Boiler Tube Coating

Preventing Boiler Tube Corrosion

Boiler Tube Coatings for CFB, PC-Fired, BFB, and Grate Boilers 

IGS prevents fireside corrosion on-site in grate-fired WtE (EfW) boiler tubes with high-alloy corrosion-resistant cladding, or coating. On-site thermal spray coating delivers a more reliable solution for preventing boiler tube corrosion than a more fragile ceramic coating. 

IGS leverages decades of experience with more than 500 boiler reliability applications. We are at the forefront of maximizing run time while minimizing outage frequency and cost. 

IGS solutions have been successfully implemented to provide scalable, proactively manageable, and fully refurbishable boiler tube protection from fly ash erosion and fireside corrosion. 

SMART Solution for Boiler Reliability 

  • Systematic Approach to Boiler Reliability 
  • Materials and Equipment Engineered for Specific Results 
  • Applications by Trained and Certified Teams 
  • Results are Measured, Documented, and Monitored 
  • Testimonials Prove Performance! 

Systematic Approach to Boiler Reliability 

We understand the wear patterns and problem areas in the boiler by investigating the following: 

  • Capture all boiler specific information; year commissioned, size, fuel blend, nominal thickness, and previous UT data, among others 
  • Understand maintenance and operational philosophy 
  • Consider past tube failures, type, and locations 
  • Consider past solutions 
  • Consider trends, and wear occurrences that differ 
  • Document with images while accurately noting location 
  • Inspection and thickness mapping of existing cladding (if any), taking three readings looking out for preferential corrosion 

Boiler Tube Coating Vs. Cladding – What is the difference? 

While applied using a similar method to more traditional thermal spray coatings, the performance of High Velocity Thermal Spray (HVTS) goes beyond the usual expectations of a spray coating in reducing corrosion in boiler tubes. Therefore, to help customers differentiate, we refer to our HVTS solution as a thermal spray cladding. 

Corrosion Resistant Boiler Tube Coatings in the Market 

Refractory was the first protection against corrosive flue gases in boiler tubes, but limited heat exchange properties cut thermal efficiency. Refractory alloys can be used but due to the excessive cost of such material the main material used for building boiler is carbon steel or low alloyed steel. The implementation of a surface protection layer is the most cost-effective solution. Even a thin layer can deliver significant improvement on corrosion resistance. 

The use of ceramic coatings seems an attractive approach, however, the thermal expansion mismatch and the fragility of such a coating makes it unreliable. Ceramic coatings are more likely to crack than thermal spray coatings, or cladding, and corrosion can develop underneath the protective layer which can peel off, leaving little protection. 

Corrosion Resistant HVTS Metal Spray Cladding 

The benefit of High Velocity Thermal Spray is the application of a thin layer of material without dilution and heat-affected zone (HAZ). 

IGS HVTS processes ensure finely structured cladding, with an order of magnitude, lower permeability and greater homogeneity. Changes in feedstock chemistry have further improved performance by significantly reducing stress, increasing bond strength, and mitigating oxide content. By addressing the root cause of these microstructural defects through the process and material chemistry, HVTS can be successfully employed in the field. We work during shutdowns, with high production rates and low costs. As with welding and other cladding technologies, surface preparation, material, process, and procedure criteria are defined in specifications. HVTS generates no Heat Affected Zone on the pressure parts and does not place residual stresses on the base metal since the temperature of the base metal remains low even without water in the boiler tubes. 

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IGS On-Site Thermal Spray Cladding 

Integrated Global Services provides on-site thermal spray cladding inside CFB, PC-Fired, BFB, and Grate Boilers in the European Union, including UK, Germany, Netherlands, Sweden, and France, from our operations center in the Czech Republic. Being an international company, we clad in the United States, Middle East, Japan, South-East Asia, and Africa. 

The IGS HVTS systems demonstrate excellent corrosion resistance with little or no indications of metal loss in extreme conditions of waste incinerators and refuse-derived fuel (RDF) grate-fired boilers. Whereas, 625 weld-overlaid components must be replaced at end of life, IGS HVTS can be reliably refurbished or even replaced in-situ without replacing the underlying component. The corrosion resistance coupled with the ease of application in-situ makes the selection of such IGS claddings favorable in areas where weld alloy 625 fails. 

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