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Belzona® Repairs Fgd Wet Lime Slurry Distribution Boxes



Power (POWR)



Solids Handling Machinery (SHM)


Customer Location:

Power Plant, Illinois, USA


Application Date:

Early Summer 2015


Application Situation:

Distribution boxes are part of a wet FGD process involving wet lime slurry being dumped through a transfer hose that is moved between three chambers in one box.



Lime slurry had worn away the existing rubber liner through the steel, and had created holes and washed out areas towards the bottom of the boxes in the cyclone areas.



Belzona 1121 (Super XL-Metal)

Belzona 2911 (Elastomer QD Conditioner)

Belzona 2111 (D & A Hi-Build Elastomer)

Belzona 9811

Belzona 1812 (Ceramic Carbide FP)



Steel and Rubber


Application Method:

The application was carried out in accordance with Belzona Know-How System Leaflet SHM-7. Surface preparation was done by using a MBX bristle blaster and Belzona roughing brushes. Belzona 1121 was used to seal all holes and rebuild the metal substrate back to its original thickness. Then, Belzona 2911 was used to condition the surface. Belzona 2111 was applied to rebuild worn rubber areas and it was also used as a bonding agent for Belzona 9811. A layer of Belzona 9811 wear tiles was embedded into Belzona 2111 to help absorb the impact behind the tiles. Belzona 1812 was then used as a grout and to fill/seal any voids.


Belzona Facts:

New distribution boxes are more than double in costs and have a thin rubber liner (no tile) in comparison to the Belzona repair. Downtime to reline the entire box with just rubber was substantial and costly. Thus, the customer was able to lay the box down and rotate it for the Belzona application just feet away from its original position. This was one of four we are scheduled to do.


Photographs Description

  1. Lime slurry being poured into the box
  2. Distribution box had been laid on its side for the application to start with welded plate covering one hole visible in the cyclone area
  3. Belzona 9811 being installed on top of a wet layer of Belzona 2111
  4. Belzona 1812 being installed as a grout and void filler
Case study pic one


 Case study pic two


 Case study pic three


 Case study pic four


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