Belzona protects flare stack vessels for large oil refinery site

KHIA ID: 10042
Industry: Chemical & Petrochemical (PETR)
Application: TCC-Tanks and Chemical Containment Areas (TCC)
Substrate: Carbon steel
Customer Location: Stanlow, UK
Application Date: September 2025
Products: Belzona 1391S,Belzona 1391T,Belzona 1511 (Super HT-Metal),Accessories
Problem: The customer had 2 vessels that were damaged beyond repair due to years of corrosion. The vessels were located in an area of the site that made in-situ repairs on the scale required too difficult to perform. 2 newly fabricated vessels were manufactured in India and shipped to the UK. Protective coating would be applied in the UK due to potential damage during transit.

Showing the exterior of both vessels. An idea of size of vessels can be judged by the staff in the image. 350+ sqm internal walls across both vessels.

Internal of smaller vessel, showing scaffolding for top half of the vessel. The smaller vessel had internal fixtures that also required protective coating.

Internal of larger vessel, showing 3 tiered scaffolding for access to all levels. This image shows a part blasted and prepared surface, ready for spray application.

Both vessels following spray application. Remedial sections following spark testing shown. All fixtures were coated within smaller vessel.

Application Situation
Belzona has been used extensively across the site for many years now, building a foundation of trust with the Belzona product range. They chose Belzona based on the trust of the protective coatings they have experienced on site. Belzona 1391S and Belzona 1391T were chosen due to the requirements, and could be spray applied due to the size of the application.
Application Method
Grit blasting of all areas to be coated was carried out by a third party. The Belzona 1391S was applied via a plural spray technique. Belzona 1391T was applied via Belzona applicators and brush techniques on the weld areas and the areas where spraying could not be carried out . Belzona 1511 nozzle inserts were used for 18 nozzles spread across the two vessels, and a Belzona 1391T coating was applied along with the nozzle inserts.
Belzona Facts
Belzona was chosen due to trust built over several years of applications across their site. They have first hand experience of several of the products in the range, and felt that the Belzona solution was the most accurate to their requirements. The customer was making repairs to the existing vessels fairly regularly, given the amount of required repairs, newly fabricated vessels were the customers go-to solution.
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