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What is the impact of manufacturing industrial or activated carbon on your factory roof? Are you sick of seeing corrosion in your industrial roofs when producing active carbon? If so, this article is for you.
Black carbon manufacturing roof in industrial sheds
Activated/Industrial carbon or charcoal is typically produced from natural materials like coconut shells, wood, peat, coal, and bamboo. Compared to other materials like coconut shells and wood, fruits are less commonly used in large-scale activated carbon production. This is due to factors such as availability, cost-effectiveness, and efficiency of the conversion process.
Activated carbon production roof in industrial factories
Industrial carbon or activated carbon based on its structure is one of the most used materials. Different industries use it widely for various applications. They use different methods to activate carbon. Carbon becomes activated at controlled pressures and is very porous in its structure. This has caused the cross-sectional area of carbon to be very high compared to its volume and it is widely used in factories.
Burning carbon creates activated carbons in a vacuum and in oxygen-free conditions. During the production process of active carbon on an industrial scale, smoke and corrosive vapors are produced. This manufacturing process of active carbon directly hit your industrial roof.
The coal and carbon factory has a negative effect and causes rust and corrosion specifically in metal roofs.
Before examining the industrial carbon production process and its effect on the roof of your factory, we will first discuss the types of activated carbon applications.
Activated carbon, also known as industrial carbon black, is a versatile material that finds a wide range of applications across various industries. Some common uses of industrial/active carbon include:
They use industrial carbon extensively in reinforcing fillers in the production of rubber products. such as tires, conveyor belts, hoses, and seals. It helps enhance the strength, durability, and abrasion resistance of rubber compounds.
Impact of carbon production on industrial roof corrosion
Then they add it to plastic materials to improve their mechanical properties, UV resistance, and conductivity. They also use it in the manufacturing of plastic pipes, automotive parts, packaging materials, and consumer goods.
Activated carbon is a key ingredient in the production of inks, toners, and pigments. It provides color, opacity, and UV stability to printing inks, coatings, paints, and carbon paper.
Carbon black is utilized in the manufacturing of lithium-ion batteries as a conductive additive in electrodes. It helps improve the conductivity and performance of the battery cells.
Effect of Carbon Emissions on the roof of industrial buildings
See also: Corrosion of Roofs in Lead Acid Battery Companies
Industrial carbon is used in construction materials such as asphalt, concrete, and sealants to enhance their strength, durability, and weather resistance.
Active Carbon serves as a catalyst support in chemical reactions, as a pigment in dyes and carbon paper, and as a conductive additive in electrochemical devices.
Carbon footprint and roof of industrial construction
They also add Industrial carbon to adhesives, sealants, and caulks to improve their adhesion, strength, and resistance to environmental factors.
The utilization of industrial Carbon is in drilling fluid additive in oil and gas exploration to reduce fluid loss, stabilize wellbores, and enhance drilling efficiency.
One of the applications of active carbon is to purify municipal and domestic water and sewage treatment plants. Due to its ability to adsorb organic contaminants, odors, and impurities from water and air.
Activation with hot steam is widely used for the production of industrial carbon in refineries and carbonate filtering. Hot vapors during producing industrial carbon directly hit the roof of factories. It affects carbon fiber production factories and causes roof corrosion.
The most important corrosive gases produced in filtering process:
Carbon monoxide is a colorless, odorless gas that can be produced during the heating or activation process of carbonaceous material to create activated carbon. CO is highly toxic and can pose health risks if not properly controlled.
Sulfur dioxide may be released during the production of activated carbon if sulfur-containing compounds are present in the raw materials or if sulfur-based activation methods are used. SO2 is a corrosive gas that can cause environmental pollution as well as roof corrosion.
Sulfur oxides can accelerate the corrosion of steel and other metal alloys by forming sulfuric acid. This is done in the atmosphere or on the metal’s surface, when expose to water, moisture or oxygen. Then sulfuric acid produced by manufacturing active carbon can corrode roof of industrial sheds.
Read: How does sulfuric acid cause roof corrosion in factories + Solution
Hydrogen sulfide can be formed during certain thermal processes involved in activating carbon. H2S is highly toxic and has a characteristic rotten egg smell. It can also corrode metal equipment and infrastructure.
When the sulfur traps the moisture on steel roofs, it creates iron oxides or pyrophoric. The iron oxides produced by active carbon production eat your metals and galvanized industrial roof.
Nitrogen oxides, such as nitric oxide (NO) and nitrogen dioxide (NO2), can be generated during combustion processes or high-temperature reactions in activated carbon production. NOx gases are corrosive and can contribute to air pollution and respiratory problems.
Chlorine compounds, such as hydrogen chloride (HCl), are the byproduct of manufacturing active carbon that can cause corrosion in your industrial roof. When chlorine compounds are released into the atmosphere as gases, they can react with water vapor and other pollutants in the air to form acidic substances like hydrochloric acid (HCl) and other corrosive compounds.
The acidic nature of chlorine compounds can react with the surfaces of metal, concrete, or asphalt roofs. These reactions can corrode the protective coatings and surface layers of the roof, leading to degradation and structural damage over time.
UPVC (unplasticized polyvinyl chloride) roofs are resistant to hot corrosive fumes and gases from active carbon production for several reasons:
UPVC roof sheets are resistant to a wide range of chemical substances, including corrosive fumes and gases that active carbon will produce them. It is non-reactive to acids, alkalis, and other corrosive compounds. This makes UPVC panels an ideal material for environments where heat exposure and chemicals are common.
Reliable industrial roof in active carbon production
UPVC has a high melting point and can withstand high temperatures without deforming or degrading. This property makes your UPVC roof suitable for applications where industrial carbon production processes.
As we know, to make industrial carbon, coal is placed in a vacuum environment and heated to 700-1000 degrees Celsius and a lot of heat is produced. Then they expose the carbon to chemicals such as argon and nitrogen and again heat the carbon to 1200 degrees Celsius and expose it to oxygen and steam.
UPVC polyroof sheets can withstand the high heat produced in heating tanks and furnaces. They remain stable and durable for 40 to 50 years without reacting with corrosive chemicals.
UPVC roofs do not rust or corrode like metal roofs when exposed to corrosive toxic fumes. This resistance to corrosion ensures the longevity and durability of the roof in harsh industrial of carbon manufacturing environments.
Sepidfam Varna (POLYROOF) is the largest manufacturer of UPVC sheets in Iran. We ship Polyroof’s waterproof and fireproof products to all parts of the world with the aim of providing security and increasing the durability of your industrial roof for production of carbon and active coal.
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