Boiler tube failure
03-29-2007, 07:24 PM,
#1
Boiler tube failure
Hi,

I've been working on a project of biomass cofiring with coal. The operators notice an increase in the number of boiler tube failure due to impingement (probably).

I would like to submit them to apply a kind of ceramic coating in the boiler walls. However, as I'm not a specialist of that stuff, I don't know if it's feasible for the following reasons:

- there's a surface of about 500 m2 to be coated
- which coating method is the most suitable for this application
- which coating material could be used as well
- is it economically feasible... basically what's the cost of coating 500m2: I guess that my client will not run a coating if it's more expensive than changing the tubes!

I will be grateful for your answer to my questions.

Florent
Reply
04-03-2007, 01:40 PM,
#2
RE: Boiler tube failure
Hi Florent

Sign0016 to the Surface Engineering Forum.

Many do apply surface treatments to boiler tubes to increase life and reduce number of plant shut-downs to replace tubes. It is difficult to say which process and coating type would be best for your particular application without detailed appraisal and some research. Hopefully, we will get some additional input from people who specialise in boiler tube coatings.

Link to previous thread on boiler tubes
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01-11-2008, 03:16 PM, (This post was last modified: 02-19-2009, 10:46 PM by djewell.)
#3
RE: Boiler tube failure
There are many companied who only spray boiler tubes, so there are also quite a few products to protect tubes from wear and corrosion. They use twin-wire arc and HVOF to apply the coatings. I think they use mostly metals to get the best heat transfer properties.[/align]

In selecting a coating, first determine if failure is coming first from wear or corrosion. Second, where in the boiler are the tubes located? Third, at what temperature do they operate? Fourth, is it an oxidizing, neutral, or reducing atmosphere? This is very important, as the coating will fail very quickly if you choose wrong. Contact me off-line for specific product recommendations.
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01-11-2008, 05:36 PM,
#4
RE: Boiler tube failure
Hi,

Look this:
(link dead)
Ion



Flo24 Wrote:Hi,

I've been working on a project of biomass cofiring with coal. The operators notice an increase in the number of boiler tube failure due to impingement (probably).

I would like to submit them to apply a kind of ceramic coating in the boiler walls. However, as I'm not a specialist of that stuff, I don't know if it's feasible for the following reasons:

- there's a surface of about 500 m2 to be coated
- which coating method is the most suitable for this application
- which coating material could be used as well
- is it economically feasible... basically what's the cost of coating 500m2: I guess that my client will not run a coating if it's more expensive than changing the tubes!

I will be grateful for your answer to my questions.

Florent
Reply
01-12-2008, 10:49 AM,
#5
RE: Boiler tube failure
Hi, if the power plant can afford, use HVOF method, if not, offer them arc sprayed coating. I am in this field, have sprayed too much of them. In the case the tube wall is impinged as you said, HVOF spray coating is recommended, but it's really expensive, you can quote the plant US$2500/sqm and above. If economic solution is perferred, arc spraying with some very special wear-resistent cored wire (usually newly developed after year 2000) is the way. email me if you want: jeffsays163@hotmail.com
Reply
03-22-2017, 09:53 AM,
#6
RE: Boiler tube failure
Hi Florent, just following up on an old post about boiler tube coatings. What did you finally do and how is the long term results.

IN the meantime there are some great developments; The Hand-Held AK-HH Gun and Portable Thermal Spray System for Manual Deposition of Metal and Carbide Coatings: http://kermetico.com/ak/hand-held-portab...rmal-spray

and Spray on Ceramic Coatings from Fireside Coatings. https://www.firesidecoatings.com/

used in combination an applicator can get some great results.

Stephen James Booth
www.ipsteknokraft.com
www.teknokraft.com
Indonesia WhatsApp +6281905603262

Reply
11-14-2017, 03:26 AM,
#7
RE: Boiler tube failure
Ceramic Coatings as stand alone solution or top coat over HVAF or HVOF

https://firesidecoatings.com/ceramic-coatings/xp-61/

XP-61

Resistant to 1600° F (871° C)
Resistant to severe cyclic conditions
Corrosion/Erosion resistant
Non insulating
Reduces slagging and fouling
Resist gases, oils, solvents and most acids
Non-toxic and odorless
Adheres to carbon steel, stainless steel, refractory and other organic surfaces
Good mechanical bonding
Stephen James Booth
www.ipsteknokraft.com
www.teknokraft.com
Indonesia WhatsApp +6281905603262

Reply
11-26-2017, 09:47 AM, (This post was last modified: 03-02-2020, 12:08 PM by Bridhett.)
#8
RE: Boiler tube failure
(11-14-2017, 03:26 AM)Stephern Booth Wrote: Ceramic Coatings as stand alone solution or top coat over HVAF or HVOF

https://firesidecoatings.com/ceramic-coatings/xp-61/

XP-61

Resistant to 1600° F (871° C)
Resistant to severe cyclic conditions
Corrosion/Erosion resistant
Non insulating
Reduces slagging and fouling
Resist gases, oils, solvents and most acids
Non-toxic and odorless
Adheres to carbon steel, stainless steel, refractory and other organic surfaces
Good mechanical bonding

That's good to know Stephen. Thanks for sharing the info.
Reply
06-22-2019, 01:19 PM,
#9
RE: Boiler tube failure
About on site arc spray operations, do you sandblast surfaces? Or just bond coat after rough abrasive cleaners?
Reply




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