HPC COATING

VALTERRA HPC REPORT

SP Coatings Africa’s Success at Valterra Platinum’s Rustenburg Base Metals Refining (RBMR)

Project Overview: Superior Product 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 and Solutions:

The HPC application at Valterra Platinum’s Rustenburg Base Metals Refining (RBMR) facility was executed on Deaerator #1, where traditional cladding and lagging had allowed moisture ingress and corrosion under insulation (CUI) to develop.

Upon removal of the existing insulation system, severe corrosion was identified on inlet lines and surrounding vessel areas. The environment presented typical refining challenges, including humidity, process temperature fluctuations, and complex pipe geometry around elbows and undersides of the vessel.

To mitigate further degradation and eliminate the root cause of CUI, Superior Product Coatings Africa implemented a high-performance coating (HPC) system. The solution included:

• Full removal of cladding and lagging
• Mechanical surface preparation (wire brushing and sanding)
• Wash-down and substrate cleaning
• Progressive high-build HPC application
• SP Seal Coat topcoat for moisture sealing

This system was selected to provide long-term corrosion resistance while removing dependence on conventional insulation systems that trap moisture.

Performance and Results

Following preparation, HPC was applied in controlled build-up stages to ensure full encapsulation of the substrate. The system was progressively layered from 1–3mm through to a final achieved thickness of 10–15mm, as confirmed in the project’s final DFT readings.

The target of the project was energy saving more so than corrosion. We saved 48,9% steam reduction on the deaerator and 4,8-5,2% steam saving across the entire system

Client Satisfaction

The successful completion of the HPC proof-of-concept application at RBMR reinforced Valterra Platinum’s confidence in the performance capabilities of the HPC system.

The project demonstrated measurable corrosion mitigation, structural preservation, and improved asset protection without reinstating traditional lagging systems. The collaboration between the application team and site personnel ensured successful delivery under challenging site conditions.

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 Superior Product Coatings Africa’s ability to deliver high-build, corrosion-resistant coating systems in complex industrial environments.

By replacing conventional insulation systems with a 10–15mm HPC barrier and SP Seal Coat sealing layer, the project successfully:

• Arrested active corrosion
• Mitigated corrosion under insulation
• Strengthened structural integrity
• Delivered a durable, moisture-resistant protective system

This project confirms HPC as a sustainable and technically robust alternative to traditional cladding systems in high-humidity refining operations.