Glass Flake Lining for the Dyes and Dye Intermediates Industry
October 30, 2026
Glass flake linings and coatings for
Glass Flake Lining for FGD Systems in Thermal Power Plants
Glass Flake Lining for FGD Systems in Thermal Power Plants
Flue gas desulphurisation (FGD) has become a standard part of coal-fired power generation in India. To meet sulphur dioxide emission norms, utilities and captive power plants are installing wet limestone FGD systems across their units. These systems remove sulphur dioxide from flue gas by scrubbing it with limestone slurry, but in doing so they create one of the most corrosive environments in any industrial plant.
Hot, wet, acidic flue gas, chlorides, fluorides and abrasive slurry attack carbon steel and concrete from every side. Without proper protection, absorbers, ducts, chimney liners and tanks can corrode within a short period, forcing costly unplanned outages. CHEMIPROTECT supplies and applies glass flake coating and lining systems designed to protect FGD equipment and keep power units running.
Why FGD Equipment Corrodes So Quickly
Several aggressive conditions act together inside an FGD system:
- Acid condensation. When flue gas cools below its acid dew point, sulphuric acid condenses on surfaces, especially at the wet-dry interface.
- Chlorides and fluorides. Coal contains chlorine and fluorine, which concentrate in the scrubber liquor and attack metals.
- Temperature cycling. Start-ups, shutdowns and bypass operation expose surfaces to changing temperatures.
- Abrasion. Limestone and gypsum slurry wears away weak coatings, particularly near spray zones and agitators.
- Permeation. Water vapour and acidic species slowly migrate through ordinary coatings and reach the steel beneath.
Ordinary paint systems and thin coatings are rarely enough. FGD service needs a barrier that resists chemical attack, permeation, abrasion and heat together.
How Glass Flake Lining Works
A glass flake lining is a resin system filled with thin flakes of glass. When applied, the flakes align roughly parallel to the surface and overlap like layers of tiles. Any moisture or acid trying to reach the steel must travel a long, winding path around the flakes. This “tortuous path” effect greatly reduces permeation compared with an unfilled resin of the same thickness.
The flakes also improve the lining’s resistance to abrasion and reduce shrinkage stresses during curing, which helps adhesion to the substrate. The resin matrix provides chemical resistance, while the glass provides the barrier. To understand these benefits in more detail, read our guide on glass flake coating for corrosion protection.
FGD Areas We Protect
FGD area | Main exposure | Protection focus |
Absorber shell and floor | Acidic slurry, chlorides, abrasion | High-build glass flake lining with abrasion resistance |
Inlet duct and wet-dry interface | Hot gas, acid condensation, temperature swings | Heat- and acid-resistant glass flake system |
Outlet duct | Saturated acidic gas and condensate | Permeation-resistant barrier lining |
Chimney flue liners | Acid condensate on cooler surfaces | Continuous lining over steel flue cans |
Limestone slurry and gypsum tanks | Abrasive slurry, mild acidity | Abrasion-resistant glass flake lining |
Process water and effluent tanks | Acidic wastewater, chlorides | Chemical-resistant tank lining |
Hydrocyclone and pump areas | Slurry splashing and wear | Localised protective coating |
Each area has different operating conditions, so the resin type, lining thickness and number of coats should be selected for the actual service. Our technical team reviews temperature, chemistry and abrasion levels before recommending a system.
The CHEMIPROTECT Glass Flake Range
CHEMIPROTECT manufactures the MIPROGLASS family of glass flake products, including the MIPROGLASS 101 series, the MIPROGLASS 201 series and the MIPROGLASS Primer VE. Grades such as MIPROGLASS 101 SV, MIPROGLASS 201 SV and the hybrid grades are offered for different chemical and thermal duties. See the full glass flake product range and ask our team which grade suits each FGD zone.
Surface Preparation and Application
A glass flake lining is only as good as its preparation and application. For FGD projects, the typical sequence is:
- Inspection. Check the substrate for corrosion, pitting, weld defects and contamination.
- Weld and edge preparation. Grind sharp edges and weld spatter so the lining builds evenly.
- Abrasive blasting. Blast steel to a clean, roughened profile suitable for lining adhesion.
- Priming. Apply the specified primer soon after blasting to prevent flash rusting.
- Lining application. Apply glass flake layers by spray, roller or trowel to the specified thickness.
- Inspection between coats. Check thickness and visual quality before the next layer.
- Holiday testing. Use spark testing to find pinholes and repair them before commissioning.
- Curing. Allow full cure under suitable temperature and humidity before the system enters service.
Controlled humidity and temperature during application are important, especially inside large absorbers. Dehumidification and heating may be needed on site.
Glass Flake Versus Other FGD Linings
FGD designers can choose from several protection methods. Each has its place:
- Glass flake linings give a strong barrier at moderate thickness and can be applied in the field and repaired locally.
- Rubber linings offer good abrasion resistance but can be sensitive to high temperatures and require skilled application.
- Acid-resistant brick and tile linings suit very harsh, high-temperature zones. CHEMIPROTECT also supplies acid resistant bricks and acid-resistant mortars for these duties.
- Alloy cladding is effective but expensive, especially for large areas.
Many plants use a combination: glass flake for most surfaces, with brick or other systems in the most severe zones. Our article on glass flake lining versus epoxy coating explains how barrier linings compare with standard coatings.
Planning Around Shutdowns
Power plants measure downtime in lost megawatt-hours, so lining work must fit planned outages. Good planning includes:
- Surveying the equipment before the shutdown to estimate repair and lining areas.
- Arranging blasting, dehumidification, access scaffolding and materials in advance.
- Scheduling coats and curing time within the outage window.
- Agreeing inspection hold points with the plant’s quality team.
CHEMIPROTECT works with plant engineers to plan lining work so units return to service on schedule.
Benefits for Power Plants
- Longer equipment life for absorbers, ducts, chimneys and tanks.
- Fewer unplanned outages caused by corrosion failures.
- Lower maintenance cost through durable, repairable linings.
- Support for emission compliance by keeping FGD systems available.
- Field application without removing equipment from site.
Related Solutions
Power plants also use CHEMIPROTECT systems beyond FGD. See our pages on chemical resistant coating for power plants and acid resistant lining for scrubbers. For water and effluent areas, read about chemical resistant lining for ETP plants.
Inspection and Maintenance After Commissioning
A glass flake lining performs best when it is inspected regularly. During each planned outage, plant teams should check the absorber, ducts and tanks for blisters, cracks, mechanical damage or areas of wear near spray headers and agitators. Small defects can be repaired quickly by preparing the damaged area and applying fresh lining, which prevents corrosion from spreading under the surrounding film. Keeping a record of inspection findings and repairs helps plants predict future maintenance needs and plan lining work well before an outage begins. CHEMIPROTECT can support periodic inspections and recommend repair scopes based on what is found.
Frequently Asked Questions
Why is glass flake preferred for FGD absorbers?
The overlapping glass flakes create a strong barrier against permeation of moisture and acid, while the resin resists chemical attack. This combination suits the wet, acidic FGD environment.
Can glass flake linings handle FGD temperatures?
Glass flake systems are available in resin types suited to different temperature ranges. The correct grade depends on the actual operating and upset temperatures, which we review before recommending a system.
Can damaged areas be repaired?
Yes. Glass flake linings can be repaired locally after proper surface preparation, which is useful during short outages.
How is lining quality checked?
Thickness checks and spark (holiday) testing are used to confirm coverage and find pinholes before commissioning.
Do you supply materials only or also apply them?
CHEMIPROTECT offers materials and application support. Contact us to discuss your project scope.
Protect Your FGD System
Share your FGD equipment details, operating temperatures and outage schedule. We will recommend a glass flake lining system and application plan. Contact CHEMIPROTECT or explore our services.
Let’s Blog
Latest Blog
When used with chemical resistant masonry units and the proper membrane MIPRO-VE will protect concrete and steel sub base from chemical attacks and physical abuse. MIPRO-VE is silica filled vinyl ester mortar supplied in two parts .
Glass Flake Lining for Steel Pickling Lines
October 27, 2026
Glass flake linings for steel pickling
Glass Flake Lining for Desalination Plants and Seawater Cooling Systems
October 24, 2026
Glass flake linings for desalination plants,