Cetek Technology for Coal-fired Power Plants: Ceramic Coatings
Transcript of Cetek Technology for Coal-fired Power Plants: Ceramic Coatings
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Cetek Technology for Coal-fired Power Plants:
Ceramic Coatings
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Cetek Agenda• Challenges/Solutions in the Coal-Fired
Power Industry• Introduction to Cetek • Case Study I:
– 820 MW Supercritical Boiler– 420 MW Subcritical Boiler– 420 MW Subcritical Boiler
• Case Study II: 650 MW Supercritical Boiler• Cetek Coating Benefit Summary
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Challenges in the Coal-Fired Power Industry: Slagging
• Inefficiency – $20 billion USD in North America
• Current Solutions– SS tubes
• Very expensive, Cl attack– Online Cleaning
• Soot Blowing– Erosion, Cost
• Water Blasting– Tube Quenching
• Explosive Blasting– Boiler Damage
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– Increases thermal transfer to boiler tubes
– Lowers maintenance costs
• Eliminates damage to slope or other components due to large falling clinker
Slagging Solution: Ceramic Coating
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Challenges in the Coal-Fired Power Industry: Corrosion
• Primary cause of 50% of forced outages
• Current Solutions– High Alloy Tubes
• Very expensive, cycling issues– Overlay
• Weld Overlay– Cost, Cracking, Application Time
• Thermal Spray– Cost, Porosity, Hazards
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• Minimizes Forced Outages
• Increases reliability • Lowers
maintenance costs– Increased run
times– Longer boiler tube
life
Corrosion Solution: Ceramic Coating
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Cetek’s Ceramic Coating Technology
• 15 years industrial experience• Multiple industries
– Power Generation– Refining– Chemical Processing– Steel
• Thousands of coating applications• Benefits delivered
– Corrosion Prevention– Fouling Prevention– Fuel Savings– NOX Reduction– Production Increases
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Case Study I: 820 MW Supercritical Boiler 420 MW Subcritical Boiler 420 MW Subcritical Boiler
Trials to Full Scale Projects
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Spring 2006 Unit 4
March 27, 2006
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Spring 2006 Unit 4Unit Properties
• 820 MW CE Supercritical• T-fired, 8-corner• Commissioned 1973 • 2004
• Low NOx Burner use initiated• Eastern Bituminous Coal 2.5% Sulfur
• WashedObjectives
• Test Cetek’s Ceramic Coating in a high corrosion environment– Minimize the corrosion rate
• ~500 µm per year• Show a slag reduction
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833'-8"
804'807'810'-6"
845'-6"
840'
837'-8"
841'
117
#4
221
98
80
862'-8"
858'
854'850'-4"
224
73
#1
183
155
Bottom Bend of Lower Slope
163
127
202
198
169
Top Bend of Lower Slope
Unit 4: “A” Front Wall
= March 2001 Weld Overlay= April/May 2004 Weld Overlay=8.0m2 of aluminum metal spray= 2 waterwall panels installed = Cetek installed 2006 1m wide by 4m high
Areas Treated1m x 4m’ area “A” Furnace
Right of burner #4Top Burner
elevation
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Spring 2006 Unit 4• 6 month Inspection
– Coating Intact • Thickness readings taken by Plant and Cetek were
in proper coating range– No visible damage to coating– Slag on coated area is significantly less
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Spring 2006 Unit 4
Per Plant Management: Per Plant Management: ““Coating still has a green hue to it Coating still has a green hue to it and there is no visible slag build up on the tubes.and there is no visible slag build up on the tubes.””
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Spring 2006 Unit 4• Spring 2008
– 2 years in service– Significant slag reduction– No wastage in areas of coating vs.
~500 µm per year in region around coating
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Fall 2006 Unit 5
November 1, 2006
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Fall 2006 Unit 5Unit Properties
• 420 MW CE Sub-critical Drum, T-fired• Commissioned 1976 • 2003: Low NOx Burner use initiated• Eastern Bituminous Coal 3.5% - 4.5% Sulfur
– 30% WashedObjectives
• Minimize the corrosion rate– 711 µm average per year over the last outage cycle (up
to 1.27mm per year)• Minimize slag
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Fall 2006 Unit 5Front Wall
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Fall 2006 Unit 5Rear Wall
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Fall 2006 Unit 5Side Walls
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Fall 2006 Unit 5• One year later, Sept 2007 forced outage
note from Plant Management stated:– The walls looked very clean where the Cetek
coating had been applied. – There were sheets of slag above the coated
areas on the waterwalls. – The coating was still visible.
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Fall 2006 Unit 5• Spring 2008 Inspection
– Coating Intact– Minimal WW loss of +/- 75 µm
• Inspected every 67cm vertical ; every 5 tubes– Slag still not attaching to tubes
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Unit 5 vs. Unit 6 Comparison Fall 2006-18 month run
Unit 5• 370 m2 of coating applied
• No tube leaks in coated areas
• No Slagging on coated surfaces– Increase in Heat
Absorption
• Max of 75 µm loss in waterwall tubes
Unit 6• No coating applied due to
shortened outage
• 2 tube leaks in targeted areas– Result 2 Forced Outages
• 6.5 Days offline
• 711 µm avg per year loss in targeted areas (up to 1.27mm per year)
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Spring 2008 Unit 6
May 1, 2008
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Spring 2008 Unit 6Unit Properties
• 420 MW CE Sub-critical Drum, T-fired• Commissioned 1978 • 2003: Low NOx Burner use initiated• Eastern Bituminous Coal 3.5% - 4.5% Sulfur
– 30% Washed
Objectives• Minimize slag
– Decrease Furnace Exit Gas Temperature• Minimize the corrosion rate
– ~711 µm average per year over the last outage cycle (up to 1.27mm per year)
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Spring 2008 Unit 6• Areas Treated
– Front Wall, 247 Tubes– Rear Wall, 247 Tubes– Side Wall, 194 Tubes
• All tubes are 5.1cm on 6.4cm center.– El. 803 to El. 845 (12.8 m)– Total surface area 1,050 m2
• Additional Outage Work Completed– New Final Reheat Section Installed
• Stainless steel• Reduced surface area
– Not related to a performance issue
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Spring 2008 Unit 6• Initial Benefits to date
– Slag Reduction > Increased Boiler Efficiency• Economizer Exit Gas Temp reduced by 17°C
– Pre vs. Post Outage: 382°C vs. 365°C• Boiler Heat Rate Improvements (vs. pre outage)
– July 15th: 11.3 KCal/kWh– August 5th : 19.6 KCal/kWh– $575,000 annual savings
• NOx Reduction– Estimated 4.3% under same pre outage firing
conditions.– Estimated 72,350 Kg/year
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Unit 6 – Boiler Heat Rate Improvement
Source: Plant Management, using HRDR system.
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Spring 2008 CVU6• Project tracking
– Per Plant Management: • “We have seen a 18.1 KCal/kWh reduction in
these 3 parameters in August compared to pre-outage.”
• “The results of the testing showed a drop in FEGT of 62.0°C on Unit 6.” (Testing completed by third party)
• “This year the Unit 6 NOx is 22.6% below our target. 345 tons of NOx less than the target.”
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Case Study II 650 MW CE Supercritical Boiler
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Case Study II: 650 MW C-E Supercritical Boiler
Unit Properties• Currently operated at 700-
720 MW• T-fired, 8-corner• Double Reheat Unit• Commissioned 1969 • 2001
• Low Nox Burners• March 2007
• Fluidized Gas Desulfurization
• Intelligent soot blowing system
Results after 6 Months• Coated Areas require 93%
less soot-blowing frequency than uncoated areas to achieve same results
• Coated unit projected soot blowing steam utilization savings of $130,000/yr (side benefit of coating)
• Reduced furnace exit gas temp.
• Minimized waterwall cycling
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Case Study II
Cerak M870
Cerak M670
Total Area of 405m2
Cerak M870 = 362m2
Cerak M670 (Chemical Set Coating) = 43m2
13m
5.5m
3m
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Case Study II
Cerak M670
Cerak M870
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Case Study II
Uncoated Area
Coated Area
Front-wall after 3 months of boiler operation
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3 WALL BLOWER D13 NOT AT REST3 WALL BLOWER D14 NOT AT REST3 Tube Crown Temp Right D133 Tube Crown Temp Right D14Gross Load, EXDESC=Gross Load
ZS3BS01D13
ZS3BS01D14
TE3BS01D13D
DEG FTE3BS01D14D
DEG F3LOAD
MW
3 Temp WB D Lev el 13&14
7/16/2007 9:26:44.881 AM 7/23/2007 9:26:44.881 AM7.00 day s
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0
1
0
1
700
800
700
800
650
900
709.18
734.80
751.25
FALSE
FALSE
Case Study II
Uncoated Area Delta T: 50°C Frequency: 14 Times
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3 WALL BLOWER D17 NOT AT REST3 WALL BLOWER D18 NOT AT REST3 Tube Crown Temp Right WB D173 Tube Crown Temp Right WB D18Gross Load, EXDESC=Gross Load
ZS3BS02D17
ZS3BS02D18
TE3BS02D17D
DEG FTE3BS02D18D
DEG F3LOAD
MW
3 Temp WB D Lev el 17 & 18
7/16/2007 9:11:13.614 AM 7/23/2007 9:11:13.614 AM7.00 day s
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0
1
0
1
650
750
650
750
650
800
709.77
704.07
703.63
FALSE
FALSE
Case Study II
Coated Area Delta T: 18°C Frequency: 7 Times
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Cetek Coating Benefit Summary• Cetek Ceramic Coatings proven to significantly
reduce slag and increase efficiency– Improve heat transfer– Minimize thermal cycling– Minimize soot blowing– Lower FEGT
• Cetek Ceramic Coatings proven to minimize corrosion– Extend tube life– Decrease tube leaks
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Cetek Coating Benefit Summary• Improves heat rate• Lowers NOx
• Reduces maintenance costs• Increases asset life• Increases reliability• Increases efficiency• Decreases forced outages
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20600 Sheldon Road, Brook Park, OH 44142Telephone: 216/362-3900 Fax: 216/362-3901Internet: http://www.ceteklimited.com
The Cetek Service Portfolio includes Ceramic Coatings,
High Temperature Inspections& Hot Refractory Repairs
For More Information Contact: