I. Background and Application Scenarios
In the chemical and petrochemical industries, storage tanks and reactors serve as core equipment for media storage and chemical reactions. These assets are frequently exposed to extreme temperature fluctuations (-40°C to 200°C), acid/alkali corrosion, and solar radiation heat accumulation. Such conditions often lead to media evaporation loss, equipment aging, high energy consumption, and increased safety risks.
This solution utilizes Aerogel Thermal Insulation Coating with an integrated "Insulation + Anti-corrosion" design. Specifically engineered for the external walls of tanks and reactors, it meets the core demands for industrial energy conservation and long-term equipment stability. This solution complies with the SH/T 3022-2019 Design Standard of Coating Anti-corrosion for Equipment and Pipeline in Petrochemical Industry.
II. Core Parameters
Temperature Range: -40°C to 200°C; maintains a stable nanoporous structure at high temperatures with no risk of brittle cracking at low temperatures.
Thermal Conductivity: ≤ 0.044 W/(m·K).
Corrosion Resistance: Excellent acid and alkali resistance.
Solar Reflectance: ≥ 0.85; Near-Infrared Reflectance: ≥ 0.85 (effectively blocks solar radiation).
Safety & Environment: Non-toxic and harmless; water-based formula with no irritating odor.
III. Core Advantages
1. Integrated Insulation & Anti-corrosion: Eliminating Dual Hazards
By combining a "nanoporous insulation layer" with a "dense anti-corrosion film," this coating simultaneously solves the common pain points of Corrosion Under Insulation (CUI) and poor thermal performance found in traditional methods. The aerogel's nanopores create an "infinite thermal baffle effect" to suppress heat conduction and radiation, while the anti-corrosion primer and cross-linked resin form a dense barrier against moisture and acid/alkali penetration, preventing equipment rust at the source.
2. Wide Temperature Adaptability: Constant Stability & Significant Energy Savings
The coating maintains stable physical and chemical properties across a wide operating range (-40°C to 200°C) without cracking or chalking. In high-temperature summer conditions, it significantly reduces the surface temperature of storage tanks, preventing media vaporization and evaporation loss. In winter, it prevents equipment freezing and cracking, ensuring the stability of storage and reaction processes.
3. Thin, Durable, and Easy to Apply: Outstanding Comprehensive Benefits
The thin profile does not add significant weight to the equipment and easily adapts to the complex curved surfaces of tanks and reactors. The application requires only 3–4 steps using airless spraying or brushing, reducing the construction period by 50% compared to traditional insulation. With a service life of ≥ 8 years and a hydrophobic, anti-fouling surface, it reduces maintenance frequency and downtime losses.
IV. Application Process
1. Pre-construction Preparation
Surface Treatment: Remove oil, rust, welding slag, and other attachments from the equipment surface. For carbon steel/stainless steel, the rust removal standard must reach Sa2.0 (compliant with GB/T 8923.1) to ensure the surface is clean, dry, and free of loose debris.
Environmental Requirements: Construction temperature should be between 5°C and 40°C, with relative humidity ≤ 85%. Construction is strictly prohibited during rain, snow, or high winds to prevent coating blistering or loss of adhesion.
2.Coating application process
| Coating Type | Application Requirements | Thickness Specification | Interval / Recoat Time |
| Epoxy Zinc-Rich Primer | Brush or spray (2 coats). Apply evenly with no sagging. | 30–40 μm per coat; Total thickness: 60–80 μm | 60–120 minutes between coats |
| Aerogel Thermal Insulation Mid-coat | Stir evenly with an electric mixer (up to 5% water can be added to adjust viscosity). Airless spray ≥ 2 coats. | 1–2 mm per coat; Total thickness according to design requirements | ≥ 6 hours at 15–25°C; extend to over 8 hours in low-temperature environments |
| Weather-Resistant Topcoat | Use matching heat-reflective topcoat. Brush or spray (2 coats). | 30–40 μm per coat; Total thickness: 60–80 μm | 60–120 minutes between coats |
- Maintenance: After construction is completed, allow natural drying for ≥72 hours (under normal temperature and ventilation conditions), or extend to 96 hours in low temperature and high humidity environments. Avoid early exposure to moisture and corrosive media;
- Acceptance criteria: The coating appearance should be uniform without cracking or sagging, and the dry film thickness should meet the design requirements. The thermal insulation effect should be verified through infrared temperature measurement.
VI. Application Benefits
By leveraging the integrated thermal insulation and anti-corrosion properties of aerogel coatings, this solution achieves a triple objective for chemical and petrochemical storage tanks and reactors: operational safety, energy reduction, and service life extension.