IGS anti-slagging ceramic coating provides a long-term solution in a pulverised coal boiler. The boiler experienced excessive slagging due to fuel diversification.
Three sulfuric acid alkylation unit (SAAU) reactors on the critical path experienced corrosion. Solution: IGS HVTS applied within three days. Outcome: Millions of dollars saved. The alternative solution would have taken 21 days to apply.
IGS Cetek team was invited to install the high emissivity ceramic coating system to improve the radiant heat transfer efficiency and decrease fuel firing and bridgewall temperature. Before the heater was brought down for coating, online convection cleaning was performed.
This dual approach allowed the heater to operate with a greater throughput. Hot Convection Cleaning (HCC) recovered much of the steam loss, allowing the heater to function as needed.
HCC was completed online with 4 shifts, while the coating was completed safely and on time within 3 days during the shutdown.
The performance of the unit was evaluated after the coating installation and the results were exceptionally good.
There was a 3.5% increase in throughput, with very minor loss in steam production. Additionally, the energy consumed per unit of product produced decreased by 2%.
An inspection after 18 months in service showed that the coating was still in good condition.