†Enhancing Methanex Titan Cooling Tower: A Sustainable Reinforcement Solution Methanex is a global leader in methanol production, known for its strong commitment to operational excellence and adherence to industry best practices. The company prides itself on quickly addressing any issues within its facilities to maintain top-tier performance. One such facility, the Methanex Titan Cooling Tower, is situated in the Caribbean and built with reinforced concrete, making it a critical part of the plant’s infrastructure. Addressing Structural Integrity at Methanex Caribbean Plant The Methanex facility in the Caribbean recently underwent a major structural reinforcement project. The first phase focused on a 10' x 50' section along the western wall of the cooling tower, where significant spalling and concrete degradation had occurred. This damage was caused by saltwater intrusion, leading to steel corrosion and expansion, which in turn triggered further spalling and exposed rebar. To ensure the most effective repair strategy, HJ3 conducted a detailed survey to identify the most urgent areas needing attention. Empowering Structural Resilience: Phase One and Two Repairs In the second phase of the project, HJ3 expanded the work to include the repair of 15 support columns on both the North and South walls. These columns had suffered from environmental exposure, chemical damage, and weather-related wear. The assessment highlighted high-priority exposed rebar and structural cracks that required immediate action. Replacing these columns entirely would have been costly and time-consuming, so HJ3 opted for a more efficient and sustainable solution. Swift and Efficient Repairs: Savings and Sustainability HJ3 completed both phases of the repairs in just four weeks, achieving a 50% cost reduction compared to a full replacement. This not only saved money but also minimized downtime, ensuring the plant could continue operating smoothly without interruption. Restoring Structural Integrity: How It Was Done In phase one, HJ3 used CarbonSeal carbon fiber reinforcement to restore the 10' x 50' section of the west wall. The process involved cleaning and preparing the surface, applying a specialized primer, and then saturating and installing the carbon fiber system. In phase two, the same method was applied to reinforce 15 columns, with additional steps like zinc-coated rebar and anchor plates to prevent curling during curing. HJ3's Innovative Reinforcement Process Each phase began with thorough surface preparation according to HJ3's strict guidelines. After cleaning and priming, the carbon fiber reinforcement was carefully applied, followed by high modulus paste and two protective topcoats. For phase two, brace plates were added to ensure long-term stability and durability. Sustainability and Cost-Effectiveness: The Results By reinforcing the cooling tower instead of replacing it, Methanex avoided massive waste and environmental impact. The project prevented five tons of concrete and steel waste, nearly 30,000 tons of CO2 emissions, 4 million kWh of energy use, and over 264,000 gallons of water. The cost savings were impressive, and the structure will now last another 20 years, avoiding a potential shutdown that was expected within a year of the initial inspection. Elevate the Structural Integrity of Your Facilities If you're concerned about the strength of your cooling towers or want to learn more about HJ3’s carbon fiber reinforcement solutions, reach out to our experienced team. We’re here to help you protect your infrastructure while saving costs and reducing environmental impact. Contact us today to discuss your needs. ††Conical Twin Screw And Barrel,Plastic Sheet Machine Screw And Barrel,Extruder Screw And Barrel,Plastic Sheet Machine Zhejiang Guangming Plastics Machinery Co.,Ltd. , https://www.gmscrews.com
