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<p><font size="5"><b>I</b></font><b><font size="5">ntroduction to powder enameling of hot water tanks</font></b></p>
<p>
<img border="0" src="../../../IMAGES/Kwikot%2002.jpg" alt="Online powder enamelling system for big boilers during production" width="563" height="388"></p>
<p><b><u><a name="Introduction"><font size="4">Introduction</font></a></u></b></p>
<p>Porcelain enameling of hot water tanks (HWT's), like electrical & solar
boilers, started in Europe some decades
ago and is nowadays considered as the most durable anti-corrosion coating for
warm water equipment. </p>
<p>Studies by the CISP, the Italian enameling association, showed that the expected
<a href="#Comparison of expected lifetime">lifetime of enameled boilers</a> is
much longer then alternative coatings like galvanizing and/or organic powder
painting.</p>
<p>Initially enameling was exclusively done by means of various liquid
application methods, which require large capital investments and a high level of
process knowledge & skills on an operational level to obtain a good and constant
quality.</p>
<p>The introduction of electrostatic dry powder enamel application for the
inside of HWT's, which technology simplifies the enameling process
significantly and eliminates virtually all liquid, gaseous and/or solid waste
emissions, resulted in growing number of boiler enamelling plants with this
technology worldwide.</p>
<p>This webpage, which is a part of
<a target="_parent" href="http://www.ditmer.nl">Ronald Ditmer's website</a>, is intended to provide newcomers in the
enameling industry a comprehensive documents about the features & benefits of
the powder enamelling process and the available coating equipment.</p>
<p>For further information, please feel free to
<a target="_self" href="../../../address.html">contact me</a></p>
<p> </p>
<p><b><font size="4"><a name="Description of technology">Description of
enameling process</a></font></b></p>
<p>Porcelain enamel is a glass alike coating which may be applied on a metal
substrate in either a liquid or powder form and is cured above 800 degrees
Celsius to obtain its excellent corrosion protective properties.</p>
<p>According to the German standard (DIN 4753/3) the enamel layer should be at least 150 and
should not exceed 500 microns.</p>
<p>The boilers should be manufactured from an enamelable steel grade and its
design & utilized welding methods should be in accordance to the international
recognized guide lines. </p>
<p> </p>
<p><b><font size="4"><a name="Comparison of expected lifetime">Comparison of
expected lifetime with various coating methods</a></font></b><a href="../../../IMAGES/hot_wa2.gif"><img border="2" src="../../../IMAGES/hot_wa1.gif" width="153" height="109" align="right"></a></p>
<p>Studies by the CISP, the Italian enameling association, showed that compared
with alternative corrosion protection methods, like galvanizing, organic powder
coating and duplex coatings, a porcelain enamel coating may provide the longest
lifetime expectancy for warm water tanks.</p>
<p> Click op the diagram on the right
side, to see the CISP results in further details. </p>
<p> </p>
<p><b><font size="4"><a name="Available enameling processes">Available enamel
application methods</a></font></b></p>
<p>The porcelain enamel layer may be applied by means of the following
application methods :</p>
<p>- Flow coating</p>
<p>- Liquid spraying</p>
<p>- Vacuum</p>
<p>- Powder spraying</p>
<p> </p>
<p><b><font size="4"><a name="Benefits of powder enameling">Benefits of powder enameling</a></font></b></p>
<p>The electrostatic application of dry powder enamels has many benefits versus traditional wet application methods, such as :
</p>
<ul>
<li>
<p>
Shorter lead time and less process steps, thanks to elimination of enamel preparation and drying.
</p>
</li>
<li>
<p>Almost 100 % material utilization, thanks to automatic recovery of any
over-spray powders.
<p>
</li>
<li>
<p>Environmental friendly, because there are no air, waste water or solid waste emissions.
</p>
</li>
<li><p>Simple systems with high level of automation helps to reduce your labor
cost and guarantee a good and constant finishing quality.
</p>
</li>
<li><p>Powder enamel systems require less factory space then all equipment for
wet
enamel process.
</p>
</li>
</ul>
<p><a href="http://www.ronaldditmer.nl/benefits/index.htm">Click here</a> for further
information about the benefits of electrostatic dry powder versus wet
application methods.</p>
<p> </p>
<p><b><font size="4"><a name="Available powder enameling systems">Available
powder enameling systems</a></font></b></p>
<p>Depending upon the required hourly productivity, there are two different
enameling plant concepts :</p>
<p>- <a target="_self" href="../../../EXAMPLES/boilers.html">Online solutions</a> for large production quantities. </p>
<p>- <a href="Offline%20solution%20at%20Leov.htm">Offline solutions</a> for small and medium sized production quantities. </p>
<p><a href="../../../IMAGES/Leov%20system.jpg">
<img border="2" src="../../../IMAGES/Leov%20system_small.JPG" alt="Offline boiler enameling system" width="100" height="75"></a>
<a href="../../../IMAGES/Kwikot%2001.jpg">
<img border="2" src="../../../IMAGES/Kwikot%2001_small.jpg" alt="Online boiler enameling system" width="100" height="75"></a></p>
<p> </p>
<p><b><u><font size="4"><a name="Turnkey solutions">Turnkey solutions</a></font></u></b></p>
<p>Ditmer Trading & Consulting B.V. is specialized to provide independent
consultancy and/or project management to enable trouble-free realization of complete enameling plants for
inside coating of hot water tanks with porcelain enamel powder on a turnkey
base. <a target="_self" href="../../../DTC.htm">Click here for our contact
details</a></p>
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