Careers IGS HVTS® Delivers Long-term WtE Boiler Corrosion Protection in Finland
This case study examines the successful implementation and performance of HVTS® (High Velocity Thermal Spray) technology at a Waste-to-Energy (WtE) plant in Finland. The project demonstrates how HVTS cladding technology, developed by Integrated Global Services (IGS), can effectively protect WtE boiler components from corrosion in aggressive operating environments.
The Challenge
WtE boilers face significant challenges with fireside corrosion of boiler wall tubes and furnace components. This is particularly true for modern high-efficiency plants operating at elevated pressures and temperatures. Without adequate protection, these conditions can lead to:
- Rapid depletion of corrosion allowances
- Unexpected outages due to tube leaks
- Higher maintenance costs
- Reduced operational reliability
The Facility and Operating Environment
In 2016, Finland implemented its historic ban on landfill waste disposal, marking a significant shift in the country’s waste management strategy.
For this facility to continue operating optimally, maintaining boiler reliability and efficiency was key. After three years in operation, the plant faced potential corrosion issues in the second pass dividing wall of their boiler, a critical area exposed to corrosive flue gases. Consequently, the plant manager sought an effective WtE boiler corrosion protection solution.
Boiler Specifications
- Number of Units: 1 unit / Grate system, boiler, and steam generator
- Throughput per Unit: 20 t/h
- Total Plant Capacity: 160,000 t/a
- Thermal Capacity: 58.5 MW
- Steam Parameters: 40 bar / 402°C
- Fuel Type: Mixed waste
Solution Implementation
The plant approached IGS Europe for a solution to stop the metal wastage issues. After a thorough technical evaluation, HVTS was chosen as the best solution to protect the boiler from further degradation.
HVTS Specifications:
- Applied at a nominal thickness of 500 microns
- Creates dense protective layers while minimizing internal stresses
- Uses ultra-fine particles in a dense pattern, creating longer pathways from surface to substrate that effectively prevent permeation
This corrosion-resistant alloy (CRA) cladding creates a robust barrier against further wastage.
Project Scope
- 2019: Initial application on the front side of the dividing wall (57.31 m² area)
- 2023: Extension to the back side of the dividing wall (57.31 m² additional area)
Inspection Results
- 2022 Inspection: The cladding applied in 2019 remained in excellent condition, with no visible mechanical damage and original thickness maintained across protected areas.
- 2024 Inspection: Further confirmed the durability and quality of the HVTS application in both areas, validating its performance and successful protection of base materials.
Key Results
- Zero coating failures over 5 years of operation (since 2019)
- No thickness loss detected
- Complete protection of underlying base material
- Improved reliability
- No unexpected outages due to corrosion
Conclusion
This project demonstrates the long-term effectiveness of IGS HVTS technology in protecting WtE boiler components. After five years of operation, the initial application continues to provide excellent protection with no signs of degradation, validating the technology’s reliability and cost-effectiveness for WtE applications.
The successful implementation and performance have established a strong foundation for future collaboration between IGS and the facility, with potential expansion to protect additional unprotected areas.
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