Valterra – HPC® Coating on Deaerator, Platinum Refinery (South Africa)
Market: Energy & Mining / Industrial Refining
Location: Rustenburg, South Africa
Products: HPC® Coating
Courtesy of: SP Coatings Africa – Valterra Platinum / RBMR
Project Overview
SP Coatings Africa completed a High Performance Coating (HPC®) application at Valterra Platinum's Rustenburg Base Metals Refining (RBMR) facility on Deaerator #1.
Following the removal of traditional cladding and lagging, corrosion under insulation (CUI) was identified on the vessel and inlet lines. To arrest corrosion and eliminate future moisture ingress, the substrate was mechanically prepared and encapsulated with a high-build HPC® system.
Challenges & Solutions
The HPC® application at Valterra Platinum's RBMR facility was executed on Deaerator #1, where traditional cladding and lagging had allowed moisture ingress and CUI to develop. Upon removal, severe corrosion was identified on inlet lines and the surrounding vessel, presenting typical refining challenges — humidity, process temperature fluctuations, and complex pipe geometry around elbows and vessel undersides.
To mitigate further degradation, SP Coatings Africa implemented a comprehensive HPC® system:
- Full removal of existing cladding and lagging
- Mechanical surface preparation — wire brushing and sanding
- Wash-down and substrate cleaning
- Progressive high-build HPC® application (1–3mm through to 10–15mm final DFT)
- SP Seal Coat topcoat for moisture sealing
Performance & Results
HPC® was applied in controlled build-up stages to ensure full encapsulation of the substrate — progressively layered from 1–3mm to a final achieved thickness of 10–15mm, confirmed by the project's final DFT readings.
Client Satisfaction
The successful completion of the HPC® proof-of-concept at RBMR reinforced Valterra Platinum's confidence in the system's performance capabilities. The project demonstrated measurable corrosion mitigation, structural preservation, and improved asset protection — without reinstating traditional lagging systems.
The results established a foundation for continued support and potential future HPC® applications across similar assets within the facility.
Conclusion
The Valterra HPC® application at Rustenburg Base Metals Refining showcases SP Coatings Africa's ability to deliver high-build, corrosion-resistant coating systems in complex industrial environments. By replacing conventional insulation with a 10–15mm HPC® barrier and SP Seal Coat sealing layer, the project successfully:
- Arrested active corrosion
- Mitigated corrosion under insulation (CUI)
- Strengthened structural integrity
- Delivered a durable, moisture-resistant protective system
- Achieved near-50% steam reduction on the treated deaerator
