Boiler GRH.ppt

Stronger with…
Castolin Eutectic
1
CASTOLIN France / Argumentaire UIOM Juin 2010 / Didier MATTIUZZI
didier.mattiuzzi@castolin.fr / 01 69 82 69 05
Castolin Eutectic‘s History in Boiler Coating
█ First trials in Boiler protection in USA in 1973
█ Arc, Combustion, Plasma, PTA, HVOF, spray and fuse technologies
█ Global Boiler Coating team formed in 1990.
█ Boiler OEM partners (ABB,Babcock, etc) and operators (RWE, CEGB,
TIRU, etc)

Stronger with…
Castolin Eutectic
2
Powders, wires and densification Know-How
█ Alloy
• Powder or cored wire
█ Process
• Thermal Spray: Arc, Combustion, HVOF, Plasma
• Welding
• Fusing, densification
█ Choice of Coating System
• Cost
• Speed, access for on site work
• Corrosion/wear performance, bonding, smoothness, thickness

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Castolin Eutectic
3
CastoLab® Services - Coating on site

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Castolin Eutectic
4
CastoLab® Services – Coating in workshops

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Castolin Eutectic
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Quality, reliability and technology
█ Consumable-ISO 9001, TUV, Lloyds of London
█ Equipment-CE
█ In house ASTM G65 Wear Testing. Erosion, impact, high temperature
█ Independent corrosion testing HCl (33%), HNO3 (55%), H2SO4 (96%) and
acetic acid (80%)
█ CastoLab investments
DIN 50021
Neutral salt spray test with a 5%
sodium chloride solution to 240hrs.

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Castolin Eutectic
6
Boiler Issues
Tube thins due to:
█ Erosion
█ Corrosion

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Castolin Eutectic
7
Boiler Coating - Difference between types
█ Erosion
█ Corrosion
Arc Wire
Arc/powder
plus Densification
S&F
Power- Coal
Power- Coal-Low NOx
Waste incineration
Waste with Power

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Castolin Eutectic
8
Boiler issues - Corrosion
█ Chlorine content in Municipal Waste estimate
Drivers for corrosion problems
█ Lower grade coal- more sulphur
█ Higher combustion temperatures
due to emission limits (NOx)
█ Longer outages needed 3-5 years
█ Higher Steam temperatures
█ More waste/biomass combustion

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Castolin Eutectic
9
Waste Incineration and Energy
Power
Incineration
█ ~70 MVA Waste Power Plants in Germany with further 30 plants planned
█ 1.5 % of the total gross energy production with Waste Power Plants
█ Fuel supplement is tyres, textiles, plastics, pellets

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Castolin Eutectic
10
Waste Treatment EU 27 (2007)
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
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Country
Waste
treatment
Deponierung Verbrennung Recycling Kompostierung
█ Internship at Castolin Eutectic
05.08.2010 – 01.10.2010
Philipp Staudt
Incineration Distribution

Stronger with…
Castolin Eutectic
11
Biomass
█ The market of biomass
power plants is very big
and growing.
█ In Germany alone more
than 200 plants existed in
2008. A study conducted
by “ecoprog / Fraunhofer
UMSICHT”in 2009
mentions 130 planned
biomass power plants in
Europe for the next few
years.
05.08.2010 – 01.10.2010
Philipp Staudt

Stronger with…
Castolin Eutectic
12
Results Waste-to-Energy
█ The waste-to-energy market is the most interesting for our S+F technology.
█ There are about 430 installations in Europe. The biggest market by numbers
is France while the highest amount of waste is burned in Germany.
█ The total amount of treated waste is about 70 000 000t and there are more
than 800 boilers. More than 23 000 GWh of electricity and more than 40 000
GWh of heat are produced every year.
█ The biggest operators come from France. Those are Veolia, GDF Suez
Novergie and Tiru in that order. The biggest Operator outside of France is
E.ON.
05.08.2010 – 01.10.2010
Philipp Staudt

Stronger with…
Castolin Eutectic
13
Reference
Belt
NOVERGIE VALORLY à Lyon
SET MONT BLANC 74 PASSY / NOVERGIE
COMPAGNIE DE CHAUFFAGE URBAIN DE
GRENOBLE
By-pass tubes
NOVERGIE VALORLY à Lyon
NOVERGIE VEDENE
VEOLIA ORLEANS
SETMI VEOLIA TOULOUSE
OSTENDE IVOO (dernier mètre des panneaux)
NOVERGIE CARHAIX
LAVERA ENERGIE
VEOLIA VALENE
Tubes Open pass
• TIRU St OUEN NOVERGIE
• Tubes porteurs
• VEOLIA CGECP
Evaporator tubes
• VEOLIA CHALON EN CHAMPAGNE
• VEOLIA LASSE
• VEOLIA CGECP

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Castolin Eutectic
14
References in Germany
EVT Oberkirch EVT Stuttgart
Müllverbrennung Göppingen RWE Frimmersdorf
HKW Köhler Oberkirch Schmidt
Heißdampfgesellschaft Stadtwerke Rheinbraun Kraftwerk Wachtberg
Pforzheim Hornitex Nidda
EBV Siersdorf Herzogenrath Saarbergwerk KW Fenne Völklingen
Eisenwerk Baumgarte Bielefeld Feldmühle Arnsberg
MVA Stadtwerke Düsseldorf-Flingern BASF Ludwigshafen
EVT Gaisburg EVT Berrenrath
Rheinbraun Frechen EVT Goldenberg
Preußenelektra Kraftwerk Heyden MHKW Essen-Karnap
BEWAG Heizkraftwerk Moabit Berlin Hüttenwerke Krupp Mannesmann
Kraftwerk Neurath VEBA Kraftwerk Scholven
Portland Zement Dotternhausen e.on (RWE) Kraftwerk Weisweiler
e.on Kraftwerk Korbetha VEAG HKW Berlin
Egger, Brilon GHP Beeskow

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Castolin Eutectic
15
Coated Tubes produced in CastoLab

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Castolin Eutectic
16
Publications and patents
█ Patents
• BTC 561
• BTC 251
█Publications
• Energy magazine
• ASM Materials Week
• Power Engineer

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Castolin Eutectic
17
Boiler Team France : already 5 years of R&D to improve performances of boilers in
waste incinerators
BoilerTeam :

Stronger with…
Castolin Eutectic
18
BoilerTeam : some results
BTC 8995CH Weld INCONEL 625
After6 months: Strong pitting
12 months. No change in coating
New Coating
CASTOLIN 8995CH
in working conditions
850°C/390°C !
After 6 month of competition
with inconel 625 (right)
CASTOLIN 8995CH still in
place after 12 months

Stronger with…
Castolin Eutectic
19
Development of Spray and Fuse for Panels
█ GROUP R&D Project to develop automated Spray and Fuse for Panels
█ More difficult as can not rotate and it is not symetric
█ Need multiple Spray guns and fusing facility
█ Looking at flame, oven, induction fusing.

Stronger with…
Castolin Eutectic
20
Arc wire spraying of coal boilers
█ 3 cored wires specifically developed and proven in boilers
█ Advantages:
█ No gases, combustion. Simple deposition
█ High spray rate
█ Highest coating density and bonding of cold processes

Stronger with…
Castolin Eutectic
21
CastoLab inPoland – Arc Wire Spray Boiler
coating capabilities
█ Two spray booths, and two grit blasting chambers allowing on direct
part transfer between them.
█ All equipment installed in heated halls allowing an operation through
whole year.
█ Probably the heaviest duty ventilation/filtration system in Europe
meeting all ecological regulations.
█ 40 certified spray operators ready to complete jobs in extremely short
time

Stronger with…
Castolin Eutectic
22
Potential markets for anti erosion arc
spray coatings.
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
160.0
TWh/year
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Power generation from lignite

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