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Copyright © 2012JGC Corporation All rights reserved
THERMAL SPRAY COATINGAPPLICATIONS
FOR REFINERY & BOILER
JGC CorporationStart Up & Operation Service Department
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Copyright © 2012JGC Corporation All rights reserved
Thermal Spray is a technology to form coating by depositing molten materials on metal surfaces at high speed.
MetalAlloyCermetCeramic
(Coating Materials)
Combustion Flame Plasma
Spray Gun
Coating DepositionParticle Impact
Molten Particle Acceleration
Base Metal
(Heat Sources)
Un-molted Meta
Gas Hole
Base Metal
Molten Particle
What is Thermal Spray?
Copyright © 2012JGC Corporation All rights reserved
Examples of Field Applications
CDU Tower Corrosion Protection
FCC Cat Section Applications
Boiler Tube Applications
Other Applications
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Copyright © 2012JGC Corporation All rights reserved
1. CDU Tower Corrosion Protection
Copyright © 2012JGC Corporation All rights reserved
Stainless steel cladding is typically installed in top head of the distillation tower to protect against acid corrosion.
Due to the long service life, corrosion of the metal cladding has been increasing.
Ni/Cr alloy or Ni-base alloy coating is one of the options for top head repair.
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Copyright © 2012JGC Corporation All rights reserved
Φ 8500
Clad PortionTop and Weld SeamArea : 65 ㎡42
0025
80
CS Shell PortionTL ~#1 Accumulator TrayArea : 70 ㎡
Example of Actual ApplicationCoating MaterialNi-base alloy + SiO2 Sealing
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Step 1 - Check the site condition and working environment
Step 12 - Remove the materials, equipment, cleaning
Step 4 - Check the appearance of the surfaces to be coated
Step 2 - Carry in the equipment and materials
Step 3 - Setting up, wiring and trial run of TSC equipment
Step 5 - Cure the un-coated area and confined space ventilation
Step 6 - Blasting for removing the scale
Step 7 - Intermediate inspection (visual observation of chips, cracks, etc.)
Step 8 - Grid blasting for surface treatment
Step 9 - Intermediate inspection (visual observation, roughness checking)
Step 10 - Thermal spraying (manual) and sealing
Step 11 - Final inspection (thickness checking, visual observation, etc)
Process of On-site TSC Work
7Work Duration:12 Days
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This process consisting of TSC sprayed with Arc Wire Process and “Sealer”
Coating materials are as followsFor TSC = NiCr base alloy or Ni base alloyFor Sealer = SiO2 System material
This coating is applicable from ambient temp to high temperature up to 450℃
Expected lifetime of the coating would be at least 5 years or more (depends on the operating condition)
Hybrid Thermal Spray Coating
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【Sealer】Corrosion resistance material which need the interspaces to fix itself
【EP-JB coating】Corrosion resistance layerwithout interspaces
Hybrid
Composition of Hybrid Coating
【TSC layer】Corrosion resistance layer with interspaces
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Cross-Section of Hybrid LayerDepth of the sealers’ penetration (Ni-Cr system TSC layer)
Above photos show that SiO2 sealer penetrate deeply enough to the poresin the TSC layer ( almost all of the pores are filled with the sealer).
Pores Si penetrate into the pores
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Copyright © 2012JGC Corporation All rights reserved
TSCArea
TSC Area
Non TSCArea
After 4 years, performance of TSC was confirmed
TSC area : Sprayed film was still in
good condition and no increase of corrosion was observed
Non TSC area : Surface was rusty and
increase of corrosion was observed
Actual Performance of TSC
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Advantage of TSC Wide range of material selection
High deposition rate of coating
Low cost and simple work
No heat to affect base metal
The best material can be selected for the service.
One third of the cost compared to strip lining.
TSC can be applied repeatedly because there are no metallurgical effect on shell material.
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135㎡ can be sprayed within 2 weeks during TA.
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2. FCC Cat Section Applications
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2. FCC Cat Section Applications The severest operating conditions.
Erosion caused by catalyst flowHigh temperature corrosion
Damage to mechanical components in FCC Cat Section is a problem for reliable, long-term continuous operation.
Damage can be effectively prevented or mitigated with various metal coatings using TSC technology.
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Feed InjectorAir Distributer
Rx Stripper
Rx Cyclone Internal
Rx PlenumChamber
Slide Valve Stem
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Rg PlenumChamber
Rg Cyclone Internal
FCC Cat Section Applications
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Rx / Rg Plenum Chamber HVOF/Cr3C2-Cermet
Anti-Erosion Coating Arc Flame/Fe-Cr-B
Anti- Erosion Coating
Rx / Rg Cyclone Y Sleeve Self-Fluxing Alloy/Fe-Cr-B
Anti-Erosion Coating
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Examples of Actual Applications
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Rg Air Grid Nozzle HVOF/Cr3C2-Cermet
Anti-Erosion Coating VPS/Cr3C2-Cermet
Anti-Erosion Coating
Plug Valve Stem HVOF/Cr3C2-Cermet
Anti-Erosion Coating
Examples of Actual Applications
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Main FractionatorBottom Pump HVOF/Cr3C2-Cermet
Anti-Erosion Coating
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Examples of Actual Applications
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3.Boiler Tube Applications
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Confidential
Water leak damage of reheat combustion chamber tube
Corrosive compound contained in fossil fuel ashes and its MPPetroleum Fuel(Heavy oil, Asphalt,Petroleum coke)
Coal
Chemical compound MP ℃ Chemical compound MP ℃
V2O5 690 K3Fe(SO4)3 618
NaVO3 560 K3Al(SO4)3 654
Na2SO4 884 Na3Fe(SO4)3 624
2Na2O・3V2O5 565 Na3Al(SO4)3 646
10Na2O・V2O5 573 KFe(SO4)2 694
Na2O・V2O4・5V2O5 625 NaFe(SO4)2 690
5Na2O・V2O4・11V2O5 535 Na2SO4/K2SO4 884/1,069
Damage of Steam Generating Boiler Tube
Cross section of reheat combustion chamber tube damaged by high-temperature corrosion
Cross section of air heater tube damaged by high-temperature corrosion
Cross section macro structure of reheat combustion chamber tube of coal fired boiler
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Example 1 : Thermal Spray for Generating Tube
Industry : Iron and Steel Capacity : 260t/h (Evaporation)Spray area : Generating Tube inside furnaceMaterial : 50Ni-50Cr
Applying Thermal Spray Finished Repair damage by
weld overlay
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Example 2 : Thermal Spray for Generating Tube
Industry : Paper makerCapability : 120t/hSprayed area : Generating Tube inside furnaceMaterial : 50Ni-50Cr
Spraying Finished
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Corrosion resistance of thermal spray layer applied to superheater tube of Heavy oil fired boiler
Test result of Corrosion resistance/50Cr-50Ni
Corrosion test result of Ni-Cr-(Fe) alloy with 80%V2O5-20%Na2SO4 ashes
Mass Loss(mg/cm3 16hr)
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4.Other Applications
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Other Applications1. Rotating Machinery Applications Developed and used for wear protection and thermal
barrier of machine parts. Permanent repair of critical components of rotating
machines. pump shafts, mechanical seal sleeves, etc. piston rods, piston rings gas turbine blades, combustion chambers
2. Aluminum Thermal Spray Coating for CUI protection Al coating is the ultimate option for CUI protection. Plant owners no longer need to be concerned about
CUI.
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Copyright © 2012JGC Corporation All rights reserved
Thank youfor
your attention!
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