintain lithium-ion batteries at 19°C ±1.5°C to maximise safety yet is not possible for a single skin storage module to provide this level of environmental control as it will consistently overheat and freeze throughout the year. 

The dangers of mislabelling and the importance of expert advice

A significant issue in the UK market is the influx of products labelled as "fire-rated" without meeting the necessary standards. Many of these products are sold based on the misconception that fire rating merely involves preventing flames from passing through. This misunderstanding can lead to businesses and individuals purchasing storage solutions that are woefully inadequate for their needs.

The consequences of using improperly rated storage can be severe. In the event of a fire, a unit that does not provide sufficient insulation and temperature control can allow heat to build up inside, potentially causing primary containers to fail and lead to the release of harmful fumes, or the destruction of critical materials.

To ensure safety, it’s imperative to purchase fire-rated storage from trusted experts like Chemstore. We are a BSIF Registered Safety Supplier and our products are designed and tested to meet the rigorous requirements set out in HS(G)51, ensuring that you have the highest level of protection.

Conclusion

Understanding the difference between fire rated and fire-resistant storage is not just a matter of semantics—it’s a matter of safety. In scenarios where the contents of a storage unit are sensitive to heat or flammable, relying on inadequate storage can lead to catastrophic consequences. By choosing fire rated storage solutions from reputable providers like Chemstore, you can ensure that your materials are protected not just from flames, but from the heat that can be just as deadly. Don’t take risks with fire safety; understand what you’re buying and why it matters.

For more information, visit www.chemstore.co.uk

Hart faces Climate challenges

Business and Climate have to work together says Gordon Kipling, Northern Sales Manager, Hart Door Systems. “Climate Change are two words which are in frequent use certainly as we in Britain inevitably discuss the weather. But there is a serious side effect because adverse weather can have grave implications for business be it buildings on a farm, day to day manufacturing and all that entails or residential in particular tower blocks.

“We take a global view with the development of Hart’s Typhoon shutter being a good example of a response to Typhoon storms in the Far East. Typically thanks to Climate Change a major storm hit Northumberland a few years ago inflicting major damage to an isolated grain silo. Here Hart’s Typhoon shutters were retrofitted for protection from future storms.

“As more and more Atlantic storms are forecast to hit the British Isles there has been increasing demand for Hart’s Speedor Storm doors. Speedor is Hart’s trusted, innovative, solution for the ‘high-speed’ door and it has been developed further for specific manufacturing requirements, hence Cleanroom, Conveyor, Mini and of course Storm. All feature cutting-edge technology and a commitment to excellence in applications where operational efficiency, safety and reliability are required.

“The Speedor Storm variant offers protection from the elements, withstanding winds of up to 70 mph. The wind resistance is delivered via a unique guide system working in combination with other carefully designed features. Strength is through multi-layered PVC and textile which are both long-lasting and tear-resistant. Horizontal curtain braces add additional wind resistance. Seals are also a key feature provided by PVC extrusion and rubber draught seals. Safety features are paramount and the Speedor Storm includes a pressure-sensitive bottom edge, anti-fall protection and photocell technology.

“Operating methods include floor loops, radar, photo beam, radio, movement sensors, hand-held or vehicle-mounted radio transmitters, push button and pull cords. Operation can be set to include or exclude pedestrians as desired. Warning lights or klaxons can be incorporated and the operation of a Speedor Storm can be integrated into a Building Management system if required.

“Climate Change is with us for the future and in a similar vein so is Speedor Storm.”

www.hartdoors.com

Polymeric Solutions for Maintenance Problems for Lithium Mining

As the global demand for lithium continues to surge, driven by the rise of electric vehicles and renewable energy technologies, the maintenance challenges faced by lithium mining operations have become increasingly critical. Belzona, a leader in industrial protective coatings, headquartered in Miami Lakes, Florida, is addressing these challenges head-on with its innovative polymeric solutions. Designed to combat corrosion, abrasion, and chemical damage, Belzona's coatings are playing a pivotal role in extending the life of critical mining equipment, supporting the industry's efforts to meet growing demands while promoting sustainability.

Polymeric Solutions for Maintenance Problems for Lithium Mining

Batteries are a highly sought-after product due to the ever-growing need for green electric appliances and devices. Phones, solar panels, and electric vehicles (EVs) all need batteries to operate, and this has led to an increase in the need for materials used to manufacture batteries. Lithium is one material whose need has increased tenfold. Some of the already large lithium mines in South America, Asia, and Australia have had to expand to meet the high demands of energy and tech companies.

Lithium-ion batteries play an important role in reducing climate change. EVs reduce the need for gasoline and diesel fuel. In addition, energy companies use lithium-ion batteries to store electricity generated from wind and solar farms to mitigate the use of energy generated from coal and natural gas. However, lithium mining does have its drawbacks. It is responsible for over 1.4 million US tons (1.3 million metric tons) of carbon annually. For every one US ton (0.9 metric ton) of mined lithium, 16.5 US tons (15 metric tons) of CO2 are released into the air (earth.org).

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Figure 1 An example of a lithium-ion battery for mobile devices

The Environmental Impact of Lithium Mining

Additionally, the lithium mining process is very intense in the surrounding environment. Part of the process involves extracting lithium from saltwater reserves. It risks polluting the local water sources, threatening humans and local animal and plant biodiversity. The batteries themselves can also be harmful to the environment. They can leech damaging chemicals and other byproducts into the environment when they are discarded. It can cause fires, water pollution, air pollution, and health problems. Despite the negatives, the current process is the most cost-effective way to obtain lithium; however, other materials are being researched to manufacture greener batteries (earth.org).

How is Lithium Mined?

The current lithium mining process involves drilling underground to access mineral-rich brine found under salt flats. Then, the brine is pumped into large evaporation pools on the Earth’s surface. The Sun slowly evaporates the brine pools over months or years leaving behind minerals like potassium, sodium, and lithium. The lithium is then extracted in different ways but usually involves a chemical process by which reagents are incorporated to form a saleable compound of lithium at a processing facility that can be transported to customers.

There are other less common lithium mining processes such as extracting directly from mineral ore. During this process, the mineral is extracted, heated, and pulverized. Then, it is combined with reagents to create a slurry that is heated, filtered, and concentrated via evaporation to produce a saleable lithium form (Samco.com).

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Figure 2 Evaporation pool used during lithium mining

Solving Corrosion During Lithium Mining

Corrosion is a common maintenance problem found in lithium mines due to the presence of brine, a water-based solution high in minerals, especially salt. Brine accelerates corrosion because of an increase in dissolved ions, which allows electrons to move freely between the brine and metal substrate causing rust. A metal object does not need to be submerged for corrosion to occur as increased moisture in the air and salt spray can also rust metal substrates (sciencing.com).

A manufactured paint or coating can stop corrosion because it can prevent the ions from interacting with the metal substrate. Belzona polymeric coatings are applied on various substrates from aluminum, steel, iron, and more to stop the materials from corroding.

During lithium mining, equipment, and assets often find themselves in the presence of brine or moisture. A pump is used to transport brine from the underground reservoir to the evaporation pools. The pump can suffer from rust and corrosion due to the mineral-rich water; however, a Belzona 1000 Series coating can prevent the piece from corroding. The coatings also repair the piece as specific products such as metal repair epoxy paste, Belzona 1111 (Super Metal), and corroded metal repair material, Belzona 1121 (Super XL-Metal) can help rebuild metal loss. Rebuilding can reduce the need for a new part especially the downtime from waiting for a new part.

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Figure 3 Pump repaired with Belzona 1111 (Super Metal) suffering from corrosion due to saltwater medium

Other equipment in contact with water or moisture such as froth flotation cells, pressure leaching tanks, filters, centrifuges, evaporators, mixers-settlers/ extraction columns, and electrolysis equipment can all potentially be coated with a Belzona 1000 Series to protect them from further corrosion and replacement.

Solving Abrasion and Physical Impact During Lithium Mining

The equipment may become physically damaged also as they deal with rough materials like mineral particles of varying sizes. The particles can slowly deteriorate the surface of metal or rubber equipment. Pumps are an example of equipment that is physically damaged by solid particles, but conveyor belts and loaders are also a great example of two pieces of equipment made of different materials that suffer from similar damage. Both assets carry and transport lithium and other solid materials. During this phase of the lithium mining process, the assets endure harsh wear and tear, damaging their integrity. Holes will appear in conveyor belts and metal loss will slowly abrade the surface of the loader.

Belzona can provide a quick return-to-service with the Belzona 2000 Series, a product line engineered to repair flexible components. Tears and abrasions on conveyor belts are repaired without the need for hot work with Belzona’s elastomer products which provide a much-needed increase in durability, elasticity, and tear resistance.

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Figure 4 Conveyor belt back in operation after repaired with Belzona 2311

Additionally, loaders and other metal equipment such as filters, haul trucks, drills, crushers, and grinding mills can be coated with Belzona 1000 Series to rebuild metal substrates that have abraded. Belzona 1311 (Ceramic R-Metal) and other products in the range can rebuild the equipment’s surface while safeguarding it from further abrasion. The coating creates a sturdy barrier between the rough material and the substrate, and it is reinforced by the composition of the coating.

Chemical Resistant and High-Temperature Coatings for Lithium Mining

Reagents are an important part of lithium mining. Usually, these reagents are strong chemicals like sulfuric acid. Additionally, depending on the mining process, it can involve high-temperature reactions. Coatings in the Belzona 1000 Series and 4000 Series include products to protect assets during high-temperature operations or with chemicals. If there is a high concentration of sulfuric acid (98%) then Belzona 4311 or Belzona 4341 would be an appropriate choice. Lower concentrations can be resisted with other Belzona 4000 Series coatings; however, any coating performance is highly dependent on temperature.

Belzona 1511 (Super HT-Metal) or Belzona 1813 offer high-temperature resistance of up to 150 °C (302 °F) and 200 °C (392 °F) respectively. They have been formulated to protect metal surfaces from abrasive attack (Belzona 1813) and corrosive attack (Belzona 1511) at high temperatures and are resistant to a wide range of chemicals.

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Figure 5 Chute coated with Belzona 1813 for high-temperature resistance

Belzona’s Importance to Greener Lithium Mining Practices

Lithium mining is integral to the production of batteries that power a variety of essential green technologies, from EVs to renewable energy storage systems. Despite its significant environmental footprint, including carbon emissions and potential water pollution, advancements in mining processes and material science are making strides toward mitigating these impacts. One of the critical challenges faced by the industry is the maintenance of equipment exposed to harsh conditions, such as corrosion, abrasion, and chemical attack.

Belzona's range of polymeric solutions offers robust protection and repair options for mining equipment. By preventing corrosion, repairing physical damage, and providing chemical and high-temperature resistance, these solutions not only extend the lifespan of critical assets but also enhance operational efficiency and safety. As the demand for lithium continues to rise, the application of innovative maintenance solutions like Belzona's will be crucial in supporting sustainable mining practices and the transition to a greener, more sustainable future.

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Figure 6 Electric vehicle

www.belzona.com