IGS leverages decades of experience with over 500 Circulating Fluidized Bed (CFB) Boiler High Velocity Thermal Sprayed (HVTS) cladding applications to stay at the forefront of maximizing run time and minimizing outage frequency and cost for CFB Boilers globally. IGS HVTS cladding has been successfully used over the past decade to provide scalable (we adjust cladding thickness to meet specific wear rates in different locations), proactively manageable and fully refurbishable boiler tube protection from fly ash erosion and fireside corrosion. Our service renders mechanical repair of boiler tubes in Circulating Fluidized Bed Boilers an unnecessary practice.
The problem: an example of CFB Boiler erosion
CFB Boilers by design offer a number of advantages over conventional boiler designs, including the ability to fire a wide range of fuels and lower combustion temperatures which reduce emissions. The bottom approximately one-third of these boilers is generally protected by castable refractory, but the top approximately two-thirds have exposed tubes to maximize radiant and convective heat transfer. These boilers operate by combusting fuel in a fluidized bed of non-combustible particles which causes CFB erosion.
As bed material particles recirculate in the furnace, it causes metal wastage of the furnace water wall / evaporator panels by corrosion-erosion mechanisms, an unavoidable consequence of this design of boiler. This fireside corrosion is typically found at refractory to water wall / evaporator interface, field weld joints in the furnace (typically 4-8 meters above the refractory interface), and at tubes upstream of the cyclone inlet(s) at the top of the furnace as fly ash travels out of the furnace and into the cyclone.
IGS High Velocity Thermal Sprayed cladding is ideal for protecting CFB boiler tubes from fireside corrosion and fly ash erosion metal wastage. For CFB Boilers, IGS applies high alloy materials with both ceramic and metallic components to produce a homogenous (particles typically <50um), hard (typically in excess of 1,200Hv300), and tough layer providing optimal application and performance properties for CFB Boilers. We utilize only the true High Velocity application process, where atomization of the material occurs before or in a supersonic gas stream, the only way in which to achieve such optimal cladding properties needed for reliable and predictable long-term cladding performance.
IGS HVTS offer our customers the following advantages over other thermal spray and cladding solutions:
Find out more about SMART Gard solution characteristics, alloy features, technological benefits, erosion resistance, and much more.
IGS is the pioneer in the use of Thermal Spray claddings in CFB boilers. We have completed over 500 CFB applications over the past two decades. Having completed so many applications over so many years uniquely positions IGS as the knowledge leader in materials, application technology, installation, refurbishment and operating methods. Simply stated, we are the best positioned to know what works and what does not in many varying CFB Boiler types burning a wide range of fuels across the globe. Where others may be experimenting, IGS has trusted and proven solutions.
Over the past decade, we have leveraged this experience and knowledge to develop unique materials and methods to provide reliable and predictable protective barriers in the most challenging CFB boilers globally. We have learned that:
HVTS cladding offering creates value for CFB boiler owners and operators by ensuring reliability and predictability of the performance of their boiler assets. Customers who view the reliability and dependability of their units as mission-critical to their revenue generation and/or their customers will experience the economic benefit of IGS technology and approach to CFB Boiler reliability. Through our strategically placed operations in the Americas, Europe, Africa, CIS, Middle-East, and Asia Pacific regions, we focus on creating value for our customers globally by ensuring the reliable and dependable performance of their mission-critical assets.