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TECHNOLOGY - PROTECTIVE COATINGS IP has introduced universal primers suitable for ballast tank protection. claimed to offer even lower levels of friction. The paint manufacturer said that the new coatings represented the ‘next generation’ foul release technology, using fluoropolymer chemistry to improve on the silicone’s performance. Marine organisms stick to a vessel’s hull by secreting an adhesive that is either hydrophobic or hydrophilic. Intersleek 900 is a patented fluoropolymer foul release coating, which presents the organisms with an amphiphilic surface, combining hydrophilic and hydrophobic properties in order to minimise the chemical electrostatic adhesion between the surface and the fouling organism, whether the adhesive is hydrophobic or hydrophilic. Better foul release This technology confers overall 40% better foul release properties than its silicone-based predecessors and a 50% reduction in slime build up, IP claimed. It also produces unprecedented levels of average hull roughness of 72 microns, which gives a 38% improvement in the friction coefficient over Intersleek 700. IP said that the ultra-smooth hull produced by the new coating reduces water resistance, cutting fuel consumption and emissions. What this means is that the new technology is now available to slower speed vessels, including tankers, whereas the previous coatings generation were only applicable to vessels moving at a higher speed. For example, vessels steaming at 10 knots can now take advantage of the new coating. Tankers often trade in the spot market and may have periods of idleness while awaiting a charter, or to load/discharge. IP claimed that Intersleek 900’s static fouling resistance in port is some 80% better than its predecessor. Depending on the application and the inservice conditions, fuel and emission savings recouped using the new coating were originally forecast to be 6%, compared with self-polishing copolymers containing biocides, according to IP. The paint manufacturer estimated that over a five year period, a VLCC coated with a selfpolishing copolymer anti-fouling could reap savings of 9,000 tonnes of fuel if coated with Intersleek 900, thus reducing its CO2 emissions by 31,000 tonnes and saving around $3.6 mill. In-service experience with a range of vessels has shown savings of up to 9%, which is considerably higher than IP’s original forecasts. Tanker applications Among the testimonials from shipowners were comments from Mumbai-based Mercator Lines. The company specified Intersleek 900 to the underwater hull area of the Aframax Prem Pride in October 2007, while undergoing drydocking in Dubai. Mercator also specified the coating of a larger hull area on her near sister Prem Divya in June 2008. Mercator’s general manager Amit Agarwal explained; “We continued to closely monitor the performance of both vessels in service. In 2008, we achieved up to 6% fuel savings on Prem Pride using Intersleek 900. This year (2009), with even more data, we can confirm that the fuel and emission savings have been maintained on this vessel. “While we continue to be happy with the performance of Intersleek 900 on Prem Pride, we fully expect an improvement on Prem Divya, as we had increased the areas of the underwater hull coated to include the flat bottom. The detailed monitoring of the performance of the Prem Divya has confirmed that we are now achieving up to 9% reduction in fuel consumption under comparable conditions,” he concluded. Mumbai-based Mercator Lines chose Intersleek 900 for the 105,000 dwt Prem Divya just nine months after Prem Pride had her vertical sides coated with IP’s latest generation patented fluoropolymer at Dubai Drydocks World. However, the second coating involved the entire underwater area of the 1998-built vessel during the tanker’s second special survey hull upgrade. “We had monitored the Prem Pride’s fuel consumption closely,” explained Agarwal at the time. “At corresponding engine speeds, the vessel was consuming up to 6% less fuel, depending on weather conditions, after the application of Intersleek 900. We originally calculated projected savings based on a bunker price of $450 and found we were saving nearly three tonnes of fuel a day. And while bunker prices continue to climb, our payback period just gets shorter. The added advantages of no biocides, reduced drydocking times and lower CO2 emissions convinced us that this is the technology we need”. Prior to investing in Intersleek 900 technology, Mercator had undertaken a detailed cost benefit analysis, taking references from owners who had already adopted the new hull coating. The process involved calculating the savings generated by easier through-life hull coatings management including a smaller volume of paint required at subsequent dockings, an improvement in environmental footprint and fuel consumption savings. Fuel savings of this magnitude add up to an environmental benefit equivalent to almost 11,000 tonnes of CO2 emitted, 100 tonnes less SOx and 200 tonnes less of NOx. As at October last year, more than 250 vessels had been coated with Intersleek 900, including prestigious cruise vessels, such as 34 TANKEROperator January/February 2010
TECHNOLOGY - PROTECTIVE COATINGS Intergard 787 being applied on the outside shell of a newbuilding. Queen Mary 2. Along with its predecessors, the new coating has picked up several awards along the way. Universal primer range IP has recently unveiled a new range of universal primers for the newbuilding market. The company said that is being introduced to address the productivity, regulatory, performance and commercial needs of shipyards and shipowners alike – worldwide. Shipbuilders and owners can now better choose how they meet productivity and performance targets and comply with the IMO’s Performance Standard for Protective Coatings (PSPC) and new regional regulations limiting Volatile Organic Compound (VOC) emissions, such as the EU’s Solvents Emissions Directive, IP claimed. While newbuilding yards all have different construction methods, build different vessels, are exposed to seasonal fluctuations in climatic conditions and are subject to global and local regulation, the new range of universal primers offers shipyards worldwide customised products to meet those different needs, the company said. For the newbuilding yard, the product range offers universal application, high volume solids with low VOC, year round workability with fast drying, low temperature cure and long overcoating intervals. For the shipowner, the range provides long term asset protection with controlled through life maintenance costs, high performance corrosion and abrasion resistance and PSPC compliance. Leading the range is Intershield® 300. With a proven, 21-year track record on over 9,000 vessels, Intershield 300 is the industry benchmark in IMO PSPC compliant anticorrosive performance, claimed IP. This abrasion resistant, (>9%) aluminium pure epoxy coating can be applied to multiple vessel areas over mechanically prepared shop primer and offers long term asset protection and control of through life maintenance costs and is available worldwide. New Intershield® 300HS, is a high solids version of the original technology, which offers 78% volume solids, lower VOC and application direct from the can without thinning. With the aluminium content maintained >9%, Intershield® 300HS will continue to deliver the same corrosion control as the earlier version. It is currently available in the EMEA range and will be available worldwide from mid-2010. Another primer is new Intergard® 7600, which is a light coloured, pure epoxy universal primer providing good abrasion resistance. IP said that it offered excellent application properties, low temperature workability and true long term overcoating intervals with no requirement for surface roughening. Also available is Intergard® 787, which is a high, 80% volume solids light coloured aluminium pure epoxy coating with good corrosion protection and abrasion resistance. Intergard® 787 can help meet the environmental challenge on VOC emissions and has an excellent track record on South Korean newbuildings. It is currently available in that country. New Intergard® 5600 and Intergard® 5620 complete the range. These light coloured, epoxy universal primers have evolved from Intergard® 403 and Intergard® 423 technology. These products have excellent sprayability all year round and have proven long term anti-corrosive performance with an extensive track record, IP said. TO *Fuel Economy Due to Improvements in Ships’ Hull Surface Condition 1976-86 by RL Townsin, D Byrne, TE Svensen and A Milne. • Custom built and series product • Technically reliable • Well proven designs • Continuous technical development • Dependable partner • Customer oriented approach DAMEN DOUBLE HULL OIL TANKER MTS ‘SHANNON FISHER’ STANDARD OF EXCELLENCE DAMEN SHIPYARDS BERGUM Member of the DAMEN SHIPYARDS GROUP CUSTOM BUILT IN SERIES PRODUCTION P.O. Box 7 phone +31 (0)511 46 72 22 info@damen-bergum.nl 9250 AA Bergu m fax +31 (0)511 46 42 59 www.damen-bergum.nl The Netherlands January/February 2010 TANKEROperator 35
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