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GENERATING PROFILE WITH ULTRA HIGH PRESSURE HYDROBLASTING

www.zirtec.com.br

Presentation:

Marco Canton Division Coordinator Flow Hydroblasting Fan Tso Min Technical Director Roberto Menegon Potters President Marcos Ribeiro General Manager - Flow Brazil

Zirtec is a specialized company in Surface Preparation and Finishing. Zirtec represents industry-leading companies, like Flow (Hydroblasting) and is also manufacturer of blasting equipment and industrial washers. Zirtec is one of the biggest distributors of spare parts and abrasives to dry blasting processes.

Theme: - Generating profile with Ultra High Pressure Hydroblasting. Topics:

- The Ultra High Pressure Hydroblasting - Conventions and Principles - Procedures for Opening Blasting Profile - Definition and properties sought in an ideal system - Partnership to produce and Tests - Product Definition and Application in the works - How it works (hardware) - Zirflocos production, numbers and Benefits - Questions

THE ULTRA HIGH PRESSURE HYDROBLASTING

THE ULTRA HIGH PRESSURE HYDROBLASTING CONVENTIONAL SYSTEM

UHP - Hydroblasting Pump

How the Ultra High Pressure Hydroblasting works Today PRINCIPLE OF HYDROBLASTING - Restoration of pre-existing original Profile.

1
Speed: Three times the sound speed Aprox. 1.000 meters / second Pressure: 40.000 to 55.000 psi [2.760 to 3.800 bar] Rotation: 3.000 rpm Water Flow: 2.5 to 3.2 gallons / minute [9,5 to 12,1 liters / minute] Abrasive: Water

BLASTING PROCESSES TO OPEN PROFILE


There are many situations that require opening profile. How is it done today: 1 Dry Abrasive Jet (Steel Shot, Copper Slag, Abrazul, Sinterblast, etc.). 2 - SpongeJet (Case particles with sponge) 3 - Low Pressure Wet Jet (90 to 100 PSI) with abrasive. 4 - High Pressure Wet Jet (5,000 to 10,000 PSI) with abrasive. 5 - Ultra High Pressure Wet Jet (from 36,000 PSI) with abrasive

In all these cases there are advantages and disadvantages.

1 DRY ABRASIVE JET


ADVANTAGES - Low investment cost - Many Applicators - Robust Operation

DISADVANTAGES - High dust generation - High volume of disposal of abrasive - Need to ventilation - Need for strong illumination - Operator Discomfort

2 - SPONGEJET
ADVANTAGES - Recoverable - Dry process DISADVANTAGES - Lower moisture resistance - The sponge become saturated with dust quickly - Requires confined enviroment - Requires special equipment for recycling

3 LOW PRESSURE WET JET (90 to 100 psi) WITH ABRASIVE


ADVANTAGES - Low investment cost - Many Applicators - Robust Operation

DISADVANTAGES - High waste generation - Problems with the disposal of waste - Dirty work enviroment (Mud)

4 - HIGH PRESSURE WET JET (5,000 to 10,000 psi) WITH ABRASIVE

ADVANTAGES - Relative low cost of equipment - Doesnt need air compressor (engine included)

DISADVANTAGES - High-level disposal of abrasive

5 ULTRA HIGH PRESSURE WET JET WITH ABRASIVE


(Starting from 36.000 psi) ADVANTAGES - Good Productivity - Few equipments in the market

DISADVANTAGES - Lack of ideal abrasive

PROCEDURES FOR BLASTING OPENING PROFILE

What is missing ?
- Productivity of the work as a whole. - Abrasive without risks for the operators and the environment. - Small volume of waste.

CONCEPT
(Ultra High Pressure working together with Abrasive)

1 - Generation of roughness requires high impact abrasive. 2 - Ultra High Pressure generates high-impact at short distance. 3 - Kinetic Energy Formula:
Where:

M V2 Ec = 2
The kinetic energy increases with the square of the velocity: This mean that if a car crash happens at 160 km/h will cause 4 times more damages than at 80 km/h or 16 times more damages than at 40 km/h or 64 times more damages than at 20 km/h

Ec= Kinetic Energy V = Velocity M = Mass

4 The waterjet with the speed of almost 1,000 m/sec

can provide the high impact and its the perfect accelerator vehicle to the abrasive particles. 5 Consequence: Can minimize the amount of abrasive.

Properties of the Ideal Abrasive 1 Inert


(No reaction in the presence of other materials)

2 Moderate Aggressiveness of the Abrasive


(Allowing extended tools and accessories life)

3 No Crystallized Free Silica


(Exempted of Quartz, Cristobalite and Tridymite witch causes Silicosis Disease)

4 - No Heavy Metals
(Exempted of metals and highly chemically reactive and bio-cumulative, material witch organisms are not able to eliminate.)

5 - Without Impregnable Salt


(Exempted of chlorides - Contaminants that will result in outbreaks of corrosion)

6 - Production on Industrial Scale


(Easy production and enough to supply the world wide market)

7 - Moisture Repellent
(Not Laying gravel form in the presence of moisture.)

8 - Proven Quality
(Manufacturing quality control)

9 - Abundant
(No supply and logistics problems.)

10 - Ecological and Safe


(Do not cause problems to the operator or the environment and ease disposal)

Tabulation of properties (abrasive economically viable)

Aluminium Oxide Abrasul Garnet Glass Beads Zirflocos

Meets the criteria Requires attention Doesnt meet the criteria

Partnership ZIRTEC + POTTERS for the creation of the abrasive ZIRFLOCOS to answer well to all questions established. Each particle is coated with moisture repellent. This feature means that there is greater fluidity in the system and prevents the aggregation and sedimentation of particles in the presence of moisture. His geometric shape generates much higher productivity than the regular glass beads.

TWO YEARS TESTING PHASE

TEST Determining the profile

Profile viewed by microscope (50 X)

Profile viewed by microscope (200 X)

Contrast between the surface prepared and not prepared

prepared prepared

Not prepared

Not prepared

30x

80x

DEFINITION The Zirflocos is an inert abrasive specially designed to work with Hydroblasting at Ultra High Pressure aiming to enhance the operation of surface preparation, coating removal, mill scale, and open-profile. The abrasive is stored in a hopper and is carried by the venturi effect caused by the mixer gun. This mixer gun is adapted at the Hydroblasting manual tool. The Zirflocos is made of 100% glass flakes and crystal-fil. Zirflocos is composed of inert materials witch do not pollute or harm the environment and the waste can be freely and easily discharged. The Zirflocos poses no hazard to the operator and maximize results.

FICHA TCNICA E DE SEGURANA

Nota: Esta uma traduo do original norteamericano editado pela OSHA. Organizao do trabalho que cuida das condies de trabalho e risco dos operadores.

ZIRFLOCOS IN REGULAR WORKS

TEST INTERNATIONAL PAINT RJ

Profile: 60 to 90 m

Waste: Disposable Easily.

OPERATING DIAGRAM

OPERATION FLOWCHART

TOOL FOR APPLICATION OF ZIRFLOCOS

ACTUAL CONTRACT - TBAR S. SEBASTIO - SP

ACTUAL CONTRACT - GUARAREMA - SP

ACTUAL CONTRACT - TBAR SO SEBASTIO - SP

KEY BENEFITS
1 - Successfully Remove Mill Scale. 2 - Meets most requirements of roughness: up to 90 mm 3 - Free of Salt Contaminants. 4 - Good Productivity: from 10 to 12 m / hour 5 - Low Cost: about 20% above the waterjet UHP. 6 - Good adhesion for coverage : from 25 to 29 Mpa. 7 - Low amount of residue after the operation: Dry blast: 40 to 80 kg / m UHP + Zirflocos: from 2,5 to 4 kg / m 16 to 20 times less

ADDITIONAL BENEFITS "Work on Tanks" 1 Less quantity of equipment allocated


No need of Air Compressors and Ventilation.

2 Minor generation and removal of material


The amount of waste abrasive Zirflocos is much lower.

3 Increased thermal comfort


There is no heat generation

4 Personal Protective Equipment lighter and more comfortable for the operator.
No need for indirect air for the operator.

SOME NUMBERS 1 Work Pressure:


36.000 to 40.000 psi [2.480 to 2.760 bar]

2 Water Flow:
2,0 to 6,0 gpm (8,0 to 19,0 liters / min)

3 - Finishing Reachable:
White metal (Sa3 or WJ 1)

4 - Abrasive consumption:
2,5 to 4,0 kg / m

5 - Productivity:
10 to 12 m / hour / tool
(Note: On Oil Tanks with profile from 60 to 80 m)

6 - Abrasive consumption per hour :


2,5 to 4,0 kg / m x 10 to 12 m / hour = 25 to 48 kg / hour
(depending on the desired finish)

7 - Cost: (Considering US$ 1.00 = R$ 1,778 07/10/2011)


US$ 1.65 to 2.30 / kg - (varies depending on volume)

GENERATING PROFILE WITH ULTRA HIGH PRESSURE HYDROBLASTING

THANK YOU VERY MUCH ! Special thanks:


CEPEL.......................................Fragata CENPES....................................Quintela BLASPINT.................................Isidoro, Aluizio, Joo e Luiz
- Those interested in downloading this material:

www.zirtec.com.br/zirflocos