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Refractory Services

Refractory Services for Circulating Fluidized Bed Burning Coal, Waste Coal, and Biomass

Since their inception in 1978, circulating fluidized bed (CFB) boilers have played an important role in the generation of electricity to the grid and the supply of steam to host facilities. CFB boilers offer advantages over conventional boilers such as the ability to fire a wide range of fuels, lower combustion temperatures, and reduce emissions.

Refractory failures are the most problematic, time consuming, and costly failures in CFB boilers. Thermally induced failures result from rapid or erratic heating or cooling of the refractory while taking the unit in and out of service, leading to uneven expansion or contraction of the refractory causing spalling and cracking. Loss of refractory in the lower section of a CFB can result in tube failure and if not arrested soon enough, flooding the bed. Anchoring system failures are a leading cause of refractory failures. This may be due to poor anchoring design, lack of anchor density, or improper attachment welds. IGS has years of experience in terms of providing both new construction and post startup refractory services in circulating fluidized bed boilers.

Refractory Services Provided for CFB Boilers

  • Lower combustor refractory
  • Refractory as part of Bed nozzle replacement
  • Refractory for Vortex finder
  • Loop Seal Return Leg refractory
  • Cyclone long wall refractory
  • Cyclone target wall
  • Replace vertical bull nose refractory
  • Replace burner refractory

IGS Experience

IGS has many experienced project managers, superintendents, foreman, safety managers, and refractory technicians available to support our refractory projects in the United States. We have made a significant investment in equipment to support our people. Our site management has experience working in Alstom, Pyropower, B&W, and Valmet CFB boilers, both during new construction and after startup.

We understand the difference in providing technical expertise for long term solutions to improve boiler efficiency, operational performance, and capacity as opposed to just offering a contractor’s patch repair mentality. We understand the dynamics of working in an outage, where every minute saved means less opportunity cost lost for the owner. Our refractory field service division is non-union, which provides a more efficient and lower cost model for our customers without regional experience limitations. Furthermore, to support our refractory services, IGS can provide welding services per our MIG, TIG, GMAW, and SMAW weld procedures to eliminate the need for multiple contractors on site.

Optimized Solutions for Boiler Refractory Repair

Over the past decade, IGS has leveraged our refractory experience and knowledge to develop a customer focused team, with an onsite project manager coordinating communications and scheduling, and with reliable and predictable performance in terms of budgets and schedules. Customers who view reliability and dependability of the refractory in their boilers as mission critical to their revenue generation should contact IGS for maximum boiler reliability, reduction of  premature failure risk, and fewer unplanned outages.

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