The alloy construction of reheat tubes was being attacked by the flue gas after wet scrubbing. The apparent problem is that the coal being burned is high in chlorides — 0.03% by weight — resulting in a huge spike (10X) in slurry chlorides around 12000 ppm. The 316 L outlet reheater tubing is showing pitting from chlorides in the flue gas. Internal water temp is 200°F in the tubes with external flue gas at 180°F. Steam at 600°F is sprayed into the scrubber column below the reheater tubes at scheduled intervals. These conditions are similar to conditions experienced in the Jet Bubble Reactors, scrubbers and ductwork made of alloy that are being attacked by high chloride coal burning. Advanced Polymer Coatings Avon Ohio 44011 U.S.A. www.adv-polymer.com +01 440-937-6218 Phone +01 440-937-5046 Fax 800-334-7193 Toll-Free in USA & Canada CASE STUDY FGD System in Coal Fired Power Plant The two wet scrubbers were designed and built 30-40 years ago. The FGD system is a 65 MW coal-fired power plant in Michigan. It is equipped with an electrostatic precipitator and a wet flue gas desulfurization (FGD) system for emission controls. The plant consumes approximately 550 tons of coal per day. Tubes were coated from above and below with specialized spray equipment using Chemline ® 784/32 Gray top coat. After Scrubber #1 was coated, the client decided to immediately to line the reheat tubes in Scrubber #2. The client was satisfied that the stainless tubes were lined within budget and will extend the life expectancy of the tubes. No significant heat transfer loss has been detected and the scrubber is working at peak performance. ChemLine ® Reheater tubes after lining from APC has proved that under the most challenging environments of heat, corrosion and wear, the ChemLine ® coating will provide long term solutions to coal burning with chloride contamination of the flue gas. Reheater tubes detailing corrosion Reheater tubes viewed from above after blasting and before lining
Transcript
The alloy construction of reheat tubes was being attacked by the flue gas after wet scrubbing. The apparent problem is that the coal being burned is high in chlorides — 0.03% by weight — resulting in a huge spike (10X) in slurry chlorides around 12000 ppm. The 316 L outlet reheater tubing is showing pitting from chlorides in the flue gas. Internal water temp is 200°F in the tubes with external flue gas at 180°F. Steam at 600°F is sprayed into the scrubber column below the reheater tubes at scheduled intervals.
These conditions are similar to conditions experienced in the Jet Bubble Reactors, scrubbers and ductwork made of alloy that are being attacked by high chloride coal burning.
+01 440-937-6218 Phone+01 440-937-5046 Fax800-334-7193 Toll-Free in USA & Canada
CASE STUDY
FGD System in Coal Fired Power Plant
The two wet scrubbers were designed and built 30-40 years ago.
The FGD system is a 65 MW coal-fired power plant in Michigan.
It is equipped with an electrostatic precipitator and a wet flue
gas desulfurization (FGD) system for emission controls. The plant
consumes approximately 550 tons of coal per day.
Tubes were coated from above and below with specialized spray equipment using Chemline® 784/32 Gray top coat. After Scrubber #1 was coated, the client decided to immediately to line the reheat tubes in Scrubber #2. The client was satisfied that the stainless tubes were lined within budget and will extend the life expectancy of the tubes. No significant heat transfer loss has been detected and the scrubber is working at peak performance.
ChemLine® Reheater tubes after lining from APC has proved that under the most challenging environments of heat, corrosion and wear, the ChemLine® coating will provide long term solutions to coal burning with chloride contamination of the flue gas.
The two wet scrubbers were designed and built 30-40 years ago. The FGD system is a 65 MW coal-fired power plant. It is equipped with an electrostatic precipitator and a wet flue gas desulfurization (FGD) system for emission controls. The plant consumes approximately 550 tons of coal per day.
The alloy construction of reheat tubes was being attacked by the flue gas after wet scrubbing. The apparent problem is that the coal being burned is high in chlorides- 0.03% by weight resulting in a huge spike (10X) in slurry chlorides around 12000 ppm. The 316 L outlet reheater tubing is showing pitting from chlorides in the flue gas. Internal water temp is 200F in the tubes with external flue gas at 180 F. Steam at 600 F is sparged into the scrubber column below the reheater tubes at scheduled intervals
These conditions are similar to conditions experienced in the Jet Bubble Reactors, scrubbers and ductwork made of alloy that are being attacked by high chloride coal burning.
Michigan Coal Fired Power Plant
The FGD system is a 65 MW coal-fired power plant. It is equipped with an electrostatic precipitator and a wet flue gas desulfurizer (FGD) system for emission controls. The plant consumes approximately 550 tons of coal per day.
Reheater tubes viewed from above after blasting and before lining
The two wet scrubbers were designed and built 30-40 years ago. The FGD system is a 65 MW coal-fired power plant. It is equipped with an electrostatic precipitator and a wet flue gas desulfurization (FGD) system for emission controls. The plant consumes approximately 550 tons of coal per day.
The alloy construction of reheat tubes was being attacked by the flue gas after wet scrubbing. The apparent problem is that the coal being burned is high in chlorides- 0.03% by weight resulting in a huge spike (10X) in slurry chlorides around 12000 ppm. The 316 L outlet reheater tubing is showing pitting from chlorides in the flue gas. Internal water temp is 200F in the tubes with external flue gas at 180 F. Steam at 600 F is sparged into the scrubber column below the reheater tubes at scheduled intervals
These conditions are similar to conditions experienced in the Jet Bubble Reactors, scrubbers and ductwork made of alloy that are being attacked by high chloride coal burning.
Michigan Coal Fired Power Plant
The FGD system is a 65 MW coal-fired power plant. It is equipped with an electrostatic precipitator and a wet flue gas desulfurizer (FGD) system for emission controls. The plant consumes approximately 550 tons of coal per day.
Reheater tubes viewed from above after blasting and before lining
The two wet scrubbers were designed and built 30-40 years ago. The FGD system is a 65 MW coal-fired power plant. It is equipped with an electrostatic precipitator and a wet flue gas desulfurization (FGD) system for emission controls. The plant consumes approximately 550 tons of coal per day.
The alloy construction of reheat tubes was being attacked by the flue gas after wet scrubbing. The apparent problem is that the coal being burned is high in chlorides- 0.03% by weight resulting in a huge spike (10X) in slurry chlorides around 12000 ppm. The 316 L outlet reheater tubing is showing pitting from chlorides in the flue gas. Internal water temp is 200F in the tubes with external flue gas at 180 F. Steam at 600 F is sparged into the scrubber column below the reheater tubes at scheduled intervals
These conditions are similar to conditions experienced in the Jet Bubble Reactors, scrubbers and ductwork made of alloy that are being attacked by high chloride coal burning.
Michigan Coal Fired Power Plant
The FGD system is a 65 MW coal-fired power plant. It is equipped with an electrostatic precipitator and a wet flue gas desulfurizer (FGD) system for emission controls. The plant consumes approximately 550 tons of coal per day.
Reheater tubes viewed from above after blasting and before lining
Reheater tubes detailing corrosion
Reheater tubes detailing corrosion Reheater tubes viewed from above after blasting and before lining
X ChemLine® 784/32 has temperature resistance to 400°F (204°C)
X Superior resistance to acids, alkalis, solvents, oxidizing agents
X Thermal cycling -40° to 400°F (-40° to 204°C)
X Flex stressing
X Wear and abrasion
X Impact resistant
CASE STUDY
ChemLine® is a revolutionary lining for the flue gas desulphuriziation process with these key benefits:
X ChemLine® is a specially formulated polymer coating for handling the high temperature and abrasion requirements of FGD systems.
X ChemLine® is a cross-linked organic-inorganic multifunctional polymer coating that exhibits high flexibility and toughness.
2
Case Study: FDG CoatingsIn Coal Fired Power Plant
— 2 —
Tubes were coated from above and below with specialized spray equipment using ChemLINE 784-32 Gray Top Coat. After Scrubber #1 was coated, the client decided to immediately to line the reheat tubes in Scrubber #2.
The client was satisfied that the stainless tubes were lined within budget and will extend the life expectancy of the tubes. No significant heat transfer loss has been detected and the scrubber is working at peak performance.
ChemLINE from APC has proved that under the most challenging environments of heat, corrosion and wear, the ChemLINE polymer will provide long term solutions to coal burning with chloride contamination of the flue gas. We welcome discussions from other clients that find that their alloy construction has had similar corrosive conditions.
See the follow pages for information on the ChemLINE® 784 Technology.
Tubes abrasive blasted and primed with Red ChemLine 784-32
Reheater tubes before lining. Reheater tubes after lining.
Case Study: FDG CoatingsIn Coal Fired Power Plant
— 2 —
Tubes were coated from above and below with specialized spray equipment using ChemLINE 784-32 Gray Top Coat. After Scrubber #1 was coated, the client decided to immediately to line the reheat tubes in Scrubber #2.
The client was satisfied that the stainless tubes were lined within budget and will extend the life expectancy of the tubes. No significant heat transfer loss has been detected and the scrubber is working at peak performance.
ChemLINE from APC has proved that under the most challenging environments of heat, corrosion and wear, the ChemLINE polymer will provide long term solutions to coal burning with chloride contamination of the flue gas. We welcome discussions from other clients that find that their alloy construction has had similar corrosive conditions.
See the follow pages for information on the ChemLINE® 784 Technology.
Tubes abrasive blasted and primed with Red ChemLine 784-32
Reheater tubes before lining. Reheater tubes after lining.
Case Study: FDG CoatingsIn Coal Fired Power Plant
— 2 —
Tubes were coated from above and below with specialized spray equipment using ChemLINE 784-32 Gray Top Coat. After Scrubber #1 was coated, the client decided to immediately to line the reheat tubes in Scrubber #2.
The client was satisfied that the stainless tubes were lined within budget and will extend the life expectancy of the tubes. No significant heat transfer loss has been detected and the scrubber is working at peak performance.
ChemLINE from APC has proved that under the most challenging environments of heat, corrosion and wear, the ChemLINE polymer will provide long term solutions to coal burning with chloride contamination of the flue gas. We welcome discussions from other clients that find that their alloy construction has had similar corrosive conditions.
See the follow pages for information on the ChemLINE® 784 Technology.
Tubes abrasive blasted and primed with Red ChemLine 784-32
Reheater tubes before lining. Reheater tubes after lining.
This case study provided by Paul D. Turner from Chemical Containment Systems, Inc.
Tubes abrasive blasted and primed with ChemLine® 784/32
Reheater tubes before lining Reheater tubes after lining
CASE STUDY
Follow-up Inspection– A $100,000 Savings
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The facility owner talked with several coatings companies about coating the reheat tubes, however, two backed out, as well as several contractors, noting they “did not have a lining to handle this aggressive exposure.”
Ultimate Corrosion Control (UCC) was the only local contractor to bid on the project, submitting ChemLine® 784/32 as the lining. UCC lined the fi rst scrubber banks last November and after UCC demonstrated that ChemLine® 784/32 would perform, the second scrubber was added to the order. After 6 months of service, UCC and Chemical Containment Systems (CSS) were invited to inspect the tubes.
Observations and Comments:1. The upper bank was discolored to dark brown but was
fully intact. One tube had suffered physical mechanical damage to the topcoat of a 6 inch long area of one tube. The ChemLine® 784/32 basecoat remained intact and was not breached, but the top coat was damaged. There was no deterioration of the basecoat.
2. The lower bank was discolored to light tan with no damage whatsoever. The lower bank is about 50°F lower in temperature.
3. The underside of the lower bank was inspected by standing on the mist eliminator section and looking up. The underside of the tubes was where the severe corrosion was found. This area was fully intact.
4. A build up on the tubes (carbon, mineral and ash) easily came off from the tubes by hand or water hose.
5. The owner commented that no ineffi ciencies from heat transfer after lining were detected. Flue gas was reheated in the scrubber as was before the lining job. In fact, in one scrubber, extra tubes were installed to compensate for coating the tubes. The other scrubber did not have extra tubes. The owner advised that there was no signifi cant difference in effi ciency between scrubbers.
6. The owner decided to coat an additional tube bank with ChemLine® 784/32 after this inspection was completed and accepted.
7. The owner advised UCC and Chemical Containment Systems that the utility saved at least 100K by coating existing tubes versus upgrading to new tubes.
8. UCC made the owner a believer in its capabilities and ChemLine® 784/32 performed to the owner’s satisfaction. This was a perfect combination of a very satisfi ed coatings manufacturer, applicator, facility owner!
(Below Photos) Deposit build up on the tubes (carbon, mineral and ash) easily comes off by hand or water hose.
(Above Photos) Coated reheater tubes at six months inspection shown in excellent condition.
