A specialist corrosion protection system has been applied to an overhead crane at a German biomethane plant, where harsh operating conditions inside a composting hall present significant challenges for steel infrastructure.
Steelpaint completed the refurbishment of the 40-tonne double-girder overhead crane at Nordfuel’s biomethane facility in Friesoythe, replacing an ageing coating system that had reached the end of its service life following prolonged exposure to aggressive biological conditions.
The project demonstrates the importance of selecting durable protective coatings for equipment operating in bioenergy and waste processing facilities, where moisture, ammonia and organic compounds can accelerate corrosion.
Corrosion challenges inside composting halls
Composting halls are among the most demanding industrial environments for steel structures. High humidity, fluctuating temperatures and gases released during biological decomposition can rapidly degrade conventional protective coatings.
According to Steelpaint, atmospheres within these facilities often contain ammonia, carbon dioxide and organic acids that increase the risk of microorganism-induced corrosion, particularly on heavily used equipment such as overhead cranes.
Nils Baumfalk, Key Account Manager – Protective Coatings at Steelpaint, said these operating conditions vary considerably depending on the materials being processed and the environmental conditions inside the facility.
“Unlike standard industrial facilities, exposure conditions can vary considerably depending on temperature, humidity and the composition of the organic material being processed. The atmosphere often contains ammonia, carbon dioxide, organic acids and by-products of biological decomposition that can accelerate the deterioration of conventional protective coatings.”
Refurbishing critical lifting equipment
The overhead crane plays an essential role in handling biomass, including woodchip and organic waste, within the Nordfuel biomethane plant.
Following abrasive blasting, Steelpaint’s application partner, Kruse Oberflächentechnik, applied a two-coat protective system comprising a Stelcatec-L-PR primer and Stelcatec-L-NT topcoat.
The refurbishment replaced the previous corrosion protection system, helping extend the operational life of equipment exposed to aggressive processing conditions.
Designed for demanding industrial environments
Steelpaint says its coating system has been developed for applications where conventional zinc-based coatings may deteriorate more rapidly due to prolonged exposure to moisture and aggressive chemical environments.
Dmitry Gromilin, Technical Service Manager at Steelpaint, said ammonia-containing atmospheres present particular challenges because electrolyte films, organic acids and chloride deposits generated through biological processes can accelerate corrosion.
“Ammonia-containing atmospheres represent a significant challenge for conventional zinc coating systems, in that electrolyte films, organic acids, and chloride-containing deposits from biological processes can lead to the rapid deterioration of the coating protecting steel.”
The company says the moisture-curing coating can be applied in temperatures ranging from -5°C to 50°C and at relative humidity levels of up to 98%, making it suitable for refurbishment projects where environmental conditions are difficult to control.
Supporting long-term infrastructure resilience
Maintaining cranes and other material handling equipment is essential for the reliable operation of biomethane and composting facilities, where equipment downtime can disrupt processing operations.
Steelpaint said the Nordfuel project builds on previous applications of its corrosion protection systems within biofuel plants and steel hydraulic engineering projects, with further equipment at the facility expected to undergo refurbishment.
As bioenergy facilities continue to expand across Europe, durable corrosion protection remains an important consideration for extending the service life of critical infrastructure operating in highly aggressive environments.
