Devcon DFense Blok® Restores Coal Power Plant Efficiency with Advanced Chute Protection

Restoring Durability and Efficiency: How Devcon DFense Blok® Transformed a Coal Power Plant’s Chute System

In the demanding environment of coal-fired power generation, equipment durability and operational efficiency are paramount. One coal power plant recently faced a serious operational challenge when its transfer chutes—essential for transporting coal powder after crushing and screening—suffered extensive wear. The culprit? Aggressive coal dust containing corrosive chlorides that caused rapid deterioration through abrasion.

To address this, the plant turned to Devcon DFense Blok®, an industrial-strength epoxy coating system designed specifically for high-wear environments. What followed was a swift and highly effective in-situ repair that not only restored the chute’s functionality but also enhanced its resilience far beyond previous levels.

The Challenge: Abrasive Coal Dust Causing Severe Wear

Transfer chutes in coal plants are exposed to relentless material flow. The combination of fine coal particles and harsh chemical properties—especially chlorides—leads to significant surface degradation. This power plant’s chutes had reached a point where coal transport was abruptly interrupted, putting operational efficiency and electricity output at risk.

The traditional solution might have involved replacing the entire chute—a costly and time-intensive approach that risked extended downtime. Instead, the plant's engineers opted for a long-lasting surface protection solution to restore the chute and minimize future maintenance.

The Solution: DFense Blok’s Multi-Step Application

Devcon’s solution involved a two-part protective application designed for maximum adhesion and durability:

1. Surface Priming with DFense Blok Surface Wetting Agent
   First, a specially formulated surface wetting agent was applied to the chute. This served as a primer, enhancing the bonding strength of the epoxy coating that followed.
2. Application of Devcon DFense Blok Epoxy
   After priming, the DFense Blok epoxy—consisting of a resin and hardener mixture—was prepared using a jiffy mixer to ensure uniformity. The epoxy was then applied to the chute’s inner surfaces.
3. Surface Smoothing with Solvent
   For optimal material flow and reduced buildup, the epoxy coating was smoothed out with solvent. This finishing touch helped create a slick, wear-resistant surface that would minimize future particulate accumulation and friction.

This meticulous process ensured that the repair would hold under intense conditions while extending the lifespan of the equipment.

The Result: Superior Abrasion Resistance and Minimal Downtime

The application of Devcon DFense Blok yielded immediate and impactful results:

• 4X Abrasion Resistance Compared to Competitors
  Independent evaluations showed that DFense Blok outperformed other industrial epoxy coatings by providing four times the abrasion resistance—critical for minimizing wear from coal dust.
• Extended Equipment Lifespan
  The inclusion of the surface wetting agent significantly improved the epoxy’s bonding and longevity, ensuring that the repair would endure for years without recurring maintenance needs.
• Operational Continuity
  Perhaps the most impressive outcome was the plant’s ability to resume operations within hours. Because the chute repair was conducted in-situ, the team avoided major disruptions to power generation.

Conclusion: A Reliable Solution for Demanding Environments

For industries where time, durability, and efficiency are non-negotiable, Devcon DFense Blok provides a proven solution. This coal power plant’s experience showcases how high-performance epoxy systems can restore damaged infrastructure rapidly and reliably.

Instead of replacing major components or enduring extended downtime, facilities can count on DFense Blok to deliver long-term protection and peace of mind.