Protective Epoxies for Cyclone Interiors: A Targeted Wear Solution

Problem: Costly Wear from Recycled Wood Processing

An OEM customer manufacturing pallet feet from recycled wood faced severe equipment wear. Wood chips and dust were processed through large steel cyclones, where the constant impact and sliding abrasion caused excessive internal wear—damaging the cyclone lining in just 3 months.

With high replacement costs looming, the customer needed a long-lasting protective solution that could be applied to the interior walls of the cyclones to extend service life and reduce maintenance costs.

Solution: A Tailored Multi-Coating Strategy

Having previously used Devcon products to repair and protect metal equipment, the OEM selected a combination of three Devcon epoxy-based protective coatings:

• Devcon DFense Blok®
• Devcon Wear Guard™ 300RTC
• Devcon Wear Guard™ Fine Load

Each coating was chosen for its specific performance characteristics to address the cyclone’s various wear zones. Instead of relying on a single solution, the OEM utilized the combined strengths of all three products for maximum protection.

Application Process

1. Surface Preparation:
   The cyclone was taken offline, and all abrasive materials were removed. The interior surface was then abraded to promote strong adhesion.
2. Targeted Coating Application:
• DFense Blok was applied to high-impact areas, where it offers superior resistance to heavy abrasion.
• Wear Guard Fine Load was used in regions where fine particles (less than 1/8") made contact, delivering effective protection against smaller-scale abrasion.
• Wear Guard 300RTC was applied in wet/dry zones subject to high temperatures and wear, offering thermal and chemical resistance.

Thanks to Devcon's user-friendly packaging and fast-curing formulations, the entire coating process was completed efficiently—getting the cyclone back in service within just 3 days.

Outcome: Durable Protection, Reduced Costs

By applying Devcon’s industrial-strength epoxy coatings, the OEM avoided costly cyclone replacements and significantly reduced downtime. The coatings now serve as sacrificial wear layers, absorbing damage instead of the steel structure, with predictable and manageable wear rates.

The success of this application ensures easy, scheduled reapplication when needed—making this a sustainable, long-term maintenance solution.

Summary

Devcon DFense Blok, Wear Guard Fine Load, and Wear Guard 300RTC provided a custom, high-performance solution to an aggressive wear problem—saving time, money, and equipment. With the cyclone back online in 3 days, the OEM now benefits from extended equipment life and minimized operational disruptions.

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FAQs – Devcon Coating Solution for Recycled Wood Cyclone Wear

Q1: Why was a multi-coating approach used instead of a single product?
A: The cyclone experienced different types of wear in various zones—high impact, fine particle abrasion, and thermal/wet/dry conditions. Using a combination of Devcon DFense Blok®, Wear Guard™ Fine Load, and Wear Guard™ 300RTC allowed the OEM to target each wear type with the most suitable protective coating, maximizing overall equipment life.

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Q2: How long does the protective coating last?
A: While wear life depends on the specific operating conditions (abrasive load, particle size, moisture, and temperature), the new coating system significantly extended service life beyond the previous 3-month failure point. The coatings act as sacrificial layers, making wear predictable and allowing for planned maintenance rather than emergency repairs.

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Q3: How long does the application process take?
A: The entire process—from surface preparation to full cure—was completed in just 3 days. This rapid turnaround minimized downtime and got the equipment back online quickly.

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Q4: Can these coatings be reapplied during regular maintenance?
A: Yes. One of the benefits of epoxy coatings like Devcon’s is that they can be reapplied as part of scheduled maintenance. Proper surface preparation is key to ensuring strong adhesion for reapplication.

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Q5: What kind of surface preparation is required before applying the coatings?
A: The cyclone interior must be cleaned of all wood dust and debris. The surface is then abraded (via grit blasting or similar methods) to promote mechanical bonding of the epoxy coatings. Clean, dry, and roughened surfaces ensure optimal adhesion.

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Q6: Are these coatings resistant to high temperatures and chemical exposure?
A: Yes. Devcon Wear Guard™ 300RTC is specifically formulated for high-temperature environments and offers chemical resistance, making it ideal for zones exposed to thermal cycling and occasional moisture.

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Q7: What tools or skills are needed to apply these coatings?
A: Application is straightforward and can be completed by trained maintenance teams using basic tools such as spatulas, rollers, or trowels. Devcon’s user-friendly packaging and fast-curing formulas simplify the process, although proper surface prep and curing conditions must be followed.

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Q8: Can this solution be used in other industries facing similar wear challenges?
A: Absolutely. Devcon’s protective coatings are versatile and can be applied in industries such as mining, cement, power generation, and any sector where equipment is exposed to abrasion, impact, or chemical attack.