Power Boilers

Critical Observations

• Thermal Shock: Affects the combustor, loop seal, and openings.
• Erosion & Chemical Attack: Cyclone inlets are exposed to erosion and chemical attack.
• Abrasion, Erosion & CO Decomposition: Bull Nose and combustor zones are prone to abrasion, erosion, and CO decomposition.
• Loop Seal Failures: Often result from thermal shock and abrasion.

Material & Design Approach

• Low Thermal Expansion: Minimizes crack formation during thermal cycling.
• High Mechanical Strength & Fracture Toughness: Enhances durability under demanding operating conditions.
• High Thermal Conductivity: Reduces localized thermal stress and improves overall lining performance.

Maintenance & Repair

• Ceramic Anchors: Ceramic anchors are recommended for overhead areas and COC ducts to ensure reliable refractory support.
• Anchor Inspection: Inspect and replace damaged anchors before refractory installation to maintain lining integrity.
• Localized Crack Repair: Remove damaged refractory material and repair localized cracks using plastic refractory without shuttering.

Advanced Materials: Phosphate-bonded, low-porosity aluminous castables/plastics, ideal for CFBC / AFBC / WTE / WHRB / PC Fired boilers with lining thickness as low as 25 mm.

Application Practices

• Plastic Ramming Mixes: Recommended for dense, wear-prone zones requiring superior abrasion resistance.
• Low-Porosity Gunning Castables: Enable faster installation while maintaining reliable lining performance.
• Lime-Free Monolithic Refractories: Recommended wherever possible to improve refractory performance and service life.