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08444 Extending the Service Life of Furnace Wall Tubes Using Thermal-Sprayed Coatings

Picture for 08444 Extending the Service Life of Furnace Wall Tubes Using Thermal-Sprayed Coatings
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Product Number: 51300-08444-SG
ISBN: 08444 2008 CP
Author: Michio Tanabe, Yoichi Matsubara, Akihiro Takeya, and Yoshinobu Sochi
Publication Date: 2008
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In response to ongoing problems resulting from corrosion in furnace wall tubes at waste incineration plants a nickel-based self-fluxing alloy coating fused by induction heating has been developed and is in service in several locations. It has been shown to greatly extend the service life of furnace wall tubes due to its excellent corrosion resistance and heat resistance. Fusing of the coating by induction heating, compared with conventional coatings, provides a far stronger metallurgical bond at the interface, while minimizing the inclusion of pores. In addition, these coated tubes are less costly than those with welded coatings, while the induction heating process reduces distortion in the products, facilitating easier final assembly. After a successful first experimental application of tubes in a boiler wall, 11 units (five six-meter tubes per unit) were put to the test in a Waste to Energy (WTE) boiler in Taiwan. These units revealed virtually no corrosion on the exposed surfaces after over three years of service, while showing an improved water heating efficiency over that of the original tubes. Over 600 similar units are now being employed both on walls and roofs in four incinerators in Taiwan, with further installations in progress.
In response to ongoing problems resulting from corrosion in furnace wall tubes at waste incineration plants a nickel-based self-fluxing alloy coating fused by induction heating has been developed and is in service in several locations. It has been shown to greatly extend the service life of furnace wall tubes due to its excellent corrosion resistance and heat resistance. Fusing of the coating by induction heating, compared with conventional coatings, provides a far stronger metallurgical bond at the interface, while minimizing the inclusion of pores. In addition, these coated tubes are less costly than those with welded coatings, while the induction heating process reduces distortion in the products, facilitating easier final assembly. After a successful first experimental application of tubes in a boiler wall, 11 units (five six-meter tubes per unit) were put to the test in a Waste to Energy (WTE) boiler in Taiwan. These units revealed virtually no corrosion on the exposed surfaces after over three years of service, while showing an improved water heating efficiency over that of the original tubes. Over 600 similar units are now being employed both on walls and roofs in four incinerators in Taiwan, with further installations in progress.
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