The power station of Langerlo was built in 1976, with two units powered by fuel oil. In 1986, the power station was converted to a coal power station, due to its proximity to the coal mines located in Genk. Since mining activity in Belgium declined and ceased in 1992 with the closing of the last mine in Zolder, the power station in Langerlo remained the last one driven by coal. In 1997 and 1999 the power station was enlarged. In 1999 the fume and gas purification was expanded and 2 gas turbines were built. Today the power station has a capacity of 556 MW, driven by a mix of coal, biomass(pellets) and gas.
For the expansion plans in 1997, ZINGA was prescribed for corrosion protection of 7500 m² construction steel by the engineering company Tractebel.
Even before, ZINGA was already a stock item at Electrabel companies for patch repair. Because of the expansion, several large beams turned out to be too big for HDG at local galvanisers’ baths and hence were treated with ZINGA.
The beams were coated with 2 x 60 μm DFT after steel fabrication at Victor Buyck to provide a good corrosion protection in a harsh industrial environment.
An inspection at the Power Station in 2014 (after 17 years), now run by Electricity company E.ON, found the beams in good condition showing no signs of corrosion and with a Zinc depletion of only 20 μm DFT.
Alcoa LTD is a worldwide producer of, among others, aluminium. One of the places where they produce aluminium is Point Henry in Australia. Because this production takes up a lot of energy, they produce it themselves in a power plant running on coal in Anglesea, Australia. ZINGA has been used on water trays that are placed at the inside of cooling towers. This application took place in Anglesea.
General contractor: Powercor – Randall Long
Paint Inspection office: Incospec – Peter Dove
Applicator: Temco (towers), Hydro-blast (trays)
Principals: Alcoa ltd – David Le Lièvre and Ross Vince
ZINGA has also been used on power pylons at Point Henry, Australia. Here it was applied on top of an old hot-dip layer. The application took place between 8 and 15 April 2005. After an inspection in November 2006, the treated towers were still in perfect condition.
In 2011, the construction of a new Waste-to-Energy facility was started. This project ‘Runcorn II’ should be finished in 2014/2015.
The facility is located in Manchester, UK where it will offer a solution for the large amount of municipal waste by using this waste to produce up to 80 MW of electricity and 54 MW of heat.
The company ‘Viridor EFW’ has awarded the contract to ‘Keppel Seghers’ (cooperation between ‘Keppel Seghers Belgium’ and ‘Keppel Seghers UK’) who will provide the technology.
The actual constructing was undertaken by the ‘Sisk Group’. In turn, they contracted ‘Fisher Engineering’ to galvanize and install heavy steel beams.
The large steel beams at the top of the building, which are too big to be hot dip galvanised, were treated with ZINGA.
At a cost of €185 million, this is the first major project in the UK where a combination of hot-dip galvanised and film-galvanised steelwork has been assembled into a single structure. It clearly illustrates that the electrical potentials of the two zincs are well-balanced, and one beam will never go anodic to another and hence no galvanic corrosion can occur.